BEL TCP3500-1024G 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 di riparare o modificare il prodotto,
se durante il funzionamento 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 personnel
qualifié 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 dispositivo prima 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 isolated devices suitable for ES1
and ES2 circuitry and are designed to be
mounted internally within a system. They are
intended for general use such as in industrial
control, communication, medical and
instrumentation equipment.
Do not use these devices in applications
where malfunction may cause injury or death.
Please see full spec of unit for further details.
Es handelt sich um galvanisch getrennte
Geräte, die für ES1- und ES2-Anwendungen
geeignet sind und für die Montage auf DIN-
Schienen und die Installation in einem
Schutzgehäuse konzipiert sind. Sie sind für den
allgemeinen Gebrauch wie z.B. in industriellen
Steuer-, Kommunikations- und
Automatisierung-Anwendungen vorgesehen.
Verwenden Sie diese Geräte nicht in
Anwendungen, bei denen eine Fehlfunktion zu
Verletzungen oder zum Tod führen kann.
I dispositivi sono isolati, adatti per applicazioni
ES1 e ES2, sono dotati di aggancio per il
montaggio su guida DIN all’interno di quadri
elettrici o contenitori di protezione, per l’utilizzo
con controllori industriali, unità di comunicazione
o apparecchi di misura.
Non utilizzare in applicazioni in cui un eventuale
guasto può comportare rischio di lesioni o di
morte.
Les produits sont isolés, appropriés
pour les circuits ES1 et ES2 et sont
équipés d'un crochet pour montage sur
rail DIN dans des armoires ou
conteneurs de protection, pour
utilisation avec les contrôleurs
industriels, des modules de
communication ou des unités de
mesure.
Ne pas utiliser ces dispositifs dans une
application où un dysfonctionnement
pourrait entraîner le risque des blessures
ou de mort.
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'apparecchio in 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'appareil dans un
environnement humide ou soumis à la
condensation. Recycler les produits et
les batteries, conformément à la
réglementation locale.

2
INSTALLATION INSTRUCTION
[email protected]
MODEL:
TCP3500-1024G
AC INPUT:
Note
3 PHASE
VOLTAGE: 115–277V / 200–480V, 3W + PE
CURRENT: 12 –5 A
FREQUENCY: 50 - 60 Hz
Input selection is automatic, no manual
change is required.
DC OUTPUT:
VOLTAGE: adjustable 10 –32 Vdc
CURRENT: 125A
POWER: MAX. 3500W
SAFETY APPROVALS
▪UL/CSA 62368-1 3rd edition
▪IEC 62368-1 3rd edition
▪CE Mark for LVD
INSTALLATION REQUIREMENTS
1. For details and mechanical drawings, access the AC-DC Data Sheet/App Notes link on the Bel Power Solutions website at:
belfuse.com/power-solutions and go to the respective TCP3500 listing.
2. Inside the power supply are 3 input fuses with rating 20A/500V. Recommended rating of upstream fuse or circuit breaker is 40A per phase.
CAUTIONS
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-use equipment according to the requirements of the safety standard used for that equipment. This power supply is not
designed to be operated outside of an enclosure which provides a means of mechanical, electrical, and fire protection. To maintain SELV requirements,
the outputs should not be connected together in any manner which causes the total output voltage to exceed 60 VDC.
PROTECTIVE EARTHING
The Power Supply must be properly grounded to mains protective earth termination at end use.
ENVIRONMENTAL CONDITIONS:
TRANSPORTATION & STORAGE:
Ambient Temperature Range -40 °C to +85 °C
Relative Humidity Range: 5% to 95% RH Non-Condensing
Altitude: to 12 192 m (40 000 feet) ASL
OPERATION:
Ambient Temp. Range -20°C to +70°C (at 100% load)1
Relative Humidity Range: 10% to 90% RH Non-Condensing
Altitude: to 3048 m (10 000 feet) ASL
Note: 1Cooling plate temperature range -20°C to +50°C (at 100% load).
WARNING
1. The equipment is for business use (Class A) and has acquired electromagnetic conformity registration. Therefore, the sellers and users are
required to take caution in this regard.
2. The AC Leakage Current exceeds 3.5mA at maximal input voltage and frequency (3 x 528Vac / 60Hz). Typical values are: ~1.8mA at input 3 x
200 –208Vac (L-L) / 50 - 60Hz; ~3.0mA at 3 x 400Vac (L-L) / 50Hz and ~4.1mA at 3 x 528Vac (L-L) / 60Hz.
3. Switch-off the input AC power before doing any intervention or manipulation with the unit! Do not touch output contacts –discharging time is 2
minutes after turn-off!
4. In order to ensure maximal useful lifetime of the power supply, minimal time between SWITCH-OFF and SWITCH-ON of the input AC power is 30
seconds and it is not allowed more than 100 cycles within 120 minutes otherwise damage of power supply can occur.
5. Hot Surface –Do not touch the case when the machine is running or stopped for a period of time to prevent burns.
SERVICING
In case of failure, the Power Supply must be returned to a Bel Power Solutions Authorized Service Center. There are no user serviceable parts in the
Power Supply.
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-performance to published specifications. The product(s) must be returned to a Bel Power
Solutions Authorized Service Center for repair with a Bel Power Solutions preassigned RMA number.
Bel Power Solutions assumes no liabilities for consequential damages of any kind through the use or misuse of its products by any user. No other
obligations are expressed or implied.
Please note that the specifications, terms, and conditions stated are subject to change without notice.
NUCLEAR AND MEDICAL APPLICATIONS
Bel Power Solutions products are not designed, intended for use in, or authorized for use as critical components in life support 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.

