DC-DC CONVERTER- MODEL 90-30

DC-DC CONVERTER- MODEL 90-30
VANNER Incorporated
90 Series Owner’s Manual
VANN-Bus 90-Series
Boost Regulator System
Table of Contents
Introduction………………………………………………….…………………
3
Specifications…………………………………………………….………….…
4
Theory of Operation……………...……………………………………………
5
Typical Applications…………………………...…………….…………..……
8
Installation Instructions………………………….………...………………….
10
Testing and Troubleshooting…………………………………………………
13
CAN Bus Interface…………………………………..………………………… 15
90-Series Converter Isolator CAN System
1
OWNER’S MANUAL
VANNER Incorporated
Introduction
Introduction
Thank you for purchasing a Vanner 90-30 Boost Regulator. We are confident that you will be very pleased with its
performance because our 90-Series Converters are designed and manufactured by skilled professionals using the
highest standards in workmanship. With minimum maintenance and care, you can be assured of many years of
trouble free service.
General Description
The Vanner VAN-Guard System is an efficient and highly reliable method of maintaining isolation between your 24Volt DC starting system and your 24-Volt DC auxiliary system. In addition to providing regulated 24-Volt power,
the system provides charging to the 24-Volt auxiliary battery, when conditions permit, which significantly extends
battery life. Ideally suited for vehicle and alternate energy applications, the VAN-Guard is designed to save your
batteries and the money you would spend replacing them. Users of the Vanner VAN-Guard know that it is the most
cost effective and dependable solution for 24-Volt systems.
A typical system would include a 24-Volt DC-starting system, a 24-Volt DC auxiliary system, and the 90-Series.
The 90-Series connects to the 24-Volt starting system, 24-Volt auxiliary system and ground terminals of the battery
system. When the auxiliary battery requires charging, the VAN-Guard ensures that the current is transferred from
the starting batteries, when conditions permit, and that the auxiliary batteries can not drain the starting batteries
when loads are left on. This isolation between the two 24-Volt systems ensures that the starting batteries will
maintain the power required to start the vehicle, and provides a stable 24-Volt supply for operating accessories.
NOTE: The Vanner VAN-Guard System is an extremely reliable device and, when installed according to the
instructions, will provide reliable operation for an indefinite period of time. However, if a system abnormality
should develop that would cause a VAN-Guard malfunction, damage to the battery system could result if 24-Volt
loads are present.
90-Series Converter Isolator CAN System
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OWNER’S MANUAL
VANNER Incorporated
Specifications
Specifications
90-Series Boost Regulator
Model Number
90-30CAN
Input Voltage 24v
18 to 32 v
Efficiency (Peak)
>97%
Max 24v Input Amps
32
Output Voltage
??
Output Amps (24v)
0-?
Standby Current
20 milliamps nominal at 28.4V
Operating Temp.
-40°C to +75°C (-40°F to 167°F)
Storage Temp.
-54°C to +95°C (-65°F to 203°F)
Serviceable
Environmental
Considerations
Mounting Location
Yes
Cast aluminum enclosure provides protection against salt, fungus, dust, water, fuel vapors and all fluids associated with commercial
and off-highway vehicle operations. IP rated 56.
Mount on a flat surface close to the batteries to allow short cable runs. Location should be protected from battery acid and gases.
Weights
90-Series Converter Isolator CAN System
8.8 lbs.
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OWNER’S MANUAL
VANNER Incorporated
90 Series Owner’s Manual
90-Series Dimensional Specifications
0.31
(7)
5/16-18 x 9/16
STUD
TORQUE 120
LB-IN MAX
10.6
(269)
8.0
(203)
5.1
(130)
1.3
(33)
8.0
(203)
8.5
(216)
3.4
(86)
4.0
(102)
Figure 1 - 90-30 Dimensions
90-Series Converter Isolator CAN System
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OWNER’S MANUAL
VANNER Incorporated
90 Series Owner’s Manual
Theory of Operation
Ibatt
Iout
F1
F2
90-60 Output
Voltage and
Battery Temp
Sensor
Current
Sensor
(80A)
GND
12v Battery
24 V
Alternator
IN
OUT
VANN-Guard
90-60CAN
Converter /
Isolator
24v
Starting
Battery
12v Battery
12v Battery
24v
Auxilliary
Battery
24 Volt
Loads
12v Battery
Battery
Negative
Sense Line
CAN
Figure 2 - 90-30 Stand Alone System
The Boost Regulator is a state of the art device that implements software controlled power management.
