Polyamp PU1000 User manual

PU1000/PU600 INSTALLATION MANUAL
10229-15.doc
Polyamp AB, Sweden www.polyamp.com Page 1 (10)
PU1000/PU600
Installation manual

PU1000/PU600 INSTALLATION MANUAL
10229-15.doc
Polyamp AB, Sweden www.polyamp.com Page 2 (10)
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
uninsulated ”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...............................................................................................................................................4
3 PARALLEL CONNECTION ...........................................................................................................................5
3.1 SERIES DIODE ON THE OUTPUT........................................................................................................................5
3.2 CURRENT SHARING.........................................................................................................................................5
3.3 VOLTAGE ADJUSTMENT WITH CURRENT SHARING.....................................................................................6
4 MULTIPLE LOADS AT THE OUTPUT........................................................................................................6
4.1 SHORT-CIRCUITS ............................................................................................................................................6
5 ALARM ..............................................................................................................................................................7
5.1 OVER AND UNDER VOLTAGE ALARM ..............................................................................................................7
5.2 OVER TEMPERATURE......................................................................................................................................7
6 SENSE.................................................................................................................................................................7
6.1 EXTERNAL SENSE ...........................................................................................................................................7
6.2 INTERNAL SENSE ............................................................................................................................................8
7 INHIBIT .............................................................................................................................................................8
8 OUTPUT OVER VOLTAGE PROTECTION................................................................................................8
9 INRUSH CURRENT LIMIT............................................................................................................................8
10 ISOLATION VOLTAGE TEST.....................................................................................................................8
10.1 DC ISOLATION TEST OUTPUT TO CASE ..........................................................................................................8
10.2 DC ISOLATION TEST INPUT TO OUTPUT AND INPUT TO CASE......................................................................9
10.3 AC ISOLATION TEST INPUT TO OUTPUT AND INPUT TO CASE......................................................................9
11 TROUBLE SHOOTING .................................................................................................................................9
11.1 THERE IS NO OUTPUT VOLTAGE ....................................................................................................................9
11.2 THE INPUT FUSE BLOWS WHEN THE INPUT IS CONNECTED..........................................................................9
11.3 THE CONVERTER STARTS AND STOPS REPEATEDLY .................................................................................10
11.4 THE CONVERTER STOPS AFTER SEVERAL HOURS .....................................................................................10
11.5 FAULT REPORT ...........................................................................................................................................10

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1 Before installation
On the front panel label the following is displayed:
Converter type, input voltage range, nominal output
voltage, serial number, options, article number,
isolation voltages and ambient temperature range.
The converter type name consists of model name
PU1000 or PU600 followed by input code and
output voltage. Two examples:
•”Type: PU1000 110/48” has input code ”110”
and nominal output voltage 48Vd.c.
•”Type: PU600B24” has input code ”B” and
nominal output voltage 24Vd.c.
Input, output and case are galvanically separated
from each other. You can thus choose how you
want the system connected.
The input is protected against reverse polarity by a
parallel diode at the input on models with input
code 24, 48, 72, A, B and C. This diode, however,
is only intended to blow an external input fuse. 110,
220, 440 and D input codes have an inrush current
limit thyristor, which also works as a series diode.
The input shall be fused with an approved fuse with
a slow blow characteristic and high breaking
capacity. See table 1.
PU1000 input fuses
Input voltage code Time delay fuse
24 63 A
48 35 A
72 25A
110 16 A
220 8 A
440 6A
PU600 input fuses
Input voltage code Time delay fuse
A 80 A
B 50 A
C 20 A
D 10 A
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.
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.
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 shall be mounted in an enclosure,
which meets the demands of EN60950 regarding
fire, voltage hazard and mechanical strength.
The converter is supplied with mounting brackets.
With these you can mount the converter in any
direction. The converter is convection cooled and
in order to get sufficient cooling there shall be a
minimum of 30 to 50 mm 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 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.
1. Remove plastic cover.
2. Connect protective earth to the connection
marked no 40. Use a ring terminal that has been
crimped by an appropriate tool.
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 5.
•If you intend to use multiple loads, please
consult 4 Multiple loads at the output on
page 6.
•If you intend to use the alarm, please consult
5Alarm on page 7.
•If you intend to use output voltage sense,
please consult 6Sense on page 7.
•If you intend to use inhibit, please consult 7
Inhibit on page 8.

