VANNER VANN-Bus 90-Series Converter-Isolator System Owner’s Manual
- June 12, 2024
- VANNER
Table of Contents
Incorporated
90 Series Owner’s Manual
VANN-Bus 90-Series
Converter-Isolator System
With CAN Capable Smart Monitor™
Introduction
Thank you for purchasing a Vanned 90-60 Converter-Isolator. We are confident that you will be very pleased with its performance because our 90-Series Converters are designed and manufactured by skilled professionals using the highest standards in workmanship. With minimum maintenance and care, you can be assured of many years of trouble free service.
General Description
The Vanned VAN-Bus CAN Power Management System is an efficient and highly
reliable method of maintaining isolation between your 24-Volt DC starting
system and your 24-Volt DC auxiliary system. In addition to providing
regulated 24-Volt power, the system provides charging to the 24-Volt auxiliary
battery, when conditions permit, which significantly extends battery life.
Ideally suited for vehicle and alternate energy applications, the VAN-Bus is
designed to save your batteries and the money you would spend replacing them.
Users of the Vanned VAN-Bus know that it is the most cost effective and
dependable solution for 24-Volt systems.
The CAN (Controller Area Network) Capable Smart Monitor is a device designed
to monitor and report the status of several critical functions in the vehicle
electrical system. This unit provides real-time fault signals over the CAN bus
to the vehicle electrical system controller. Fault indications can then be
given from the vehicle’s electrical system controller. Battery-monitoring
algorithms have been incorporated into the 90-60 Series VAN-Bus, transmitting
real time battery state of charge, state of health, and run time messages over
CAN.
A typical system would include a 24-Volt DC-starting system, a 24-Volt DC
auxiliary system, and the 90-Series.
The 90-Series connects to the 24-Volt starting system, 24-Volt auxiliary
system and ground terminals of the battery system. When the auxiliary battery
requires charging, the VAN-Bus ensures that the current is transferred from
the starting batteries, when conditions permit, and that the auxiliary
batteries can not drain the starting batteries when loads are left on. This
isolation between the two 24-Volt systems ensures that the starting batteries
will maintain the power required to start the vehicle, and provides a stable
24-Volt supply for operating accessories.
NOTE: The Vanner VAN-Bus CAN Power Management System is an extremely reliable
device and, when installed according to the instructions, will provide
reliable operation for an indefinite period of time. However, if a system
abnormality should develop that would cause a VAN-Bus malfunction, damage to
the battery system could result if 24-Volt loads are present.
Specifications
90-Series Converter-Isolator
Model Number| 90-60CAN
Input Voltage 24v| 18 to 32 v
Efficiency (Peak)| >97%
Max 24v Input Amps| 32
Output Voltage| Programmed via CAN
Output Amps (24v)| 0-62
Standby Current| 20 milliamps nominal at 28.4V
Smart Monitor| Alarm Low/High Voltage, Imbalance, Under voltage protect
override, VAN-Bus fault Battery Monitoring
Operating Temp.| -40°C to +75°C (-40°F to 167°F)
Storage Temp.| -54°C to +95°C (-65°F to 203°F)
Serviceable| Yes
Environmental Considerations| Cast aluminum enclosure provides protection
against salt, fungus, dust, water, fuel vapors and all fluids associated with
commercial and off-highway vehicle operations. IP rated 56.
Mounting Location| Mount on a flat surface close to the batteries to allow
short cable runs. Location should be protected from battery acid and gases.
Weight| 8.8 lbs.
90-Series CAN Dimensional Specifications
Theory of Operation
The Converter-Isolator is a state of the art device that implements software
controlled power management.
When the unit has been installed and the system is engaged, the 90-Series will
look at the input voltage line to determine if there is sufficient voltage to
turn the unit on. If there is not, then the unit does not turn on.
If there is then the unit performs a “soft start” cycle that will ramp up the
output current to the default setpoint of 60-Amps DC. If at some point during
the soft start cycle the output voltage plateaus at a lower value than
20-Volts, then the Output current limits to a lower value than 60-Amps. If the
Output Voltage climbs to the default setpoint of 20-Volts, then the unit will
continue operation, regulating the output voltage to the default values.
The 90-Series is also capable of being controlled by the CAN Bus. Through CAN
communication (J1939 Standard) the unit can have many of its operating
parameters adjusted. The adjustments are:
- Input Voltage Setpoint
- Output Voltage Setpoint
- Current Limit Setpoint
- Battery Type
- Bulk Charge Voltage
- Float Charge Voltage
- Battery Temperature Coefficient
If during normal operations the unit should have an output voltage dip, below
20-Volts, again the unit will limit the current below the 60-Amp Default. If
the unit’s output voltage rises above 30-Volts then the unit will power off
for 10 seconds and perform a restart procedure including the soft start
sequence.
