Polyamp PC1400 User manual

PC1000-PC2000 INSTALLATION MANUAL
10275-8.doc
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Page 1 (14)
PC1000 / PC1400 /PC2000
Installation manual

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Warranty
All Polyamp DC/DC converters are warranted against defective material and
workmanship. This warranty is valid for 24 months from the date of delivery.
We will repair or replace products which prove to be defective during the
warranty period. The warranty is valid only if the converter is used within
specification.
Manual
This manual is as complete and actual as possible at the time of printing.
However, the information may have been updated since then. Polyamp AB
reserves the right to make changes in this manual without notice.
The exclamation point within an equilateral triangle is intended to alert the user to presence of
important operating and maintenance instructions in the literature accompanying
The lightning flash with arrowhead, within an equilateral triangle, is intended to alert the user to
presence of un-insulated ”dangerous voltage” within the products enclosure that may be of sufficient
magnitude to constitute a risk of electric shock to persons
Caution!
To prevent the risk of electric shock, do not open enclosure. No serviceable parts inside. Refer
servicing to qualified service personnel only

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CONTENTS
1 BEFORE INSTALLATION...............................................................................................................................4
2 INSTALLATION................................................................................................................................................5
3 PARALLEL CONNECTION ............................................................................................................................6
3.1 SERIES DIODE ON THE OUTPUT ........................................................................................................................6
3.2 CURRENT SHARING .........................................................................................................................................6
3.3 VOLTAGE ADJUSTMENT WITH CURRENT SHARING ...........................................................................................7
4 MULTIPLE LOADS AT THE OUTPUT.........................................................................................................7
4.1 SHORT-CIRCUITS.............................................................................................................................................7
5 ALARM ...............................................................................................................................................................8
5.1 OVER AND UNDER VOLTAGE ALARM ...............................................................................................................8
5.2 OVER TEMPERATURE.......................................................................................................................................8
6 SENSE..................................................................................................................................................................9
6.1 EXTERNAL SENSE............................................................................................................................................9
7 INHIBIT ..............................................................................................................................................................9
8 OUTPUT OVER VOLTAGE PROTECTION.................................................................................................9
9 INRUSH CURRENT LIMIT...........................................................................................................................10
10 ISOLATION VOLTAGE TEST....................................................................................................................10
10.1 DC ISOLATION TEST OUTPUT TO CASE.........................................................................................................10
10.2 DC ISOLATION TEST INPUT TO OUTPUT AND INPUT TO CASE ........................................................................10
10.3 AC ISOLATION TEST INPUT TO OUTPUT AND INPUT TO CASE ........................................................................10
11 MAINTENANCE............................................................................................................................................11
12 TROUBLE SHOOTING................................................................................................................................11
12.1 THERE IS NO OUTPUT VOLTAGE...................................................................................................................11
12.2 THE INPUT FUSE BLOWS WHEN THE INPUT IS CONNECTED............................................................................11
12.3 THE CONVERTER STARTS AND STOPS REPEATEDLY......................................................................................11
12.4 THE CONVERTER STOPS AFTER SEVERAL HOURS..........................................................................................11
12.5 FAULT REPORT............................................................................................................................................12

