AC/DC Power Supply Unit

INSTALLATION AND USER MANUAL
AC/DC Power Supply Unit
Thrane & Thrane A/S
AC/DC Power Supply
Installation and User Manual
Document number: TT98-129099-B
Release date: September 24, 2009
Disclaimer
Any responsibility or liability for loss or damage in connection with the use of this
product and the accompanying documentation is disclaimed by Thrane & Thrane. The
information in this manual is provided for information purposes only, is subject to
change without notice and may contain errors or inaccuracies. Manuals issued by
Thrane & Thrane are periodically revised and updated. Anyone relying on this
information should acquire the most current version e.g. from http://www.thrane.com or
from the distributor. Thrane & Thrane is not responsible for the content or accuracy of
any translations or reproductions, in whole or in part, of this manual from any other
source.
Copyright
© 2009 Thrane & Thrane A/S. All rights reserved.
DISPOSAL
Old electrical and electronic equipment marked with this symbol can
contain substances hazardous to human beings and the environment.
Never dispose these items together with unsorted municipal waste
(household waste). In order to protect the environment and ensure the
correct recycling of old equipment as well as the re-utilization of individual components,
use either public collection or private collection by the local distributor of old electrical
and electronic equipment marked with this symbol.
Contact the local distributor for information about what type of return system to use.
Safety summary
1
The following general safety precautions must be observed during all
phases of operation, service and repair of this equipment. Failure to comply
with these precautions or with specific warnings elsewhere in this manual
violates safety standards of design, manufacture and intended use of the
equipment. Thrane & Thrane assumes no liability for the customer's failure
to comply with these requirements.
Observe marked areas
Under extreme heat conditions do not touch
areas of the unit that are marked with this
symbol, as it may result in injury.
KEEP AWAY FROM LIVE CIRCUITS
Operating personnel must not remove equipment covers. All repair and
servicing tasks must be made by qualified maintenance personnel. Do not
service the unit with the power cable connected. Always disconnect and
discharge circuits before touching them.
MAKE SURE THE UNIT IS GROUNDED DURING OPERATION.
Warning! Never insert or remove a power supply while its power
switch is in the On (|) position. Make sure the power
switch is Off (O) first.
iii
About the manual
Intended readers
This manual is an installation and user manual for the AC/DC
Power Supply system. It is important that you observe all safety
requirements listed in the beginning of this manual, and operate
the AC/DC Power Supply according to the instructions and
guidelines in this manual. All installation must be done by
qualified service personnel.
Manual overview
This manual has the following chapters:
•
Introduction contains a description of the principle of operation
and uses and features of the power supply.
•
Installation contains step-by-step guidelines how to install the
power supply as a stand-alone unit or in a combined setup and
describes the connectors.
•
Service and repair contains information on support, how to
return units for repair and instructions how to exchange the
fuses.
Typography
In this manual, typography is used as indicated below:
Bold is used to emphasize words and to indicate connector names
of the unit.
Italic is used to emphasize the paragraph title in cross-references.
Example: “For further information, see Connecting Cables on
page...”.
iv
2
Table of Contents
Chapter 1
Introduction
General description ............................................................ 1
Features .............................................................................2
Block diagram ....................................................................3
Applications .......................................................................4
Chapter 2
Installation
Unpacking ..........................................................................5
Installing the AC/DC Power Supply .....................................6
Installing 2 or 3 AC/DC Power Supply units .......................14
Chapter 3
Service and repair
Contact for support ............................................................17
Repair and servicing .........................................................17
Exchanging the fuses ....................................................... 18
Returning units for repair .................................................20
App. A
Technical specifications
App. B
Special installation
Glossary
......................................................................................... 27
Index
.........................................................................................29
v
Table of Contents
vi
1111
Chapter 1
1
Introduction
Introduction
General description
The TT-6080A AC/DC
Power Supply can deliver
300 W output power on
average with a peak of
370 W for a minimum of
2 minutes. This is useful
for MF/HF applications
and DSC transmissions of
2 minutes duration. It is
AC powered with a
battery switch-over function.
