0245b-En 2

Operating Instructions
Switch Mode Power Supply

AC 3000 CAN
AEG Power Supply Systems GmbH

Department: AE
Name: Hördler/Schenuit/Wes
Revision status: 09
Date: 06.08.2002
Operating Instructions
0245 BAL, en
Operating Instructions Switch Mode Power Supply AC 3000 CAN
Contents
Notes on these Operating Instructions ...........................................4

1. Safety Instructions!................................................................6
1.1 Important Instructions and Explanations ..................................6
1.2 Accident Prevention Regulations .............................................6
1.3 Qualified Personnel..................................................................6
1.4 Liability .....................................................................................7
1.5 Regulations ..............................................................................7
2. General Information ...............................................................8
2.1 System Description ..................................................................8
2.2 Type Overview AC3000 ...........................................................8
2.3 Principle of Operation, Electrical ..............................................8
2.4 Circuit Diagram ........................................................................9
3. Functional Description ........................................................10
3.1 Input .......................................................................................10
3.2 Output Curve..........................................................................10
3.3 Changing the CVCC Curves ..................................................11
3.4 External Setpoint....................................................................11
3.5 Temperature-Dependent Voltage Control ..............................11
3.6 External Sensor Lead Output Voltage U0 ...............................12
3.7 Mains Voltage Monitoring.......................................................13
3.8 Output Voltage Monitoring .....................................................13
3.9 Monitoring of Functions..........................................................14
3.10 Temperature Monitoring.........................................................14
3.11 Reset......................................................................................14
3.12 ON / OFF Switch ....................................................................14
3.13 External ON / OFF .................................................................15
3.14 Parallel Operation ..................................................................15
3.15 CAN BUS interface X12 .........................................................15
3.16 RS 232 Service InterfaceX13.................................................16
3.17 DIL Switch S3.........................................................................16
3.18 DIL Switch S4.........................................................................17
3.19 Signalling ...............................................................................17
3.20 Pin Assignment X11...............................................................18
4. Start-Up .................................................................................19
4.1 Installation ..............................................................................19
4.2 Connection .............................................................................19
4.3 Connecting the Loads / Battery..............................................19
4.4 Isolation..................................................................................20
5. Operation ..............................................................................21
5.1 Menu ......................................................................................21
5.2 Key Assignment .....................................................................22
5.3 Significance of the Boxes.......................................................22
6. Maintenance .........................................................................28
7. Trouble Shooting .................................................................28
7.1 No Output Voltage Present ....................................................28
7.2 Output Voltage Deviation .......................................................28
8. Technical Data......................................................................29
Page 2 of 32 0245 BAL, en

8.1 General Technical Data .........................................................29

8.2 Technical Data of the AC 3000 Series ...................................31
9. Dimensioned Drawing .........................................................32

Notes on these Operating Instructions
Duty to Provide Information

These operating instructions must be read carefully by all persons working
with or on the switch mode power supply prior to installation and initial
start-up.
These operating instructions are a composite part of the switch mode
power supply.
The operator of this unit is obliged to communicate these instructions to all
personnel transporting or starting the switch mode power supply or per-
forming maintenance or any other work on the unit.
Validity
These operating instructions comply with the current technical specifica-
tions of the switch mode power supply at the time of publication. The con-
tents do not constitute a subject of contract, but serve information purposes
only.
AEG reserves the right to make modifications with regard to contents and
technical data in these operating instructions without prior notification. AEG
cannot be held liable for any inaccuracies or inapplicable information in
these operating instructions, as no obligation to continuously update the
data and maintain their validity has been entered into.
Warranty
Our goods and services are subject to the general conditions of supply for
products of the electrical industry and our general sales conditions. We re-
serve the right to alter any specifications given in these operating instruc-
tions, especially with regard to technical data, operation, weights and di-
mensions.
Claims in connection with supplied goods must be submitted within one
week of receipt, along with the packing slip. Subsequent claims cannot be
considered.
AEG will rescind all obligations such as warranty agreements, service con-
tracts etc. entered into by AEG or its representatives without notice in the
event of maintenance and repairs being carried out with anything other than
original AEG parts or spare parts purchased by AEG.
Structure
These operating instructions for the switch mode power supply are struc-
tured so that all work necessary for starting up, maintenance and repair of
the unit can be performed by qualified personnel.
Illustrations are provided to clarify and facilitate certain steps.
If any work poses possible danger to personnel and the unit, the safety in-
structions in chapter 1 are to be observed.

Hotline
Our service department is available on the Hotline number given below:
AEG Power Supply Systems GmbH

Emil-Siepmann-Strasse 32
59581 Warstein
Germany
(++49- 29 02) 7 63-100
FAX (++49- 29 02) 7 63-680
http://www.aeg.de
Copyright
No part of these operating instructions may be reproduced or transmitted
by any mechanical or electronic means without the express prior written
permission of AEG.
© Copyright AEG 1998. All rights reserved.

