BEL LBC Series User manual

READ THIS CAREFULLY BEFORE
INSTALLATION!
VOR DER INSTALLATION BITTE FOLGENDE
SICHERHEITSHINWEISE BEACHTEN!
LEGGERE ATTENTAMENTE PRIMA
DELL’INSTALLAZIONE!
A LIRE ATTENTIVEMENT AVANT
L’INSTALLATION!
Before operating, read this document
thoroughly and retain it for future reference.
Non-respect of these instructions may
reduce performances and safety of the
devices and cause danger for people and
property.
The products must be installed, operated,
serviced and maintained by qualified
personnel in compliance with applicable
standards and regulations.
Do not open the device, it does not contain
replaceable components, the tripping of the
internal fuse (if included) is caused by an
internal failure.
Do not repair or modify the device, if
malfunction or failure should occur during
operation, send unit to the factory for
inspection.
No responsibility is assumed by Bel Power
Solutions for any consequences deriving
from the use of this material.
Lesen Sie dieses Dokument vor der
Inbetriebnahme sorgfältig durch und bewahren
Sie es zum späteren Nachschlagen auf.
Die Nichtbeachtung dieser Anweisungen kann die
Funktion und Sicherheit der Geräte
beeinträchtigen und birgt Gefahren für Personen
und Eigentum.
Die Geräte müssen von qualifiziertem Personal
unter Einhaltung der geltenden Normen und
Vorschriften installiert, betrieben, gewartet und
instand gehalten werden.
Öffnen Sie das Gerät nicht, es enthält keine
austauschbaren Komponenten, das Auslösen der
internen Sicherung (falls vorhanden) ist stets auf
tiefergehende Fehler im Schaltkreis zurück zu
führen.
Reparieren oder modifizieren Sie das Gerät nicht.
Sollte während des Betriebs eine Fehlfunktion
oder ein Defekt auftreten, schicken Sie das Gerät
zur Überprüfung ins Werk.
Bel Power Solutions übernimmt keine Haftung für
die Folgen, die sich aus dem Einsatz dieses
Gerätes ergeben.
Prima dell’installazione, leggere
attentamente questo documento istruzioni e
conservarle per future consultazioni.
L’inosservanza delle presenti istruzioni può
compromettere le caratteristiche e la
sicurezza dell’apparecchio e causare
pericolo per le persone e le cose.
Il prodotto deve essere installato, utilizzato e
riparato da personale qualificato e nel
rispetto delle normative vigenti.
Non aprire il prodotto, esso non contiene
componenti sostituibili, il guasto del fusibile
interno (se previsto) è causato da un guasto
interno.
Non tentare diriparare o modificare il
prodotto, se durante ilfunzionamento si
verificano guasti o anomalie, inviarlo al
produttore per il controllo.
Bel Power Solutions non si assume nessuna
responsabilità per qualunque conseguenza
derivante dall’uso di questo materiale.
Lire ces instructions avant l'installation,
conserver ce manuel pour référence future.
Défaut de se conformer à ces instructions
peut affecter les caractéristiques et la
sécurité du dispositif, et causer du danger
aux personnes ou aux biens.
Les produits doivent être installés, exploités
et entretenus par du personnelqualifié et en
conformité avec les règlements.
N'ouvrez pas le produit, il ne contient aucune
pièce réparable, le déclenchement du fusible
interne (le cas échéant) est causé par un
défaut interne.
Ne pas essayer de réparer ou modifier le
produit ; si des défaillances se produisent
pendant le fonctionnement, retourner le
produit au fabricant pour inspection.
Bel Power Solutions n'assume aucune
responsabilité des conséquences éventuelles
découlant de l'utilisation des produits.
CAUTION
ACHTUNG
ATTENZIONE
AVVERTISSEMENT
RISK OF BURNS, EXPLOSION, FIRE,
ELECTRICAL SHOCK, PERSONAL
INJURY.
Never carry out work on live parts! Danger of
fatal injury!
The product’s enclosure may be hot, allow
time for cooling product before touching it.
Do not allow liquids or foreign objects to
enter into the products.
To avoid sparks, do not connect or
disconnect the device before having
previously turned-off input power and wait
for internal capacitors discharge (minimum 2
minutes).
