PM50/PM80 Installation manual

PM50/PM80 Installation manual
PM50/PM80 INSTALLATION MANUAL
PM50/PM80
Installation manual
Polyamp AB, Sweden
www.polyamp.com
10231-12.doc
Page 1 (7)
PM50/PM80 INSTALLATION MANUAL
Warranty
All Polyamp DC/DC converters are warranted against defective material and
workmanship. This warranty is valid for 5 years 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 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
Polyamp AB, Sweden
www.polyamp.com
10231-12.doc
Page 2 (7)
PM50/PM80 INSTALLATION MANUAL
CONTENTS
1
BEFORE INSTALLATION ........................................................................................................................ 4
2
INSTALLATION ......................................................................................................................................... 4
3
CONNECTING THE OUTPUTS FOR SERIES, PARALLEL OR MASTER/SLAVE OPERATION5
4
PARALLEL CONNECTION OF TWO CONVERTERS OR MORE .................................................... 5
5
ISOLATION VOLTAGE TEST ................................................................................................................. 5
5.1
5.2
5.3
5.4
6
DC ISOLATION TEST OUTPUT TO CASE ........................................................................................................ 5
DC ISOLATION TEST INPUT TO OUTPUT AND INPUT TO CASE ....................................................................... 6
AC ISOLATION TEST INPUT TO OUTPUT AND INPUT TO CASE ....................................................................... 6
DC ISOLATION TEST OUTPUT1 TO OUTPUT2 ................................................................................................ 6
TROUBLE SHOOTING .............................................................................................................................. 6
6.1
6.2
6.3
6.4
THERE IS NO OUTPUT VOLTAGE .................................................................................................................. 6
THE INPUT FUSE BLOWS WHEN THE INPUT IS CONNECTED ........................................................................... 7
THE CONVERTER STARTS AND STOPS REPEATEDLY ..................................................................................... 7
FAULT REPORT ........................................................................................................................................... 7
Polyamp AB, Sweden
www.polyamp.com
10231-12.doc
Page 3 (7)
PM50/PM80 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, article number and
batch number. The converter type name consists of
model name PM50 or PM80 followed by input
code and output voltages. Two examples:
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
 ”Type: PM50B15-15” has input code ”B”
and nominal output voltage 2x(12-16) Vd.c.
2 Installation
 ”Type: PM80 110/24-24” has input code
”110” and nominal output voltage 2x24Vd.c.
The converter shall be mounted in an enclosure,
which meets the demands of EN60950 regarding
fire, voltage hazard and mechanical strength.
Input, outputs and case are galvanically separated
from each other. The two outputs are also
galvanically separated from each other. You can
thus choose how you want the system connected.
The converter is supplied with mounting brackets.
With these you can mount the converter in any
direction on a wall or on a DIN 35mm rail.
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.
PM50 input fuses
Input voltage code
Time delay fuse
A
T 6.3 A H, 250
B
T 4A H, 250
C
T 1.6 A H, 250
D
T 1A H, 250
PM80 input fuses
Input voltage code
Time delay fuse
24
T 5A H, 250
48
T 3,15 A H, 250
110
T 1.6 A H, 250
220
T 0.63 A H, 250
The converter is convection cooled and in order to
get sufficient cooling there shall be a minimum of
30 to 50 mm space 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
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 and if possible to
reduce ambient temperature.
To meet the EMC specifications in the enclosed
”declaration of conformity” use twisted-pairs for
connecting input and output. Shielded cables are
not necessary.
1. Connect protective earth to the connection
2.


Table 1. Recommended input fuses.
There are two reasons 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
3.
4.
marked no 17. Use a ring terminal that has been
crimped by an appropriate tool.
Connect the output. The converter outputs are
short-circuit proof by a constant current limit
which works unlimited in time.
Use the supplied jumpers according to
Connecting the outputs for series, parallel or
master/slave operation on page 5.
If the converter is to be connected in parallel
with another unit at the output, please consult
Parallel connection of two converters or more
on page 5.
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.
Start the converter with your external input
disconnection device.
Beware of hazardous voltages!
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Page 4 (7)
PM50/PM80 INSTALLATION MANUAL
5. The output voltage can be adjusted with the
potentiometer marked ”V.ADJ” on the front
panel. Clockwise turn increases the output
voltage. The potentiometer has one (1) turn.
6. 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 Connecting the outputs for
series, parallel or master/slave
operation
You can choose how the two (2) outputs of
the converter shall be connected with the
jumpers that are supplied with the
converter. Connect the jumper(s) as drawn
in ‫ א‬to configure the outputs in series,
parallel or a master/slave configuration
with or without isolation between the two
outputs. ”15-15” output are adjusted to
12.0Vd.c. at delivery.