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1 Before installation
Before installation we recommend that you
read this and next section of this manual. If any
problem occurs, consult 12 Trouble shooting.
If the converter includes a fan, please notice 11
Maintenance.
On the front panel label the following is
displayed: Converter type, input voltage range,
nominal output voltage, serial number, options
and article number. The converter type name
consists of model name PC1000, PC1400 or
PC2000 followed by input code and output
voltage. Two examples:
•Type: “PC2000 110/48” has input code “110”
and nominal output voltage 48Vd.c.
•”Type: “PC1000 24/24” has input code “24”
and nominal output voltage 24Vd.c.
If you intend to parallel connect the output,
please check that option C is supplied. It
means series diode on output.
Input, output and case are galvanically
separated from each other. You can thus
choose how you want the system connected.
The output can be connected with any pole to
protective earth or as a floating output with
max ±150V to the protective earth. It means
that maximum 3 units can be put in series.
The electrical safety system is a class I, which
means that protective earth has to be
connected. The 110 and 220 input code models
can also be used as class II equipment without
protective earth. Although units installed in
dirty environments shall be connected to
protective earth.
On 110 and 220 input code the feeding system
can be defined as Primary circuit (Max
250Va.c.) and as Secondary circuit.
On 24 and 48 input code the feeding system
can be defined as Secondary circuit voltage,
and SELV voltage.
The cables used for input and output feeding
shall be dimensioned to fit the fuse rating and
continuous current as well as intended ambient
temperature range and insulations demand due
to the voltage used.
The input is protected against reverse polarity
by combination circuit with inrush current
limit circuit. If reverse voltage occurs at
installation the converter will not start. The
reverse voltage will not cause damage to the
unit.
The input shall be fused with an approved fuse
with high breaking capacity. We recommend
following fuses ratings and fuses. Please note
that in installation class I with protective earth,
the fuse shall be on the pole not in connection
with the protective earth.
PC1000 input fuses
Input voltage code Time delay fuse
24 63 A, Siemens 3NA3 022
48 35 A, Siemens 3NA3 014
110 16 A, Siemens 3NA3 005
220 10 A, Siemens 3NA3 003
PC1400 input fuses
Input voltage code Time delay fuse
48 50 A, Siemens 3NA3 020
110 20 A, Siemens 3NA3 007
220 10 A, Siemens 3NA3 003
PC2000 input fuses
Input voltage code Time delay fuse
48 63 A, Siemens 3NA3 022
110 25 A Siemens 3NA3 010
220 16 A, Siemens 3NA3 005
Table 1. Recommended input fuses.
There are two reasons we do not include the
fuse.
1. DC-networks should be fused at the
distribution point to protect the cable.
2. Different applications require different
types of fuses.
To meet the EMC specifications in the
enclosed “declaration of conformity” use
twisted-pairs for connecting input, output,
alarm, inhibit and voltage sense. Shielded
cables are not necessary.
If the converter is mounted in an electric
vehicle, an external series diode on the input is
recommended. Please contact your Polyamp
dealer.
If the converter supplies a DC-motor, we
recommend an external parallel diode at the
motor poles to protect against reverse voltages.

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For the disconnection ability, an external
disconnection device, which is able to
disconnect both polarities, shall be
incorporated with the input power supply cord.
The disconnection device must be properly
labelled and easy accessible.
2 Installation
The converter is supplied with mounting
brackets intended for 19”-rack mounting. The
PC1000 converter is convection cooled and in
order to get sufficient cooling there shall be a
minimum of >30 mm space around the unit
except for the sides. PC1000 is only intended
for horizontal mounting.
PC1400 and PC2000 use an internal fan and
need therefore minimum >30mm space around
the unit except for the sides. The cooling fins
at the rear shall never be covered. The fan
cooled versions can be mounted in any
direction. For mounting plate or chassis
mounting please use the L220-1 brackets.
Note that the expected life of the converter is
dependant on converter temperature. For every
10°C that the temperature is lowered the
expected life is approximately doubled. It is
therefore crucial to cater for good ventilation
and if possible to reduce ambient temperature.
To meet the EMC specifications in the
enclosed “declaration of conformity” use
twisted-pairs for connecting input, output,
alarm, inhibit and voltage sense. Shielded
cables are not necessary.
On 24 and 48 input code the input cables are
individual. On 110 and 220 input code use a
cable cord with external approved insulation
for the Primary circuit and Secondary
hazardous voltage rating.
1. Remove front cover with 4 screws.
On 24 and 48 inputs separate inlets. On 110
and 220 input code put the cable into the
cable inlet and fix it with the cable clamp
after connection. See Figure 1. Cable
connection for 24V and 48V inputs. And Figure
2. Cable connection for 110V and 220V inputs.
2. First connect protective earth in connector
K3 marked with an earth symbol. Then
connect the input.
3. Connect the output. The converter output is
short-circuit proof by a constant current
limit which works unlimited in time.
Therefore there is no need to fuse the load
(unless you use multiple loads, see below).
The current limit is fixed to 105% of
nominal output current.
•If the converter is to be connected in
parallel at the output or if you use
current sharing for equal current sharing,
please consult 3 Parallel connection on
page 6.
•If you intend to use multiple loads,
please consult 4 Multiple loads at the
output on page 7.
•If you intend to use the alarm, please
consult 5 Alarm on page 8.
•If you intend to use output voltage
sense, please consult 6 Sense on page 9.
•If you intend to use inhibit, please
consult 7Inhibit on page 9.
4. Mount the front cover
5. Start the converter with your external input
disconnection device.
•The output voltage can be adjusted
+10% to -5% of nominal output voltage
with the potentiometer marked V.ADJ
on the front panel. Clockwise turn
increases the output voltage. The
potentiometer has 15 turns. If you are
using current sharing, the procedure of
adjusting the output voltage is described
in 3.3 Voltage adjustment with current
sharing on page 7.
6. When the converter is to be disconnected,
switch-off the input voltage with the
disconnecting unit. Disconnect the input
cables first, then output and last the
protective case connection.