1. Safety Instructions!
1.1 Important Instructions and Explanations

The instructions for operation and maintenance, as well as the following
safety regulations must be complied with to ensure the safety of personnel
as well as the function of the unit. All personnel installing/dismantling, start-
ing up or servicing the unit must be familiar with and observe these safety
regulations. Only qualified personnel may perform the described work with
tools, equipment, test equipment and materials intended for the purpose
and in perfect working condition.
1.2 Accident Prevention Regulations

Compliance with the accident prevention regulations valid in the respective
country and the general safety regulations in accordance with IEC 364 is
mandatory.
The following must be observed prior to any work on the switch mode
power supply:
- disconnect the power supply,
- secure against reactivation,
- verify that the unit is disconnected from the power supply,
- earth and short the circuit,
- cover or isolate any neighbouring live parts.
1.3 Qualified Personnel

The switch mode power supply may only be transported, installed, con-
nected, started, serviced and operated by qualified personnel who are fa-
miliar with the pertinent safety and installation regulations. All work per-
formed must be inspected by responsible experts.
The qualified personnel must be authorised by the responsible safety offi-
cer to perform the work.
Qualified personnel is defined as personnel

- having completed training and gained experience in the respective
field,
- familiar with the pertinent standards, rules and regulations and acci-
dent prevention regulations,
- having received instruction on the mode of operation and operating
conditions of the switch mode power supply,
- capable of recognising and preventing dangers.
Regulations and definitions for qualified personnel are contained in
DIN 57105/VDE 0105, Part 1.

1.4 Liability
No liability is accepted if the switch mode power supply is used for applica-
tions not intended by the manufacturer. Any necessary measures for pre-
vention of injury or damage to equipment is the responsibility of the opera-
tor or user. In the event of any claims in connection with the switch mode
power supply please contact us quoting:
- the type designation
- works number
- reason for claim
- period of use
- ambient conditions
- operating mode
1.5 Regulations
The switch mode power supply units comply with current DIN and VDE
regulations. VBG4 is met on the basis of compliance with the regulation
VDE 0106, Part 100.
The specifications of VDE 0100, Part 410, "Functional extra-low voltage
with safe isolation" are complied with when applicable.
The CE sign on the unit confirms the conformance to the basic EC regula-
tions for 73/23 EEC - Low voltage and for -89/336 EEC - Electromagnetic
compatibility, if the installation and commissioning instructions described in
the operating manual are observed!

2. General Information
2.1 System Description

The switch mode power supply AC 3000 provides an output power of 3.0
kW. Typical applications are the installation as mains power supply or as
secure power supply with a battery connected in parallel.
The switch mode power supply works in accordance with a CVCC curve
acc. to DIN 41772 or DIN 41773. It is a preassembled unit ready for con-
nection. The connections are provided on the front of the unit for easy ac-
cess. The operating and indication elements are installed on the front of the
unit.
Due to its high efficiency, the unit is of compact design as a 19 inch panel
mounting unit with 4 height modules.
It is ready for installation in module racks according to DIN 41494.
2.2 Type Overview AC3000
Type designation Supply Output Output

voltage voltage current
E230 G24/100 BWrug-Cpü 230V AC 24 V DC 100 A
2.3 Principle of Operation, Electrical

The unit converts the single-phase AC voltage into a smoothened DC volt-
age. Transistors then convert this voltage into an AC voltage of 100 kHz.
With the aid of a transformer the following is accomplished:
- electrical isolation
- voltage adjustment to the secondary side.
The 100 kHz AC voltage on the secondary side is rectified by diodes. The
voltage ripple is reduced by a downstream output filter. The output voltage
and output current are controlled by pulse-width modulation of the transistor
switches on the primary side.
For further details, please refer to the circuit diagram on the following page.

2.4 Circuit Diagram
Figure 1 Circuit diagram AC 3000 CAN

3. Functional Description
The respective unit settings can be found in Technical Data Sheet (see
chapter 8).
3.1 Input
The AC3000 switch mode power supplies are operated in the 230V AC cir-
cuit. The input voltage is protected against short circuits outside the rack.
Protection must therefore be provided individually for each rack.
An integrated acceleration stage limits the making current of the switch
mode power supply to a value smaller than the rated input current.
3.2 Output Curve

The output curve is a CVCC curve in accordance with DIN 41772 with ap-
prox. 1 % voltage step inclination. Due to the inclination, the load can be
distributed quite evenly in the case of parallel operation of several switch
mode power supplies.
The pivot of the inclined curve is at 50% Irated. The rated value of the out-
put voltage is defined at 50% Irated.
The voltage step in dependence of the output current is inclined by a corre-
sponding connection of the analog controller.
Ua
100%
50%
50% 100% Ia
Figure 2 Output curve
CAUTION!
In the case of mains undervoltage or if the unit voltage is higher
than 32V, the max. possible input current must be ascertained
and limited to max. 16A by reducing the current setpoint.

