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 a 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%rms from maximum output voltage (1MHz bandwidth)
In S and T versions the resolution is defined by an 8-bit A/D converter of a
microcontroller. Measured using nominal output voltage.
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, 280V, 10mm23m output cables
Enclosure Aluminum case, IP20
Weight 7.1 kg without cables
Output Grounding Floating
Ambient temperature range 0°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
EN 60950-1
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 60VDC the charger doesn’t fulfill 1.2.8.7 (Safety Extra Low
Voltage). Standard parts (2.1 Protection against electric shock) must be taken into account in installation.
EN60335-2-29:2004
EN60335-1:2002 +A11:2004 +A1:2004 +A12:2006 +A2:2006
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 36V it doesn’t fulfill article 10.101 (“The no-load d.c. output voltage
shall not exceed 42.4V”).
EMC Limits EN55022 Class B, Application must be discussed 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
*) 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 (TTL 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
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 typical characteristics PAP 3200
12
V
10
18
200
(V)
(
A
)
14
6
100
2
18V

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 (Typical)
Dimensions
Installation
The location must be dry, dust-free and indoors. Equipment must be connected to an earthed mains 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 in order 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.

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 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 0-5Cdc 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 the charging process. In normal power supply operation an orange
led indicates a healthy output voltage.
Stand-by LED is 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 the power supply’s output is switched ON.
Over current 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. For more information about use with an AI or S option, ask the
manufacturer.
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.
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.

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 (TTL 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/isolated from output
**) Connected to the output –
***) Not available for voltage versions over 72V. MAX allowed
voltage 72V!
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.

Switched Mode Power Supply
Operating manual PAP3200
Perämiehenkatu 6, FIN 24100 Salo, Tel. [phone], Fax [phone], [email protected], www.powerfinn.fi
6
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
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
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 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 +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 as 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 as the analog
control card is used between 0 and +5V. 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 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 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 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.
KP016_00330_012_7_EN_1.doc