Eltek Valere DCR PSR327-8.1 LV User manual

DC Power Rack
DCR PSR327-8.1 LV/HV
USER MANUAL
UM_DCR_PSR327_8.1_E_R2.0

DC Power Rack
DCR PSR327-8.1 LV/HV
User Manual
Page 2 (28)
©2009. ELTEK VALERE DEUTSCHLAND GmbH. UM_DCR_PSR327_8.1_E_R2.0
Notes to this manual
ATTENTION! Read this manual very carefully before installing and commissioning the DC power rack.
This manual is a part of the delivered DC power rack. Familiarity with the contents of this manual is
required for installing and operating the DC power rack.
The rules for prevention of accidents for the specific country and the general safety rules in
accordance with IEC 364 must be observed.
The function description in this manual corresponds to the date of publishing.
Technical changes and changes in form and content can be made at any time by the manufacturer
without notice. There are no obligations to update the manual continually.
The module is manufactured in accordance with applicable DIN and VDE standards such as VDE 0106
(part 100) and VDE 0100 (part 410). The CE marking on the module confirms compliance with EU stan-
dards 2006-95-EG (low voltage) and 89/339 EWG (electromagnetic compatibility) if the installation and
operation instructions are followed.
Supplier:
ELTEK VALERE DEUTSCHLAND GmbH
GB Industrial
Schillerstraße 16
D-32052 Herford
+ 49 (0) 5221 1708-210
FAX + 49 (0) 5221 1708-222
Email [email protected]
Internet http://www.eltekvalere.com
2009. ELTEK VALERE DEUTSCHLAND GmbH. All rights reserved.

DC Power Rack
DCR PSR327-8.1 LV/HV
User Manual
Page 3 (28)
©2009. ELTEK VALERE DEUTSCHLAND GmbH. UM_DCR_PSR327_8.1_E_R2.0
The current revision status of this user manual is the following:
Revision: 2.0
Date: 2009-06-05
Revision Description of change Writer Date
00 Preliminary version RTH 2008-02-01
01 First edition RTH 2008-02-15
02 Minor addition in the section “rear side connection” RTH 2008-02-28
03 “Recommended wire cross section” for the output
inserted RTH 2008-03-04
04 Index of figures inserted, minor text modifications,
section “Can-Bus termination” reworked. RTH 2008-06-03
1.0 Designation of the alarm relay outputs corrected,
new revision status numbering (X.X) introduced. RTH 2008-12-18
2.0 Section “Extensions” added. RTH 2009-06-05

DC Power Rack
DCR PSR327-8.1 LV/HV
User Manual
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©2009. ELTEK VALERE DEUTSCHLAND GmbH. UM_DCR_PSR327_8.1_E_R2.0
Table of Contents
1. SAFETY INSTRUCTIONS AND WASTE DISPOSAL RULES .......................................................6
2. GENERAL INFORMATION ...............................................................................................................7
2.1 Block Diagram ..........................................................................................................................................7
2.2 Possible Configurations.........................................................................................................................8
2.3 Perspective View ....................................................................................................................................9
2.4 Available Options and required Equipment ......................................................................................9
2.5 Cooling and Air Flow Direction .......................................................................................................... 10
3. HANDLING ..................................................................................................................................... 11
3.1 Storage ................................................................................................................................................... 11
3.2 Commissioning...................................................................................................................................... 11
3.2.1 Communication Interface............................................................................................................................. 12
3.2.2 Can-Bus Termination..................................................................................................................................... 12
3.2.3 CAN Address Designation ............................................................................................................................ 13
3.2.4 Assembling ...................................................................................................................................................... 13
3.2.5 Rear View/Electrical Connectors ............................................................................................................... 14
3.2.6 Connection Table ........................................................................................................................................... 15
3.2.7 Schematic Diagram (Example of use) ....................................................................................................... 16
3.2.8 Connection Board........................................................................................................................................... 17
4. MAINTENANCE............................................................................................................................. 19
5. TECHNICAL SPECIFICATIONS .................................................................................................... 20
5.1 Dimensional Drawings:........................................................................................................................ 22
6. EXTENSIONS................................................................................................................................. 23
6.1 Schematic diagram DCR PSR327-8.1 and -10.8 connected in parallel ................................... 24
7. NOTES............................................................................................................................................ 25

