MICRO-POWER PAP3200 User manual

PAP3200 Datasheet & Manual
Micropower Oy, Joensuunkatu 7 D, FI-24100, Finland
www.micropower.fi
[e-mail], i[email protected] 1 JuRi Rev013 21.5.2020
PAP3200 Datasheet & Manual
Features:
Switched mode power supply/charger
Wide output range 0…320 VDC & 0…200 A
Analog control by an external 0…5VDC
Power failure alarm output
Master-slave connection
Micropower PAP/PAC series is a high power, lightweight, advanced power supply series using modern switching technology.
All units can be used as a power supply or constant voltage battery charger. The output voltage and output current can be
adjusted from 0 to maximum value with internal adjustment trimmers, with an optional 0-5 V analog control or serial bus.
Technical data
Variable
Unit
INPUT DATA
Input phase
-
1 Phase
Input voltage supply
VAC
70…264 (70…230 reduced power)
VDC
70…369
Frequency
Hz
47…63
Input current
A
16
Recommended input fuse
A
16
Input cable area
mm2
3x1,5
Input cable length
m
1,5
Input connector
-
CEE 7/7, moulded
BATTERY CONNECTIONS
Battery cable
mm²
10
Battery cable length
m
3,0
Battery cable connection (in charger)
-
Busbar terminals (available only in 12 V, 24 V, 36 V
and 48 V models, otherwise 2 m cables)
ELECTRIC DATA
Power factor
-
> 0,98
Efficiency (230Vac, 100% load)
%
89
Inrush current (Limited by an NTC resistor)
-
soft start
Output ripple (f < 1 MHz)
%rms
< 1 from maximum output voltage (< 1 MHz
bandwidth). Resolution is defined by an 8-bit or 10-
bit A/D converter of a microcontroller. Measured
using nominal output voltage.
Output Grounding
-
Floating
PROPERTIES
Short circuit protection
-
Electrical current limit
Wrong polarity protection
-
Fuse (Not included in 12 V model)
Overcurrent protection
-
Electrical current limit
Isolation
input-chassis
VAC
1500
input-output
VAC
3750
output-chassis
VAC
700
Standards
safety
-
EN 60950-1:2001
LIMITATIONS
Conformity can be limited depending on the end
application output control method or unit mechanical
structure.
Note: If the charger’s rated output voltage is higher than
60 VDC the charger does not fulfil 1.2.8.7 (Safety Extra Low
Voltage). Standard parts (2.1 Protection against electric
shock) must be considered in installation.
EN60335-2-29:2004
EN60335-1:2002 + A11:2004 + A1:2004 + A12:2006
+ A2:2006

Micropower Oy, Joensuunkatu 7 D, FI-24100, Finland
www.micropower.fi
[e-mail], i[email protected] 2
EN50366:2003 + A1:2006
LIMITATIONS
Conformity can be limited depending on the end
application output control method or unit mechanical
structure.
Note: If the charger’s rated output voltage is higher than
36 V it doesn’t fulfil article 10.101 (“The no-load DC output
voltage shall not exceed 42.4 V”).
EMC
-
EN55032 Class B, Application must be discussed in
detail
Protection class
mechanical
IP
IP20 metal enclosure
electrical
-
Class 1
Mounting
-
Wall, bench
Cooling
-
Temperature controlled fan
Operating temp range
°C
0…+40 (fixed assembly)
Maximum ambient temperature
°C
+55
Temperature protection
-
Processor controlled on/off
HMI
-
LED
CHARGER DIMENSIONS
Charger weight excl. cables
kg
7,10
Outer dimensions
W x H x D
mm
400 x 250 x 80
Power supply models
Master-slave connection (24V models as type designation example)
Master units
Slave units
PAP3200/24 trimmer adjustment (RS-232 bus out)
PAP3200/24S (TTL control bus in/out)
PAP3200/24AI analog control (RS-232 bus out)
PAP3200/24SH (Slave unit with relay, RS-232 bus in/out
1,5 m cable set for master slave connection included in slave unit. Cable connected to J101 of the slave unit, other ends open.
•Cyclic battery chargers including charging algorithms
•Temperature compensation, external LED, external ON-OFF
Model
Input voltage range *)
Nominal
output
voltage
Voltage
setting range
Current
setting
range
Maximum
output
power
Installation/dimensions
(width x height x depth)
PAP3200/12
70-264 Vac/70-369 VDC
12 Vdc
0-18 Vdc
0-200 A
3200 W
Wall /bench 400x250x80 mm
PAP3200/24
70-264 Vac/70-369 VDC
24 Vdc
0-36 Vdc
0-127 A
3200 W
Wall /bench 400x250x80 mm
PAP3200/36
70-264 Vac/70-369 VDC
36 Vdc
0-54 Vdc
0-95,5 A
3200 W
Wall /bench 400x250x80 mm
PAP3200/48
70-264 Vac/70-369 VDC
48 Vdc
0-72 Vdc
0-64 A
3200 W
Wall /bench 400x250x80 mm
PAP3200/72
70-264 Vac/70-369 VDC
72 Vdc
0-108 Vdc
0-42 A
3200 W
Wall /bench 400x250x80 mm
PAP3200/110
70-264 Vac/70-369 VDC
110 Vdc
0-165 Vdc
0-25 A
3200 W
Wall /bench 400x250x80 mm
PAP3200/160
70-264 Vac/70-369 VDC
160 Vdc
0-240 Vdc
0-20 A
3200 W
Wall /bench 400x250x80 mm
PAP3200/220
70-264 Vac/70-369 VDC
220 Vdc
0-320 Vdc
0-14 A
3200 W
Wall /bench 400x250x80 mm
*) Reduced power 70-230 VAC / 70-260 VDC, see Figure 2
Intelligent optional models (24V models as type designation example)
Model
Option description
Cable set
PAP3200/24AI
Analog control by external 0–5 VDC voltage.
Control signal isolated from power supply input and output.
1,5 m, modular connector
(other ends open)
PAP3200/24H
Power failure alarm relay. Indicates input and module failures.
2 m cable (other ends open)
PAP3200/24AIH
Analog control and power failure relay
Analog + relay cables
Customized versions on request