The AC/DC Power Supply has an on/off switch. It is lit when the power is
turned on. All connectors are placed at the same end of the power supply to
simplify mounting and installation. The connector panel is protected by a
transparent lid. To secure an installation with heavy cables an optional cable
relief bracket can be installed.
When mounted vertically the AC/DC Power Supply fulfills IP32 in areas with
more than 42 V and IP22 in other areas. This means that the unit is protected
against the intrusion of solid objects (including body parts like fingers), dust,
water etc.
1
Chapter 1: Introduction
Features
The AC/DC Power Supply has the following features:
 IEC 60945 Maritime approval
 Two DC connectors, output, range: 28.7 V - 31.2 V
 Output power 300 W continuous, 370 W peak (2 min., 100-240 VAC) or
270 W continuous, 333 W peak (2 min., 90-100 VAC)
 AC input (100-240 VAC operating) with fuse (6.3 A)
 Automatic selection of input voltage range
 AC alarm
 On/off switch
 Daisy-chaining of up to three units to give up to 900 W.1
 Short circuit protection
 Over-temperature protection (shutdown with automatic restart)
 Battery switch-over in case of AC supply failure, secured by 2 fuses (30 A)
 No forced cooling required
 IP 3X for internal high voltage areas (>42 V), IP 2X in other areas
 IP X2 when vertically mounted (wall) and connector panel is facing down
1.
2
Output power capability depend on the mounting position (horizontal or
vertical), input voltage, ambient temperature and ventilation at the place of
installation.
Features
1111
Chapter 1: Introduction
Introduction
Block diagram
The following drawing shows the block diagram of the AC/DC Power Supply.
Mains AC
AC Input
L
N
Chassis
AC/DC
converter
DC+
DCChassis
DC1
28.7-31.2 VDC
output
DC+
DCChassis
DC2
28.7-31.2 VDC
input / output
Chassis
AC LED
N C : Op en w hen o k
C OM : C om m on
N O: C lose d wh en ok
C ha ssis
Output LED
I/O connector,
for future use
Battery+
BatteryChassis
24 VDC
Battery input
AC ALARM
AC alarm output
Block diagram
3
Chapter 1: Introduction
Applications
The AC/DC Power Supply is designed
to be used with BGAN-X and
FleetBroadband terminals. It can be
used as a stand-alone DC power
supply or as a building block in a
larger power supply.
When more power is needed than one
power supply can give, i.e. 300 W, you
can stack up to three power supplies
on top of each other and connect them.
When stacking 2 or 3 units the load on
each of the units is automatically
balanced among the units.
4
Applications
2222
Chapter 2
Installation
The AC/DC Power Supply can be mounted on its own as a single unit, or you
can daisy-chain and stack up to 3 units. The AC/DC Power Supply can also be
fitted in a 1 U rack mount.
Unpacking
The following items are included in the delivery:
•
TT-6080A AC/DC Power Supply
•
1 AC fuse, 6.3 A
•
2 battery fuses, 30 A
•
4 mounting bolts for mounting 1 unit, M6X55 mm, DIN912 Unbrako
•
Cable-relief bracket, comb-style
•
AC/DC Power Supply Installation and user manual (this manual)
Optional accessories
The following optional accessories are available and can be ordered:
•
Mounting and cable-relief bracket, heavy duty, order number: 406080Aopt.001
•
4 mounting bolts for mounting 2 AC/DC Power Supply units, M6X100 mm,
DIN912 Unbrako, order number: 406080A-opt.002
•
4 mounting bolts for mounting 3 AC/DC Power Supply units, M6X140 mm,
DIN912 Unbrako, order number: 406080A-opt.003
5
Installation
2
Chapter 2: Installation
Installing the AC/DC Power Supply
You can mount the AC/DC Power Supply in a vertical or horizontal position.
When mounted in a vertical position, with the connector panel pointing
downwards, the unit fulfills IP32 in areas with more than 42 V and IP22 in
other areas.
Warning! Never insert or remove a power supply while its power
switch is in the On (|) position. Make sure the power
switch is Off (O) first.