The current setpoint I1-4 to be set on the device can be ascertained using
the following formula:
I1-4 = UE * IE*PF * η / (U1-4 + UΔ)
UE = Input voltage [V]
IE = Input current max. 16A permissible
PF = Power factor = 0.99
η = Efficiency = 0.88
U1-4 = set voltage setpoint [V]
UΔ = voltage drop to be compensated [V]
on the output lines when operated with
sensor leads.
3.3 Changing the CVCC Curves

At time of delivery, the first CVCC curve is active (trickle charge). By insert-
ing wire bridges on X11, the characteristic curves can be adjusted for the
respective unit application.
The following curves are to be adjusted:
1. CVCC curve Trickle charge Factory settings
2. CVCC curve High-rate charging Bridge X11:5 and + UO
3. CVCC curve Diode test/Battery test Bridge X11:6 and + UO
4. CVCC curve Manual charging Bridge X11:5, X11:6 and UA
CAUTION!
When the second or fourth CVCC curve is switched on, it may be
necessary to readjust the overvoltage monitoring of the output
voltage.
3.4 External Setpoint

The switch mode power supply DC3000 has two setpoint inputs which are
bound to the unit output with respect to their potential. The setpoint levels
on X11.2 and X11.4 are to be switched with reference to the analog ground
X11.1, whereby the analog ground must be equated with the unit output L-
The voltage and/or current setpoint can be switched from internal to exter-
nal setpoint with the menu box 22 (refer to chap. 5.3). As a standard, the
setpoint is set to internal values.
In order to adapt the supplied level as well as possible to the existing auto-
mation systems, the level range can be switched by means of the DIL swit-
ches S4.3 to 6. The following level ranges can be set:
0 - 20mA Ri = 494Ω
0 - 4V Ri = >10kΩ
0 - 10V Ri = 10kΩ
3.5 Temperature-Dependent Voltage Control

If enclosed batteries are used, a temperature-dependent charging voltage
is advisable. The temperature-dependent voltage control of the first CVCC
curve is achieved by connecting a thermistor of 10kΩ to Pin 1 and 11 of the
signal connector X11. For this operating mode, the DIL switch S3.6 must be
switched on and switch S3.7 switched off.

The sensor (AEG reference no. 8000001495) available as an option, is

connected using a two-pin supply line with a cross-section of ≥0.25mm².
The sensor can be connected directly on the battery surface or on a battery
pole. For larger distances (over 2m) the use of a shielded line is recom-
mendable; connect the shield to the unit housing.
The inclination of the temperature-dependent voltage curve can be
changed by the temperature coefficient. The standard setting of the tem-
perature coefficient is -4mV/K*cell within a range of -10 to +50°C. The
break points of the voltage curve result either from the voltage value at -
10°C or +50°C, or from the setting range of the output voltage. The pivot of
the temperature-dependent voltage curve is fixed at a reference tempera-
ture of 20°C.
NOTE:
i If the active sensor is faulty (sensor lead broken or short circuit)
the output voltage returns to the value at 20°C.
CAUTION!
If necessary, the response values of the output voltage monitoring
must be readjusted.
.
Ub [V]
30
25
20
-30 -20 -10 10 20 30 40 50 60 70 80

Tb [°C]
Figure 3 Temperature-dependent charging voltage
3.6 External Sensor Lead Output Voltage U0

Unwanted voltage drops in the load circuit, e.g. caused by terminals, supply
lines, decoupling diodes, etc. can be compensated via sensor leads by
means of the output voltage control.
The maximum voltage drop to be compensated is approx. 4V.
The connection points for the sensor leads are connected internally to the
unit output via thermistors (overload protection). This prevents damage to
the unit due to sensor lead break, polarity reversal or short circuit.
When operated with external sensor lead connection, correct function is
only possible when the supply line resistance is <5 Ω.

The displayed setpoint, e.g. U1 = xx.x V, corresponds to the voltage at the

end of the sensor cables. The operating display Uo = xx.x V corresponds to
the value at the output terminals.
3.7 Mains Voltage Monitoring

The mains voltage monitoring ensures the intrinsic safety of the unit against
overloads and overvoltages. The response values are fixed factory settings.
Mains undervoltage monitoring:
The unit is switched off if the value drops below the switching point.
Display: The LED "mains" goes off.
Message: Indicator relay "Collective fault"
When the hysteresis voltage is exceeded, the unit automatically resumes
operation.
Mains overvoltage monitoring:

The unit is switched off if the value exceeds the switching point.
Display: The LED "mains" goes off.
When the voltage level drops below the hysteresis voltage, the unit auto-
matically resumes operation.
3.8 Output Voltage Monitoring
Overvoltage monitoring UO>:

The unit switches off if the output voltage reaches the disconnecting
threshold. The unit switches back on if the voltage falls below the
disconnecting threshold within a certain period of time.
If the output voltage remains above the disconnecting threshold after 3
internal tests, the unit is switched off permanently after a delay of
approx. 60 sec.
Display: LED "UO>" is on
Deactivation: Reset via On / Off switch of the unit
Reset button,
external On / Off or CAN bus command.
Undervoltage monitoring UO<:
As soon as the output voltage drops below the monitoring threshold, the
monitor signals with a response delay of t = approx. 3 s.
Display: LED "UO<" is on
Deactivation: automatic, as soon as the output voltage exceeds the moni-
toring threshold.
When sensor cables are used for operation, the values for output voltage
monitoring must be increased by the compensated voltage drop in the load
circuit.