DC Power Rack
DCR PSR327-8.1 LV/HV
User Manual
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©2009. ELTEK VALERE DEUTSCHLAND GmbH. UM_DCR_PSR327_8.1_E_R2.0
Index of Figures
Figure 1) - Block diagram ..................................................................................................................................................7
Figure 2) - DC power rack fully equipped......................................................................................................................9
Figure 3) - Rack air flow.................................................................................................................................................. 10
Figure 4) - Rack mounting points................................................................................................................................. 11
Figure 5) - Front view of the empty rack ................................................................................................................... 12
Figure 6) - CAN-Bus termination switches ................................................................................................................ 12
Figure 7) - Rotary switch= CAN address selector ................................................................................................... 12
Figure 8) - Rear view........................................................................................................................................................ 14
Figure 9) - Rear electrical connectors ........................................................................................................................ 14
Figure 10) - Schematic diagram ................................................................................................................................... 16
Figure 11) - Top view of the connection board ........................................................................................................ 17
Figure 12) - Rack dimensions........................................................................................................................................ 22
Abb. 13) System extension........................................................................................................................................... 23
Figure 14) DCR PSR327-10.8 and DCR PSR327-8.1 connected in parallel ........................................................ 24

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DCR PSR327-8.1 LV/HV
User Manual
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©2009. ELTEK VALERE DEUTSCHLAND GmbH. UM_DCR_PSR327_8.1_E_R2.0
1. Safety Instructions and Waste Disposal Rules
Warning!
Because several components of operating electrical devices are charged by dangerous voltage, the
improper handling of electrical devices may be the cause of accidents involving electrocution, injury,
or material damages.
Operation and maintenance of electrical devices must be performed by qualified skilled
personnel such as electricians in accordance with EN 50110-1 or IEC 60950.
Install the module only in areas with limited access to unskilled personnel.
Before starting work, the electrical device must be disconnected from mains. Make sure that it
is earthed.
Do not touch connector pins as they can be charged with dangerous voltage up to 30 seconds
after disconnection.
Only spare parts approved by the manufacturer must be used.
All electric devices must be disposed of separate from domestic waste at collecting points that have
been set up by the government or municipal authority.
“Separate collection is the precondition to ensure specific treatment and recycling of WEEE and is
necessary to achieve the chosen level of protection of human health and the environment in the
Community.”
The above statement from EU directive 2002/96/EC applies to all electric devices installed within
EU countries.
In countries outside the EU, different rules may apply regarding waste disposal of electric devices.
For more information about waste disposal of your discarded equipment, contact your
ELTEK VALERE DEUTSCHLAND partner.

DC Power Rack
DCR PSR327-8.1 LV/HV
User Manual
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©2009. ELTEK VALERE DEUTSCHLAND GmbH. UM_DCR_PSR327_8.1_E_R2.0
2. General Information
The DC power rack is a connection unit ready for integration in system cabinets with standard 19’’
frame. A high voltage (HV) and low voltage (LV) version is available. The unit can be equipped with a
maximum of three rectifiers of type PSR327 (PSR312) and one DC controller UPC3 and delivers an
output power up to 8100W. After safe mechanical and electrical connecting, the unit is ready for
operation.
The DC controller UPC3 is easy to configure by software and adapts the system to customer’s
applications and battery parameters.
Extensions:
If more output power is required, the power supply system can be extended with racks of type
DCR PSR327-10.8. This rack is designed to be fitted with four rectifiers PSR327 (PSR312). For more in-
formation about extensions see section 6. “Extensions”.
2.1 Block Diagram
DCR PSR327-8.1 LV/HV
Figure 1) - Block diagram