Important
6
To ensure adequate cooling of the AC/DC Power Supply an
unobstructed space of minimum 5 cm must be maintained
around all sides of the unit except for the bottom side.
Installing the AC/DC Power Supply
Outline and dimensions
2222
Chapter 2: Installation
The following drawing shows the AC/DC Power Supply and the position of the
mounting holes. It is mounted with four mounting bolts.
4 mounting bolts for mounting 1 unit, M6X55 mm, DIN912 Unbrako
Installation
•
Installing the AC/DC Power Supply
7
Chapter 2: Installation
Protective lid for the connector panel
The connectors are protected
by a plastic lid. To access a
connector you have to
remove the lid. To make
room for the connector
cables you must remove the
U-shaped cutout for the
respective cable in the
plastic protective lid.
Removing the protective lid to connect the cables
To connect the cables you
must remove the protective
lid.
To do this, unscrew the two
screws (M3x7mm” Torx-8)
as shown in the picture and
put the lid aside.
8
Installing the AC/DC Power Supply
AC input
The AC/DC Power Supply is typically AC powered. To connect the AC input do
as follows:
2222
Chapter 2: Installation
Installation
1. Connect the Mains cable to the connector marked MAINS AC.
Mains AC
Connector type
Spring terminal, dual-row connector
Wire cross section
Up to 2.5 mm2
L
Line
AC power cord: brown (Europe), black (USA)
N
Neutral
AC power cord: blue (Europe), white (USA)
Chassis
AC power cord: green/yellow (Europe), green
(USA)
Fuse
6.3 A. It is accessible from outside the housing. It
is positioned next to the on/off switch.
To remove the fuse turn the device that holds the
fuse and extract it.
2. Remove the u-shaped cut-out for this input from the protective lid.
3. In order to be able to daisy-chain up to three AC/DC Power Supply units the
Mains AC connector has two terminals:
•
Use one terminal for the incoming mains power
•
Use the other terminal for the mains power going to the next AC/DC
Power Supply
Installing the AC/DC Power Supply
9
Chapter 2: Installation
DC output
The AC/DC Power Supply supplies a DC output. To connect the DC output DC1
do as follows:
1. Connect the DC cable to the connector marked DC1 and the equipment that
must be powered.
DC 1
Connector type
Spring terminal
Wire cross section
Up to 6 mm2
Maximum load
30 A
+
DC out, plus
-
DC out, minus
Chassis
2. Remove the u-shaped cut-out for this input from the protective lid.
When connecting 2 or 3 units in parallel, the combined power may be drawn
from a single connector. A single connector can handle 30 A.
Caution!
10
If you need more than 3x300 W or 30 A you need
to follow special guidelines when connecting the
required AC/DC Power Supply units. Refer to
Wiring four or more AC/DC Power Supply units on
page 25 to see how to connect the AC/DC Power
Supply units to meet these requirements.
Installing the AC/DC Power Supply
2222
Chapter 2: Installation
DC output or optional input for daisy-chaining
The second DC connector of the AC/DC Power Supply can be used for 2
purposes, to provide DC output or to serve as an input connector when daisychaining up to 3 AC/DC Power Supply units.
1. To have a second DC output:
Connect the DC cable to the connector marked DC1 and the equipment that
must be powered.
2. To daisy-chain a second AC/DC Power Supply.
Connect the cable from DC1 in AC/DC Power Supply unit 1 to DC2 in AC/DC
Power Supply unit 2.
Connect the DC cable to the connector marked DC 2 and the equipment
that must be powered.
3. Remove the u-shaped cut-out for this input from the protective lid.
To daisy-chain a third AC/DC Power Supply repeat step 2. The connector
specifications are the same as for DC1.
To see an overview how to connect AC/DC Power Supply units in a daisy chain
see Wiring for daisy-chaining on page 16.
Installing the AC/DC Power Supply
11
Installation
To connect the DC2 input do as follows:
Chapter 2: Installation
Battery input
You can connect an external 24 V emergency battery to the AC/DC Power
Supply to make sure the unit is operational in case the AC input fails. The
battery input is protected against wrong polarity of the battery.