When the unit has been installed and the system is engaged, the 90-Series will look at the input voltage line
to determine if there is sufficient voltage to turn the unit on. If there is not, then the unit does not turn on.
If there is then the unit performs a “soft start” cycle that will ramp up the output current to the default
setpoint of 30-Amps DC. If at some point during the soft start cycle the output voltage plateaus at a lower
value than 20-Volts, then the Output current limits to a lower value than 30-Amps. If the Output Voltage
climbs to the default setpoint of 20-Volts, then the unit will continue operation, regulating the output
voltage to the default values.
If during normal operations the unit should have an output voltage dip, below 20-Volts, again the unit will
limit the current below the 30-Amp Default. If the unit’s output voltage rises above 30-Volts then the unit
will power off for 10 seconds and perform a restart procedure including the soft start sequence.
Furthermore, if the unit experiences an over temperature condition, it will also enter into a current limit (a
10% reduction in the output current capacity) to reduce internal temperatures. If this condition persists, the
unit will again reduce current output, until the unit gets out of the internally monitored thermal danger
zone. If the temperature continues to rise, the unit will again power off for 10 seconds and attempt a
restart. If the temperature remains high, then the unit will NOT operate until the temperature is within the
rated operating temperatures.
90-Series Converter Isolator CAN System
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OWNER’S MANUAL
VANNER Incorporated
90 Series Owner’s Manual
Installation Instructions
Do not exceed the specified torque of 120 in-lbs. when connecting cables to the terminal posts (Input,
Output, and GND) during installation of all the VAN-Guard Models. Torque values higher than specified
may damage the product, reduce performance, and/or create hazardous conditions. Products damaged by
improper torque are not covered by the warranty.
Do not connect more than one conductor per terminal post on any Vanner VAN-Guard. Multiple wires
and cables may overstress internal components, resulting in poor performance or creating hazardous
conditions. Products damaged by the installation of multiple conductors per post are not covered by the
warranty.
Fault protection devices MUST be installed between the VAN-Guard and the power source (battery). A
fault protection device would be any fuse or circuit breaker properly rated for the maximum DC current
obtainable. This advisory is in accordance with SAE, NEC and UL, for mobile power applications. Install
per applicable codes or within 18” of the battery. See Wire and Fuse Sizing Chart on page 10 of this
manual or contact Vanner at 1-800-227-6937 or [email protected] if assistance is needed in sizing
fault protection devices.
Caution: This equipment tends to produce arcs and sparks during installation. To prevent fire or explosion,
compartments containing batteries or flammable materials must be properly ventilated. Safety goggles
should always be worn when working near batteries
Mounting Location –The VAN-Guard may be mounted in any orientation, on a flat mounting surface
suitable to support the VAN-Guard during application. Do not mount in zero-clearance compartment that
may result in the VAN-Guard overheating. Locate so that contact by people is unlikely.
Environmental Protection – Your VAN-Guard has been designed to withstand direct exposure to rain and
moisture. The VAN-Guard has also been tested for exposure to direct pressure spray, but continual
exposure to direct pressure spraying may reduce the VAN-Guard serviceable life. Vanner covers any
damage due to water contamination only through the terms of our factory warranty.
Wiring Sequence– The VAN-Guard is internally protected for reverse polarity. The wiring sequence is not
an issue with the VAN-Guard products.
Strain Relief – The VAN-Guard has an integral strain relief. The VAN-Guard is designed with wells for the
lug to sit into to resist bolt loosening from cable movement, and the strain relief is designed to further
inhibit cable movement. The diagram below shows the proper orientation for the attachment of the strain
relief and the #10-32 mounting hardware that is supplied.