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4. Connect the input cables. Bundle input cables
together at the terminals separated from the output
cables. Make the same arrangement on the output
side. This is to make sure one cable will not bridge
the insulation barrier in case of coming lose.
5. Start the converter with your external input
disconnection device.
Beware of hazardous voltages!
•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 6.
5. Replace plastic cover.
6. When the converter is disconnected, switch-off
the input voltage with the disconnecting unit.
Disconnect the input cables first, then output
and last the protective case connection.
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. Connect your
load to the + output after the series diode, see
Figure 1.
Another reason for connecting two or more
converters in parallel is to get more power. Use the
output with series diode, see Figure 1.
You should not use external sense when the unit
are 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.
When the series diode is used the total output
power of the converter must be 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 (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 1. The plus poles can either be
connected as in Figure 1 or have separate cables to
the load.
At light load (if the total load is less than 5% of the
total rated power) the yellow ”C. MASTER” LED
might flicker between the units. As the load
changes different units ”C. MASTER” LED might
be lit. All this is normal.

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Figure 1. 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 ”C. MASTER” LED might be
lit on most units.
To increase the output voltage:
1. Choose a unit where the ”C. MASTER” 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 ”C. MASTER” 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 ”C.
MASTER” 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 ”C. MASTER” 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.
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 2. 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

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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.
Figure 2. 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”.
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”.
Figure 3. Alarm contact.
The relay is isolated 2500Va.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. When the output voltage is
normal, the relay contact is in the position printed
on the front panel.
5.2 Over temperature
All models have thermal protection. If the converter
is overheated it reduces its maximum output power.
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 below
+55°C when the unit has sufficient cooling. The
converter 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
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

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load. The maximum voltage compensation is 5% of
nominal output voltage.
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. Remove the jumpers from the sense inputs at
the removable connector.
2. Connect a twisted-pair (0.25mm2-1.5mm2)
between the sense terminals of the converter
and the load, see Figure 4. 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 4. External sense.
Figure 5. Feature contact.
6.2 Internal sense
If external sense is not used, the jumpers shall be
connected between ”+SENSE” and ”+V” and
between ”-SENSE” and ”-V”, as they are at
delivery. The converter then regulates the voltage at
its output screw terminals.
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.
9 Inrush current limit
Models with input codes 110, 220, 440 and D are
equipped with ”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 a
thyristor, which also acts as a series diode.
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 delivery see Table 2. Warning! An
isolation test shall only be performed by
personnel aware of the dangers and hazards of
the test.
Input
code Isolation In/out,
In/case
Output
voltage
Vd.c.
Isolation
out/case
24, 48,
72, A, B 2.0kVd.c. 24, 48 2.0kVd.c.
110, 220,
440,C, D 2.5kVa.c. 24, 48 2.0kVd.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.
4. Connect your isolation tester between output
and case. See Figure 6. Raise the voltage of the
isolation tester from 0 to 2000Vd.c. Check that

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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 2000Vd.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 2500Va.c. for one (1) minute
between input to output and case on units with
input codes 110, 220, 440, C and D.
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
4000Vd.c (2500V x √2 x 1.1 ≈4000Vd.c where
1.1 = safety factor). Follow the instructions in 0
10.2 DC isolation test input to output
and input to case above but test with 4000Vd.c.
instead of 2000Vd.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 2500Va.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 Trouble shooting
11.1 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 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.
4. Check that the ”INHIBIT” input is not short-
circuited. See 7Inhibit on page 8.
5. Check that the ”SENSE” is connected correctly.
See 6Sense on page 7.
6. The unit is broken. Contact your Polyamp
dealer.
11.2 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.

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Some models have ”inrush current limit”. Fore
further information consult 9 Inrush current
limit on page 8.
2. The unit is broken. Contact your Polyamp
dealer.
11.3 The converter starts and stops
repeatedly
All models have an over/under voltage protection
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. Your supply does not have enough current
capacity so the input voltage to the converter
drops below specified limit.
11.4 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
to high. See 5.2 Over temperature on page 7 for
further information.
11.5 Fault report
We suggest that you return a faulty converter to:
POLYAMP AB
Box 229 / Bäckgatan 10
S-597 25 ÅTVIDABERG
SWEDEN
Tel: [phone]
Fax: [phone]
or to your local Polyamp distributor.
To help us locate the fault, please describe the fault
and how and when it occurred.