Furthermore, if the unit experiences an over temperature condition, it will
also enter into a current limit (a 10% reduction in the output current
capacity) to reduce internal temperatures. If this condition persists, the
unit will again reduce current output, until the unit gets out of the
internally monitored thermal danger zone. If the temperature continues to
rise, the unit will again power off for 10 seconds and attempt a restart. If
the temperature remains high, then the unit will NOT operate until the
temperature is within the
rated operating temperatures.
Converter-Isolator functionality
All functionality described in this section requires that the Monitor
Ignition Input (Terminal B) be connected to +24v in order to be active. Please
see the above figure for placement of the current and temperature sensors.
A. Switched Sensor Supply Output
This output is used to provide +5v for Vanner VSS Series current sensors and
temperature sensor.
The +5v output is switched for low power shutdown and sleep mode operation.
B. Ignition (Enable) Input
This input powers the Converter-Isolator. When this pin is taken to +24V the
Converter-Isolator becomes active.
C. CAN Shield
This connection is used to make common the shield on the CAN cable. This is
required for noise considerations in vehicle electrical systems.
D. CAN Low
This is the connection for the vehicle’s public CAN bus. The Smart Monitor
will communicate faults to the vehicle’s electrical system controller via the
CAN bus.
E. CAN High
This is the connection for the vehicle’s public CAN bus. The Smart Monitor
will communicate faults to the vehicle’s electrical system controller via the
CAN bus.
F. Not Connected
This pin is not currently used.
G. Not Connected
This pin is not currently used.
H. Sensor Ground
Connect ground for current sensors and Smart Sensors here.
J. Single Current Sensor (+24V) Signal Input
The monitor can record incoming and outgoing battery current on the upper
(+24V) battery. The output from the current sensor monitoring the +24v battery
line should be connected to this input.
Note that the arrow on the current sensor should pointed toward the battery
if it is connected to the positive terminal of the battery.
K. Not Connected
This pin is not currently used.
L. Temperature Sensor
The monitor can record the temperate of the batteries. The output from the
Vanned temperature sensor should be connected to this input.
M. +24V Battery Input Sense (Starting Batteries)
If this pin is connected directly to the +24V battery positive by a separate
line, it will improve the accuracy of the Converter–Isolator input voltage
when load current is drawn. See “Remote Sense” below for more information.
N. +24V Battery Output Sense (Auxiliary Batteries)
If this pin is connected directly to the +24V battery positive by a separate
line, it will improve the accuracy of the Converter-Isolator balance of the
batteries when load current is drawn. See “Remote Sense” section below for
more information.
P. Battery Ground Remote Sense
If this pin is connected directly to the battery ground by a separate line, it
will improve the accuracy of the Converter-Isolator voltage measurement of the
batteries when load current is drawn. See below for more information.
The monitor output from the unit is a through a Deutsch brand connector P/N:
HDP20-18-14PN.
The mating connector is the Deutsch P/N: HDP26-18-14SN housing with Deutsch
P/N: 1062-160622 socket contact.
Remote Sense (Terminals M, N, and P)
There are three inputs for this function, +24 Input (starting), +24 Output
(auxiliary), and Ground.
They are for remote sense of the starting and auxiliary battery voltages. This
makes the Conversion function insensitive to wire, fuse and connection voltage
drops. All three sense lines must be connected for this function to work
properly. It is usual for the battery connections to be brought to a
distribution point from where connections are made to the rest of the vehicle.
Since the battery charge current is the only current which the battery cables
carry for most of the time it is convenient to connect the sense wires to
these distribution points. This should not introduce a significant error. In
fact, when the system stabilizes and the batteries are charged there will be
almost no error. Should the external sense lines be removed, or operating
improperly, the Converter will default to internal readings.
The sense wires can be 16 or 18AWG as the input impedance is high, and the
wire gauge can be set for mechanical strength requirements. This allows cost
savings and freedom of configuration in the Converter power connection wiring,
and more freedom in Converter location. The Converter current carrying wire
gauge can be the minimum size listed in this manual’s wire size table for a
given Converter rating, up to four times the distance listed. This sets a
maximum voltage drop of 0.4V, which is reasonable from efficiency and fault
detection considerations.
Installation Instructions
Do not exceed the specified torque of 120 in-lbs. when connecting cables to
the terminal posts (Input, Output, and GND) during installation of all the
VAN-Bus Models. Torque values higher than specified may damage the product,
reduce performance, and/or create hazardous conditions. Products damaged by
improper torque are not covered by the warranty.
Do not connect more than one conductor per terminal post on any Vanned VAN-
Bus. Multiple wires and cables may overstress internal components, resulting
in poor performance or creating hazardous conditions. Products damaged by the
installation of multiple conductors per post are not covered by the warranty.
Fault protection devices MUST be installed between the VAN-Bus and the power
source (battery). A fault protection device would be any fuse or circuit
breaker properly rated for the maximum DC current obtainable. This advisory is
in accordance with SAE, NEC and UL, for mobile power applications. Install per
applicable codes or within 18” of the battery. See Wire and Fuse Sizing Chart
on page 10 of this manual or contact Vanner at
1-800-227-6937 or
pwrsales@vanner.com if assistance is needed in
sizing fault protection devices.
