Eltek PSR312 User manual

RECTIFIER
PSR312
USER MANUAL
Eltek_UM_PSR312_21TE_E_R6.0

Rectifier
PSR312
User Manual
Page 2 (20)
©2011. ELTEK DEUTSCHLAND GmbH.
Eltek_UM_PSR312_21TE_ E_R6.0
Notes to this manual
ATTENTION! Read this manual very carefully before installing and commissioning the specified module.
This manual is a part of the delivered module. Familiarity with the contents of this manual is required for
installing and operating the specified module.
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
standards 2006-95-EG (low voltage) and 2004-108-EG (electromagnetic compatibility) if the installation
and operation instructions are followed.
Supplier:

ELTEK DEUTSCHLAND GmbH
BU Industrial
Schillerstraße 16
D-32052 Herford

+ 49 (0) 5221 1708-210
FAX
+ 49 (0) 5221 1708-222
Email
[e-mail]
Internet
http://www.eltek.com
Please note: No part of this document may be reproduced or transmitted in any form or by any means -
electronic or mechanical, including photocopying and recording- for whatever reason without the explicit
written permission of Eltek Deutschland GmbH.
Changes and errors excepted.
2011. ELTEK DEUTSCHLAND GmbH. All rights reserved.

Rectifier
PSR312
User Manual
Page 3 (20)
©2011. ELTEK DEUTSCHLAND GmbH.
Eltek_UM_PSR312_21TE_ E_R6.0
The current revision status of this user manual is the following:
Revision: 6.0
Date: 2010-11-23
Revision
Description of change
Writer
Date
00 First edition RTH 2008-01-03
01
Minor text modifications, sections “Commissioning”, “Output
power diagram” and “Monitoring” reworked, index of figures
inserted.
RTH 2008-05-15
1.2
Minor text modifications, new revision status numbering
introduced. RTH 2008-11-04
2.0
Section 4.2.1 “Start-up behaviour” inserted; Technical
specifications: Adjustable output voltage range changed.
RTH 2009-04-29
3.0 Section 4.5 “Monitoring” reworked. RTH 2009-05-15
4.0
Minor text modifications, section 4.7 “Default value setting for
NiCd batteries” inserted.
RTH 2009-07-10
5.0 Technical specifications: “Internal decoupling circuit” corrected. RTH 2009-07-24
6.0 Input frequency range updated. RTH 2010-11-23

Rectifier
PSR312
User Manual
Page 4 (20)
©2011. ELTEK DEUTSCHLAND GmbH.
Eltek_UM_PSR312_21TE_ E_R6.0
Contents
1A. Safety Instructions ................................................................................................................................................... 5
1B. Electric Waste Disposal............................................................................................................................................ 5
2. General Information..................................................................................................................................................... 6
3. Main Data/Equipment................................................................................................................................................. 6
3.1 Available Options and Assembly Equipment: ................................................................................................. 7
3.2 Front view/Front side LED panel ....................................................................................................................... 8
3.3 Rear Side Connection........................................................................................................................................... 9
3.4 Cooling and Air Flow Direction..........................................................................................................................10
3.5 Communication Interface .................................................................................................................................10
4. Handling.......................................................................................................................................................................11
4.1 Storage .................................................................................................................................................................11
4.2 Commissioning ....................................................................................................................................................11
4.2.1 Start-up behaviour.......................................................................................................................................11
4.3 Charge Characteristic/Output Power Diagram ............................................................................................12
4.4 LED Indications ....................................................................................................................................................13
4.5 Internal Monitoring .............................................................................................................................................13
4.6 Threshold & Default Values..............................................................................................................................14
4.7 Default value setting for NiCd batteries .......................................................................................................14
5. External Functions.....................................................................................................................................................15
6. Maintenance ...............................................................................................................................................................15
7. Trouble Shooting........................................................................................................................................................16
8. Technical Specifications ..........................................................................................................................................17
8.1 Dimensional Drawings:.......................................................................................................................................19
Index of Figures
Figure 1) - DC Power Rack DCR PSR327-3.6 LV ...............................................................................................................................7
Figure 2) - DC Power Rack DCR PSR327-4.8 LV ...............................................................................................................................7
Figure 3) - Front view ............................................................................................................................................................................8
Figure 4) - Male connectors.................................................................................................................................................................9
Figure 5) - Module air flow ................................................................................................................................................................ 10
Figure 6) - PSR312/24-50 Output Power Diagram ...................................................................................................................... 12
Figure 7) - Screenshot “PC software for CAN dongle” ................................................................................................................ 14
Figure 8) - Module dimensions ......................................................................................................................................................... 19