3.9 Monitoring of Functions

As soon as the input voltage is connected and the unit is switched on, the
following routines are automatically carried out:
- Self test of the µ controller
- Mains voltage within the tolerance range?
- Unit switch and ext. On?
- Unit address set to 0? *
- Switch on BOOSTER.
- Booster voltage O.K.?
- Switch on DC/DC transformer
- Output overvoltage monitor did not respond?
Display: LED "Operation" is on
If a unit address from 1- 31is set, the switch mode power supply expects a
control command from the CAN bus. On receipt of a control command, the
switch mode power supply follows the control command. If no CAN connec-
tion is recognized, the unit switches on after a delay time and continues
working with the stored voltage and current values.
Display: LED "ϑ" flashes.
If during operation the contact via CAN bus is interrupted, the switch mode
power supply automatically returns to the saved value after a time delay of
approx. 10 seconds.
Display: LED "ϑ" flashes.
3.10 Temperature Monitoring

If the temperature on the heat sink rises to > 100°C, the output capacity of
the switch mode power supply is reduced to ensure intrinsic safety.
Display: LED "ϑ" is on

If the temperature on the heat sink rises to > 110°C, the unit turns off.
Display: LED "ϑ" is on

3.11 Reset
A fault signal (response of an output monitoring) can be acknowledged with
the Reset button S1 on the front panel. The unit resumes operation, if it has
been switched off before.
A fault can also be acknowledged by switching off the unit, switching off the
output voltage, by a CAN bus command or the external On/Off function.
3.12 ON / OFF Switch

The switch mode power supply can be switched on or set to standby mode
using the S2 switch on the front panel.

3.13 External ON / OFF

The switch mode power supply can be switched off by an external signal.
The signal is applied to X11.7 and X11.8 and switches off the unit via an
optocoupler. The control voltage range lies between 10 and 24 V, the inter-
nal resistance is approx. 1.4 kΩ. The input is protected against polarity re-
versal. With higher operation voltages, the current in the control loop must
be limited to 5 - 10mA using a suitable resistor.
3.14 Parallel Operation

Due to the inclination of the individual voltage curves, the load can be dis-
tributed quite evenly in the case of parallel operation of several switch
mode power supplies. (±10 % of the rated current of the unit). A major con-
dition for this is that the unit outputs are connected to the load having the
same line diameter and length.
Safe selective monitoring of the individual switch mode power supplies is
only possible using external decoupling diodes in the output. Due to the fact
that the units can be connected in parallel, it is possible to build systems for
redundant operation in accordance with the n+1 principle. If the switch
mode power supplies are interconnected in the respective output without
decoupling diodes or fuses, the system wiring must be dimensioned for the
max. possible current.
Parallel operation of the switch mode power supplies with a temperature
sensor is possible, refer to chapters 3.5 and 3.17. The DIL switch S3 must
be switched on according to chap. 3.17.
CAUTION!
Parallel operation with temperature-dependent voltage control and
external decoupling diode in the negative branch is not permissi-
ble.
3.15 CAN BUS interface X12

The unit can be completely controlled via the CAN bus connector X12, with
the aid of a text-ABE and the PSM control unit (possible component of the
power supply cabinet).
In addition to the fault message on X11, a potential-free relay contact is
connected to X12:14 - 15. In the case of a message, the contact is con-
nected to X12:14 - 15.

3.16 RS 232 Service InterfaceX13

During the test, the unit is completey adjusted via of the RS 232 interface
and a special software. In addition, all operating parameters can be ad-
justed and visualized.
CAUTION!
The interface X13 is not a potential-free interface. The reference
potential is - UO.
The PC interface must therefore be connected to the unit via an
optical coupler.
3.17 DIL Switch S3

The DIL switch is installed below the front panel and can be accessed after
removal of the power connection cover. The DIL switch S3.1 points to the
upper edge of the unit.
All settings / changes in the setting of the DIL switch are only activated on
connection of the mains voltage or when pressing the Reset button.
Switches S3.1 to S3.5
Standard setting: Address 0 all switches open
The address of the unit can be set using these five switches. The switches
are binary coded. Switch S3.1 represents the highest bit equivalent to the
value 16
Exponent 24 23 22 21 20
Switch S3.1 S3.2 S3.3 S3.4 S3.5
The address set by means of the switches always has priority. The setting
can then no longer be changed via the menu. If unit addresses are over 31,
the ERROR ADDRESS message and the flashing LED "Operation" appear.
If the previously set address is reset to 0, the address must additionally be
reset to 0 via the menu after the next reset.
Switch S3.6
Standard setting: Switch closed
Reference for temperature-dependent voltage control.
Switch S3.7
Standard setting: Switch closed
The temperature-dependent voltage control is switched on via this switch.
At the same time it is possible to check if the battery temperature sensor is
connected correctly.
If a temperature sensor controls several units connected in parallel, the DIL
switch S3.6 must be switched on and S3.7 switched off on one unit. On all
other units, the DIL switches S3.6 and S3.7 must be switched off.
Switch S3.8
Standard setting: Switch open
Switch open: Suppression of the fault message on X12 when the unit is
switched off.