Series connection
24 to 32V (PM50?/15-15)
48V
(PM80 ?/24-24)
110 to 130V (PM50?/60-60)
Parallel connection
12 to 16V (PM50?/15-15)
24V
(PM80 ?/24-24)
55 to 65V (PM50?/60-60)
Master/slave connection
2x12 to 16V (PM50?/15-15)
2x24V
(PM80 ?/24-24)
2x55 to 65V (PM50?/60-60)
Master/slave connection
±12 to 16V (PM50?/15-15)
±24V
(PM80 ?/24-24)
±55 to 65V (PM50?/60-60)
? = Any input code.
M = Master (U1)
S = Slave (U2)
an external series diode. A series diode is necessary
if the output is connected in parallel with another
power supply or if you require redundant operation.
If a converter breaks down with an internal shortcircuit 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.
5 Isolation voltage test
Each converter has been isolation tested in factory
before delivery. The isolation voltage depends on
nominal inputs and outputs, see table 2.
Warning! An isolation test shall only be
performed by personnel aware of the dangers
and hazards of the test.
Input
code
Isolation Isolation Isolation
In/out,
out/case out1/out2
In/case
2.0kVd.c. 1.0kVd.c. 500Vd.c.
24, 48,
A, B
110, 220, 2.5kVa.c. 1.0kVd.c. 500Vd.c.
C, D
Table 2. Isolation voltages on different
converters.
5.1 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. Connect your isolation tester between output
and case. See ‫ב‬. Raise the voltage of the
isolation tester from 0 to 1000Vd.c. Check that
the leakage current does not exceed 5µA. 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 M resistor between
output and case.
Figure 1. Output connections
If you have connected the outputs master/slave, the
master should be the output with the heaviest load,
as this is the regulated output.
4 Parallel connection of two
converters or more
If the converter is to be connected in parallel at the
output with another unit we recommend the use of
Polyamp AB, Sweden
www.polyamp.com
10231-12.doc
Page 5 (7)
PM50/PM80 INSTALLATION MANUAL
If your isolation test equipment cannot supply this
current, you can perform a DC isolation test with
4000Vd.c (2500V x 2 x 1.1  4000Vd.c where 1.1
= safety factor). Follow the instructions in 5.2 DC
isolation test input to output and input to case
above but test with 4000Vd.c. instead of 2000Vd.c.
The leakage current should not exceed 5µA.
AC isolation test:
Figure 2. Output to case isolation voltage test
5.2 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.
3. Connect the input terminals together.
4. Connect your isolation tester between input and
case. See ‫ג‬. Raise the voltage of the isolation
tester from 0 to 2000Vd.c. Check that the
leakage current does not exceed 5µA. 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 M resistor between
input and case.
1. Disconnect all cables from the converter.
2. Connect the output terminals of the converter to
case. See ‫ג‬.
3. Connect the input terminals together.
4. Connect your isolation tester between input and
case. See ‫ג‬. Raise the voltage of the isolation
tester from 0 to 2500Va.c. 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 M resistor between
input and case.
5.4 DC isolation test output1 to output2
1. Disconnect all cables from the converter.
2. Connect the input terminals of the converter to
case.
3. Connect the output ”U2” terminals to case.
4. Connect the output ”U1” terminals together.
5. Connect your isolation tester between output
”U1” and case. See ‫ד‬. Raise the voltage of the
isolation tester from 0 to 500Vd.c. Check that
the leakage current does not exceed 5µA. 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 M resistor between
output ”U1” and case.
Figure 3. Input to output and input to case
isolation voltage test
5.3 AC isolation test input to output and
input to case
You can also test 2500Va.c. for one (1) minute
between input to output and case on units with
input codes 110, 220, C and D.
Beware of the rather high capacitive earth
currents (about 50mA) that will occur during
this test.
Figure 4. Output ”U1” to output ”U2” isolation
test
6 Trouble shooting
6.1 There is no output voltage
1. Check that the input fuse is not broken.
Polyamp AB, Sweden
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Page 6 (7)
PM50/PM80 INSTALLATION MANUAL
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 shortcircuit on the output.
 Disconnect the input.
 Disconnect the load.
 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.
 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.
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.
6.2 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.
3. The unit is broken. Contact your Polyamp
dealer.
6.3 The converter starts and stops
repeatedly
1. The converter may be in current limit due to
excessive output current, a too capacitive load
or an external short-circuit on the output.
 Disconnect the input.
 Disconnect the load.
 Connect the input again and measure the
output voltage.
If the converter now starts the load was too
heavy or too capacitive or there was a shortcircuit.
 If there is an external short-circuit, remove
it.
 If the load is too large, decrease the load or
consult your Polyamp dealer.
 If the load is too capacitive (approximately
1000F), consult your Polyamp dealer.
6.4 Fault report
We suggest that you return a faulty converter to:
POLYAMP AB
Box 229 / Bäckgatan 10
S-597 25 ÅTVIDABERG
SWEDEN
Polyamp AB, Sweden
www.polyamp.com
10231-12.doc
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