Rectifier
PSR312
User Manual
Page 5 (20)
©2011. ELTEK DEUTSCHLAND GmbH.
Eltek_UM_PSR312_21TE_ E_R6.0
1A. Safety Instructions
Warning!
Because several components of operating electrical modules are charged by dangerous voltage, the
improper handling of electrical modules may be the cause of accidents involving electrocution, injury, or
material damages.
•Operation and maintenance of electrical modules 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 module must be disconnected from mains. Make sure that
the module 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.
1B. Electric Waste Disposal
Separate collection is the precondition to ensure specific treatment and recycling of waste electrical
and electronic equipment and is necessary to achieve the chosen level of protection of human health
and the environment.
In the case of waste disposal of your discarded equipment we recommend to contact a waste
management company.

Rectifier
PSR312
User Manual
Page 6 (20)
©2011. ELTEK DEUTSCHLAND GmbH.
Eltek_UM_PSR312_21TE_ E_R6.0
2. General Information
The PSR312 rectifier rectifies sinusoidal AC input voltage to DC output voltage.
The PSR312 is a hot plug-in module with rear side connectors and is designed to be mounted in an
assembly set 19’’ sub rack (see section 3.1). Due to the state-of-the-art circuitry design, the unit has
very low losses and therefore very compact dimensions, low weight and high power density.
The PSR312 rectifier can be used in all DC applications with or without battery.
The rectifier is delivered with factory set default values for lead acid batteries. If the rectifier is to be
used for NiCd batteries, the default values must be parameterized accordingly using a CAN dongle and
special software.
The nominal output power per unit is 1.2 kW. Up to a maximum of 48 modules can be switched in parallel
to increase the system output power or to build redundant power supply systems (n + 1-principle).
3. Main Data/Equipment
Type Designation Article Code Nominal Output Voltage Nominal Output Current
PSR312/24-50 101-012-148.00 24 VDC 50 ADC
Nominal input voltage:
230 V
AC
Nominal input current:
5.8 A
AC
Input frequency range:
16⅔ to 60 Hz (+5 %)
Nominal output power:
1.2 kW
For more specific data, see section 8 please.

Rectifier
PSR312
User Manual
Page 7 (20)
©2011. ELTEK DEUTSCHLAND GmbH.
Eltek_UM_PSR312_21TE_ E_R6.0
3.1 Available Options and Assembly Equipment:
Designation Article Codes
DC Power Rack DCR PSR327-3.6 LV (assembly set 19’’ sub rack 3U
incl. backplane for three PSR312/24 V rectifiers and one
UPC3-24 V DC controller), DCC-CB1 connection board included.
102-327-318.LV01
DC Power Rack DCR PSR327-4.8 LV (assembly set 19’’ sub rack 3U
incl. backplane for four PSR312/24 V rectifiers). 102-327-408.LV01
Cover plate (with handle) to cover empty PSR slots,
1/4 x 19’’, 3U; RAL 7035 881-MEC-BPL.03.21.B
Monitoring, control and signalling unit (DC controller) UPC-24 V 301-003-498.02
DCC-CB1; connection board (with MSTB screw terminals) necessary
to connect all measuring, control and signalling wires over the
backplane of the sub rack to the control unit UPC3 (spare part)
302-DCC-CB1.00
CAN dongle, incl. software; necessary to change the internal default
values of the rectifier (e.g. for NiCd application). 880-CAN-DNG.00
Figure 1) - DC Power Rack DCR PSR327-3.6 LV fully
equipped with three PSR312 rectifiers and one
UPC3 DC controller
Figure 2) - DC Power Rack DCR PSR327-4.8 LV fully
equipped with four PSR312 rectifiers