DC Power Rack
DCR PSR327-8.1 LV/HV
User Manual
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©2009. ELTEK VALERE DEUTSCHLAND GmbH. UM_DCR_PSR327_8.1_E_R2.0
2.2 Possible Configurations
One up to three rectifiers PSR327 (PSR312) with output voltages according to the table below, plus one
DC controller UPC3 (obligatory) can be integrated into one rack.
Designation of the
rack Article code
For rectifier/
output voltage
Necessary type of
DC controller UPC3//Article
code
PSR312/24VDC UPC3-24V//301-003-498.02
PSR327/48VDC
DCR PSR327-8.1 LV 102-327-318.LV01
PSR327/60VDC
UPC3-48/60V//301-003-
598.02
PSR327/110VDC UPC3-110V//301-003-798.02
DCR PSR327-8.1
HV 102-327-318.HV01
Input voltage = 230VAC
PSR327/220VDC UPC3-220V//301-003-898.02
Output power of the rack, equipped with PSR312:
Number of installed
Rectifiers (PSR312)
Output power (without
redundancy) Output power (n + 1) Output power (n + 2)
1 1200W --- ---
2 2400W 1200W ---
3 3600W 2400W 1200W
Output power of the rack, equipped with PSR327:
Number of installed
Rectifiers (PSR327)
Output power (without
redundancy) Output power (n + 1) Output power (n + 2)
1 2700W --- ---
2 5400W 2700W ---
3 8100W 5400W 2700W

DC Power Rack
DCR PSR327-8.1 LV/HV
User Manual
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©2009. ELTEK VALERE DEUTSCHLAND GmbH. UM_DCR_PSR327_8.1_E_R2.0
2.3 Perspective View
Figure 2) - DC power rack fully equipped with three rectifiers PSR327
and one DC controller UPC3.
Fastening elements according to figure 2) Comment
1 Four screws M6 to fix the sub rack to the frame of the system cabinet
2 Two adjustable assembly brackets (on the left and right side) to fix the
sub rack to the rear frame of the system cabinet.
Component parts of the
sub rack
3 Two captive screws are used for each module to secure it to the sub
rack
Component parts of the
modules
2.4 Available Options and required Equipment
Description Article code
DCC-CB1; connection board (with MSTB
screw terminals), required to connect all
measuring, control and signalling wires over
the backplane of the subrack to the DC controller UPC3, see section 3.2.8
“Connection Board”
302-DCC-CB1.00
(Included in delivery of
the sub rack)
Cover plate (with handle) to cover empty slots, 1/4 x 19’’, 3U, colour RAL
7035 881-MEC-BPL.03.21.B
Temperature sensor KTY81-220 T092 with cable of 4m length 302-TMP-KTY.04
CAN-Bus connection cable, length 0.5m (other lengths available) 880-KAB-CAN.05
Extension rack DCR PSR327-10.8
for four rectifiers PSR327 (312),
see section 6. “Extensions”.
For 24-60VDC:
102-327-408.LV01
For 110-220VDC:
102-327-408.HV01
1
3
3
2
1

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DCR PSR327-8.1 LV/HV
User Manual
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©2009. ELTEK VALERE DEUTSCHLAND GmbH. UM_DCR_PSR327_8.1_E_R2.0
2.5 Cooling and Air Flow Direction
The PSR327 (312) units are cooled with internal fans. The airflow is from the front to rear side. The fans
are monitored and speed-controlled dependent on module temperature. To provide sufficient air flow, a
minimum space (see figure 3, item “A”) of 50 mm is required between the backplane of the rack and the
rear cabinet wall as well as an unobstructed supply of air to the front of the modules.
Figure 3) - Rack air flow

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DCR PSR327-8.1 LV/HV
User Manual
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©2009. ELTEK VALERE DEUTSCHLAND GmbH. UM_DCR_PSR327_8.1_E_R2.0
3. Handling
3.1 Storage
Power racks must be stored in a dry, dust free environment with a storage temperature in accordance
with the specific technical data (see section 5).
3.2 Commissioning
1. Carefully unpack the unit and mount it on your power supply cabinet with 4 screws M6 (1) at the
front side.
2. Adjust the assembling brackets (2) on the left and right side of the rack with the relevant nuts of
the rear cabinet frame and tighten the brackets with 4 screws M6 (3) as shown in figure 4).
3
2
1
3
1
Figure 4) - Rack mounting points
REMARK: Before assembling the rectifier modules, the following settings must be done on the empty
rack:
1. CAN-Bus termination
2. CAN address designation
For details, see the following sections.