3.18 DIL Switch S4

The DIL switch is installed below the upper unit cover near the front panel.
The switch can be accessed after removal of the upper unit cover. The DIL
switch S4.1 points to the left side of the unit.
Standard setting: all switches open
Standard setting*: S4.3 OFF, S4.4 OFF
The level range for the external setpoint can be set using these two
switches.
S4.3 S4.4 Level range Internal resistance

ON ON 0 - 20mA 494Ω
OFF ON 0 - 10V 10kΩ
OFF OFF 0 - 4V >10kΩ

Standard Einstellung *: S4.5 OFF, S4.6 OFF
The level range for the external current setpoint can be set using these two
switches.
S4.5 S4.6 Level range Internal resistance

ON ON 0 - 20mA 494Ω
AUS ON 0 - 10V 10kΩ
OFF OFF 0 - 4V >10kΩ

Standard setting: all switches open / not assigned.
3.19 Signalling
The following signals are indicated via LEDs on the front side.
- mains: Mains voltage within the permissible tolerance

- operation: Unit can be operated without faults and loss of power
- UA> Output overvoltage monitor responded
- UA< Output undervoltage monitor responded
- ϑ Unit heat sink too hot
The unit is equipped with a liquid-crystal display. The voltage and current
values are displayed with two decimals before and one decimal after the
decimal point. When Displayed values are > 100, no decimals are dis-
played after the decimal point. The display accuracy corresponds to class 1
related to the nominal output value of the unit.

3.20 Pin Assignment X11

If a temperature sensor controls several units connected in parallel, X11:1
and X11:11 must be connected on all units. The DIL switch S3.6 and S3.7
must be switched off on one unit. On all other units, the DIL switches S3.6
and S3.7 must be switched off.
Pin Function
1 Analog ground
2 + ext. voltage adjustment
3 free
4 + ext. current adjustment
5 2nd V curve
6 3rd V curve
7 (+) remote shut-down
8 (-) remote shut-down
9 + UA sensor lead
10 - UA sensor lead
11 Battery temperature sensor
12 Indicator relay Collective fault NC
13 Indicator relay Collective fault COM
14 Indicator relay Collective fault NO
Table 1 Terminal assignment X11 (signal interface)
Potential-free relay contact (changeover contact)

- "Collective fault" If this message appears, X11:13 - 14 open
or X11:12 - 13 close.
- The maximum contact load is 60V DC ≤ 0.6A
Electrical isolation to the unit output max. 60V

4. Start-Up
4.1 Installation
The switch mode power supplies (SMPS) are to be installed in suitable
module racks in acc. with DIN 41494.´The SMPS functions with natural air
cooling. The intake air temperature must not exceed 45 °C. If several units
are installed one above the other in one cabinet, there must be either a
forced-air cooling system installed, or a vertical distance between the units
of at least 134 mm = 3 height mo-dules must be guaranteed.
Air guides must be installed between the installation levels in such a way
that the air intake temperature of the individual installation levels does not
exceed the permanently permissible ambient temperature. Cabinets must
be designed for an ambient temperature of 40 °C. The power loss per unit
is approx. 410 - 465W.
4.2 Connection
Before connecting the unit to the mains supply, ensure that the mains volt-
age given on the rating plate complies with the existing mains voltage. The
unit is connected to the mains with a 3-pin terminal (L1, N, PE) on the front
of the unit (X1). If one pin on the output side is grounded, the SMPS must
be grounded via the separate PE connection on the front of the unit. In this
case, the PE conductor on the input side must not be connected (ground
loops). The cross-section of the PE conductor must be chosen in acc. with
VDE 0100 Part 540 depending on the type of installation.
NOTE:
i The discharge current lies below 3.5 mA. Prior to start-up, a PE
conductor connection must be established.
The DC connection (X2) and the PE connection of the unit are

established with the connection bolt behind the cover on the right-hand side
of the unit.
CAUTION!
When the mains is connected, the switch mode power supply car-
ries potentially fatal voltages.
4.3 Connecting the Loads / Battery

The switch mode power supply has an amplified smoothing module with
electrolytic capacitors in the output. If the de-energized capacitors are
switched over to the battery by engaging the DC isolator or DC fuse, this
causes a large surge of charging current. This can be avoided by switching
the unit on before engaging the isolator. This is the only way to ensure the
capacitors are charged to the unit output voltage with a high charging
stage.
Only now may the output circuit be closed by engaging the DC isolator or
the DC fuse.
The output circuit can be closed immediately in the case of units with a de-
coupling diode.

NOTE:
i Observe correct polarity of the DC lines.
4.4 Isolation
Even when switched off, the switch mode power supply can carry voltage
from charged capacitors and external signals. For this reason the terminals
must be tested prior to dismantling the unit to ensure that they are de-
energized.
The capacitors can be discharged via an external resistor on the mains
terminals X1 or DC terminals X2: L+ and L-.
- Switch the unit off
- Switch off mains voltage
- Isolate the SMPS output from the load / disconnect the battery
- Disconnect interfaces X11, X12

5. Operation
5.1 Menu
The switch mode power supply is equipped with a liquid-crystal display and
three keys for operation on the front of the unit. The functions of the unit are
split up in a software menu. The menu comprises menu boxes and input
boxes. The menu boxes serve for indication only, while values can be
changed in the input boxes.
S O F TW AR E 2 4 V / 1 0 0 A NO U a = , V U1 = , V U > = , V ADDRE S S :
P I 1 7 8E x x I U ERROR I a = , A I 1 = , A U < = , V 2 3
01 02 03 04 05 06 07
Operating Display
C H A NGE
03 03
A DD R= 2 3
08
NO E RR O R 1 E RROR 1 0
ER R O R S U> T _ B _ TRCR
09 09 18
DE L E T E
E RRORS
19
DE L E T E
<- Y N- >
20
02 02 02 02
C H A NG E C H A NG E C H A NG E CHA NGE CHA NGE

