Powerfinn PAP3200 User manual

Switched Mode Power Supply
Operating manual
PAP3200
Perämiehenkatu 6, FIN 24100 Salo, Tel. [phone], Fax [phone], [email protected], www.powerfinn.fi
1
Features:
Wide output range 0…320Vdc
Analog control by an external
0…5Vdc
Power failure alarm output
Master-slave connection
Powerfinn PAP series is a high power, lightweight, advanced power supply 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 by an external 0-5V analog control, with internal adjustment
trimmers or from serial bus.
Specifications
Input voltage 70…264Vac 1–phase ( 70…230Vac, reduced power )
70…369Vdc
Efficiency 89% at full load, >90% at 50% load ( 230Vac input )
Input current 16A ( max)
Frequency 47–63Hz
Power factor >0,98
Inrush current soft start
Output ripple <1% from output voltage, rms
Mechanics Wall mounting, see dimensions p. 3
Connectors Input Input power cord
Output Models 12V, 24V, 36V, 48V copper busbar terminals
Models 72V, 110V, 160V, 220V 10mm
2
3m output cables
Enclosure Aluminum case, IP20
Weight 7,1 kg without cables
Output Grounding Floating
Ambient temperature range -20°C…+40°C at full load, abs. max. +55°C
Overtemperature protection Processor controlled on/off
Overcurrent protection Electrical current limit
Reverse polarity protection With fuse ( 12VDC version doesn’t have fuse )
Standards Safety Class 1
EN60335-2-29:2004
EN60335-1:2002 +A11:2004 +A1:2004 +A12:2006 +A2:2006
EN50366:2003 +A1:2006
Conformity can be limited depending end application,
output control method or unit mechanical structure
EMC Limits EN55022 Class A or B, Application must discuss in detail

Switched Mode Power Supply
Operating manual
PAP3200
Perämiehenkatu 6, FIN 24100 Salo, Tel. [phone], Fax [phone], [email protected], www.powerfinn.fi
2
Power Supply Models
Model Input voltage
*)
Nominal
output
voltage
Voltage
Setting
range
Current
setting
range
Max
power
Installation/dimensions
(width x height x depth)
PAP3200/12 70…264Vac/70…369Vdc 12Vdc 0–18Vdc 0–200A 3000W Wall /bench 400x250x80mm
PAP3200/24 70…264Vac/70…369Vdc 24Vdc 0–36Vdc 0–127A 3200W Wall /bench 400x250x80mm
PAP3200/36 70…264Vac/70…369Vdc 36Vdc 0-54Vdc 0–95.5A 3200W Wall /bench 400x250x80mm
PAP3200/48 70…264Vac/70…369Vdc 48Vdc 0–72Vdc 0–64A 3200W Wall /bench 400x250x80mm
PAP3200/72 70…264Vac/70…369Vdc 72Vdc 0–108Vdc 0–42A 3200W Wall /bench 400x250x80mm
PAP3200/110 70…264Vac/70…369Vdc 110Vdc 0–165Vdc 0–25A 3000W Wall /bench 400x250x80mm
PAP3200/160 70…264Vac/70…369Vdc 160Vdc 0–230Vdc 0–20A 3000W Wall /bench 400x250x80mm
PAP3200/220 70…264Vac/70…369Vdc 220Vdc 0–320Vdc 0–14A 3000W Wall /bench 400x250x80mm
PAP3200/300 70…264Vac/70…369Vdc 300Vdc 0–300Vdc 0–11A 3000W Wall /bench 400x250x80mm
*)
Reduced power 70…230Vac
Intelligent optional models (24V models as type designation example)
Model Option description Cable set
PAP3200/24AI Analog control by external 0–5Vdc 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 mains and module failures. 2 m cable (other ends open)
PAP3200/24AIH Analog control and power failure relay Analog + relay cables
Master-slave connection (24V models as type designation example)
Master units Slave units
PAP3200/24 trimmer adjustment (RS232 bus out) PAP3200/24S (RS232 control bus in/out)
PAP3200/24AI analog control (RS232 bus out) PAP3200/24SH (slave unit with relay, RS-232 bus in/out)
Cable set for master slave connection included in slave unit, 1,5 m (Cable connected to slave units connector J101, other ends open)
Customized versions on request
•Cyclic battery chargers including the charging algorithms
•Temperature compensation, sense, external LED, external ON-OFF
Characteristics
12V
10
18
200
(V)
(A)
14
6
100
2
18V
24V
20
40
50 100
(V)
(A)
36V
54V
36V
30
60
40 100
(V)
(A)
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
Nominal output current / voltage characteristics PAP 3200