GEFAHR VON VERBRENNUNGEN,
EXPLOSIONEN, FEUER, STROMSCHLAG,
PERSONENSCHÄDEN.
Führen Sie niemals Arbeiten an
spannungsführenden Teilen durch! Gefahr von
tödlichen Verletzungen! Das Gehäuse des
Gerätes kann heiß sein, lassen Sie Zeit zum
Abkühlen des Gerätes, bevor Sie es berühren.
Lassen Sie keine Flüssigkeiten oder Fremdkörper
in die Geräte eindringen.
Um Überschläge zu vermeiden, schließen Sie das
Gerät nicht an oder trennen Sie es nicht ohne
vorher die Eingangsspannung abgeschaltet zu
haben, und warten Sie die Entladung der internen
Kondensatoren ab (mindestens 2 Minuten).
RISCHIO USTIONI, ESPLOSIONE,
INCENDIO, SCOSSA, LESIONI GRAVI.
Non effettuare mai operazioni sulle parti
sotto tensione! Pericolo di lesioni letali!
Il contenitore può scottare, lasciar quindi
raffreddare il dispositivoprima di toccarlo.
Non far entrare liquidi o oggetti estranei nel
dispositivo.
Per evitare scintille, non collegare o
scollegare l'apparecchiatura prima di avere
tolto tensione di ingresso e prima che sia
avvenuta la scarica dei condensatori interni
(min. 2 minuti).
RISQUE DE BRULURES, EXPLOSION,
INCENDIE, ELECTROCUTION, DOMMAGE
AUX PERSONNES.
Ne jamais effectuer des opérations sur les
parties sous tension! Danger de mort!
Le boîtier peut produire des brûlures, le
laisser refroidir avant de toucher l'appareil.
Ne faire pas pénétrer des liquides ou des
corps étrangers dans l'appareil.
Pour éviter des étincelles, ne pas connecter
ou déconnecter l'équipement jusqu'à ce que
la tension d'entrée a été supprimée et avant
qu'il n'ait eut lieu la décharge des
condensateurs internes (minimum 2 minutes).
INTENDED USE
BESTIMMUNGSGEMÄSSER BETRIEB
USO PREVISTO
UTILISATION
These are component type devices for
internal installation within system equipment.
The devices should be used for railway
applications only.
Do not use these devices in applications
where malfunction may cause injury or death.
Please see full spec of unit for further details.
Dies sind Komponenten für die interne Installation
in Systemgeräten. Die Geräte solten nur für
Eisenbahn Anwendungen verwendet werden.
Verwenden Sie diese Geräte nicht in
Anwendungen, bei denen eine Fehlfunktion zu
Verletzungen oder zum Tod führen kann. Weitere
Informationen finden Sie in der vollständigen
Spezifikation des Geräts.
I dispositivi sono di tipo componente per
l’installazione all’interno
dell’apparecchiatura. I dispositivi son per
l’utilizzo per ferrovia applicazioni.
Non utilizzare in applicazioni in cui un
eventuale guasto può comportare rischio di
lesioni o di morte.
vedere le specifiche complete del
dispositivo per ulteriori dettagli
Ce sont des types de composant pour une
installation interne d'équipement de système.
Les appareils peuvent être utilisés pour des
chemin de fer applications.
Ne pas utiliser ces dispositifs dans une
application où un dysfonctionnement pourrait
entraîner le risque des blessuresou de mort.
Pour de plus amples informations, se référer
à la fiche technique du produit
ENVIRONMENTAL CHARACTERISTICS
UMGEBUNGSBEDINGUNGEN
CARATTERISTICHE AMBIENTALI
CARACTÉRISTIQUES
ENVIRONMENTALES
Installation in a Pollution Degree 2
environment.
Do not use in wet area or subject to moisture.
Carefully recycle the product and related
batteries according to local regulations.
Installation in einer Umgebung mit
Verschmutzungsgrad 2.
Nicht in nassen Bereichen oder unter Feuchtigkeit
verwenden.
Das Gerät und die zugehörigen Batterien sind
entsprechend den lokalen Vorschriften zu
recyceln bzw. zu entsorgen.
Usare in ambienti con Grado di
Inquinamento 2.