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Figure 1. Cable connection for 24V and 48V
inputs.
Figure 2. Cable connection for 110V and 220V
inputs.
3 Parallel connection
If a redundant power supply system is
requested, two or more converters can be
connected in parallel. To achieve redundancy
the number of converters must be dimensioned
to carry the whole load even if one converter is
faulty. The unit you will install must be
equipped with option C series diode, please
check on the type code label.
You should not use external sense when there
are several units connected in parallel on the
output.
3.1 Series diode on the output
The series diode protects the converter output
from external voltage sources. A series diode is
necessary if the output is connected in parallel
with another power supply or if you require
redundant operation. If a converter breaks
down with an internal short-circuit on the
output and other converters are connected in
parallel on the output, the broken unit will
short-circuit the others if the series diode is not
used. This might cause excessive heat or even
fire in the faulty unit.
If the series diode is used, the alarm relay will
switch to “ALARM” on the faulty unit if one
converter breaks down in a redundant power
supply system. Otherwise there will be no
alarm indication from a faulty converter unless
all units are in current limit and the output
voltage drops 10% below nominal output
voltage.
On models with option C the output power of
the converter is derated. See data sheet.
•On 24Vd.c. output by 10%.
•On 48Vd.c. output by 5%.
Do not forget to fuse the inputs separately to
achieve redundancy.
3.2 Current sharing
All models include the automatic current
sharing feature, which we recommend to use in
parallel configuration. A maximum of 10 units
can be connected in parallel.
If more than 10 units should be connected in
parallel, contact Polyamp.
Connect a cable (0.25-1.0mm2) with a
maximum length of 3.0m between the
“CURRENT SHARE” connectors of all units.
The converter with the highest output voltage
will then automatically become “current
master”. This converter will then run with a
few percent higher output current than the
others. If the master converter for some reason
breaks down, another converter automatically
becomes “current master”.
To achieve good power sharing, the voltage
drop between the minus poles must be kept as
low as possible, see Figure 3. It is important
that all cables between the converters and the