Micropower Oy, Joensuunkatu 7 D, FI-24100, Finland
www.micropower.fi
[e-mail], i[email protected] 3
Characteristics
Dimensions
1
2
V
1
0
1
8
2
0
0
(
V
)
(
A
)
1
4
6
1
0
0
2
1
8
V
54V
36V
30
60
40 100
(V)
(A)
24V
20
40
50 100
(V)
(A)
36V
48V
40
80
5030
(V)
(A)
72V
60
20
10
108V
72V
60
120
20 40
(V)
(A)
165V
110V
100
180
10 20
(V)
(A)
240V
160V
200
250
10 15
(V)
(A)
100
5 20
320V
220V
200
300
10 15
(V)
(A)
100
5
Figure 1. Typical output voltage-current characteristics.
Figure 2. Typical output power - Input voltage characteristic.

Micropower Oy, Joensuunkatu 7 D, FI-24100, Finland
www.micropower.fi
[e-mail], i[email protected] 4
Installation
The location must be dry, dust-free and indoors. Equipment must be connected to an earthed input socket outlet. For
unplugging the unit, make sure the wall socket is near and in an easy access area. The acceptable full power temperature
range is 0°C…+40°C. The thermal protection will cause the unit to power down at too high an operating temperature. The
power supply is not waterproof. Keep it dry and away from areas with high humidity to avoid the risk of electrical shock and
damage to the charger.
Wall mounting
The power supply can be mounted to the wall with the two mounting holes on
both ends of the power supply unit as shown in the figure.
It is recommended that the power supply is mounted vertically on to the wall.
It is suitable for mounting on a concrete or other non-combustible surface
only.
Leave at least 10 cm free space at the cooling fan end and at both sides of the
power supply to ensure sufficient ventilation.
When used as a charger, the charging process generates explosive hydrogen
gas. Install the power supply as far away from the battery as possible to
prevent hydrogen gases from entering the charger. Keep the area well
ventilated. Never use an open flame or equipment that produces sparks close to the power supply and battery.
Charging operation
1. Ensure that the power supply is switched off and that the environment meets the conditions as described in the
previous section.
2. Connect the output cables to the load / battery terminals: + cable to the + terminal and –cable to the –terminal
3. Turn the power on by turning the switch to position 1.
4. During normal power supply operation / charging process, the STATUS LED is continuously orange.
5. To avoid sparking, turn off the power supply before disconnecting the cables.
DC Input connection
The power supply input cable is connected as follows:
L negative or positive DC supply input
N positive or negative DC supply input
PE protective earth
Output voltage and current limit adjustment
Trimmer or analog control adjustable modules, type example PAP3200/24 or PAP3200/24AI:
The output voltage and output current limit of the power supply can be adjusted as follows:
•Trimmer adjustable models: with the multi-turn potentiometers accessible from the top cover.
•Analog controllable models by an external 0-5 VDC voltage. See detailed description.
Both voltage and current can be adjusted from zero to the maximum value. Maximum 3200 W / 3000 W output power is
available within the adjustment range.
Temperature compensated models, type example PAP3200/24T:
The power supply includes 16 pre-programmed output voltages that are set by the code switch. See the setting table for
this unit. Any of these 16 different voltage settings can be taken in use and additionally be adjusted within ±5% using the
trimmer on the top cover. See the instructions for choosing the programmed voltage and the fine-tune adjustment.
LED
STATUS LED indicates different phases during the charging process. In normal power supply operation,an orange led
indicates a healthy output voltage.
Stand-by LED is ON when input network (AC) is connected, but the power supply’s output is switched OFF by the switch on
top cover. Stand-by LED goes OFF when the power supply’s output is switched ON.

