Teseo PA 5840 Series User manual

1
PA 5840 - Automotive
bAttery simulAtors
user mAnuAl
601-306A
Advanced Test Equipment Rentals
www.atecorp.com 800-404-ATEC (2832)
®
E
s
t
a
b
l
i
s
h
e
d
1
9
8
1

PA 5840
PA 5840 - Automotive
bAttery simulAtors
user mAnuAl

1 Safety Instructions 5
1.1 Classicationofdangers 5
1.2 Warningsymbolsonthetestsystem 6
1.3 Excessvoltagecategory 6
1.4 Rangeofvalidity 7
1.5 Safetyofoperation 7
1.6 Personnel 7
1.7 Responsibilityforsafetyprecaution 8
1.8 Reductioninoperationalsafety 8
1.9 Asagreeduse 8
2 Introduction 9
2.1 Introduction 9
2.2 Features 9
3 Installation/set-up 11
3.1 Checkingtheshipment 11
3.2 Deliverycontents 11
3.2.1 Standardaccessories 11
3.2.2 Documentation 11
3.3 Set-up 11
3.3.1 Operatingposition 12
3.3.2 Linevoltageconnectionandgrounding 12
3.4 PA5840frontpanelconnectors 13
3.4.1 Thecontrolconnector 13
3.4.2 PincountofthecontrolI/ODSubconnector 14
3.4.3 Thefunctiongeneratorinputconnector 14
3.4.4 Theoutputconnectors 15
3.4.5 Thepoweroutputconnectors 16
3.4.6 Thesenseoutputconnectors 16
3.4.7 Rearpanelconnectors 16
Contents

4
PA 5840
4 Operation 17
4.1 Themainswitch 17
4.2 Thesystemstopbutton 18
4.3 Theoutputvoltage(RMS)display 19
4.4 Theoutputcurrent(RMS)display 19
4.5 Theviewcurrentlimitbutton 19
4.6 TheerrorsLEDs 20
4.7 Thecompensationbutton 21
4.8 Thegainbutton 22
4.9 Thecurrentlimitationbutton 22
4.10 Theoutputrangebutton 23
5 Applications 24
5.1 CompliantwithISO7636(andsimilar)fortransientimmunity 24
5.2 Voltagevariationsforstartingproles 24
5.3 Fastrisetimeforcallengingvoltagedipapplications 25
5.4 Voltagerippleandsinewavenoisesimulations 25
5.5 ExampleapplicationwithNSG5500andNSG5600 26
6 Maintenance 27
6.1 Cleaningtheequipment 27
6.2 Movingandstoringtheamplier 27
6.3 Protection 28
7 Specications 29
7.1 Envionmentalconditions 29
7.2 Technicalcapabilities 29
7.3 Pictures 32
7.3.1 Frontview 32
7.3.2 Rearview 32
7.3.3 Declarationofconrmity(CE) 33
8 Addresses 34

5
1.1Classicationofdangers
1 sAFety instruCtions
CAUTION! It is imperative that you read the follow-
ingsafetyinstructionsand all safety instructions in
the manuals of connected peripheral systems before
installingandstartingthetesterforthersttime.
The electrical and mechanical safety equipment must
not be removed, put out of operation or bypassed.
Handle all safety equipment with care. If a safety device
shouldbebrokenorisnotworking,thesystemmust
be put out of operation until the safety equipment
is repaired or exchanged and fully in working order
again.
Thesafetyinstructionsinthismanualareclassiedindifferentlevels.Thetable
belowshowsasurveyovertherelationofsymbols(ideograms)andkeywords
tothespecicriskandthe(possible)consequences.

6
PA 5840
1.2Warningsymbolsonthetestsystem
Differentwarningsymbolsareplacedonthetestsystem.Thetablebelow
showsasurveyovertherelationofsymbols(ideograms)andkeywordstothe
specicriskandthe(possible)consequences.
1.3Excessvoltagecategory
ThetestequipmentPA5840,asdescribedinthismanual,isrelatedtotheexcess
voltagecategoryIIaccordingIEC60664.
Warning
symbol Signalword Denition
DANGER!
Possiblydangeroussituation,thatmaycause
damagetopersonsorheavydamagetothe
testerand/ortheequipment
CAUTION!
Situation,thatmaycausedamagetothetester
and/ortheequipment
NOTE! Usertipsandotherimportantorusefulinfor-
mationandcomments
Pictogramm Denition
Possiblydangeroussituationthatcanresultininjuries
andseriousdamagetotheequipment.
Situationthatcanresultindamagetotheequipment.