Caution: This equipment tends to produce arcs and sparks during
installation. To prevent fire or explosion, compartments containing batteries
or flammable materials must be properly ventilated. Safety goggles should
always be worn when working near batteries
Mounting Location –The VAN-Bus may be mounted in any orientation, on a flat
mounting surface suitable to support the VAN-Bus during application. Do not
mount in zero-clearance compartment that may result in the VAN-Bus
overheating. Locate so that contact by people is unlikely.
Environmental Protection – Your VAN-Bus has been designed to withstand direct
exposure to rain and moisture. The VAN-Bus has also been tested for exposure
to direct pressure spray, but continual exposure to direct pressure spraying
may reduce the VAN-Bus serviceable life. Vanned covers any damage due to water
contamination only through the terms of our factory warranty.
Wiring Sequence– The VAN-Bus is internally protected for reverse polarity. The
wiring sequence is not an issue with the VAN-Bus products.
Strain Relief – The VAN-Bus has an integral strain relief. The VAN-Bus is
designed with wells for the lug to sit into to resist bolt loosening from
cable movement, and the strain relief is designed to further inhibit cable
movement. The diagram below shows the proper orientation for the attachment of
the strain relief and the #10-32 mounting hardware that is supplied.
Wire Size and temperature rating
Cables connecting the VAN-Bus to the batteries must be sufficiently sized to
prevent unwanted voltage drops. These voltage drops (loss) must be less than
0.05 VDC between the VAN-Bus’s +24 volt terminal and the battery +24 volt
terminal (Battery B positive terminal), less than 0.10 VDC between the VAN-
Bus’s Input terminal and the battery +24 volt terminal (the jumper between
Battery A and Battery B), and less than 0.05 VDC between the VAN-Bus’s GND
terminal and the battery ground terminal (Battery A negative terminal that is
connected to chassis ground). In most installations, the VAN-Bus’s terminals
are wired directly to the battery terminals (reference fault protection) to
prevent voltage loss that could occur in switch contacts, connections, and
long wire runs. Since the VAN-Bus can be operated in temperatures up to 75ºC,
use wire rated at least 90ºC. See Wire and Fuse Size Chart.
Wire and Fuse Size Chart
Wire Size AWG| Ring Terminal AMP or UL recognized equal| Max wire length, in
feet, between VAN-Bus
and battery to keep voltage drop under 0.1 volt. The chart assumes wire
carries no other load and wire temperature is below 80ºC.
---|---|---
90-60CAN
8| 33462| 2.1
6| 33466| 3.2
4| 33470| 5.9
2| 322870| 8.7
1| 321867| 10.9
1/0| 321867| 13.8
2/0| 321870| 17.6
Fuse F1| 120 amp
Fuse F2| 100 amp
Crimp the ring terminals using AMP ROTA-CRIMP 600850 (2/0 – 8ga).
AMP Product Information Center:
800-522-6752
AMP Tooling Assistance Center:
800-722-1111
Note: The wire gages listed are for use without remote sense; see the
monitor section for applications using the remote sense capability.
Testing and Troubleshooting
CAUTION
Servicing of electrical systems should only be performed by trained and
qualified technical personnel.
Equipment Required
Voltmeter having 0.01 volt resolution. (Fluke Model 87, or higher,
Multimeter recommended).
Clamp-on current meter (Fluke Model 36 Clamp-on Meter recommended).
Vanned Repair Service
Vanned offers a quick turn around factory repair service. Send the unit to the
address below with a note instructing us to repair it.
Include your name, phone number, shipping address (not a P.O. Box Number), and
your purchase order number.
Test Procedure for VAN-Bus 90-Series CAN Power Management Systems
The VAN-Bus is working properly if:
- The 24 volt DC loads are being operated continuously and are within the rated capacity of the VAN-Bus and;
Vanned VAN-Buss are electronically protected against reverse polarity damage
therefore the DC connection sequence is not an issue.
Vanned VAN-Buss will not function properly unless all three-battery
connections are made. Battery A and Battery B voltages both must be above 8
volts for the unit to turn ON.
Vanner VAN-Buss may be used in parallel with other VAN-Buss and Vanner
Equalizer models.
Please note that the Input, Output and GND stud positions and orientation are
different on VAN-Bus 90Series than on other Vanned Equalizers.
Vanned Incorporated
4282 Reynolds Drive
Hilliard, Ohio 43026
1-800-AC POWER
(1-800-227-6937)
Tel:614-771-2718
Fax:614-771-4904
www.vanner.com
e-mail:pwrsales@vanner.com
Part Number D913789-C, 8/15/2022
Printed in U.S.A.
90-Series Converter Isolator CAN System
OWNER’S MANUAL
Documents / Resources
|
VANNER VANN-Bus 90-Series Converter-Isolator
System
[pdf] Owner's Manual
VANN-Bus 90-Series Converter-Isolator System, VANN-Bus 90-Series, Converter-
Isolator System, Isolator System
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References
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