TCP3500-1024G
3
Asia-Pacific
[phone]
Europe, Middle East
[phone]
North America
[phone]
© 2020 Bel Power Solutions & Protection
BCM.00495_D
CONNECTORS POSITION
Fig. 1 Rear View - Connectors Position
INPUT POWER CONNECTOR: PINOUT
Connector type: Weidmüller 1081850000
Mating part: Weidmüller 1173520000
SIGNAL NAME
PIN #
TYPE
RECOMMENDED WIRES
V MAX
I MAX
Earth
Earth / Chassis
Min. 2.5 mm2
AC Line 1
L1
Input Power AC Fused
Min. 2.5 mm2
528 Vrms (line to line)
16 Arms (per line)
AC Line 2
L2
Input Power AC Fused
Min. 2.5 mm2
AC Line 3
L3
Input Power AC Fused
Min. 2.5 mm2
POWER OUTPUTS CONNECTOR –+/- BUS-BARS
Connector type: Bus-bar see Fig.1
Mating part: Ring terminal for M4 screws, with appropriate cross section for wire.
SIGNAL NAME
PIN #
TYPE
SIGNAL REFERENCE
LOW LEVEL
HIGH LEVEL
V MAX
I MAX
Vout+
+
Output Power DC
Vout-
-
32 VDC
125 ADC
Vout-
-
Output Power DC
-
-
Note: Maximal mounting torque for the BUS-BARS is 2.0 Nm (please see the Fig. 2)

4
INSTALLATION INSTRUCTION
[email protected]
SIGNAL NAME
PIN #
TYPE
SIGNAL
REFERENCE
LOW LEVEL
HIGH LEVEL
V MAX
I MAX
SENSE+
+
Sense line for Vout+ –voltage drop
compensation for positive pole
Vout+
-
-
SENSE-
-
Sense line for Vout- –voltage drop
compensation for negative pole
Vout-
-
-
SENSE LINES INPUT CONNECTOR - PINOUT
Connector type: Phoenix Contact, MC 1.5/ 2-G-3.81
Mating part: Phoenix Contact, MC 1.5/ 2-ST-3.81
LED SIGNALING
LED NAME
COLOR
STATUS
OPERATING CONDITIONS
AC-OK
Green
ON
AC Input Voltage is within operation range
DC-OK
Green
ON
Output is Enabled and Operational
OT/FAIL
Orange
ON
Blinking
Over Temperature conditions inside the unit or FAIL appeared (e.g. Overload)
FW upgrade via RS485-1
SIGNAL INPUT CONNECTOR –PINOUT
SIGNAL NAME
PIN #
TYPE
SIGNAL
REFERENCE
LOW LEVEL
HIGH LEVEL
V MAX
I MAX
RS485-1A
1
RS485 Half Duplex, Differential pair 1
RS485-1B
+/-60 mA
@ 60 Ω, 0 pF2
-7 to 12 VDC
8 mA
RS485-2A
2
RS485 Half Duplex, Differential pair 2
RS485-2B
+/-60 mA
@ 60 Ω, 50 pF2
-7 to 12 VDC
8 mA
ADDR-INIT IN
3
The unit’s address change required
SRTN
<0.4 VDC
>2.5 VDC
3.6 VDC
0.2 mA
IN OK
4
AC Power Fail Warning - open collector,
external pull-up needed to max. 7 V
SRTN
<0.4 VDC
Pull up
7 VDC
20 mA
OUT OK
5
Output Voltage Fault - open collector,
external pull-up needed to max. 7 V
SRTN
<0.4 VDC
Pull up
7 VDC
20 mA
INHIBIT
6
Output Inhibit - Open circuit or “High” to SRTN
shuts OFF Vout
SRTN
<0.4 VDC
>2.5 VDC
3.6 VDC
0.2 mA
ENABLE
7
Power Supply Enable pin –for unit enable short
this pin to SRTN
SRTN
<0.4 VDC
>2.5 VDC
3.6 VDC
0.2 mA
SRTN1
8
Internal Ground (Signal Return)
-
-
-
RS485-1B
9
RS485 Half Duplex, Differential pair 1
RS485-1B
+/-60 mA
@ 60 Ω, 50 pF2
-7 to 12 VDC
8 mA
RS485-2B
10
RS485 Half Duplex, Differential pair 2
RS485-2B
+/-60 mA
@ 60 Ω,50 pF2
-7 to 12 VDC
8 mA
Not Connected
11
-
-
-
-
OT/FAIL
12
Over Temperature /PSU Fail, open collector,
external pull-up needed to max. 7 VDC
SRTN
<0.4 VDC
Pull up
7 VDC
20 mA
PS-PRESENT
13
Power Supply Seated –signal internally
connected through 10 Ohm resistor to SRTN
SRTN
-
1 VDC
100 mA
ACSH
14
Active Current Share
SRTN
0.2 VDC
5.0 VDC
7 VDC
0.7 mA
Margin
15
Optional –analog signal for Output Voltage
adjustment –Not connected
-
-
-
1SRTN and Vout- are connected together inside the power supply.
2120 Ωresistors connection required between RS485-xA and RS485-xB on both sides externally.
Connector type: Würth Elektronik, 61801529221
Mating part: Würth Elektronik, 61801529321

