MEAN WELL DBU-3200 3200W Intelligent Single Output Battery Charger Owner’s Manual

MEAN WELL DBU-3200 3200W Intelligent Single Output Battery Charger

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Features

• Charger for lead-acid batteries (Gel, flooded and AGM) and Li-ion batteries (lithium iron and lithium manganese)
• Built-in default 3 stage charging curves and programmable curve
• Built-in l2C interface, PMBus protocol (Optional CANBus protocol)
• Universal AC input/ Full range
• Built-in active PFC function
• Forced air cooling by built-in thermal controlled DC fans
• Output voltage and current programmable
• Built-in OR-ing FET
• Active current sharing up to 6400W(1 + 1)
• Protections: Battery under voltage I Battery no connection / Short circuit/ Over voltage/ Over temperature
• Optional conformal coating
• 5 years warranty

Description

DBU-3200 is a 3200W single output AC/DC enclosed charger in 1 U low profile with high power density, 37W/inch3 • It is an intelligent charger that has pre-loaded programmable charging curves for different types of lead-acid and Ii-ion batteries. Output programmable function allows user to adjust the charging voltage and current via the built-in potentiometer or PM Bus protocol. Various protection mechanisms as well as the temperature compensation function are provided to assure normal and safe system operation.

Applications

• Large scale DC UPS or emergency backup system
• Marine battery charger module
• Electric scooter or vehicle charger station
• Wastewater treatment system
• Electrolysis system

GTIN CODE

MW Search: https://www.meanwell.com/serviceGTIN.aspx

Model Encoding/ Order Information

SPECIFICATION

RECOMMENDED BATTERY

CAPACITY(AMP HOURS) Note.3

| ****

330 ~ 1000Ah

| ****

180 ~ 550Ah

LEAKAGE CURRENT FROM BATTERY (Typ.)| 1.5mA
INPUT| VOLTAGE RANGE Note.4| 90 ~ 264VAC        127 – 370VDC
FREQUENCY RANGE| 47 ~ 63Hz
POWER FACTOR (Typ.)| 0.97/230VAC at full load
EFFICIENCY (Typ.)| 93.5%| 94.5%
AC CURRENT (Typ.) Note.4| 17A/230VAC
INRUSH CURRENT (Typ.)| COLD START 55A/230VAC
LEAKAGE CURRENT| <2mA/ 230VAC
PROTECTION| OVER VOLTAGE| 31.5 – 37.5V| 63 – 75V
Protection type: Shut down o/p voltage, re-power on to recover
OVER TEMPERATURE| Shut down o/p voltage, recovers automatically after temperature goes down
FUNCTION| OUTPUT VOLTAGE PROGRAMMABLE(PV)| Adjustment of output voltage is allowable to 75 ~ 125% of nominal output voltage. Please refer to the Function Manual.
OUTPUT CURRENT PROGRAMMABLE(PC)| Adjustment of output voltage is allowable to 20 -100% of rated current. Please refer to the Function Manual.
AUXILIARY POWER| 5V@ 0.3A, tolerance ± 10%, ripple 150mVp-p , 12V@ 0.8A, tolerance ± 10%, ripple 450mVp-p
REMOTE ON-OFF CONTROL| By electrical signal or dry contact Power ON:short Power OFF:open. Please refer to the Function Manual
TEMPERATURE COMPENSATION| -3mV / °C /cell/ (12V = 6 cells; 24V = 12 ce lls ; 48V = 24 cells)
ALARM SIGNAL| Isolated signal output for T-alarm and DC-OK
ENVIRONMENT| WORKING TEMP.| -30 ~ +70″C (Refer to “Derating Curve”)
WORKING HUMIDITY| 20 – 90% RH non-condensing
STORAGE TEMP., HUMIDITY| -40- +85°C, 10 – 95% RH non-condensing
TEMP. COEFFICIENT| ±0.03%/°C (0 ~ 50°C)
VIBRATION| 10 ~ 500Hz, 2G 10min./1cycle, 60min. each along X, Y, Z axes
SAFETY &

EMC

(Note 6)

| SAFETY STANDARDS| UL62368-1, CSA C22.2 No. 62368-1, TUV BS EN/EN62368-1, EAC TP TC 004 approved
WITHSTAND VOLTAGE| I/P-O/P:3KVAC I/P-FG:2KVAC O/P-FG:1.5KVAC
ISOLATION RESISTANCE| I/P-0/P, I/P-FG, O/P-FG:100M Ohms/ 500VDC I 25°C! 70% RH
EMC EMISSION| Parameter| Standard| Test Level/ Note
Conducted| BS EN/EN55032 (CISPR32)| Class B
Radiated| BS EN/EN55032 (CISPR32)| Class A
Harmonic Current| BS EN/EN61000-3-2| Class A
Voltage Flicker| BS EN/EN61000-3-3| —–
EMC IMMUNITY| BS EN/EN55035, BS EN/EN61000-6-2
Parameter| Standard| Test Level/ Note
ESD| BS EN/EN61000-4-2| Level 3, 8KV air ; Level 2, 4KV contact
Radiated| BS EN/EN61000-4-3| Level 3
EFT/ Burst| BS EN/EN61000-4-4| Level 3
Surge| BS EN/EN61000-4-5| 2KV/Line-Line 4KV/Line-Earth
Conducted| BS EN/EN61000-4-6| Level 3
Magnetic Field| BS EN/EN61000-4-8| Level 4
Voltage Dips and Interruptions| BS EN/EN61000-4-11| >95% dip 0.5 periods, 30% dip 25 periods,