MO N I T O R U / I C TR L U - C HA R . I - CH AR . T . CO E F F .
21 22 23 24 25
== Menu box
CHA NG. U> U CT R L U 1 CHA R . I1, I 2, I3 T . COE F F .
U> = , V I NT ER N A L U1 = , V = , A - 4mV == Input box
26 27 28 29 30 (system always returns to the
menu box one level higher)
Menu selection:
CHA NG. U < I CT R L U 2 CHA R . I 4 CHA R .
U< = , V I NT ER N A L U2 = , V I 4= , A via -key
31 32
32 33 34 via -key
via -key
U 3 CHA R .
U3 = , V via + -key
35 The system returns to the operating display from all

menus after no key has been pressed for a certain period:
U 4 CHA R . Menu 01-03: after 1s
Menu boxes: after 10s
U4 = , V Input boxes: after 2min.
36
Figure 4 Software menu tree
When the unit is switched on, the menu boxes 01 to 04 are briefly displayed
one after the other, menu box 04 is always active in normal mode. In the
case of a fault, the system automatically switches to menu box 03. This box
displays the current error message until the error is eliminated, or another
box is selected by pressing a button.

5.2 Key Assignment

Within the diffent boxes, the buttons have different functions.
Key functions within a Key functions within an

menu box: input box:
Box to the left Reduce value
Box to the right Increase value
Box down Accept value and

continue
Figure 5 Key assignment
The arrow keys ⇐ and ⇒ take you to the various menu boxes within a
level. At certain locations within a level, e.g. on box 02, 03, 07... the ⇓ key
takes you to the boxes below this level.
If, for example, the menu box 25 is selected and, for a longer period, no
button is pressed, the system automatically returns to the error state (box
03) or the operating display (box 04).
As a rule, the current parameter value is copied into a buffer when an input
box is activated. This buffer value can then be changed. The buffer value is
only transferred to the parameter memory when the take-over key ⇓ has
been pressed. If you do not want to take over the new value, the process
can be interrupted using the cancel function.
NOTE: Cancel function
i You can return to menu box 02 from anywhere within the menu
tree using the cancel function. The arrow keys ⇐ and ⇒ must be
pressed simultaneously to activate the cancel function.
5.3 Significance of the Boxes
Menu box 01 Designation of the software used, saved on EPROM
S O F T W A R E
P U x x x E x x
xxx refers to the date of the software
xx corresponds to the state of modifications
Menu box 02 Set type of unit
2 4 V / 1 0 0 A
I U
alternatively:
2 4 V / 1 0 0 A
I U / T
/T automatic recognition when operated with a temperature sensor

Menu box 03 Unit status
N O
E R R O R
alternatively:
S U P P L Y
S T A N D B Y
Unit in standby operation, via unit switch
S U P P L Y
B U S O F F
Unit in standby operation, via CAN bus command
R E M O T E
E X T . O F F
Unit in standby operation, via external contact
E R R O R
U >
Monitor U> responded
E R R O R
U <
Monitor U< responded
E R R O R
T _ B _ S E N S
Battery temperature sensor lead broken or short circuit
E R R O R
H E A T S I N K
Heat sink too hot, lead broken or short circuit
E R R O R
I N P U T
Input voltage not within the tolerance
E R R O R
A D D R E S S
Switches S3.1- S3.5 address set > 31

E R R O R
B O O S T E R
Booster fault
Menu box 04 Actual values
U a = , V
I a = , A
present actual voltage and actual current value
Menu box 05 Setpoints, independent of the selected voltage curve
U 1 = , V
I 1 = , A
present voltage and current setpoint
Menu box 06 Output Voltage Monitoring
U > = , V
U < = , V
Response value overvoltage or undervoltage monitor
Menu box 07 Unit address
A D D R E S S :
0
Unit addresses from 0 to 26 are possible
Input box 08 Changing unit address

Access via box 07 with arrow key ⇓
C H A N G E
A D D R =
Unit addresses from 0 to 31 are possible
Adjustment is only possible when address is set to 0 on the DIL switch S3.
Menu box 09 - 18 Error journal
E R R O R x
x corresponds to the error code as described in menu box 03

The last ten messages are saved.
Menu box 19 Delete error journal

Access via boxes 09 - 18

D E L E T E
E R R O R S
Input box 20 Delete error journal

D E L E T E
< - Y N - >
Then the system automatically switches to menu box 03
Menu box 22 Changing external setpoint U / I

C H A N G E
U / I C T R L
Input box 27 Changeover setpoint U internal / external

U C R T L
I N T E R N A L
alternatively:
U C R T L
E X T E R N A L
You can switch from one setting to the other using
the arrow keys ⇐ and ⇒.
Input box 32 Changeover setpoint I internal / external

I C R T L
I N T E R N A L
alternatively:
I C R T L
E X T E R N A L
You can switch from one setting to the other using
the arrow keys ⇐ and ⇒.
Menu box 21 Changing response values of the monitors

Access via box 22 with arrow key ⇐ or box 25 with key ⇒

C H A N G E
M O N I T O R
Input box 26 Changing response value monitor U>

C H A N G . U >
U > = , V
Changing the value in steps of 0.1V
Input box 31 Changing response value monitor U<

