Related Manuals for Teseo PA 5840 Series
Summary of Contents for Teseo PA 5840 Series
- Page 1 ® Advanced Test Equipment Rentals www.atecorp.com 800-404-ATEC (2832) PA 5840 - Automotive bAttery simulAtors user mAnuAl 601-306A...
- Page 2 PA 5840 - Automotive bAttery simulAtors user mAnuAl PA 5840...
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Page 3: Table Of Contents
Contents Safety Instructions 1.1 Classification of dangers 1.2 Warning symbols on the test system 1.3 Excess voltage category 1.4 Range of validity 1.5 Safety of operation 1.6 Personnel 1.7 Responsibility for safety precaution 1.8 Reduction in operational safety 1.9 As agreed use Introduction 2.1 Introduction 2.2 Features Installation/set-up 3.1 Checking the shipment 3.2 Delivery contents 3.2.1 Standard accessories 3.2.2 Documentation 3.3 Set-up 3.3.1 Operating position 3.3.2 Line voltage connection and grounding 3.4 PA 5840 front panel connectors 3.4.1 The control connector 3.4.2 Pin count of the control I/O DSub connector... - Page 4 Operation 4.1 The main switch 4.2 The system stop button 4.3 The output voltage (RMS) display 4.4 The output current (RMS) display 4.5 The view current limit button 4.6 The errors LEDs 4.7 The compensation button 4.8 The gain button 4.9 The current limitation button 4.10 The output range button Applications 5.1 Compliant with ISO 7636 (and similar) for transient immunity 5.2 Voltage variations for starting profiles 5.3 Fast rise time for callenging voltage dip applications 5.4 Voltage ripple and sine wave noise simulations 5.5 Example application with NSG 5500 and NSG 5600 Maintenance 6.1 Cleaning the equipment 6.2 Moving and storing the amplifier 6.3 Protection Specifications 7.1 Envionmental conditions 7.2 Technical capabilities 7.3 Pictures...
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Page 5: Safety Instructions
1 sAFety instruCtions 1.1 Classifi cation of dangers 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 fi rst time. The electrical and mechanical safety equipment must not be removed, put out of operation or bypassed. -
Page 6: Warning Symbols On The Test System
Warning Signal word Definition symbol Possibly dangerous situation, that may cause damage to persons or heavy damage to the DANGER! tester and/or the equipment Situation, that may cause damage to the tester CAUTION! and/or the equipment User tips and other important or useful infor- NOTE! mation and comments 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 specific risk and the (possible) consequences. Pictogramm Definition Possibly dangerous situation that can result in injuries and serious damage to the equipment. Situation that can result in damage to the equipment. 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. PA 5840... -
Page 7: Range Of Validity
1.4 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 confirms to the power specification given on the type label (on the back of the test equipment). Do not touch any conductive parts at the output connectors, the fixture 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. -
Page 8: Responsibility For Safety Precaution
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 specifications. PA 5840... -
Page 9: Introduction
2 introDuCtion 2.1 Introduction The PA 5840 range of battery simulators are high performance power amplifi ers providing a stable and rugged power source for laboratory applications. The amplifi ers have been designed specifi 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 amplifi 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 specifi cations. Types of testing include supply voltage variations, dips and drops, ISO pulses 2b and 4, load dump pulse, starting profi 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. 2.2 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). - Page 10 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 amplifiers. To avoid excessive heat the PA 5840 range includes a range selection switch on the front panel to enable the amplifier 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 amplifier 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. PA 5840...