95% interruptions 250 periods

OTHERS

| MTBF| 494.2K hrs min.   Telcordia SR-332 (Bellcore); 44.8K hrs min. MIL-HDBK-217F (25°C)
DIMENSION| 325.8’107’41mm (L’W’H)
PACKING| 2.76Kg;4pcs/12Kg/O .83CUFT
NOTE|

1. Modification for charger specification may be required for different battery specification. Please contact battery vendor and MEAN WELL for details.
2. All parameters NOT specially mentioned are measured at 230VAC input, rated load and 25″C of ambient temperature.
3. This is MEAN WELL’s suggested range. Please consult your battery manufacturer for their suggestions about maximum charging current limitation.
4. Derating may be needed under low input voltages. Please check the derating curve for more details.
5. The charger is considered a component which will be installed into a final equipment. All the EMC tests are been executed by mounting the unit on a 600mm’900mm metal plate with 1mm of thickness. The final equipment must be re-confirmed that it still meets EMC directives. For guidance on how to perform these EMC tests, please refer to “EMI testing of component power supplies.” (as available on http://www.meanwell.com)
6. The ambient temperature derating of 3.5″C/ 1000m with fan less models and of 5°C /1000m with fan models for operating altitude higher than 2000m(6500ft).

Product Liability Disclaimer : For detailed information, please refer to https://www.meanwell.com/serviceDisclaimer.aspx

BLOCK DIAGRAM

DERATING CURVE

STATIC CHARACTERISTICS

FUNCTION MANUAL

1. PMBus Communication Interface
   DBU-3200 supports PMBus Rev. 1.1 with maximum 1 OOKHz bus speed, allowing information reading, status monitoring, output trimming, etc. For details, please refer to the Installation Manual.

2. Charging Curve
   • By factory default, this charger performs the default curve which can be programmed via PM Bus.
   •To disable/ enable the charging curve, change to a 2 stage curve, a different curve frequently used for certain types of batteries in the industry, and so on, please refer to the Installation Manual.
   • To program the parameters of the charging curve, SBP-001, the smart battery charging programmer designed by MEAN WELL, and a personal computer are needed . Please contact MEAN WELL for details.
   • Default 3 stage charging curve
   
   Suitable for lead-acid batteries (flooded, Gel and AGM) and Li -ion batteries (lithium iron and lithium manganese).
   Embedded 3 stage charging curvesMODEL| Description| Vboost| Vfloat| CC(defau lt)
   ---|---|---|---|---
   24V| Default, programmable| 28.8| 27.6| 110A
   Pre-defined , gel batter| 28| 27.2
   Pre-defined, flooded battery| 28.4| 26.8
   Pre-defined, AGM battery| 29| 27
   48V| Default, programmable| 57.6| 55.2| 55A
   Pre-defined, gel batter| 56| 54.4
   Pre-defined, flooded battery| 56.8| 53.6
   Pre-defined, AGM battery| 58| 54

Note:
When using this charger un it, please configured the system with recommended battery capacity defined by specification. Should battery capacity in use be much smaller so that user needs to set a low current for charging, under such condition it might cause higher current ripple.

3. Front Panel LED Indicators & Corresponding Signal at Function Pins
   

OLP, fan fail and charging timeout) arises.
Red (Flashing)| The LED will flash with the red light when the internal temperature reaches 60°C; under this condit ion , the unit st ill ope rates normally without entering OTP. (In the meantime , an alarm signa l will be sent out through the PMBus interface.)
4. Output Voltage Programming (or, PV / remote voltage programming I remote adjust/ margin programming I dynamic voltage trim)

• In addition to the adjustment via the built-in potentiometer, the output voltage can be trimmed by applying EXTERNAL VOLTAGE.
  
  

  5. Output Current Programming (or, PC/ remote current programming/ dynamic current trim)

• The output current can be trimmed to 20-100% of the rated current by applying EXTERNAL VOLTAGE.
  

  6. Remote ON-OFF Control
     The power supply can be turned ON/OFF individually or along with other units in parallel by using the “Remote ON OFF” function.
     Between Remote ON-OFF and +5V-AUX| Power Supply Status
     ---|---
     Switch Short| ON
     Switch Open| OFF
  7. Temperature Compensation
     • To exploit the temperature compensation function , please attach the temperature sensor, NTC, which is enclosed with the charger, to the battery or the battery’s vicinity.
     • The charger is able to work normally without the NTC.
     