Micropower Oy, Joensuunkatu 7 D, FI-24100, Finland
www.micropower.fi
[e-mail], i[email protected] 5
Overcurrent protection
The output of the power supply is protected against overcurrent and short circuits by an automatic, self-resetting electronic
current limiter.
Series/parallel connection
Parallel operation: No restrictions, passive load sharing
Series operation: Up to 500 V total voltage. For more information about use with an AI or S option, ask the manufacturer.
Warnings
Dangerous voltages, capable of causing death are present in the power supply. Do not remove the cover. There are no
operator serviceable parts inside the unit. Refer servicing to qualified service personnel only.
This device is not meant to be used by children or people whose physical, sensory or mental attributes or lack of experience
and knowledge prevent them from using the device safely unless a person responsible for their safety supervises them or has
instructed them how to use the device.
It must be ensured that children do not play with the device.
Charge lithium batteries only with appropriate BMS (Battery Management System).
Feature selection table
Trimmer
Analog
Relay
Bus out
Bus in
Temp
Code switch
External ON/OFF
External LED
Trimmer adjustment
•
•
•
•
•
Analog control (isolated)
•
•
•
•
•
Alarm relay
•
•
•
•
•
•
•
•
Bus Out (TTL control to slave)
•
•
•
•
•
•
•
•
Bus In
•
•
•
•
•
•
Temp. compensation
•
•
•
•
•
•
•
External ON/OFF
•
•
•
•
•
•
•
•
External LED
•
•
•
•
•
•
•
•
Customized charging algorithm
chargers with code switch
•
•
•
•
•
•
•

Micropower Oy, Joensuunkatu 7 D, FI-24100, Finland
www.micropower.fi
[e-mail], i[email protected] 6
Connectors J101 and J69 for optional features
Optional relay alarm, temp. comp., Ext ON-OFF, Ext LED and serial bus connections
Screw terminals connector J101
1. Alarm relay (common) *)
2. Alarm relay (nc) *)
3. Alarm relay (no) *)
4. Aux. +12.5 V **)
5. Aux. –*) **)
6. Serial bus out *)
7. Serial bus out *)
8. Serial bus in *)
9. Serial bus in *)
10. Not connected
11. Temperature sensor +*)
12. Temperature sensor –*)
13. NOT IN USE
14. NOT IN USE
*) These connectors are floating/isolated from output
**) Disabled after 06/20. Contact manufacturer for more
information
Connector J69 option
External LED
External ON / OFF
WARNING: External LED and External ON / OFF
contact is NOT GALVANIC ISOLATED!
Note: Only one of these features possible at a time.
Connector J69
Pin
External LED
External ON/OFF
1
LED Green
NC
2
Ground
Ground
3
LED Red
NC
4
NC
ON/OFF
Alarm relay models
On models with an alarm relay, the internal alarm relay output indicates whether the output voltage is healthy or not and is
connected to terminals 1…3 of connector J101 as shown below. The alarm signal is activated in case of an AC failure or
charger failure. Both normally closed signals and normally open contacts are available.
Terminal 4 is an auxiliary control voltage for an external relay. (Feature disabled after 06/20)
Terminal 5 is the ground connection. (Feature disabled after 06/20)
Note: Auxiliary control voltage feature disabled after 06/20. Contact manufacturer for more information.
Internal alarm relay
Isolation: Technical data:
Output to case: 500 V 0,5 A@24 VDC
Output to GND: 120 V 0,5 A@120 VAC
Common is connected to NC when the power is switched off.
Common is connected to NO when the power is switched on.