Switched Mode Power Supply
Operating manual
PAP3200
Perämiehenkatu 6, FIN 24100 Salo, Tel. [phone], Fax [phone], [email protected], www.powerfinn.fi
3
Input voltage / Output power ( Uout 72V version )
Dimensions
Installation
The location must be dry, dust-free and indoor. The acceptable full power temperature range is
–25°C…+40°C. The thermal protection will cause the unit to power down at a too high operating temperature. The power
supply is not waterproof. Keep it dry and away from areas with high humidity in order to avoid the risk for electrical shock and
damages to the charger.
Wall mounting
The power supply can be mounted to the wall with the aid of the two mounting
holes on both ends of the power supply unit as shown in the figure.
The power supply can be installed horizontally or vertically. In horizontal
installation IP21 protection class can not be met.
Leave at least 10 cm free space at the cooling fan end and to the both sides of
the power supply to ensure sufficient ventilation.
When used as a charger, the charging process generates explosive hydrogen
gas. Install power supply as far away from battery as possible to prevent
hydrogen gases going inside the charger Keep the area well ventilated. Never
use an open flame or equipment that produce sparks close to the power supply
and battery.

Switched Mode Power Supply
Operating manual
PAP3200
Perämiehenkatu 6, FIN 24100 Salo, Tel. [phone], Fax [phone], [email protected], www.powerfinn.fi
4
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 will light continuous 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 0-5Cdc voltage. See detailed description
Both voltage and current can be adjusted from zero to the maximum value. Maximum 3200W / 3000W
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’s
STATUS LED indicates different phases during charging process. In normal power supply operation an orange
led indicates a healthy output voltage.
Stand-by LED lights ON when mains 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 power supply’s output is switched ON.
Overcurrent protection
The output of the power supply is protected against over currents 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 500V total voltage
Warning
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.

Switched Mode Power Supply
Operating manual
PAP3200
Perämiehenkatu 6, FIN 24100 Salo, Tel. [phone], Fax [phone], [email protected], www.powerfinn.fi
5
Feature selection table
Trimmer Analog Relay Bus out Bus in Temp Sensor Code switch External LED External
ON
-
OFF
Trimmer adjustment 
Analog control (isolated) 
Alarm relay 
BusOut (RS–232 control to slave) 
BusIn 
Temp. compensation 
Sensor 
Customized charging algorithm
chargers with code switch

External LED 
     
External ON-OFF 
     
Connectors J101 and J69 for optional features
Optional relay alarm, temp. comp., sense, 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. +12.5V
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. Battery voltage sense +
14. Battery voltage sense –
*)
These connectors are floating
**)
Connected to the output –
Connector J69 option
External LED
External ON / OFF
External LED and External ON / OFF contact
is NOT GALVANIC ISOLATED !
Only one of these features is possible at a time.
Connector
J69
External LED External ON / OFF
Pin1 LED Green
nc
Pin2 Ground Ground
Pin3 LED Red
nc
Pin4
nc
ON / OFF
Pin configuration of the modular connector J69