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distribution point has the same length. The
plus poles can either be connected as in Figure
3or have separate cables to the load.
At light load (if the total load is less than 5%
of the total rated power) the yellow “CUR.
SHARE” LED might flicker between the units.
As the load changes different units “CUR.
SHARE” LED might be lit. All this is normal.
During normal operation in a paralleled system
the “CUR. SHARE” LED is lit on at least one
unit, but it may be lit on some or all of the
paralleled units. The purpose of the “CUR.
SHARE” LED is not to indicate if current
share is working or not, but to facilitate the
voltage adjustment, see below.
Parallel output connection of several
converters powered by two input voltage
sources. See Figure 9.
Figure 3. Current share connection with series
diode.
3.3 Voltage adjustment with current
sharing
The converters must be running with 5% of
nom. load or more, and the “current share”
must be connected. If each converter output
voltage is adjusted to the same voltage, which
they are at delivery, the yellow “CUR.
SHARE” LED might be lit on most units.
To increase the output voltage:
1. Choose a unit where the “CUR. SHARE”
LED is lit. Turn the V.ADJ potentiometer
clockwise until you reach your desired
output voltage.
2. The other units should now also be adjusted
to approximately the same output voltage,
otherwise the output voltage will drop if the
master converter breaks down. Turn the
V.ADJ potentiometer slowly clockwise on
the other units until the “CUR. SHARE”
LED is lit or almost lit.
To decrease the output voltage:
1. Turn the V.ADJ potentiometer
approximately one (1) turn counter
clockwise on all converters but one. This
will not affect the output voltage yet.
2. Turn the V.ADJ potentiometer counter
clockwise on the remaining converter (if
your load current exceeds 5% of the total
rated current, this should be the only unit
with the “CUR. SHARE” LED lit) until you
reach the output voltage you desire. (If you
turn more than one (1) turn counter
clockwise you must repeat from step 1).
3. The other units should now also be adjusted
to approximately the same output voltage.
Otherwise the output voltage will drop if
the master converter breaks down. Turn
clockwise on the V.ADJ potentiometer on
the other units slowly until the “CUR.
SHARE” LED is lit or almost lit.
4 Multiple loads at the output
If you are using several loads, we recommend
fusing them separately with fast acting fuses
on the positive output branch. Some
considerations regarding short-circuits should
be taken. See below.
4.1 Short-circuits
1. If there is a short-circuit in one branch and
the total current in all branches does not
exceed 105% of the nominal current of the
converter (see label on front panel), the
output voltage will not be affected. The
time for the fuse to blow can be calculated
from the data sheet of the fuse if you know
the short-circuit current trough the fuse.
2. If there is a short-circuit in one branch and
the total current in all branches does exceed
105% of the nominal current of the
converter, the output voltage will drop until
the fuse is blown. Depending on the
impedance of the short-circuit (whether it is
abrupt or merely an overload) and the
resistance of the load cables, the effects of a
short-circuit will vary.

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Long cables reduce short-circuit currents,
resulting in longer delay until the fuse is
blown and hence an increased voltage dip.
Light overload does not necessarily result
in a blown fuse.
To reduce the voltage drop at short-circuit
and if any branch has more than
approximately 30% of the total output
current of the converter, a large external
capacitor is recommended. Such a capacitor
will supply the peak current needed to blow
the fuse, see Figure 4. To calculate the
capacitor needed, use the following
formula:
C = 1.2 x ( ISx Δt ) / ΔU
1.2 = Safety margin.
IS= Short-circuit current through the
fuse.
Δt = Time before the fuse blows (see
data sheet on the fuse).
ΔU = Acceptable voltage dip before the
fuse blows.
Example
You have a 5A fuse with fast characteristic
and the short-circuit current is 50A. The
data sheet gives you that Δt = 10ms. The
output voltage is 24V, and you can accept
10% voltage drop => ΔU=24 x 0.1= 2.4V.
The capacitance you need:
C = 1.2 x ( ISx Δt ) / ΔU = 1.2 x 50 x 0.01 /
2.4 = 250,000µF
Choose a capacitance with a rated voltage
of at least 115% of nominal output voltage
of the converter.
Repeat this calculation for all branches and
choose the highest capacitance value.
3. It is sometimes difficult to estimate the
short-circuit current when the nature of a
fault is unknown. In this case a voltage dip
might appear under some short-circuit
conditions even with a large capacitor
present. If a voltage dip is critical in one
branch it is recommended to use a separate
DC/DC converter supplying this branch.
F1
DC
DC
F2
F3
F4
C
20
21
Figure 4. Connecting multiple loads.
5 Alarm
The alarm relay switches to “ALARM” state if:
•The output voltage is not within +15% /-
10% of nominal output voltage.
•The converter is overheated.
Otherwise the relay contact is in the position
“NORMAL” as printed on the front panel.
The alarm relay can be connected in two ways:
1. Normally Open (NO).
i. Connect twisted-pair (0.25mm2-
1.5mm2) from centre pin of the
removable alarm connector and
connector pin marked “ALARM”.
2. Normally Closed (NC).
i. Connect twisted-pair (0.25mm2-
1.5mm2) from centre pin of the
removable alarm connector and
connector pin marked “NORMAL”.
The relay is isolated 2500Vd.c. from input,
output and case. The relay can switch
maximum 30V/5A (a.c. and d.c. values).
5.1 Over and under voltage alarm
The alarm relay switches to alarm and the
”REG NOT OK” LED is lit when the output
voltage is approximately 15% higher or 10%
lower than nominal output voltage.
5.2 Over temperature
All models have thermal protection. If the
converter is overheated it shut down the output
till the operating temperature has decreased.
The “OVER TEMP” LED is lit and the alarm
relay is set to alarm. This will not occur in
normal operation with an ambient temperature