C H A N G . U <
U < = , V
Menu box 23 Changing voltage curves

Access via box 24 with arrow key ⇒ or box 21 with key ⇐
C H A N G E
U - C H A R .
Input box 28 Changing characteristic curve U1

U 1 - C H A R .
U 1 = , V

U 2 - C H A R .
U 2 = , V
Input box 35 Changing U3 characteristic curve

U 3 - C H A R .
U 3 = , V


U 4 - C H A R .
U 4 = , V
Menu box 24 Changing current curves

C H A N G E
I - C H A R .
Input box 29 I1, I2, I3. Changing characteristic curve

I 1 , I 2 , I 3
= , A
Changing the value in steps of 0.1 V / 1A
Input box 34 I4. Kennlinie ändern

I 4 - C H A R .
I 4 = , A
Changing the value in steps of 0.1A
Menu box 25 Changing the temperature coefficient

C H A N G E
T . C O E F F .
Input box 30 Changing the temperature coefficient

T . C O E F F .
- 4 m V
Changing the value in steps of 1mV Value range: -1 mV bis -6 mV

6. Maintenance
CAUTION!
Disconnect the unit from the power supply for maintenance work.
Always observe the safety regulations! (see chap.1)
The SMPS is made up of state-of-the-art components which are almost

non-wearing. We do, however, recommend regular visual and functional
tests of the equipment to maintain its operational reliability and availability.
When visually inspecting the unit, check whether:
- there is any mechanical damage or foreign bodies are present,
- any conductive dirt or dust has accumulated in the unit, and
- accumulation of dust affects heat supply and dissipation.
If large quantities of dust have accumulated, the unit should as a precaution
be cleaned with dry compressed air, in order to ensure adequate heat dis-
sipation.
The intervals at which visual checks should be performed are determined
by the site conditions. The unit may not be operated in an aggressive at-
mosphere
7. Trouble Shooting
NOTE:
i All work on the unit may be carried out by specially trained per-
sonnel only. Always observe the safety regulations! (see chap.1)
7.1 No Output Voltage Present

- Mains voltage present or correct polarity?
- Switch S2 switched on?
- Unit externally switched off?
- Polarity reversal on output?
- With parallel operation: Polarity reversal on ext. decoupling diodes?
- Has monitor UO> responded (LED UO> is on)?
Press reset and check setting UO>
If all aforementioned points are o.k., proceed as follows:
- Unscrew the cover
- Observe safety instructions on the front of the unit!
- Check fuses on the printed board A1
- Check plug connections for correct position
If the fault cannot be eliminated, return the unit to the works for repair and
enclose a fault description.
7.2 Output Voltage Deviation

- Is the unit running in current limitation due to overload?
Reduce the load!
- Is the UO setting incorrect?
Adjust the output voltage!
- If an external sensor lead is used, is the sensor lead open?

8. Technical Data
8.1 General Technical Data
Making current............................... < rated input current

Necessary mains fuse ................... gL 16 A or Circuit braker 16 A ”C”
Characteristic Curve ...................... CVCC curve in acc. with DIN 41772 or
41773
Manufacturing and type test .......... in accordance with DIN 60146 Part 1-1
Emitted interference to EN 50081-1
- Conducted interference .............. in accordance with EN 55022 class "B"
- Emission...................................... in accordance with EN 55022 class "B"
Noise immunity to EN 50082-2
- Housing ....................................... ESD-Test to EN 61000-4-2,
6 kV contact, 8 kV air discharge
HF field to EN 61000-4-3,
10 V/m (30 MHz - 1 GHz)
- Power cables ............................... Burst test to EN 61000-4-4, 2 kV
Surge test to EN 61000-4-5,
2 kV asymmetrical; 2 kV symmetrical
- Control cables ............................. Burst test to EN 61000-4-4, 2 kV
Surge test to EN 61000-4-5,
2 kV asymmetrical
Safty extra-low voltage .................. with safe isolation to EN 50178
Dynamic response......................... ≤ 5% with sudden load fluctuations be-

tween 10%-90%-10% rated output cur-
rent (adjustment time t < 5 ms)
Short circuiting............................... continued short circuit protected, 1 x
rated output current
Monitoring...................................... - mains voltage green LED
- operation: green LED
- overtemperature: red LED
- output undervoltage: red LED
- output overvoltage: LED red
- collective fault max. contact load:
60 V DC ≤ 0.6 A
Parallel Operation.......................... 31 units max. when connected to CAN
bus
load distribution approx. 10 % of rated
current.
Design ........................................... 19" x 4 height modules, panel mounting
unit for installation in module rack ac-
cording to DIN 41494.