To connect the BATTERY input do as follows:
1. Connect the cable to the connector marked BATTERY and the battery.
BATTERY
Connector type
Spring terminal
Wire cross section
Up to 6 mm2
+
Battery plus
-
Battery minus
Chassis
Fuses
Two 30 A fuses, one for battery plus and one for
the battery minus. These are accessible from
outside the housing and are positioned to the
right of the protective lid.
2. Remove the u-shaped cut-out for this input from the protective lid.
12
Installing the AC/DC Power Supply
AC alarm output
•
No AC power is present.
•
The AC fuse is blown.
•
The on/off switch is in the position off.
•
The output is short-circuited or heavily overloaded.
•
An internal error has occurred.
Installation
The AC alarm output provides an alarm signal when the AC/DC Power Supply
cannot deliver the required power from the AC input. This is the case when
2222
Chapter 2: Installation
To wire the AC alarm output do as follows:
1. Connect the cable to the connector marked AC Alarm according to the pin
specifications in the table below:
AC ALARM
Connector type
Spring terminal
Wire cross section
Up to 1.5 mm2
Pin 1
Closed when ok
Pin 2
Open when ok
Pin 3
Common
Pin 4
Chassis
Installing the AC/DC Power Supply
13
Chapter 2: Installation
Installing 2 or 3 AC/DC Power Supply units
You can mount up to three AC/DC
Power Supply units in a vertical
(recommended to use the
Mounting and cable-relief
bracket, heavy duty, order
number: 406080A-opt.001) or
horizontal position. When
mounted in a vertical position,
with the connector panel
pointing downwards, the unit
fulfills IP32 in areas with more
than 42 V and IP22 in other
areas.
The mounting holes in the AC/DC
Power Supply are designed in
such a way that units fit nicely on
top of each other when being
stacked.
Important
14
To ensure adequate cooling of the AC/DC Power Supplies an
unobstructed space of minimum 5 cm must be maintained
around all sides of the group of units (except between the units
and the bottom side).
Installing 2 or 3 AC/DC Power Supply units
Mounting bolts
2222
Chapter 2: Installation
The following drawing shows the specifications of the mounting bolts needed
when installing two or three units on top of each other.
2-block mount: 4 x M6X100 mm DIN912 Ubrako
•
3-block mount: 4 x M6X140 mm DIN912 Unbrako
Installation
•
Installing 2 or 3 AC/DC Power Supply units
15
Chapter 2: Installation
Wiring for daisy-chaining
The following drawing shows how to wire the AC/DC Power Supply units when
daisy-chaining two or three units.
Combined
DC Out
TT-6080A
Mains AC
DC1
DC2
BATTERY
DC1
DC2
BATTERY
DC1
DC2
BATTERY
TT-6080A
Mains AC
TT-6080A
Mains AC
Emergency
battery
Combined
DC Out
AC Power
To daisy-chain two or three AC/DC Power Supply units proceed as follows:
1. Connect Mains AC of unit 1 to unit 2.
2. Connect DC1 of unit 1 to DC2 of unit 2.
3. For the third unit, repeat steps 1. and 2. to connect unit 2 to unit 3.
Caution!
16
If you need more than 3x300 W or 30 A you need
to follow special guidelines when connecting the
required AC/DC Power Supply units. Refer to
Wiring four or more AC/DC Power Supply units on
page 25 to see how to connect the AC/DC Power
Supply units to meet these requirements.
Installing 2 or 3 AC/DC Power Supply units
Chapter 3
Repair or repair attempts performed by unqualified personnel may limit the
warranty. The warranty on the system is defined and outlined by the
distributor that supplied the AC/DC Power Supply.
3
Service and repair
The AC/DC Power Supply is designed to operate without preventive
maintenance.
3333
Service and repair
Contact for support
For support contact the distributor that supplied the AC/DC Power Supply.
For further information on warranty and service, you may also use the
Thrane & Thrane home page at www.thrane.com
Repair and servicing
The AC/DC Power Supply does not require maintenance and adjustment apart
from routine checking of its installation.