Non far funzionare l'apparecchioin un
ambiente umido o soggetto a formazione di
condensa. Riciclare il prodotto e le batterie
collegate, nel rispetto delle normative locali
vigenti.
Utiliser les produits dans des environnements
avec degré de pollution 2.
Ne pas employer l'appareildans un
environnement humide ou soumis à la
condensation. Recycler les produits et les
batteries, conformément à la réglementation
locale.

2
OPERATION MANUAL
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MODELS:
LBC8000-1110SxxxG
LBC12000-1110SxxxG
AC INPUT:
3 PHASE
VOLTAGE: 230-277 / 400-480 Vac 3W + PE
CURRENT: 14-9 A (LBC8000)
CURRENT: 21-14 A (LBC12000)
FREQUENCY: 50 / 60 Hz
DC OUTPUT:
VOLTAGE: adjustable 80 –137.5 Vdc
CURRENT: max. 73 A (8000 W @ 110 V)
CURRENT: max. 110 A (12000 W @ 110 V)
SAFETY APPROVALS
▪CE Mark
▪China RoHS
CAUTION
These component level power supplies are intended exclusively for installation within other equipment by an industrial assembly operation or by
professional installers. These are Class 1 power supplies; the unit must be properly connected to earth ground in end use. A component power supply
should be installed in end-useequipment according to therequirements of thesafety standardusedfor that equipment. This power supply is not designed
to be operated outside of an enclosurewhich provides a means of mechanical, electrical, and fire protection.
PROTECTIVE EARTHING
The Power Supply must be properly grounded to mains protective earth termination at end use.
ENVIRONMENTAL CONDITIONS:
TRANSPORTATION & STORAGE:
Ambient TemperatureRange -40 °C to +85 °C
Relative Humidity Range:5% to 95% RH Non-Condensing
Altitude:to 12192 m (40 000 feet) ASL
OPERATION:
Ambient Temp. Range -25°C to +55°C (at 100% load),to +70°C (at 75% load)
Relative Humidity Range:10% to 90% RH Non-Condensing
Altitude (ASL): to 2500 m full power, to 3048 m (10 000 feet) derating 90% of full power
INSTALLATION REQUIREMENTS
Recommended power wires dimensions you can find in charts below. The mate parts of connectors are also described below. For the air inlet and outlet
there is required to maintain a minimum open space 10 cm. For chassis fastening you will need 6x screws M8. The preferred mounting position is vertical,
with connectors on top. The input shall be fused by: Breaker ABB, S203MT, C16, or similar. The output Battery must be protected by following fusing:
Breaker ABB, S802S-UCB125 (125A, char. B), or similar.
WARNING
1. The equipment is for business use (Class A). In a domestic environment this product may cause radio interference in which case the user may be
required to take adequate measures.
2. The AC Leakage current exceeds 3.5 mA at maximal input voltageand frequency (3 x 528 VAC / 63 Hz).It is necessary to take appropriate measures
(additional fixed grounding of the chassis).
3. Do not touch the Output connector X2 during theoperation. There is a hazardvoltage present, up to 138 Vdc.
4. Caution, this is a heavy weight unit, 24-30 kg.
SAFETY INSTRUCTIONS
Switch off the input power and disconnect battery (X2) together with connector X3, X1 and wait min.2 minutes beforedoing any maintenanceon the unit!
SERVICING
In case of failure,the unit must be returned to the Bel Power Solutions AuthorizedServiceCenter.There are no user serviceable parts inside, except of the
fan replacement. In case of failure of the fan this can be replaced without whole chassis opening. Theprocedure is described below.
CORROSION PROTECTION
The unit outside is protected by painting with Soprano 1 –Art. 095 000298-000. Insideall PC boards are protected by lacquering with Humiseal 1B73.
LIMITED WARRANTY
Bel Power Solutions warrants each power supply of its manufacture for a period of two years from the date of original shipment. This warranty applies to
defects in materials and workmanship that result in non-performanceto published specifications.The product(s) must be returned to a Bel Power Solutions
Authorized ServiceCenter for repair with a Bel Power Solutions pre-assigned RMA number.