MOUNTING SCREWS
CABLE STRAIN RELIEF
LUG WELLS
VANN-Guard
90-Series Converter Isolator CAN System
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OWNER’S MANUAL
VANNER Incorporated
90 Series Owner’s Manual
Wire Size and temperature rating
Cables connecting the VAN-Guard to the batteries must be sufficiently sized to prevent unwanted voltage
drops. These voltage drops (loss) must be less than 0.05 VDC between the VAN-Guard’s +24 volt terminal
and the battery +24 volt terminal (Battery B positive terminal), less than 0.10 VDC between the VANGuard’s Input terminal and the battery +24 volt terminal (the jumper between Battery A and Battery B),
and less than 0.05 VDC between the VAN-Guard’s GND terminal and the battery ground terminal (Battery
A negative terminal that is connected to chassis ground). In most installations, the VAN-Guard’s terminals
are wired directly to the battery terminals (reference fault protection) to prevent voltage loss that could
occur in switch contacts, connections, and long wire runs. Since the VAN-Guard can be operated in
temperatures up to 75ºC, use wire rated at least 90ºC. See Wire and Fuse Size Chart.
Wire and Fuse Size Chart
Wire
Size
AWG
#8
#6
#4
#2
#1
Ring Terminal
AMP or UL
recognized
equal
Max wire length, in feet, between VAN-Guard
and battery to keep voltage drop under 0.1
volt. The chart assumes wire carries no other
load and wire temperature is below 80ºC.
90-30
33462
33466
33470
322870
321867
Fuse F1
Fuse F2
4.2
6.4
11.8
14.4
21.8
60 amp
50 amp
Crimp the ring terminals using AMP ROTA-CRIMP 300850 (2/0 - 8ga).
AMP Product Information Center: 800-522-6752
AMP Tooling Assistance Center: 800-722-1111
90-Series Converter Isolator CAN System
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OWNER’S MANUAL
VANNER Incorporated
90 Series Owner’s Manual
Testing and Troubleshooting
CAUTION
Servicing of electrical systems should only be performed by trained and qualified technical personnel.
Equipment Required
Voltmeter having 0.01 volt resolution. (Fluke Model 87, or higher, Multimeter recommended).
Clamp-on current meter (Fluke Model 36 Clamp-on Meter recommended).
Vanner Repair Service
Vanner offers a quick turn around factory repair service. Send the unit to the address below with a note instructing us to repair it.
Include your name, phone number, shipping address (not a P.O. Box Number), and your purchase order number.
Test Procedure for VAN-Guard 90-Series Systems
The VAN-Guard is working properly if:
1. The 24 volt DC loads are being operated continuously and are within the rated capacity of the
VAN-Guard and;
Vanner VAN-Guards are electronically protected against reverse polarity damage therefore the DC
connection sequence is not an issue.
Vanner VAN-Guards will not function properly unless all three-battery connections are made. Battery A
and Battery B voltages both must be above 8 volts for the unit to turn ON.
Vanner VAN-Guards may be used in parallel with other VAN-Guards and Vanner Equalizer models.
Please note that the Input, Output and GND stud positions and orientation are different on VAN-Guard 90Series than on other Vanner Equalizers.
90-Series Converter Isolator CAN System
8
OWNER’S MANUAL
VANNER Incorporated
90-Series Converter Isolator CAN System
90 Series Owner’s Manual
9
OWNER’S MANUAL
VANNER Incorporated
90 Series Owner’s Manual
Vanner Incorporated
4282 Reynolds Drive
Hilliard, Ohio 43026
1-800-AC POWER
(1-800-227-6937)
Tel: 614-771-2718
Fax: 614-771-4904
www.vanner.com
e-mail: [email protected]
Part Number D913649-A
th
August, 27 2009
Printed in U.S.A.
90-Series Converter Isolator CAN System
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OWNER’S MANUAL
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