Warning! Never insert or remove a power supply while its power
switch is in the On (|) position. Make sure the power
switch is Off (O) first.
Important
In case of malfunctioning do not open the AC/DC Power Supply
but send it in for repair. For information how to proceed see
Returning units for repair on page 20.
17
Chapter 3: Service and repair
Exchanging the fuses
The AC/DC Power Supply has two fuses to secure AC input and input from an
external battery.
Fuse, AC input
2 fuses, battery input
Exchanging the AC fuse
To exchange the AC fuse, do as follows:
1. Locate the fuse, it is accessible from outside the housing. It is positioned
next to the on/off switch.
2. Turn the device that holds the fuse and extract it.
3. Take out the old fuse and insert a new one (type: 5x20 mm, 6.3 AT
4. Insert and fasten the fuse holder.
Caution!
18
If the AC fuse is blown directly after being
replaced there might be a serious fault in the
AC/DC Power Supply. Return the unit for repair.
Exchanging the fuses
Exchanging the BATTERY fuses
To exchange the two BATTERY fuses, do as follows:
1. Locate the fuses for battery plus and one for battery minus. These are
accessible from outside the housing, They are is positioned to the right of
the protective lid.
2. Pull out the fuses.
Service and repair
3. Insert two new fuses (type: ATO Blade Fuse, 30 A)
3333
Chapter 3: Service and repair
Exchanging the fuses
19
Chapter 3: Service and repair
Returning units for repair
To return equipment to Thrane & Thrane for repair this Return Material
Authorization (RMA) procedure must be followed. Failure to comply with this
procedure may cause shipping delays and additional charges.
Warranty returns
Equipment that qualifies for warranty repair can be returned to Thrane &
Thrane for repair or replacement at our discretion. The customer is charged
for the shipping costs to Thrane & Thrane, and Thrane & Thrane will pay the
shipping costs to return the repaired/replaced unit to the customer.
Non-warranty returns
Equipment that fails to work properly because of improper or negligent use,
abuse, shipping damaged or any other condition can still be returned to
Thrane & Thrane for repair or replacement at our discretion.
The customer will be notified of the cost to repair or replace the unit before
invoicing for repair or replacement. The customer is charged for the shipping
cost to and from Thrane & Thrane.
Repackaging requirements
An AC/DC Power Supply unit should be returned to Thrane & Thrane in the
original packaging. If the original packaging is not available, follow these
guidelines when repacking the unit(s):
1. Protect the connectors from physical damage and electrostatic discharge.
2. Wrap the unit in heavy paper or in bubble plastic sheets. Attach a tag with
model number, serial number and return address.
3. Use a strong shipping container, e.g. double-walled carton or similar.
4. Protect the front and rear panel with suitable material (cardboard, foam or
bubble plastic sheets) and insert a 7-10 cm layer of shock absorbing
20
Returning units for repair
material between all surfaces of the equipment and the sides of the
container.
5. Seal the shipping container securely.
6. Mark the shipping container FRAGILE to ensure careful handling.
Failure to do so may invalidate the warranty.
RMA procedure
Before returning units for repair, please follow this procedure:
1. Have the following information ready before calling the Customer Service
Center:
•
T&T Model number.
•
Serial number (example: 00443322).
•
A thorough description of the fault.
2. If you have purchased your AC/DC Power Supply from a Thrane & Thrane
distributor, contact the Customer Service Center of the distributor.
3. Describe the fault as thoroughly as possible and ask for assistance. In some
cases, the error may be resolved over the phone.
4. If the unit has to be returned for repair, request an RMA number.
5. Request replacement/loan unit if required.
6. Pack the equipment or parts to be returned in approved shipping
containers.
7. Write the RMA number on the outside of all shipping containers and ship
to the following address:
Thrane & Thrane A/S
Lundtoftegårdsvej 93 D
DK-2800 Kgs. Lyngby
Denmark
Returning units for repair
21
Service and repair
3333
Chapter 3: Service and repair
Chapter 3: Service and repair
22
Returning units for repair
AAAA
Technical specifications
A
The following tables show the electrical and environmental specifications of
the AC/DC Power Supply.