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below +55°C when the unit has sufficient
cooling. The converter type PC1000 is
convection cooled and there should be a
minimum of 30-50mm of free space at upper
and lower parts of the converter. If this is not
possible, we recommend the use of an external
fan.
Note that the expected life of the converter is
dependant on converter temperature. For every
10°C that the temperature is decreased the
expected life is approximately doubled. It is
therefore crucial to cater for good ventilation
and if possible reduce ambient temperature.
6 Sense
6.1 External sense
Without external sense connected the output
regulation is 0.5%. External sense is used
when voltage regulation at the load is critical.
The converter regulates the voltage at the load
and not at the output of the converter and does
thereby compensate for voltage drop in the
cables between the converter and the load. The
maximum voltage compensation is 5% of
nominal output voltage. The regulation
accuracy is 0.2% with sense.
Do not disconnect the negative power
connection from the converter to the load
before the positive, when the converter is
running and external sense is used. This might
damage the converter and it is also not
advisable for your own protection to make
adjustments in the installation with voltage
applied.
1. Connect a twisted-pair (0.25mm2-1.5mm2)
between the sense terminals of the
converter and the load, see Figure 5. The
sense leads and the power cables shall be of
approximately the same length and drawn
as close to each other as possible.Beware
of correct polarity!
Figure 5. External sense!
7 Inhibit
The converter is shut-down if the inhibit input
is short-circuited by a relay or an electrical
switch. The current through the short-circuit is
20mA. Note that there is no electrical isolation
between the “inhibit” and the output.
1. Use a twisted-pair (0.25mm2-1.5mm2) with
a maximum length of 3.0m for connection
of the “inhibit”.
8 Output over voltage protection
All models are equipped with an internal
output over voltage protection circuit (OVP). It
consists of an additional voltage regulator
operating in parallel with the main regulator.
The output voltage is limited to approximately
15% above the nominal output voltage. As
long as the OVP circuit is active the alarm
relay is set to ”ALARM” state and the red
”REG NOT OK” LED is lit.

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9 Inrush current limit
All models are equipped with an inrush current
limit feature. The input capacitors are charged
through a resistor to reduce the input current
during start up. When the converter starts this
resistor is shunted by power relay.
All models have a “slow start” feature. To
reduce input current during start up the output
capacitors are charged “slowly”
(approximately 0.1s).
10 Isolation voltage test
Each converter has been isolation tested in
factory before deliveries see Table 2.
Warning1. An isolation test shall only be
performed by personnel aware of the
dangers and hazards of the test.
Warning 2. Consecutive insulation test will
damage the Y-capacitors provoking less
EMC performance.
Input
code Isolation
In/out,
In/case
Output
voltage
Vd.c.
Isolation
out/case
24, 48,
72, 2.5kVd.c. 24, 48 2.5kVd.c.
110, 220, 3kVa.c. 24, 48 2.5kVd.c.
Table 2. Isolation voltages on different
converters.
10.1 DC isolation test output to case
1. Disconnect all cables from the converter.
2. Connect the input terminals of the converter
to case.
3. Connect the output terminals together.
Connect your isolation tester between
output and case. See Figure 6.
4. Raise the voltage of the isolation tester
from 0 to 2500Vd.c. Check that the leakage
current does not exceed 5µA.
The voltage should not be applied for more
than a few seconds or the Y-capacitors
might be damaged.
5. Turn off the isolation tester and discharge
the test voltage with a 10 MΩresistor
between output and case.
Figure 6. Output to case isolation voltage test.
10.2 DC isolation test input to output
and input to case
1. Disconnect all cables from the converter.
2. Connect the output terminals of the
converter to case.
3. Connect the input terminals together.
4. Connect your isolation tester between input
and case. See Figure 7. Raise the voltage of
the isolation tester from 0 to 2500Vd.c.
Check that the leakage current does not
exceed 5µA. The voltage should not be
applied for more than a few seconds or the
Y-capacitors might be damaged.
5. Turn off the isolation tester and discharge
the test voltage with a 10 MΩresistor
between input and case.
Figure 7. Input to output and input to case
isolation voltage test.
10.3 AC isolation test input to output
and input to case
You can also test 3000Va.c. for one (1) minute
between input to output and case on units with
input codes 110, 220.
Beware of the rather high capacitive earth
currents (about 100mA) that will occur
during this test.
If your isolation test equipment cannot supply
this current, you can perform a DC isolation
test with 4300Vd.c. Follow the instructions in
10.2 DC isolation test input to output and
input to case,but test with 4300Vd.c. instead