Protection class ............................. IP 20

Cooling .......................................... natural air cooling
Ambient temperature ..................... at UA = 30 V and IA =100 A
0°C to 45°C for individual unit
0°C to 40°C for cabinet installation
Storage temperature...................... - 20°C to + 70°C
Environmental conditions ............. IEC 721 Part 3-3 Class 3K3 / 3Z1 / 3B1 /
3C2 / 3S2 / 3M2
Site altitude.................................... up to 1000 m above sea level
Mechanical stability
and vibration resistance................. to EN 50178 Version 9.4.3.2
Surface painted with ...................... RAL 7032 (front panel)
Dimensions (w x h x d) .................. 483 x 177 x 270 mm
(19" x 4 height modules)
Weight ........................................... approx. 17.7 kg
Connections
Mains connection X1: .................... Right-angle connector, type GDM 2011*
DC output X2: ................................ M8 threaded bolt
M8 max. torque 6 Nm
PE conductor: ................................ M6 threaded bolt

Signal interface X11: ..................... Signal connector, type MCVW 1.5/14-
ST-3.81*
CAN bus interface X12 .................. 16-pin socket connector*
Manufacturer, for example,
Thomas & Betts
No. 622-1641
Service interface X13 .................... 9-pin SUB D socket connector
(* supplied with the unit)

8.2 Technical Data of the AC 3000 Series

Type E230 G24/100 BWrug-Cpü
E-Number 37205103
Nominal supply voltage 230 V AC ±15 %
Frequency 47 to 63 Hz
Current consumption 13.4 A AC Value set
Output voltage
Value set U1 26.76 V DC ± 1 %*
(2.23V/Z)
(2.4V/Z)
(1.85 V/Z)
Setting range U1 - U3 20 to 30 V DC
(2.65V/Z)
Setting range U4: 20 to 32.4V DC
Setting range external 0 - 4V / 0 - 10V / 0 - 20mA ≡
voltage setpoint: 0 to 30V DC
Output current
Value set I1-I3 100 A DC ± 2 %*
Setting range 5 to 100 A DC
Value set I4 50 A DC ± 2 %*
Setting range 5 to 80 A DC
Setting range external 0 - 4V / 0 - 10V / 0 - 20mA ≡
current setpoint: 0 to 100A DC
Temp. coefficient -4 mV/K
Setting range: -1 mV/K to -6 mV/K
Voltage ripple < 50 mV ss
Interference voltage acc. to < 1.8 mV
CCITT
Power factor 0.99
Efficiency 88 % at 30V / 100A 91% at 30V / 40A
Monitoring
Mains undervoltage Unit OFF < 185 V Unit ON > 195 V

Mains overvoltage Unit OFF < 275 V Unit ON > 265 V
DC undervoltage 24 V DC*
response value (2V/Z)
Setting range 18V DC to 28V
DC overvoltage 28.2 V DC
response value (2.35V/Z)
Setting range 20V to 37V DC
Table 2 Technical data
CAUTION!
In the case of mains undervoltage or if the unit voltage is higher
than 32V, the max. possible input current must be ascertained
and limited to max. 16A by reducing the current setpoint.
*) For installation in a power supply cabinet, refer to the technical data
sheet on power supply cabinets

9. Dimensioned Drawing
Figure 6 Dimensions

0245b-En 2

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Operating Instructions

Switch Mode Power Supply

AEG Power Supply Systems GmbH

Notes on these Operating Instructions ...........................................4

Page 2 of 32 0245 BAL, en

8.1 General Technical Data .........................................................29

Page 3 of 32 0245 BAL, en

Notes on these Operating Instructions

Duty to Provide Information

Page 4 of 32 0245 BAL, en

 AEG Power Supply Systems GmbH

(++49- 29 02) 7 63-100

FAX (++49- 29 02) 7 63-680

© Copyright AEG 1998. All rights reserved.

Page 5 of 32 0245 BAL, en

1.1 Important Instructions and Explanations

1.2 Accident Prevention Regulations

1.3 Qualified Personnel

Qualified personnel is defined as personnel

Page 6 of 32 0245 BAL, en

Page 7 of 32 0245 BAL, en

2.1 System Description

2.2 Type Overview AC3000

Type designation Supply Output Output

E230 G24/100 BWrug-Cpü 230V AC 24 V DC 100 A

2.3 Principle of Operation, Electrical

Page 8 of 32 0245 BAL, en

2.4 Circuit Diagram

Figure 1 Circuit diagram AC 3000 CAN

Page 9 of 32 0245 BAL, en

3.2 Output Curve

Figure 2 Output curve

Page 10 of 32 0245 BAL, en

3.3 Changing the CVCC Curves

3.4 External Setpoint

3.5 Temperature-Dependent Voltage Control

Page 11 of 32 0245 BAL, en

The sensor (AEG reference no. 8000001495) available as an option, is

-30 -20 -10 10 20 30 40 50 60 70 80

3.6 External Sensor Lead Output Voltage U0

Page 12 of 32 0245 BAL, en

The displayed setpoint, e.g. U1 = xx.x V, corresponds to the voltage at the

3.7 Mains Voltage Monitoring

Mains overvoltage monitoring:

3.8 Output Voltage Monitoring

Overvoltage monitoring UO>:

Page 13 of 32 0245 BAL, en

3.9 Monitoring of Functions

Display: LED "ϑ" flashes.

Display: LED "ϑ" flashes.

3.10 Temperature Monitoring

Display: LED "ϑ" is on

Display: LED "ϑ" is on

3.12 ON / OFF Switch

Page 14 of 32 0245 BAL, en

3.13 External ON / OFF

3.14 Parallel Operation

3.15 CAN BUS interface X12

Page 15 of 32 0245 BAL, en

3.16 RS 232 Service InterfaceX13

3.17 DIL Switch S3

Page 16 of 32 0245 BAL, en

3.18 DIL Switch S4

AEG Power Supply Systems GmbH