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DCR PSR327-8.1 LV/HV
User Manual
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©2009. ELTEK VALERE DEUTSCHLAND GmbH. UM_DCR_PSR327_8.1_E_R2.0
Figure 5) - Front view of the empty rack
Slot1 Slot4
UPC3
PSR327
Slot3
PSR327
Slot2
PSR327
Figure 6) - CAN-Bus termination switches (For details
see the section 3.2.2 “CAN-Bus Termination”)
Figure 7) - Rotary switch= CAN address selector
(For details see the section 3.2.3 “CAN Address
Designation”)
3.2.1 Communication Interface
The DCR PSR327 is equipped with a serial data interface in accordance with the Controller Area
Network (CAN) specification.
Several power racks and/or modules in a system can be controlled and monitored through the CAN-Bus
by a central DC controller unit UPC3.
Two CAN-Bus connectors (X6= CAN1; X7= CAN 2) are located on the rear of the sub rack
(see figure 9).
3.2.2 Can-Bus Termination
The CAN-Bus must be terminated at both ends. If no other power rack and/or module is connected
(CAN 2 not used), the CAN termination resistor must be enabled by setting the CAN termination switch
1, 2 or both (shown in figure 6) to “ON” position.
If CAN 2 is connected too, the CAN termination resistor must be disabled by setting the CAN
termination switches 1 and 2 to “OFF” position. For switch functions in detail, see the table below.
Table “CAN-Bus termination switch functions”
Switch 1 position Switch 2 position CAN-Bus termination resistor:
ON OFF Enabled
OFF ON Enabled
ON ON Enabled
OFF OFF Disabled
ATTENTION: Missing terminations or too many terminations within the system can disturb the CAN-Bus
communication. No more than two termination resistors should be activated on one bus and these
should be located at both ends of the bus.

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DCR PSR327-8.1 LV/HV
User Manual
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©2009. ELTEK VALERE DEUTSCHLAND GmbH. UM_DCR_PSR327_8.1_E_R2.0
3.2.3 CAN Address Designation
All racks (modules) within a system must be addressed for a clear identification through the control
unit.
The specific address for each rack must be designated with the CAN address selector (rotary switch)
shown in figure 7).
Rotary switch position Rack address
0 1
1 2
2 3
3 4
4 5
5 6
6 7
7 8
8 9
9 10
A 11
B 12
C 13
D 14
E 15
F 16
If only one rack is used within the power supply system, the rack must be addressed with the rack
address 1 (rotary switch position “0” according to the table above).
A second used rack must be addressed with the rack address 2 (rotary switch position “1” according to
the table above), etc.
The CAN addresses of the installed PSR rectifiers are automatically designated by the rack.
3.2.4 Assembling
After you have completed the settings, assemble the modules into the slots of the sub rack.
Fill the rack beginning with the left slot. The Slots 1 to 3 are provided for the rectifiers, slot 4 is pro-
vided for the controller unit UPC3 (see figure 5).
Empty PSR slots must be covered with cover plates (see section 2.4 “Available Options and required
Equipment”).

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DCR PSR327-8.1 LV/HV
User Manual
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©2009. ELTEK VALERE DEUTSCHLAND GmbH. UM_DCR_PSR327_8.1_E_R2.0
3.2.5 Rear View/Electrical Connectors
Grounding bolt PE
Figure 8) - Rear view
With the stickers affixed on the plexiglass guard, the connectors are labelled (X1 … X12) for a clear
identification.
Connect the input and output wires as well as the alarm wires to the rear connectors in accordance
with the connection table below.
For the connection of the measuring, control and signalling lines of the system, an external connec-
tion board is necessary (see the section 3.2.8 “Connection Board”). For the connection of the
connection board to the power rack (X12), a 50-pole ribbon cable is used.
To clarify: The drawing (see figure 9) shows the labelling of the terminal blocks.
Figure 9) - Rear electrical connectors
REMARK: The special grounding bolt (PE) of the rack itself must be grounded with the cabinet frame
(common PE of the system).
Because PE of the AC input connectors (X1.1, X2.1 and X3.1) are not connected with the
grounding bolt (PE) of the rack, they must be connected with the common PE of the system.
REMARK: The high voltage (HV) rack looks similar to the low voltage (LV) rack. The difference is, that
the connector X9 (sensor input for voltage drop compensation) is not connected for the HV rack!