Micropower Oy, Joensuunkatu 7 D, FI-24100, Finland
www.micropower.fi
[e-mail], i[email protected] 7
Optional isolated analog control
The optional isolated analog control input J1 allows full control of the output current and voltages and it provides the
measured values for both. +5 VDC supply power is available for the supply of the control logic. The isolated analog control
card is connected to the AMP Modular 6 connector J1.
Pin configuration J1
1. Ground
2. Current control input
3. Voltage control input
4. Measured current value
5. Measured voltage value
6. +5 V (max 20 mA) output
Controlling the analog card
All control voltages must be between 0 and +5 V. Higher voltages are not allowed. The control logic is positive, so that a +5
VDC control voltage gives a maximum value from the power supply, while 0 V means minimum output. As soon the control
connector is unplugged from the modular connector, the power supply is reset to the minimum output values.
The measured values can be read from the measurement signals. The measured values are scaled equal to the target values.
If the power supply is set to the voltage reference, the measured value must be equal to the target. The same counts for the
current control and its measured value.
The modular connector is isolated from the output of the power supply. This enables the possibility to parallel connect
several power supplies maintaining equal voltages. For more information on connecting power outputs in serial and using an
analog card, ask the manufacturer. See also limitations to standards on page 1.
Connection example using the internal +5 VDC supply and external potentiometers.
The +5 V can be used as a supply for external circuits. The circuit shown to the left
lets the power supply operate as a potentiometer-controlled device. It is important
to keep in mind that the +5 V output may not be loaded more than 20 mA, otherwise
proper operation cannot be guaranteed.
Calibration instructions
The manufacturer calibrates the analog control interface. Recalibration is not necessary if the analog control card is used
between 0 and +5 V. A qualified person is required for recalibration of the device. Calibration is done using a pair of multi-
meters and the schematic example given above. The calibration procedure is as follows.
1. Adjust the potentiometers to 5 V for the voltage and 2 V for the current targets. Connect a voltage meter to the
power supply output. Adjust the ‘Voltage Set’ potentiometer to the maximum output voltage.
2. Connect a voltage meter to pin 5 of the modular connector J1. Adjust the trimmer ‘Voltage Meas.’ so that the digital
voltage meter always shows the same value as pin 3 (target voltage).
3. Connect a current meter to the output so that the output is shorted. Adjust the current target potentiometer to +5
V. Adjust the ‘Current Set’ trimmer to the device maximum output current (see specifications for the device). Make
sure that the current meter has the correct measurement range. Never exceed the maximum current value for the
device. Contact the distributor in case the maximum current is not known.
4. Measure the voltage at pin 4 of the modular connector J1. Adjust using the ‘Current Meas.’ to the same voltage level
as on pin 2 (target current).
Figure 3. Pin configuration of the modular connector J1.

Micropower Oy, Joensuunkatu 7 D, FI-24100, Finland
www.micropower.fi
[e-mail], i[email protected] 8
Temperature compensation models (ex. PAP3200/24T)
The temperature compensation wire enables the charger to adjust the output voltage in accordance with the battery voltage
and changes in temperature. The resolution is defined by an 8-bit A/D converter of a microcontroller. The temperature
compensation wire and battery voltage sense cables are connected to connector J101 terminals 11…14 (see above). Connect
the cable to the battery as shown in the illustration. The temperature sensor is either glued 10 cm below the top edge of the
battery or fixed to the cable tag connected to the minus terminal of the battery.
Optional master-slave connection
Using a master power supply together with a slave unit.
The master unit can be either a trimmer adjustable model (e.g. PAP3200/24) or an analog controllable model (e.g.
PAP3200/24AI). The slave unit is a separate unit without any adjustment possibilities, e.g. type PAP3200/24S or
PAP3200/24SH, which has an alarm relay output.
If more current is needed power outputs can be connected in parallel. Slave units are controlled via the digital bus. The
communication bus OUT terminal is isolated, so that the bus outputs and input can be connected in chain. Slave unit voltage
and current setting accuracy is defined by an 8-bit A/D converter of a microcontroller. For more information about
connecting power outputs in serial and using digital communication, ask the manufacturer. See also limitations to standards
on page 1.
Serial bus connection
The bus cable is connected from the master unit (J101) to the
slave unit (J101).
J101 has the following terminal configuration:
Pin 7 of the master unit is connected to pin 9 of the slave unit.
Pin 6 of the master unit is connected to pin 8 of the slave unit.