Rectifier
PSR312
User Manual
Page 8 (20)
©2011. ELTEK DEUTSCHLAND GmbH.
Eltek_UM_PSR312_21TE_ E_R6.0
3.2
Front view/Front side LED panel
Figure 3) - Front view
The PSR312 rectifier is equipped with the
following four LED indicators:
INPUT OK
OUTPUT OK
Vout>
ALARM
For more information about the LED indicators,
see section 4.4
Two captive screws are used for each module to
secure it to the sub rack (components of the
module)

Rectifier
PSR312
User Manual
Page 9 (20)
©2011. ELTEK DEUTSCHLAND GmbH.
Eltek_UM_PSR312_21TE_ E_R6.0
3.3 Rear Side Connection
The rear side male connections (AC input voltage, DC output voltage and signals) are shown in figure 4)
and are defined in the table below.
Figure 4) - Male connectors (shown from the rear side of the module)
Pin assignment of the rear side connector:
Pin
Function
2b
L1 - Input
5b
N - Input
8b
- - -
11b
PE
13a
CAN - CVSS
13c
(-) output voltage sense link
14a
CAN - H
14c
CAN - L
15a
- - -
15c
CAN - CVCC
16a
AGND
16c
- - -
17a
Hardwarecoding CODE2
17c
Hardwarecoding CODE1
18a
Collective Alarm NC
18c
Collective Alarm COM
19a
Collective Alarm NO
19c
- - -
20a
- - -
20c
(+) output voltage sense link
22b
(-) Output
25b
(-) Output
28b
(+) Output
31b
(+) Output

Rectifier
PSR312
User Manual
Page 10 (20)
©2011. ELTEK DEUTSCHLAND GmbH.
Eltek_UM_PSR312_21TE_ E_R6.0
3.4 Cooling and Air Flow Direction
The unit is cooled with an internal fan. The airflow is from the front to rear side. The fan is monitored and
speed-controlled dependent on module temperature. To provide sufficient air flow, a minimum space
(see item “A” in figure 5) of 50 mm is required between the unit and the rear cabinet wall as well as an
unobstructed supply of air to the front of the module.
Figure 5) - Module air flow
3.5 Communication Interface
The PSR312 rectifier is equipped with a serial data interface in accordance with the Controller Area
Network (CAN) specification. The CAN-Bus connection is integrated in the rear side connector.
Several modules in a system or parallel connection can be controlled and monitored through the CAN-
Bus by a central UPC DC controller unit.
The following parameters of a specific rectifier unit can be controlled or monitored:
•Output voltage
•Output current
•Module temperature
•Module status
Furthermore, the rectifier unit receives all threshold values through the CAN-Bus from the
DC controller unit.