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DCR PSR327-8.1 LV/HV
User Manual
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©2009. ELTEK VALERE DEUTSCHLAND GmbH. UM_DCR_PSR327_8.1_E_R2.0
3.2.6 Connection Table
Assignment of the rear side connectors according to figure 9).
Connector Function Recommended wire cross section
X1 AC input 1
1 PE 2.5 mm2
2 N 2.5 mm2
3 L1 2.5 mm2
X2 AC input 2
1 PE 2.5 mm2
2 N 2.5 mm2
3 L2 2.5 mm2
X3 AC input 3
1 PE 2.5 mm2
2 N 2.5 mm2
3 L3 2.5 mm2
X4 Ethernet connector (RJ45) Cord set
X5 Measurement input
1 +V1 (battery voltage*) 0.75mm2
2 -V1 0.75mm2
3 +V2 (system voltage*) 0.75mm2
4 -V2 0.75mm2
5 +V3 (tap voltage) 0.75mm2
6 -V3 0.75mm2
X6 CAN 1 (RJ11, 6-pole) Cord set
X7 CAN 2 (RJ11, 6-pole) Cord set
X8 Rectifier fault
1 Relay output (COM, NC) 0.75mm2
2 Relay output (COM, NC) 0.75mm2
X9** Sensor input for voltage drop
compensation
1 + sense 0.75mm2
2 - sense 0.75mm2
Recommended wire cross section, calculated for a
fully equipped rack (3 rectifiers) @ output voltage
24VDC 48VDC 60VDC 110VDC 220VDC
X10 DC output (minus pole), con-
nection with M8 bolt (brass)
70mm295mm270mm225mm210mm2
X11 DC output (plus pole), connec-
tion with M8 bolt (brass)
70mm295mm270mm225mm210mm2
*It is necessary to connect the battery voltage or the system voltage, because the battery voltage or
the system voltage is to be used for the power supply of the DC controller unit UPC3.
**Not connected for the HV-rack!

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DCR PSR327-8.1 LV/HV
User Manual
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Connector Function Recommended wire cross section
X12 Terminal block for connection
to the external connection
board
Cord set (ribbon cable, 50-pole)
3.2.7 Schematic Diagram (Example of use)
Figure 10) - Schematic diagram
An external separate fuse per each input is recommended!
With this fuse each module individually can be switched ON/OFF and therefore unused slots are
isolated (higher safety level).
Recommended input fuses: 16A MCB, characteristic “B”

DC Power Rack
DCR PSR327-8.1 LV/HV
User Manual
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©2009. ELTEK VALERE DEUTSCHLAND GmbH. UM_DCR_PSR327_8.1_E_R2.0
3.2.8 Connection Board
As noted above and indicated in the schematic diagram (see figure 10), it is necessary to use an
external extension board (included in delivery of the DC power rack), to connect all measuring, control
and signalling lines of the system over the relevant connector (X12) of the DC power rack to the DC
controller unit UPC3.
All measuring, control and signalling lines can be directly connected to the connection board.
For the connection of the connection board to the DC power rack, a 50-pole ribbon cable (included in
delivery of the connection board) is used.
For the sake of completeness following a brief description of the connection board:
Figure 11) - Top view of the connection board
Overview of the possible connections according to figure 11).
Connector Function
X1 Commonly not used
X2 RJ11, 6-pole CAN connector*
X3 Terminal block for ribbon cable (50-pole)
X4 Three current measuring inputs I1-I3, for shunts 60mV
1 +I1
2 -I1
3 +I2
4 -I2
5 +I3
6 -I3
X5 Control outputs for contactors LVD, PLD 1 + 2, optocoupler; max. 60V/20mA
1 LVD (OC)
2 PLD1 (OC)
3 PLD2 (OC)
4 COMVSS
*If X2 is connected, the jumper must be removed.