71.4Rangeofvalidity
Theseinstructionsarevalidforthecompleteinstallation.Furthersafetyregula-
tionsforcomponentsinstalledinthistestequipmentoradditionalinstalled
devicesarenotsuspendedbytheseinstructions.
1.5 Safety of operation
Reliablefunctionandsafeoperationofthetestequipmentareensuredonlyif
therelevantgeneralprecautionsaswellasallsafetyinstructionsgiveninthis
manualareobserved.
Inparticular,observethefollowing:
Connect the device only to line voltage that conrms to the power
 specicationgivenonthetypelabel(onthebackofthetestequipment).
Donottouchanyconductivepartsattheoutputconnectors,thextureand
 thetestobjectduringatestrun.
Disconnectthedevicefromthemainsbeforeopeningthecasingformain
 tenanceorrepair.
Duringtheoperationofthetestequipmentalwaysobservetherelevantrules
 ofESD(ElectroStaticDischarge)protection.
ToguaranteetheEMCfeaturesofthedevice,thecontrolcomputermust
 meettherequirementsoftheEN50082,55011,61000standard.
Make sure the environmental conditions described in chapter 7.1
 Environmentalconditionsexist.
1.6 Personnel
Theequipmentmaybeoperatedbyqualiedpersonnelonly.Itmaybeopened
foradjustment,maintenanceorrepairbyauthorizedstaffonly.Teseqorits
representativemaynotbeheldresponsibleforservicenotperformedbyTeseq
personnel.

8
PA 5840
1.7 Responsibility for safety precaution
Theowner,operationsupervisorand/oroperatoroftheequipmentarerespon-
sibleforsafety.Theowner,operationsupervisorand/oroperatorareincharge
ofanysafetymeasuresthatdonotdirectlyconcernthetestequipmentitself.
Fordetails,seetherelevantaccidentpreventionregulations.Seealsothesafety
instructionsinthemanufacturer’smanualincludedwithanyadditionalinstru-
mentordeviceyouintendtousewithyourTeseqtestequipment.
1.8 Reduction in operational safety
Ifyouhaveanyreasonstosupposethatthetestequipmentisnotcompletely
safe,youmustshutitdownandputitoutofoperation.Moreover,youmust
markorlabeltheequipmentappropriatelysoitwillnotinadvertentlybeput
intooperationagain.Youshouldthencallauthorizedservicepersonnelfor
assistance.
1.9Asagreeduse
Thetestequipmentmustexclusivelybeusedfortestingelectricaldevicesand
componentsindicatedinthetechnicalspecications.

9
2.1 Introduction
ThePA5840rangeofbatterysimulatorsarehighperformancepowerampliers
providingastableandruggedpowersourceforlaboratoryapplications.The
ampliershavebeendesignedspecicallytosimulatebatterysuppliessuchas
12,24and42Vvehicleelectricalsystems.Theymaybeusedontheirownor
integratedwiththeTeseqAutomotiveEMCTestSystemconsistingofNSG5000,
NSG5200,NSG5500,NSG5600(hereafterreferredtoasNSG5000series)and
AutoStarSoftware.Theampliersareofferedinthreeframesizeswithnominal
outputcurrentsof75,150and300A(peakvalues).
DesignedtomeetEMCimmunitytestingrequirementsfortheautomotiveindu-
stry.Applicablestandardsinclude:IS07637,IS016750,JASOD001,MIL-STD-
461E,SAEJ1113aswellasautomobilemanufacturerspecications.
Typesoftestingincludesupplyvoltagevariations,dipsanddrops,ISOpulses
2band4,loaddumppulse,startingproles,powercycling,batteryrecovery,
resetbehaviour,fuelpumptransient,conductedsinewaves,groundshift,jump
startandovervoltage,aswellasprovidingaprogrammableDUTpowersource
duringallphasesoftesting.
2 introDuCtion
2.2 Features
Theoutputisprogrammableoveraminimumvoltagerangefrom-15to+60V
whichallowsthesimulationofalargerangeofpulsesandvoltagevariations.
Aremotesensinginputisprovidedtocompensateforoutputcablevoltage
drop(upto4V).Theoutputprovidesawidebandwidth(DCto>150kHz),afast
outputslewrate,lowsourceimpedance(<10mΩ),andhighpeakoutputcurrent
(typically3timesnominal).