Rectifier
PSR312
User Manual
Page 11 (20)
©2011. ELTEK DEUTSCHLAND GmbH.
Eltek_UM_PSR312_21TE_ E_R6.0
4. Handling
4.1 Storage
Modules must be stored in a dry, dust free environment with a storage temperature in accordance with
the specific technical data (see section 8).
4.2 Commissioning
Note: Before commissioning the module, make sure that the input voltage corresponds to the input
voltage range of the unit as specified on the type plate and that the output voltage of paralleled units
matches.
1. Carefully unpack the unit
2. Fill the rack beginning with the left slot.
3. Put the unit into an empty slot.
4. Carefully slide in the unit until the module connector touched the backplane connector.
5. Increase the force until the unit fits in completely. Avoid using too much force. If the unit does not
fit in, begin again at step 3.
6. Secure the module using the two captive screws (M3x12) provided with the module.
7. Switch ON the module by external MCB.
Note: The PSR312 is serially equipped with an internal output side decoupling diode. This ensures
hot plug-in capability for the module and enables the operator to add modules under operating
conditions.
Note: Before the module is to be removed it must be switched off by the external input fuse!
Caution: After switching off the module the internal capacitors are still fully charged. Do not touch
connector pins as they can still be charged with dangerous voltage after disconnection.
4.2.1 Start-up behaviour
When the PSR312 is switched on (without CAN-Bus connection) first it provides a start-up voltage
according to the table below. The start-up voltage is held for 60 seconds, than the output voltage steps
up to the internal default value.
PSR312 24 V version
Start-up voltage (V
DC
)
24.00
Default value Vo (V
DC
)
27.25
If a DC controller unit (UPC) is integrated into the system, it is powered with the start-up voltage after
the rectifier has been switched on. The output voltage immediately steps up to the value given from the
UPC unit via CAN-Bus.
If a DC controller unit (UPC) is integrated into the system (e.g. powered by the battery and due to this
operating yet) the rectifier directly provides the output voltage given from the UPC unit via CAN-Bus.

Rectifier
PSR312
User Manual
Page 12 (20)
©2011. ELTEK DEUTSCHLAND GmbH.
Eltek_UM_PSR312_21TE_ E_R6.0
4.3 Charge Characteristic/Output Power Diagram
The charge characteristic of the PSR312 is a power limited IV characteristic curve in accordance with
DIN 41772/DIN 41773.
For modules in parallel operation mode a load sharing of about ±10 % is attained due to a sloping output
voltage line (-1 % at 100 % Inom).
The module is continuous short circuit proof.
Figure 6) - PSR312/24-50 Output Power Diagram
Calculation of the output current (Io) at different output voltage values:
The PSR312 rectifier provides an output power of Vonom x Ionom= Ponom (24 V x 50 A= 1200 W)
As shown with the output power diagram (see figure 6), the nominal output current (50 A) is available at
nominal output voltage (24.0 V).
At other output voltage values (e.g. float and boost charge voltage as well), the output current is
corresponding to the following formula: Io= Ponom : Vo
Example 1):
Float charge voltage for lead acid batteries (12 cells)= 27.24 V; Io= 1200 W : 27.24 V= 44 A
Example 2):
Boost charge voltage for lead acid batteries (12 cells)= 28.8 V; Io= 1200 W : 28.8 V= 41.7 A

Rectifier
PSR312
User Manual
Page 13 (20)
©2011. ELTEK DEUTSCHLAND GmbH.
Eltek_UM_PSR312_21TE_ E_R6.0
4.4 LED Indications
Functions of front panel LED indicators:
LED Colour Function
green
INPUT OK - Mains input voltage ok
(criteria: 195 VAC ≤Vn ≤265 VAC)
green OUTPUT OK - Vout ok (criteria: Vout ≥97 % of adjusted value)*
red Vout > (criteria: Vout ≥ than adjusted operating threshold)*
red ALARM - Collective alarm**: Vin incorrect, Vout incorrect,
module overtemperature, fan failure, short circuit
*For factory set output voltage threshold values, see section 4.6
**The module is equipped with an isolated signalling contact (normally open contact).
The maximum load is 60 VDC/500 mA. The contact is time-delayed and reacts after approx. 10 sec.
4.5 Internal Monitoring
Monitored values Criteria Function
AC input voltage
I.) Mains input voltage 164 V≤ Vn≤ 195V
Linearly decreases output power.
II.) Mains input voltage <164 V
Module automatically switches off.
III.) Mains input voltage >184 V
Module switches on.
IV.) Mains input voltage >275 V
Module switches off (self-locking). It
must be manually restarted.
DC output voltage Output voltage higher than the
adjusted operating threshold*
Module automatically switches off (self
locking). The unit must be manually
restarted.
Module
temperature Heat sink temperature ≥80 °C
Module automatically switches off. It
automatically switches on when the
heat sink cools down to ≤70 °C.
Cooling fan Cooling fan malfunction
Module automatically switches off.
After 30 sec. the module automatically
tries three times to restart. If this fails,
the module switches off and must be
manually restarted.
Short circuit
Module automatically detects short
circuit operation by the output voltage
value. (criteria: Vout ≤83 % of Vnom)
Module automatically switches off after
3 seconds. After 30 seconds the
module automatically tries to restart
repeatedly.
*For factory set output voltage threshold values, see section 4.6