TCP3500-1024G
5
Asia-Pacific
[phone]
Europe, Middle East
[phone]
North America
[phone]
© 2020 Bel Power Solutions & Protection
BCM.00495_D
SIGNAL OUTPUT CONNECTOR –PINOUT
SIGNAL NAME
PIN #
TYPE
SIGNAL
REFERENCE
LOW LEVEL
HIGH LEVEL
V MAX
I MAX
RS485-1A
1
RS485 Half Duplex, Differential pair 1
RS485-1B
+/-60 mA
@ 60 Ω, 50 pF
-7 to 12 VDC
8 mA
RS485-2A
2
RS485 Half Duplex, Differential pair 2
RS485-2B
+/-60 mA
@ 60 Ω, 50 pF
-7 to 12 VDC
8 mA
ADDR-INIT OUT
3
The unit’s address change accepted
SRTN
<0.4 VDC
Pull up
7 VDC
20 mA
IN OK
4
AC Power Fail Warning - open collector,
external pull-up needed to max. 7 V
SRTN
<0.4 VDC
Pull up
7 VDC
20 mA
OUT OK
5
Output Voltage Fault - open collector, external
pull-up needed to max. 7 V
SRTN
<0.4 VDC
Pull up
7 VDC
20 mA
INHIBIT
6
Output Inhibit - Open circuit or “High” to SRTN
shuts OFF Vout
SRTN
<0.4 VDC
>2.5 VDC
3.6 VDC
0.2 mA
ENABLE
7
Power Supply Enable pin –for unit enable
short this pin to SRTN
SRTN
<0.4 VDC
>2.5 VDC
3.6 VDC
0.2 mA
SRTN1
8
Internal Ground (Signal Return)
-
-
-
RS485-1B
9
RS485 Half Duplex, Differential pair 1
RS485-1B
+/-60 mA
@ 60 Ω, 50 pF
-7 to 12 VDC
8 mA
RS485-2B
10
RS485 Half Duplex, Differential pair 2
RS485-2B
+/-60 mA
@ 60 Ω, 50 pF
-7 to 12 VDC
8 mA
Not Connected
11
-
-
-
-
OT/FAIL
12
Over Temperature /PSU Fail, open collector,
external pull-up needed to max.7 VDC
SRTN
<0.4 VDC
Pull up
7 VDC
20 mA
PS-PRESENT OUT
13
Power Supply Seated –last unit in string will
pull down this signal (external short to SRTN)
and informs Master Controller that all units in
string are seated and connected
SRTN
<0.4 VDC
>2.5 VDC
3.6 VDC
0.2 mA
ACSH
14
Active Current Share
SRTN
0.2 VDC
5.0 VDC
7 VDC
0.7 mA
Margin
15
Optional –analog signal for Output Voltage
adjustment - Not Connected
SRTN
-
-
1SRTN and Vout- are connected together inside the power supply.
Note: Maximal mounting torque for the screw locks of the signal connector is 0.3 Nm (please see the Fig. 1)
Connector type: Würth Elektronik, 61801529321
Mating part: Würth Elektronik, 61801529221

6
INSTALLATION INSTRUCTION
[email protected]
MECHANICAL DIMENSIONS
Fig. 2 Mechanical Dimensions
COOLING
The power supply should have thermal connection with low thermal resistance between aluminum plate of the
power supply and liquid cooling cold plate. The temperature difference of contact area of cold plate and power
supply should be <5°C at worst case (total power dissipation of each PSU max. 300W). Recommended is to use
heat transfer paste with thermal conductivity 2.5 W/m.K between unit and cold plate (surface roughness Ra = 3.2
of the aluminum plate is acceptable).
Recommended tightening torque of M4 screws for assembling unit to aluminum cold plate is 3.5 - 4 Nm.1)
Note 1): Recommendation is for thread cut in aluminum plate, thread length 10mm. Tightening torque depends on the material
hardness of the used aluminum cold plate and used screws.