10
PA 5840
andvisibility.Thesefacilitiesinclude:voltageinput;currentlimitinput,current
limitindicatoranddisplay,compensationmode,gainsetting,outputrange,
currentlimitation,systemstopandoutputandsenseconnectors.
Forconvenience,voltageandcurrentcontrolandmonitoringinterfaceshave
beenduplicated.BNCconnectorsareprovidedforgeneralpurposeconnec -
tiontosignalgeneratorsandanintegratedcontrolD-typeconnectorfordirect
connectiontotheTeseqNSG5000series.Theoutputterminalsareduplicated
with6mmsockettypeconnectorsforpush-interminationassuppliedwiththe
TeseqAutomotivetestsystems.
Powerdissipationisalwaysaconsiderationwithampliers.Toavoidexcessive
heatthePA5840rangeincludesarangeselectionswitchonthefrontpanel
toenabletheampliertodelivermorepowercontinuouslywhensimulatinga
12Vsystemthelowvoltagerangeisselectedwhichcanprovideareduction
inpowerdissipationwhichallowscontinuousoperationforlongerunderhigh
loadconditions.
Theamplierinputsareovervoltageprotectedandoutputsshortcircuitpro-
tected.Overtemperatureprotectionismonitoredontheinternalheatsinkand
transformer.
There are three selectable ranges for compensation / bandwidth for the
PA5840.Bandwidthsarehigh,allowingfastslewratesasrequiredbynumerous
standards.
Thecurrentlimitisprogrammablefrom10to100%oftheoutputcurrentcapa-
bility.

11
3.1Checkingtheshipment
3 instAllAtion/set-uP
Uponreceivingtheshipment,rstcheckthepackagingandouterequipment
forvisibledamage.Also,checkpackagingandcasingsofperipherals(ifany).
Recordinwritinganydefectswhichwerepossiblycausedintransit.Ifthe
shipmentshowsdamageorisnotcomplete,immediatelyadvisetheshipping
agencyand/oryourdealer.
3.2 Delivery contents
Thestandarddeliverycontainsthebasicunitaswellasseveralattachments
andaccessories.
3.2.1 Standard accessories
Onepowercable
3.2.2 Documentation
Thefollowingmanualsaresupplied:
ThisPA5840Automotivebatterysimulatorshardwareguide
3.3 Set-up
 CAUTION!Theequipmentmaybeset-upbyqualied
personnel only. It is imperative to observe the safety
instructionsatthebeginningofthismanual.Theequip-
mentwillbesafetooperateandperformtoitsspeci-
cations only under the environmental conditions found
in chapter 7.1 Environmental conditions.

12
PA 5840
3.3.1Operatingpostition
CAUTION! The equipment must be set-up stable. Oper-
atingisonlyallowedinverticalposition.Theremust
beenoughspacearoundtheequipmenttoensurea
sufcient air ow for cooling. The ventilation grilles
must be kept free.
3.3.2Linevoltageconnectionandgrounding
 DANGER!Connecttheequipmentonlytolinevoltage
conformingtothepowerspecicationgivenonthetype
label(onthebackoftheequipment).Ifthegrounding
is interrupted inside or outside the equipment, the
PA 5840 will become a source of danger. Carefully
observegroundingprecautions.Theplugonthepower
cordmaybereplacedbyqualiedpersonnelonly.
Thepowercordoftheequipmentislocatedonthebackoftheequipment.The
powerinputissecuredwithathermalmagneticcircuitbreaker(fordetails,refer
tochapter6.3Protection).
Thepowerplugandoutletmusthavegroundingcontacts.
Thesuppliedmainscablemaybeconguredonrequestorwith3-phasecon-
nectorsoritisleftwithonlytheconnectortothePA5840andontheotherend
canbewiredpertheuser’sneeds.
CAUTION! 3-phase mains connectors must be installed
onlybyqualiedpersonnel.
Whentheequipmentisbroughtfromcoldtowarmenvironment,theensuing
condensationmaybringaboutdangerousconditions.

13 DANGER! The equipment may only be switched on after
all parts have fully acclimatized.
3.4 PA 5840 Front panel connectors
3.4.1 The control connector
The“CONTROL”connectorisaninputportfromthefunctiongeneratorcard.
Connectthe9-pinDSub“CONTROL”connectortotheappropriateconnectorat
thefunctiongeneratorcardofyourNSG5000series.