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of 2500Vd.c. The leakage current should not
exceed 5µA.
AC isolation test:
1. Disconnect all cables from the converter.
2. Connect the output terminals of the
converter to case. See Figure 7.
3. Connect the input terminals together.
4. Connect your isolation tester between input
and case. See Figure 7. Raise the voltage of
the isolation tester from 0 to 3000Va.c. The
voltage should not be applied for more than
one (1) minute or the Y-capacitors might be
damaged.
5. Turn off the isolation tester and discharge
the test voltage with a 10 MΩresistor
between input and case.
11 Maintenance
A converter that includes a fan has to be
subject to maintenance. The fan needs to be
replaced by a new one every 5 year. Instruction
how to replace it, see Figure 8.
The fan has article. no. 203330 and can be
ordered from Polyamp AB, address see below.
12 Trouble shooting
12.1 There is no output voltage
1. Check that the input fuse is not broken.
2. Check that the input voltage polarity is
correct.
3. Check that the input voltage is within the
specified limits, see front label.
4. If only the red ”REG NOT OK” LED is lit,
the converter may be in current limit due to
excessive output current or an external
short-circuit on the output.
•Disconnect the input.
•Disconnect the load.
•Connect the input again and measure the
output voltage.
If the converter now starts the load was too
heavy or there was a short-circuit.
•If there is an external short-circuit,
remove it.
•If the load is too large decrease the load
or consult your Polyamp dealer.
5. Check that the “INHIBIT” input is not
short-circuited. See 7 Inhibit on page 9.
6. Check that the “SENSE” is connected
correctly. See 6 Sense on page 9.
7. The unit is broken. Contact your Polyamp
dealer.
12.2 The input fuse blows when the
input is connected
1. Check that the input voltage polarity is
correct.
2. Check that the input fuse is of time delay
type and with correct current rating. See
Table 1. All models have “inrush current
limit”. Fore further information consult 9
Inrush current limit on page 10.
3. The unit is broken. Contact your Polyamp
dealer.
12.3 The converter starts and stops
repeatedly
All models have an over/under voltage
protection on input which shuts down the
converter if the input voltage is not within
specified limits (see front label).
1. The cables to the converter input may be
under-sized, causing too high voltage drop
in the supply cables.
2. Check that there is not excessive voltage
drop in the external input disconnecting
device or in the input fuse holder due to bad
contact.
3. Your supply does not have enough current
capacity so the input voltage to the
converter drops below specified limit.
12.4 The converter stops after several
hours
If the red “OVER TEMP” LED is lit, the unit
has not sufficient cooling or the ambient
temperature is too high.
•See 5.2 Over temperature on page 8 for
further information.
•If the converter includes a fan. Check
that it is working. If not, replace it. See
11 Maintenance.

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12.5 Fault report
We suggest that you return a faulty converter
to:
POLYAMP AB
Bäckgatan 10
SE 597 53 ÅTVIDABERG
SWEDEN
Telephone:[phone]
Telefax: [phone]
Email: [email protected]
www.polyamp.com
Or to your local Polyamp distributor.
To help us locate the fault, please describe the
fault and how and when it occurred.

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Figure 8. Replacing the fan.

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Figure 9. Two supply systems with common load and parallel converter outputs.