Bel Power Solutions assumes no liabilities forconsequential damages of any kind throughthe use or misuse of its products by any user. No other obligations
are expressed or implied. Please note that the specifications, terms,and conditions statedare subject to changewithout notice.

LBC Series
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L
FAN REPLACEMENT PROCEDURE
In case of fan failureany of four (three at LBC8000) fans placedon the front panel, can be replaced.
1) Turn-off the wholedeviceand by screwdriver PH2 simply remove four outer screws (signed by red circle - not those holding the ventilation grill)
on the front panel, which contains the failed fan and pull the panel out from the chassis (see Fig. 1).
2) Disconnect the fan connector from the PC board by pressing the connector latch.
3) Now by the same screwdriver remove four screws holding thegrill together with fan on thepanel.
4) Replace the part for an original replacement part YVD.00969 (theleft end panel) or YVD.00946.0 (the rest panels). Contact our Service Center.
5) Keep the airflow direction fromoutsideto inside. Proceed with the mounting in reverseorder.
Lifeexpectance: 70 000 / 50 000 hours (YVD.00969 / YVD.00946.0) @ 40 °C, continuous operation
Figure 1: Fan replacement procedure
NUCLEAR AND MEDICAL APPLICATIONS
Bel Power Solutions products arenot designed,intended for use in, or authorized for use as critical components in lifesupport systems, equipment used in
hazardous environments, or nuclear control systems without the express written consent of the respective divisional president of Bel Power Solutions.
TECHNICAL REVISIONS
The appearance of products, including safety agency certifications pictured on labels, may change depending on the date manufactured. Specifications are
subject to change without notice.
OPERATION
First turn-on the battery breaker and only then turn-on the input AC voltagebreaker. The charger will start to supply the loadconnected at the Consumer
output (Safe mode –constant voltage, e.g. 105 Vdc, the voltagedepends on the LBC model). Inside, in series with this output, is connected an OR-ing
diode, so two or more LBC systems (preferably each onewith his own separate battery) can be at theConsumer outputs connectedin parallel, to supply
the load in redundancy.
30 seconds after the start-up thecharger will perform the battery test by decreasing the output voltage.During battery test theoutput voltage can drop
down to 80 V, if the batteryis not connected. In this case after the test the charger will be set to the Safe mode. In the o ther case (battery OK), or if the
battery will be connected afterwards,the charger will start to work in a current mode and the voltage will be set to keep the maximal charging current,
value corresponds to the measured battery temperature. The actual state can be seen by LED-s on the upper front panel (control unit) or by
communication SW / GUI.
When no temperature sensor will be connectedto the X3 connector,or any other fail will be detected, thecharger will remain to work in the Safe mode (in
this case the battery will be not fully charged). In this mode the output voltageis set below the value allowed at Tmax (charging curve dependent, e.g.
105Vdc).The Safe mode is indicated by the LED, see Datasheet BCD.00821 for details.When no battery voltagesense will be connected to the X3
connector, the charger will still work normally, only the battery voltagesymmetry will be not evaluated and reported by communication.
The charger does not have the possibility to disconnect thebattery by undervoltage, when supplied from battery only. UVLO mu stbe controlled by consumers
(typical turn-off should beless than 80 V, valuedepends on battery type).

4
OPERATION MANUAL
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Figure 2: Connectors placement
INPUT AC CONNECTOR X1 –PINOUT
SIGNAL NAME
PIN #
TYPE
RECOMMENDED WIRES
V MAX
I MAX
Earth
Earth / Chassis
Min. 4 mm2 Max. 10 mm2
528 Vrms (lineto line)
14/21 Arms (per line)
AC Line1
L1
Input Power AC Fused
Min. 4 mm2 Max. 10 mm2
AC Line2
L2
Input Power AC Fused
Min. 4 mm2 Max. 10 mm2
AC Line3
L3
Input Power AC Fused
Min. 4 mm2 Max. 10 mm2
Connector type: 4-pin terminal block HDFK 10-HV/Z (Phoenix Contact)
Mating part: Wires, max. 10 mm2,torque max. 2 Nm
OUTPUT and BATTERY CONNECTOR X2 - PINOUT
SIGNAL NAME
PIN #
TYPE
RECOMMENDED WIRES
V MAX
I MAX
CONSUMER+
Output Power DC
Min. 16/25 mm2Max. 50 mm2
137.5 VDC,
73/110 A
BATTERY+
Output Power DC
Min. 16/25 mm2Max. 50 mm2
COMMON-
Output Power DC_return
Min. 16/25 mm2Max. 50 mm2
Connector type: 3-pin terminal block HDFK 50/Z / UW50/S * (Phoenix Contact)
Mating part: Wires, max. 50 mm2, torque 3-5 Nm / 6-8 Nm *
* For models with Suffix S505G or higher
NOTE:Do not apply excessive forces onthe connector, do not band the wires close tothe connector, keepthe required torque!