Rectifier
PSR312
User Manual
Page 14 (20)
©2011. ELTEK DEUTSCHLAND GmbH.
Eltek_UM_PSR312_21TE_ E_R6.0
4.6 Threshold & Default Values
The following table shows the factory set threshold/default values internally stored in the PSR312 unit
(for lead acid battery):
Default values 24 V version
Output voltage Vo (VDC) 27.24
Over voltage V> (V
DC
)
30.00
Current limiting Iconst (A
DC
)
50.00
Note: The threshold/default values can only be changed in combination with an UPC DC controller unit.
If an UPC DC controller unit is controlling the power supply unit through the CAN-Bus, the charge voltage
is completely controlled by the UPC based on its configuration values and momentary charge state (for
example temperature compensation, boost charge, or battery test). That means that the values sent
from the UPC over CAN-Bus have top priority. During CAN-Bus communication the internally stored
values of the rectifier are invalid.
But when the CAN-Bus connection is inactive for more than five seconds (e. g. due to trouble), the
PSR312 automatically switches back to the internally stored default values. In this case it is ensured
that the battery is charged in the float charge mode.
4.7 Default value setting for NiCd batteries
If the rectifier is to be used to charge NiCd batteries the default/threshold values must be set according
to the individual battery type using a CAN dongle and PC software (see section 3.2 “Available Options
and Assembly Equipment”). A specific manual is available on request. For the adjusting range of the
output voltage please see section 8 “Technical Specifications”.
Figure 7) - Screenshot “PC software for CAN dongle”

Rectifier
PSR312
User Manual
Page 15 (20)
©2011. ELTEK DEUTSCHLAND GmbH.
Eltek_UM_PSR312_21TE_ E_R6.0
5. External Functions
If the rectifier works together with an UPC DC controller unit, the following external functions can be
used:
•Compensation of output voltage
•Temperature compensation of charge voltage
•Discharge test
•Boost charge mode
For more information about these functions, read the UPC user manual.
6. Maintenance
In general, the rectifier is maintenance-free. Exclusively the fan is a component consisting of moving
parts. By way of precaution a yearly inspection with following checks is recommended:
•Mechanical/visual inspection
•Removal of dust and dirt, especially on radiator surfaces
•Check for internal dust or humidity
It is recommended to exchange the fan every five years.
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 module.

Rectifier
PSR312
User Manual
Page 16 (20)
©2011. ELTEK DEUTSCHLAND GmbH.
Eltek_UM_PSR312_21TE_ E_R6.0
7. Trouble Shooting
Symptom
Possible reason
Corrective action
No output
voltage
Is mains voltage present?
Check
→
Mains switched to “ON” position?
Check
PSR312 module plugged in securely?
Check
Incorrect polarity or short circuit at the output?
Check
LED V> on?
1.) Switch the module off and on.
2.) Check the settings for
V> (see section 4.6).
Deviation of the
output voltage
Is the unit operating in current limiting mode
due to overload?
Reduce the load
Is the output voltage setting Vout at the DC
controller incorrect?
Adjust output voltage to nominal
values (see section 4.6)
If an external sensor lead is used for the output
voltage, is the connection faultless?
Check
If the unit still does not work even though all checks have been done, contact your sales agent or the
service department of ELTEK DEUTSCHLAND GmbH.