Switched Mode Power Supply
Operating manual
PAP3200
Perämiehenkatu 6, FIN 24100 Salo, Tel. [phone], Fax [phone], [email protected], www.powerfinn.fi
6
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. Terminal 5 is the ground connection.
Internal alarm relay
Common is connected to NC when the power is switched off.
Common is connected to NO when the power is switched on.
Isolation:
Output to case: 500V
Output to GND: 120V
Technical data:
1A@24Vdc
0,5A@120Vac
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 of these. +5VDC supply power is available for the supply of the control logic. The
analog input has an isolation value of 500 V towards the input and output of the power supply. The isolated analog
control card is connected to the AMP Modular 6 connector J1.
16 5 4 3 2
Pin configuration J1
1. Ground
2. Current control input
3. Voltage control input
4. Measured current value
5. Measured voltage value
6. +5VDC (max 20mA) output
Pin configuration of the modular connector J1

Switched Mode Power Supply
Operating manual
PAP3200
Perämiehenkatu 6, FIN 24100 Salo, Tel. [phone], Fax [phone], [email protected], www.powerfinn.fi
7
Controlling the analog card
All control voltages must be between 0 and +5V, Higher voltages are not allowed. The control logic is positive, so
that a +5VDC control voltage gives a maximum value from the power supply, while 0V means minimum output. As
soon the control connector is unplugged from the modular connector, the power supply are 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. Measured signals (both together) can be loaded
with max 20mA; otherwise proper operation cannot be guaranteed.
The modular connector is isolated from the input, output and enclosure of the power supply. This enables the
possibility to parallel or series connect several power supplies maintaining equal voltages. The number of
connected devices is not limited. The 500V insulation voltage may, however, not be exceeded. This manual
cannot be applied in case the connector of the analog card differs from a modular connector (9-pin D-connector).
In that case it is an incompatible analog controlled power supply.
Connection example using the internal +5Vdc supply and external potentiometers.
The +5V can be used as a supply for external circuits. The circuit shown to the left
lets the power supply operate ass a potentiometer controlled device. It is important
to keep in mind that the +5V output may not be loaded more than 20 mA, otherwise
proper operation cannot be guaranteed.
Instructions for calibration
The manufacturer calibrates the analog control interface. Recalibration is not necessary as long the analog control
card is used between 0 and +5V. A qualified person is required for recalibration of the device. Calibration is done
with the aid of a pair of multi-meters and the example schematic given above. The calibration procedure is as
follows.
1. Adjust the potentiometers to 5V for the voltage and 2V for the current targets. Connect a digital voltage
meter to the power supply output. Adjust the ‘Voltage Set’ potentiometer to the maximum output voltage.
2. Connect a digital voltage meter to pin 5 of the modular connector J1. Adjust the trimmer ‘Voltage Meas.’
so that the digital voltage meter shows always the same value as pin 3 (target voltage).
3. Connect a digital current meter to the output so that the output is shorted. Adjust the current target
potentiometer to +5V. Adjust the ‘Current Set’ trimmer to the for 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 using a digital multimeter 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).

Switched Mode Power Supply
Operating manual
PAP3200
Perämiehenkatu 6, FIN 24100 Salo, Tel. [phone], Fax [phone], [email protected], www.powerfinn.fi
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 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 or a higher voltage is needed, the adjustable master power supply can be connected in parallel or
in series, via the digital bus, with the slave unit, which follows the master unit but has no adjustment possibilities
by itself. Dependent on the connection, the maximum output current, or the voltage is doubled, while both power
supplies are simultaneous adjusted using the multi turn potentiometers, or external analog control. An unlimited
amount of slaves can be connected to a master unit. The power supply’s output terminals and the communication
bus terminals are isolated, so that the outputs can be connected in series for obtaining a higher voltage.
Serial bus connection
The bus cable is connected from the master unit (J101) to
the slave unit (J101). The first unit, or master unit has
potentiometers for voltage and current adjustment. An
erroneous connection of the bus cable does not cause any
damages, but causes the slave unit to not follow the
commands sent from the master unit.
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.
KP016_00330_007.doc