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SIGNAL CONNECTOR X3 –PINOUT Carefully check all connections after installation, especially pins 7,8,9,10!
SIGNAL NAME
PIN #
TYPE
SIGNAL
REFERENCE
LOW LEVEL
HIGH LEVEL
V MAX
I MAX
VBsense1
1
Battery Voltage Sense 1
X2, Pin 3
138 V
VBsense2
2
Battery Voltage Sense 2
X2, Pin 3
138 V
VBsense3
3
Battery Voltage Sense 3
X2, Pin 3
138 V
VBsense4
4
Battery Voltage Sense 4
X2, Pin 3
138 V
VBsense5
5
Battery Voltage Sense 5
X2, Pin 3
138 V
N.C. / VBsense6 *
6
Battery Voltage Sense 6 *
X2, Pin 3
138 V
TB1H
7
Temperature sensor 1 High
TB1L
Cannot handle
battery voltage!
3.3 V
TB1L
8
Temperature sensor 1 Low
Cannot handle
battery voltage!
3.3 V
TB2H
9
Temperature sensor 2 High
TB2L
Cannot handle
battery voltage!
3.3 V
TB2L
10
Temperature sensor 2 Low
Cannot handle
battery voltage!
3.3 V
GRS
11
Signal Ground **
INH / ADR0 ***
12
Inhibit, pull high to inhibit / Address 0 ***
X2, Pin 3
Floating –110 V
138 V
P_LIM / ADR1 ***
13
Power Limitation, pull high to limit /
Address 1 ***
X2, Pin 3
Floating –110 V
138 V
FA
14
Floating relay contact, normally open,
closed when in fault condition
0.4A@138Vdc
FB
15
Connector type: Combicon MSTB2.5/15-GF-1776825, male (Phoenix Contact)
Mating part: Combicon MSTB2.5/15-STF-1786967 or FKCN2.5/15-STF-1733084, female (Phoenix Contact)
* For models with Suffix S505G or higher
** Do not connect
*** Second option (address setting) on request –contact manufacturer
ETHERNET CONNECTOR X4 –PINOUT
SIGNAL NAME
PIN #
TYPE
SIGNAL
REFERENCE
NOTE
V MAX
I MAX
TxData+
1
Communication Data
10/100 Mbit
RxData+
2
Communication Data
10/100 Mbit
TxData-
3
Communication Data
10/100 Mbit
RxData-
4
Communication Data
10/100 Mbit
Connector type: 4-pin M12 D-coded female 1534630 (Phoenix Contact)
Mating part: 4-pin M12 D-coded male 1521258 (PhoenixContact)
CAN-BUS CONNECTOR X5, X6 –PINOUT
SIGNAL NAME
PIN #
TYPE
SIGNAL
REFERENCE
NOTE
V MAX
I MAX
CAN +
7
Communication Data
CAN-
250 kbit
CAN -
2
Communication Data
CAN+
250 kbit
GND
3
+5V
9
Power Supply –normally do not use
GND
Only for servicing
5.5V / 100 mA
Connector type: X5: 9-pin D-SUB male (Harting) X6: 9-pin D-SUB female (Harting)
Mating part: 9-pin D-SUB female / male
NOTE: CAN and Ethernet (TRDP) communication commands are described in a separate document Communication Interface, BCE.02158.

6
OPERATION MANUAL
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MECHANICAL DIMENSIONS
Figure 3: Front view
Weight: 23.5 kg (LBC8000) / 29.7 kg (LBC12000)

LBC Series
7
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Figure 4: Side and top view