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Page 11: Installation/Set-Up
3 instAllAtion/set-uP 3.1 Checking the shipment Upon receiving the shipment, fi 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 qualifi ed personnel only. -
Page 12: Operating Position
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 sufficient air flow 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 specification 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 qualified personnel only. -
Page 13: Pa 5840 Front Panel Connectors
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. -
Page 14: Pin Count Of The Control I/O Dsub Connector
3.4.2 Pin count of the control I/O DSub connector 3.4.3 The function generator input connector PA 5840... -
Page 15: The Output Connectors
This 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 amplifier. 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! 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! CAUTION! If used, the input voltage at the I Input con- nector must be at least 1 V (10% output limitation). -
Page 16: The Power Output Connectors
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. NOTE! The PA 5840-300 has two output connectors (modularity). For greatest accuracy. Please use the upper connector 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 configured by the factory. Please ensure the connections are made as shown in the picture below. -
Page 17: Operation
4 oPerAtion 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. NOTE! The 30 Volts range is for greater efficiency during normal 12 and 24 V battery voltage operation. -
Page 18: The System Stop Button
OFF The system is completely powered off The system is in standby mode when first starting the system or after an error condition. In order to start the system the first time, or after an error condition, the key must temporarily be placed in the “START” position START (Momentary) Used to enable the amplifier 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! 4.2 The system stop button In case, an EUT needs to be exchanged frequently, the optional safety banana... -
Page 19: The Output Voltage (Rms) Display
4.3 The output voltage (RMS) display This display shows the output voltage in RMS. 4.4 The output current (RMS) display This display shows the actual output current or the programmed current limit when pressing the “VIEW CURRENT LIMIT” button. 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” field are met. Pressing the “VIEW CURRENT LIMIT” button displays the current limit on the “OUTPUT CURRENT” display. -
Page 20: The Errors Leds
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 amplifier is turned on, and the fans are cooling, but no output is allowed. Turning the “POWER”... -
Page 21: The Compensation Button
4.7 The compensation button Pressing this button toggles between the available compensation modes. STANDARD This is the normal operating mode with a good compromise between stability and bandwidth. The bandwidth in this selection is approximately 40 kHz. CAPACITIVE This mode is specifically designed for capacitive and/or reactive loads. This reduced bandwidth, high stability mode is perfect for using during normal transient testing, conducted sine wave (CSW) testing. The bandwith in this mode is limited to approximately 3 kHz. HIGH FREQ This mode is for testing where high bandwidths are required. This mode allows frequencies up to 150 kHz. CAUTION! As with all fast amplifiers, the user should monitor the DUT to ensure no ringing or excessive over- shoot is present that could result in damage to the DUT or couplers. In case there is a question the “CAPACI- TIVE”... -
Page 22: The Gain Button
4.8 The gain button This button toggles between the available gain options of the amplifier: GAIN HIGH (x7) Indicates a gain of seven. 1 V in will result in 7 V output voltage. GAIN LOW (x1) Indicates a gain of one. 1 V in will result in 1 V output voltage. 4.9 The current limitation button This button toggles between the three current limitation modes: PA 5840... -
Page 23: The Output Range Button
PEAK OFF this selection enables no inrush current above what is set by the current limit control from the DB9 or to the I INPUT BNC connector. The current limit circuitry will start immediately. 3x I CONTROL this selection will allow an inrush current of three times the programmed current limit for 200 ms before the current limitation starts. 3x I MAX this selection will allow an inrush current of three times the maximum current available from the battery simulator for 200 ms before the current limitation starts. 4.10 The output range button This button toggles between the two available output ranges: 30 V this option selects a maximum usable range of +30 /-15 V for greater efficiency. 60 V this options selects a maximum usable range of +60 /-15 V for testing up to the full power of the battery simulator. -
Page 24: Applications