Specifications
Value
Output power at 100 VAC - 240 VAC
300 W continuous
370 W peak (2 min.)
Output power at 90 VAC - 100 VAC
270 W continuous
333 W peak (2 min.)
DC output (nominal)
31.2 VDC at 0 A
29.3 VDC at 10 A
28.7 VDC at 13 A
AC input voltage
115-230 VAC nominal,
100-240 VAC operating
Alarm in case of
AC power failure
IP rating in high voltage (>42 V)
IP 3X
IP rating in other areas
IP 2X
IP rating when mounted vertically on a wall
IP X2
Operating temperature
-25° to +55° C
23
Technical specifications
Appendix A
Appendix A: Technical specifications
24
Specifications
Value
Storage temperature
-40° to +80° C
Cooling
No forced cooling
required.
Survival temperature (power on)
-40° to +80° C
Dimensions
H: 46.5 mm, L: 354 mm,
W: 265 mm
Weight
Approx. 3.7 kg
Compass safe distance
30 cm
BBBB
Appendix B
B
If you need more than 3x300 W or 30 A you can connect more than 3 AC/DC
Power Supply units.
Important
You must connect the units as shown in the drawing. This is to
make sure that a single connector is never overloaded with
more than 30 A.
Wiring four or more AC/DC Power Supply units
User
User
-
DC
+
TT-6080A
TT-6080A
TT-6080A
TT-6080A
The cable resistance must
be > 100 m
Fuse
+
Cable lengths to achieve cable resistance higher than 100 m:
Emergency
Battery
cross section: 2.5 mm2 > 2 m
cross section: 6 mm2 > 25 m
25
Special installation
Special installation
Appendix B: Special installation
26
Glossary
C
A
AC
Alternating Current
D
DC
CCCC
Glossary
Direct Current
IEC
International Electrotechnical Commission is an international
standards organization that prepares and publishes International
Standards for all electrical, electronic and related technologies.
IP
International Protection Rating, sometimes also interpreted as
Ingress Protection Rating, consists of the letters IP followed by
two digits and an optional letter. It classifies the degrees of
protection provided against the intrusion of solid objects
(including body parts like hands and fingers), dust, accidental
contact, and water in electrical enclosures.
27
Glossary
I
Glossary
28
Index
A
AC alarm output, 13
AC input, 9
accessories, 5
applications, 4
approval
maritime, 2
B
battery input, 12
block diagram, 3
DDDD
Index
D
DC input, 11
DC output, 10, 11
dimensions, 7
document number
this manual, i
F
features, 2
fuse, 5
AC input, 9
AC, exchanging, 18
battery, 12
battery, exchanging, 19
C
D
daisy-chaining
wiring, 16
I
Index
cable-relief bracket, 5
cables
heavy, 1
combining
4 or more units, 25
up to 3 units, 4
Compass safe distance, 24
connector
AC alarm output, 13
AC input, 9
battery, 12
DC1, 10
DC2, 11
cooling requirements
several units, 14
single unit, 6
IEC 60945, 2
input
AC, 2
battery, 12
DC for daisy-chaining, 11
installation
2 or 3 units, 14
4 units or more, 25
IP rating, 1, 2, 23
L
lid
remove, 8
M
manual
document number, i
29
Index
mounting bolts, 5
1 unit, 7
2-Block mount, 15
3-Block mount, 15
O
order number
accessories, 5
mountings bolts, 5
outline, 7
output power, 2
P
peak output power, 2
power
output, 2
protective lid
remove, 8
removing, 8
R
remove
protective lid, 8
repackaging, 20
repair, 17
S
safety summary, iii
servicing, 17
several units
connecting, 16
installing, 14
specifications, 23
30
stacking several units, 4
support
contact, 17
T
technical specifications, 23
U
unpacking, 5
W
warranty return, 20
TT-98-129099-B
Thrane & Thrane A/S
•
info@thrane.com
•
www.thrane.com