     When multiple chargers are connected in parallel, please configure with the NTC as exhibited in the diagram.
     If the temperature compensation is not required, RTH+ (PIN 15) and RTH- (PIN

16. from each unit sti ll need to be connected.
    

8. Alarm Signal Output
   • There are 2 alarm signals, DC OK and T-ALARM , in TTL signal form, on CN1. These signals are isolated from output. The maximum sink current is 10mA.
   

9. Current Sharing
   DBU-3200 has the built-in active current sharing function and can be connected in parallel, up to 2 units, to provide higher output power as exhibited below:
   • The power supplies to be paralleled should use short and large diameter wiring and then connected to the load.
   • Difference of output voltages among parallel units should be less than 0.2V.
   • The total output current must not exceed the value calculated by the following equation: Maximum output current at parallel operation=(Rated current per unit) X (Number of unit) X 0.9
   • When the total output current is less than 5% of the total rated current, or say (5% of Rated current per unit) X (Number of unit) the current shared among units may not be balanced.
   • CN500/SW1 Function pin connectionParallel| PSU1| PSU2
   ---|---|---
   CN500| SW1| CN500| SW1
   1 unit| X| ON| –| –
   2 unit| V| ON| V| ON

(V: CN500 connected; X: CN500 not connected.)

(Q) DA,DB and -V(signal) are connected mutually in parallel.

MECHANICAL SPECIFICATION

Mounting Instruction

Hole No.| Recommended Screw Size| MAX. Penetration Depth L| Recommended mounting torque
---|---|---|---
1| M3| 4mm| 6-8Kgf-cm
2| M4| 5mm| 7-10Kgf-cm

Control Pin No. Assignment( CN 1) : HRS DF11-16DP-2DS or equivalent

(pin2).
The maximum load current is 0.8A. This output has the built-in “Oring diodes” and is not controlled by “Remote ON-OFF”.
2| GND-AUX| Auxiliary voltage output GND.
The signal return is isolated from the output terminals (+V & -VJ.
3| +5V-AUX| Auxiliary voltage output, 4.5-5.5V, referenced to GND-AUX (pin2).
The maximum load current is 0.3A. This output has the built-in “Oring diodes” and is not controlled by “Remote ON-OFF
4| Remote ON-OFF| The unit can turn the output ON/OFF by electrical signal or dry contact between Remote ON / OFF and +5V-AUX. (Note.2) Short (4.5 – 5.5V): Power ON; Open (-0.5 – 0.5V): Power OFF; The maximum input voltage is 5.5V.
5| DC-OK| High (3.5 – 5.5V): When the Vout ;aa 16V/32V ± 1V.
Low (-0.5 – 0.5V): When Vout e”; 16V/32V ± 1V. The maximum sourcing current is 10mA and only for output. (Note.2)
DC OK is associated with battery low protection.
6| T-ALARM| High (3.5 – 5.5V): When the internal temperature exceeds the limit of temperature alarm, or when Fan fails. Low (-0.5 – 0.5V): When the internal temperature is normal, and when Fan works normally. The maximum sourcing current is 1Om A and only for output(Note.2)
7,8,9| A0,A1,A2| PMBus interface address lines. (Note.1)
10| DO| DIP-switch interface Iines for charging curve selection . (Note .1)
11| PC| Connection for output current programming. (Note.1)
12| PV| Connection for output voltage programming. (Note.1)
13| +V (Signal)| Positive output voltage signal.

It cannot be connected directly to the load.

14| -V (Signal)| Negative output voltage signal.

It is for certain function reference: it cannot be connected directly to the load.

15| RTH+| Temperature sensor(NTC, 5KOhm) comes along with the charger can be connected to the unit to allow temperature compensation of the charging voltage.
16| RTH-

AC Input Terminal Pin No. Assignment

Control Pin No. Assignment(CN500): HRS DF11-8DP-2DS or equivalent

certain function reference; it cannot be connected directly to the load.

7

| NC| For standard model: None.
SDA| For PMBus mode l: Serial Da ta used in the PMBus interface . (Note)
CANH| For CANBus mode l: Data line used in CANBus interface. (Note)

8

| NC| For standard model: None.
SCL| For PMBus model: Serial Clock used in the PMBus interface. (Note)
CANL| For CANBus mode l: Data line used in CANBus inter face. (Note)

Note: Isolated signal, referenced to GND-AUX.

designed for DA/DB signals and parallel control function.

INSTALLATION MANUAL

Please refer to: http://www.meanwell.com/manual.html

References

• TÜV Rheinland - Home | US | TÜV Rheinland
• MEAN WELL Switching Power Supply Manufacturer
• Installation Manual-MEAN WELL Switching Power Supply Manufacturer
• Product Liability Disclaimer-MEAN WELL Switching Power Supply Manufacturer
• Global Trade Item Number (GTIN)-MEAN WELL Switching Power Supply Manufacturer

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