5 APPliCAtions 5.1 Compliant with ISO 7637 (and similar) for transient immunity The PA 5840 is designed to act as the battery source for transient immunity tests. Most transients must be coupled onto battery voltage and the NSG 5000 series with its internal coupling couples the transient and the DC voltage as required by the standards. Designed with low internal resistance, low noise and high inrush current, the PA 5840 is compliant with section 5.4 of ISO 7637-2:2004. 5.2 Voltage variations for starting profiles The PA 5840 series is often used for starting profile simulation (pulse 4 and variants). In addition, several standards require synchronized starting profiles. Utilizing the NSG 5000 series for control, the PA 5840 is the best solution for all known starting profiles with up to four synchronized starting profiles. See the specifications of the NSG 5000 series for details. PA 5840... -
Page 25: Fast Rise Time For Callenging Voltage Dip Applications
5.3 Fast rise time for challanging voltage dip applications Certain standards, such as Ford ES-XW7T-1A278-AC specify ~10 μs rise and fall times for the battery simulator. The PA 5840 is designed to fully meet the relevant standards and is often used for dips and drops applications where <10 μs rise times are specified. 5.4 Voltage ripple and sine wave noise simulations The PA 5840 is also commonly used to simulate sine wave noise on battery voltage. A user could, for example, simulate a 1 V p/p sine wave onto a 42 V network using high battery current. This is a common requirement of manu- facturers’ standards. -
Page 26: Example Application With Nsg 5500 And Nsg 5600
5.5 Example application with NSG 5500 and NSG 5600 PA 5840... -
Page 27: Maintenance
6 mAintenAnCe Under normal conditions, it does not take much effort to keep your test equip- ment in good working order. CAUTION! Protect the equipment against moisture, heat and dust. 6.1 Cleaning the equipment To clean the equipment, use a dry, clean cloth. Never use water, any other liquid or detergent. 6.2 Moving and storing the amplifier The amplifier must be installed/uninstalled only by qualified personnel. Before moving the equipment (even over a short distance), you must first turn it off and disconnect it from the mains. Remove any fixturing devices and/or test objects. Also, disconnect the amplifier from any peripherals. For longer transit, protect the equipment against humidity, dust and shock by proper packaging. The equip- ment must be stored in upright (working) position. Make sure the equipment is protected against humidity, dust and dirt. Observe the environmental conditions specified in chapter 7.1 Environmental conditions. -
Page 28: Protection
6.3 Protection The PA 5840 Automotive battery simulators are protected with a thermal mag- netic circuit breaker. The thermal element is a slow breaker to allow high inrush currents. The magnetic element is a fast breaker but set to a higher current limit than the thermal element. The different versions of the PA 5840 are equipped as follows: Type No. of phases Supply voltage U Primary current I PA 5840-75 / 100 V 100 V 25 A PA 5840-75 / 120 V 120 V 24 A PA 5840-75 / 230 V 230 V 12 A PA 5840-150 / 200 V 200 V 24 A PA 5840-150 / 400 V 400 V 12 A PA 5840-300 / 200 V 200 V 2 x 24 A PA 5840-300 / 400 V 400 V 2 x 12 A... -
Page 29: Specifications
7 sPeCiFiCAtions 7.1 Environmental conditions Temperature range: Operation at +10 to +40°C storage at -10 to +60°C Humidity: 30 to 75% (non condensing) Air pressure: 860 to 1060 hPa Protection class: IP20 7.2 Technical capabilities PA 5840-75 PA 5840-150 PA 5840-300 75 Amp (pk) 150 Amp (pk) 300 Amp (pk) General Forward voltage gain (switchable) 7/1 Bandwidth (-3 dB) DC to 40 kHz DC to 40 kHz DC to 40 kHz (standard) (standard) (standard) to 150 kHz to 150 kHz... - Page 30 PA 5840-75 PA 5840-150 PA 5840-300 75 Amp (pk) 150 Amp (pk) 300 Amp (pk) Output Peak output power (200 ms) 4.5 kW 9 kW 18 kW Ouput voltage range -15 to +60 V Max. continuous output current ±25 A ±50 A ±100 A Peak output current for 200 ms +75 A +150 A +300 A Output impedance <10 mΩ <10 mΩ <10 mΩ Output accuracy Typical <1% <2% AC signals <2% Long term drift, Uout 0.1% max Temperature drift, Uout 0.02% / °C...
- Page 31 PA 5840-75 PA 5840-150 PA 5840-300 75 Amp (pk) 150 Amp (pk) 300 Amp (pk) Mechanical specification Standard housing style / 19” wheeled cabinet construction 700 x 650 x 720 mm 700 x 650 x 720 mm Overall dimensions H x W x D 700 x 600 x 1300 mm 27.6 x 22 x 28.3” 27.6 x 22 x 28.3” 27.6 x 23.6 x 51.2” Masse (kg) 100 kg / 220 lbs 195 kg / 429 lbs 290 kg / 780 lbs Control panel (top front) 2 x Display 3 digit red LED Voltage, current 1 x Connector 9-pole male D ; I prog prog 2 x Connector BNC ; I...
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Page 32: Pictures
7.3 Pictures 7.3.1 Front view 7.3.1 Rear view PA 5840... -
Page 33: Declaration Of Confirmity (Ce)
7.3.3 DeClArAtion oF ConFormity (Ce) -
Page 34: Addresses
Manufacturer Headquarters Teseq AG Teseq AG 4542 Luterbach, Switzerland 4542 Luterbach, Switzerland T + 41 32 681 40 40 T + 41 32 681 40 40 F + 41 32 681 40 48 F + 41 32 681 40 48 sales @ teseq.com sales @ teseq.com www.teseq.com China France Teseq Company Limited Teseq Sarl T + 86 10 8460 8080 T + 33 1 39 47 42 21 F + 33 1 39 47 40 92 F + 86 10 8460 8078 chinasales @ teseq.com francesales @ teseq.com Germany Japan Teseq GmbH Teseq K.K. T + 49 30 5659 8835 T + 81 3 5725 9460 F + 49 30 5659 8834 F + 81 3 5725 9461 desales @ teseq.com japansales @t eseq.com Singapore Switzerland Teseq Pte Ltd.
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