14
PA 5840
3.4.2 Pin count of the control I/O DSub connector
3.4.3Thefunctiongeneratorinputconnector

15ThisinputsmaybeusedinspecialapplicationswhentheNSG5000seriesis
notused.AnotherfunctiongeneratormaybeusedtocontroltheDCamplier.
1Vinputis7Voutput.
TheUINPUTisthedrivingvoltageofthebatterysimulator.Theoutputofthe
batterysimulatorcanbedescribedasUOUTPUT=UINPUTxGAIN
IINPUTistheanalogcontrolofthecurrentlimit.Theinputlimitationis1-10Vas
arationoftheavailablecurrentlimitwhere1V=10%and10V=100%current
limit.Forexample,foraPA5840-150,whichhasamaximumconstantcurrent
of50A,a5Vinputwillsetacurrentlimitof25A,andamaximumpeakcurrent
of75Awhenthe“CURRENTLIMITATION”selectionis3xICONTROL.
 CAUTION!Ifused,theinputvoltageattheIInputcon-
nector must be at least 1 V (10% output limitation).
CAUTION! Do not use both I Input and control con-
nectors at the same time. Use either the I Input BNC
connector or the I Input of the control D-Subconnector.
Never terminate the I input BNC or D-Sub connectors!
3.4.4 The output connectors

16
PA 5840
3.4.5 The power output connectors
The“POSITIVE/NEGATIVEPOWER”connectorsareusedtoconnecttheoutput
totheDUT(deviceundertest)ortotheNSG5000series.
 NOTE!Seethehardwareguideoftheappropriatetest
system for more details.
3.4.6 The sense output connectors
The“SENSE”connectorsmaybeconnectedtocompensateforvoltagedropof
thecablestotheDUTortotheNSG5000series.
3.4.7 Rear panel connectors
Theconnectorsontherearpanelnormallyareconguredbythefactory.Please
ensuretheconnectionsaremadeasshowninthepicturebelow.
NOTE! The PA 5840-300 has two output connectors
(modularity). For greatest accuracy. Please use the
upper connector

17
4.1 The main switch
ThetestsystemPA5840canbeswitched“ON”and“OFF”withthemainswitch.
Theoutputrangeisselectablebetween30and60Vbypressingtheoutputrange
button.
4 oPerAtion
 NOTE!The30Voltsrangeisforgreaterefciencyduring
normal12and24Vbatteryvoltageoperation.

18
PA 5840
4.2 The system stop button
Incase,anEUTneedstobeexchangedfrequently,theoptionalsafetybanana
plugsetINA163gives the possibilitytoconnecttheEUTin aneasyandsafe
way.Withthisoptionthemax.currentconsumptionoftheEUTmustnotexceed
32 A.
DANGER! The “STOP” button does not disconnect the
testerfromthelinevoltage.
OFF Thesystemiscompletelypoweredoff
ON Thesystemisinstandbymodewhenrststartingthesystemorafter
  anerrorcondition.Inordertostartthesystemthersttime,orafter
  anerrorcondition,thekeymusttemporarilybeplacedinthe“START”
  position
START (Momentary)Usedtoenabletheamplieroutput
CAUTION! For safety, the “POWER” switch is keyed. The
key can be removed in either the “ON” or “OFF” posi-
tion. Please do not lose this key, as the system will be
unusable without it!

194.3Theoutputvoltage(RMS)display
ThisdisplayshowstheoutputvoltageinRMS.
Thisdisplayshowstheactualoutputcurrentortheprogrammedcurrentlimit
whenpressingthe“VIEWCURRENTLIMIT”button.
4.4 The output current (RMS) display
4.5 The view current limit button
This LED indicates that the current limit has been reached. The current does
not take effect until the conditions from the “CURRENT LIMITATION” eld are
met.Pressingthe“VIEWCURRENTLIMIT”buttondisplaysthecurrentlimitonthe
“OUTPUTCURRENT”display.

20
PA 5840
4.6 The errors LED
SAFETYFAIL ThisLEDlightsintheeventofthe“SYSTEMSTOP”button
   beingpressed.
POWERFAIL thisLEDwilllightifanyoftheinternalsystemvoltagecheck
   fails.
OVERTEMP thisLEDblinksasawarningthattheinternaloperating
   temperatureisreachingshutdown range. This LEDstays
   constantwhentheinternaloperatingrangereachescritical
   and thesystemisturnedto aspecialcoolingmode that
   means that the amplier is turned on, and the fans
   arecooling,butnooutputisallowed.Turningthe“POWER”
   keyto“START”after allowing asuitablecooling timewill
   returntonormaloperation.
 NOTE!Turningthe“POWER”keyto“START”willclear
all errors and return the system to normal operation.
 NOTE!Duringthesystempowerup,theLEDsandthe
temperaturewarningbeeperwillbetestedforapproxi-
mately one second.