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Connector Function
X6 Three potential free relay outputs, contact load: max. 60V/max. 500mA
1 Relay K1, NO
2 Relay K1, COM
3 Relay K1, NC
4 Relay K2, NO
5 Relay K2, COM
6 Relay K2, NC
7 Relay K3, NO
8 Relay K3, COM
9 Relay K3, NC
X7 Three potential free relay outputs, contact load: max. 60V/max. 500mA
1 Relay K4, NO
2 Relay K4, COM
3 Relay K4, NC
4 Relay K5, NO
5 Relay K5, COM
6 Relay K5, NC
7 Relay K6, NO
8 Relay K6, COM
9 Relay K6, NC
X8 Four digital inputs Din1-Din4
1 Digital input 1
2 DGND
3 Digital input 2
4 DGND
5 Digital input 3
6 DGND
7 Digital input 4
8 DGND
X9 Four digital inputs Din5-Din8
1 Digital input 5
2 DGND
3 Digital input 6
4 DGND
5 Digital input 7
6 DGND
7 Digital input 8
8 DGND
X10 Two temperature measuring inputs for sensors of type KTY81
1 +Temp. sensor 1
2 GND
3 +Temp. sensor 2
4 GND
X11 +
X12
RJ45 Ethernet connectors
X13 RJ45 ISDN connector

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4. Maintenance
In general, the system is maintenance-free.
A yearly inspection with following checks is recommended checking the following:
Correct fan operation (rectifiers)
Mechanical inspection
Removal of dust and dirt
Check for internal dust or humidity
ATTENTION! Dust combined with moisture or water may influence or destroy the internal electronic
circuits.
Dust inside the unit can be blown out with dry compressed air.
The interval between the checks depends on ambient conditions of the installed system.
For the exchange of defective fans in the rectifier modules, an additional instruction manual is available
on request.

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DCR PSR327-8.1 LV/HV
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5. Technical Specifications
Type designation DCR PSR327-8.1 LV DCR PSR327-8.1 HV
Article code 102-327-318.LV01 102-327-318.HV01
Main Data:
Modules Designed for the use of 1 up to
max. 3 rectifiers of series PSR312
(Vo= 24VDC) or PSR327 (Vo= 48;
60VDC) and 1 DC controller UPC3
(24; 48/60V version)
Designed for the use of 1 up to
max. 3 rectifiers of series PSR327
(Vo= 110; 220VDC) and 1 DC con-
troller UPC3 (110; 220V version)
Input voltage 230VAC 
Internal input fuses There are no internal fuses, we recommend an individual fuse for each
input
Nominal output voltage 24, 48, 60VDC (single-output), de-
pends on the used rectifiers
108, 216VDC (single-output), de-
pends on the used rectifiers
Max. output current
(rack fully equipped with
3 rectifiers)
150ADC
@24VDC
168ADC
@48VDC
135ADC
@60VDC
75ADC
@108VDC
37.5ADC
@216VDC
Output power PSR312: 1200 up to 3600W;
PSR327: 2700 up to 8100W
2700 up to 8100W
Electrical connectors:
AC input 3 x input (1 per each module) 
DC output 1 x output (copper busbar) 
Signalling contacts Rectifier fault: 1 x potential free relay output COM, NC; max. switching
capacity: 60VDC, 500mA
Communication interfaces 2 x isolated CAN-Bus connectors (RJ11, 6-pole), 1 x Ethernet (RJ45)
Measurement inputs 3 x (V1, V2, V3); for example: battery voltage, system voltage,
tap voltage of the battery
Sensor input 1 x for voltage drop compensation not connected
External connection 1x 50-pole terminal block for the connection of all measuring, control and
signalling lines of the system via the connection board to the control unit
UPC3