Rectifier
PSR312
User Manual
Page 17 (20)
©2011. ELTEK DEUTSCHLAND GmbH.
Eltek_UM_PSR312_21TE_ E_R6.0
8. Technical Specifications
Type designation
PSR312/24-50
Article code
101-012-148.00
AC input:
Nominal input voltage
230 V
AC
±20 %
Nominal input current
5.8 A
AC
Input frequency range
16⅔ - 60 Hz (+5 %)
Power factor
>0.99 @ P >50 %
Total harmonic distortion
<5 %
Efficiency
≥88 %
Internal input fuse
16 A (6.3 x 32 mm)
DC output:
Nominal output voltage
24 V
DC
Nominal output current
50 A
DC
@ 24 V
Nominal output power
1200 W
Charge characteristic line
IV characteristic according to DIN41772/DIN41773; power limited
Output voltage threshold V>
(factory setting)
30 V
DC
Adjustable output voltage range
21 - 33 V
DC
Default value of the charging
voltage (factory set, 2.27 V/cell;
lead acid battery*)
27.24 V
DC
Output over voltage Vo> (factory
set, 2.5 V/cell; lead acid battery*)
30 V
DC
Output under voltage Vo<
(factory set, 1.7 V/cell; lead acid
battery*)
20.4 V
DC
*Default/threshold values for charging of NiCd batteries are settable using a CAN dongle and PC software.
Voltage ripple / psophometric
acc. to CCITT-A
≤20 mVpp/
≤ 1.2 mV
Dynamic accuracy of the charge
voltage
<3 % Vnom at load changes between 10 % - 90 % - 10 % Inom;
transient time ≤1.5 ms
Short circuit protection
continuous short circuit proof; 1x Inom
Parallel operation
Yes (max. 48 units with DC controller unit UPC); current sharing ≤10 % Inom;
sloping output voltage line (-1 % at 100 % Inom)

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PSR312
User Manual
Page 18 (20)
©2011. ELTEK DEUTSCHLAND GmbH.
Eltek_UM_PSR312_21TE_ E_R6.0
Internal active low-loss
decoupling circuit
Yes, in the negative output line
Internal output fuse
80 A
Standard Features:
LED signalling
Input OK (green), Vo OK (green), Vo> (red), Alarm (red)
Main processor
16Bit Fujitsu
Isolated signalling contact
“Collective alarm”; relay COM/NO/NC, maximum contact load: 60 VDC/500 mA
Communications interface
CAN-Bus, proprietary protocol
Environmental:
Ambient temperature
Operation: -20 °C to +55 °C, storage: -40 °C to +85 °C
Climatic conditions
according to IEC 721-3-3 class 3K3/3Z1/3B1/3C2/3S2/3M2
Max. installation altitude
≤1500 m
Audible noise
<45 dB (A)
Mechanical:
Type of construction
¼ x 19’’, 3U
Cooling
Fan cooling (temperature-controlled, r.p.m.-monitored)
Connector
AC input, DC output and signals: DIN41612-M-connector
Dimensions (W/H/D)
106.3/133/326.5 mm
Minimum installation depth
438 mm (in combination with an assembly set 19’’ sub rack)
Weight
approx. 3.9 kg
Type of enclosure / Protection
class
IP20 (front panel)/1
Colour
Front panel: RAL 7035, neutral, black print RAL 9005
Compliances:
CE conformity
yes
Compliance to safety standards
EN60950-1; VDE0100 T410; VDE0110; EN50178; EN60146
Compliance to EMC standards
EN55022/24 (ITE), class “A“; EN61000-4 T2-5

Rectifier
PSR312
User Manual
Page 19 (20)
©2011. ELTEK DEUTSCHLAND GmbH.
Eltek_UM_PSR312_21TE_ E_R6.0
8.1 Dimensional Drawings:
Figure 8) - Module dimensions

Supplier:

ELTEK DEUTSCHLAND GmbH
BU Industrial
Schillerstraße 16
D-32052 Herford

+ 49 (0) 5221 1708-210
FAX
+ 49 (0) 5221 1708-222
Email
[e-mail]
Internet
http://www.eltek.com
2011. ELTEK DEUTSCHLAND GmbH. All rights reserved.