DBU-3200 is MEAN WELL's new generation intelligent battery charger with high power density.
Different battery brands and types (lead acid batteries, such as flooded, Gel, AGM, and so on, or
lithium-ion batteries, such as lithium iron, lithium manganese, and so on) may require different
charging curves and protection mechanisms for batteries, DBU-3200 is able to be accommodated
through the communication interface; parameters, such as charge voltage, charge current and taper
current, can be adjusted and the protection mechanisms for batteries can also be cancelled.
1.Notes on Operation:
◎ The charger must be installed in a dry and well ventilated area. It should not be exposed to rain
or snow.
◎ The cables between charger and battery should be kept as short as possible to prevent excessive
voltage drop. Too much voltage drop will lead to longer charging period.
◎ Please make sure charging voltage and current meet battery specification.
◎ While charging batteries in series do not mix old and new batteries in the same connection.,
◎ When connecting or disconnecting wires, please ensure the charger is OFF.
◎ Under normal operating conditions, a 5 years warranty is offered for DBU-3200. If failure results
from improper operation, the warranty will not apply to the defective units.
2.Mechanical Design and Installation Procedure
CN500
7
8
2
1
SVR
-V
CN500
SW1
FGLN
CN1
1
2
15
16
1
CN1
+V
-
+
Batteries
Warning: Before connecting a battery, please make sure
the polarity is correct to avoid damaging the charger
Figure2.1 Front panel
1
Page 4
Installation Procedure:
Please make sure the charger is OFF before connecting the battery to the output terminal. Choose a
cable with suitable wire gauge according to the charging current to connect between the charger and
the battery. Battery polarity must be connected correctly:Terminal(+) to Battery(+); Terminal(-) to
Battery(-), and take notice that the positive and negative ends are not shorted.
3.Derating Curve
3.1 Charging current vs Temperature
3.2 Charging current vs Input Voltage
100
80
230VAC
Input only
60
50
40
LOAD (%)
20
-30-250-101530506070
AMBIENT TEMPERATURE ( )℃
4.Pin Assignment
1
CN1
2
Pin No.Function
1
+12V-AUX
2
GND-AUX
3
4
5
6
7,8,9
10
11
12
13
14
15
16
Note1: Non-isolated signal, referenced to the [-V(signal)].
Note2: Isolated signal, referenced to GND-AUX.
+5V-AUX
Remote
ON-OFF
DC-OK
T-ALARM
A0,A1,A2
+V (Signal)
-V (Signal)
D0
PC
PV
RTH+
RTH-
15
16
Description
Auxiliary voltage output, 10.6~13.2V, referenced to GND-AUX (pin2).
The maximum load current is 0.8A.This output has the built-in "Oring diodes" and is not controlled by “Remote ON-OFF”.
Auxiliary voltage output GND.
The signal return is isolated from the output terminals (+V & -V).
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
The unit can turn the output ON/OFF by electrical signal or dry contact betweenand. (Note.2)Remote ON/OFF+5V-AUX
Short (4.5 ~ 5.5V) : Power ON ; Open (-0.1 ~ 0.5V) : Power OFF ; The maximum input voltage is 5.5V.
High (4.5 ~ 5.5V) : When the Vout16V/32V.≦
Low (-0.1 ~ 0.5V) : When Vout16V/32V. The maximum sourcing current is 10mAand only for output. (Note.2)≧±1VDC OK is associated with battery low protection.
High (4.5 ~ 5.5V) : When the internal temperature exceeds the limit of temperature alarm, or when Fan fails.
Low (-0.1 ~ 0.5V) : When the internal temperature is normal, and when Fan works normally.
The maximum sourcing current is 10mAand only for output(Note.2)
PMBus interface address lines. (Note.1)
DIP-switch interface lines for charging curve selection. (Note.1)
Connection for output current programming. (Note.1)
Connection for output voltage programming. (Note.1)
Positive output voltage signal.
It cannot be connected directly to the load.
Negative output voltage signal.
It is for certain function reference; it cannot be connected directly to the load.
Temperature sensor(NTC, 5KOhm) comes along with the charger can be connected to the unit to allow temperature
compensation of the charging voltage.
(HORIZONTAL)
±1V
100
90
80
70
60
50
40
LOAD (%)
30
90100115180264
INPUT VOLTAGE (VAC) 60Hz
2
Page 5
CN500
7
8
2
1
Pin No.
1,2
3,4
5,6
7
8
Function
DA
DB
-V (Signal)
SDA
SCL
Description
Differential digital signal for parallel control.
Differential digital signal for parallel control.
Negative output voltage signal.
It is for local sense; and certain function reference; it cannot be connected directly to the load.
Serial clock used in the PMBus interface.
Serial clock used in the PMBus interface.
SW1
Pin No.
1,2
Function
Terminal
resistance
Description
SW1 is the selector of terminal resistor that is designed for DA/DB signals and parallel control function.
5.LED Indicators
LED
Green
Orange
Red
Description
Float (stage 3)
Charging (stage 1 or stage 2)
Abnormal status (OTP, OLP, Fan Fail, Charging timeout)
6.Explanation of Operation Logic : (3 stage charge)
At the beginning stage of operation, the charger provides the largest current to charge the batteries,
the LED indicator will lighten in orange. After a period of time (probably a couple of hours, based on
the capacity of the batteries), charging current will decrease gradually. When the output current
reduces to 10% of its maximum value, the charger will go into “float” mode, the LED indicator will
turn to green. The relationship between charging current and charging voltage for each operation
stage is shown in the curves below:
Start
Charge Voltage
Charge Current
Color of LED
Constant Current
(CURVE_CC)
Constant Voltage
(CURVE_CV)
stage 1stage 2stage 3
OrangeGreen
Float
(CURVE_FV)
boost
V
V
float
100% CC
10% CC
STATUS
CONSTANT CURRENT
BOOST CHARGE VOLTAGE
FLOAT CHARGE VOLTAGE
DBU-3200-24
110A55A
28.8V
27.6V
FigureCharge Curve6.1
3
DBU-3200-48
57.6V
55.2V
Page 6
Explanation for 3 stage charge curve
(0) Initial stage (battery analysis)Check battery voltage level to see whether there is a battery:
connected.
(1) Stage 1 (constant current)A constant current is provided so that the battery can be quickly:
charged to 2.4V per cell.
(2) Stage 2 (constant voltage)A constant voltage of 2.4V per cell is provided until the charging:
current gradually reduces to 10%.
(3) Stage 3 (float)The output voltage switches to the float voltage, making it 2.3V per cell to keep the:
battery fully charged.
7.Charge Cureve
The factory setting is “default”, which can be programmed via PMBus.
◎ Default 3 stage charging curve
Start
Charge Voltage
Charge Current
Constant Current
(CURVE_CC)
Constant Voltage
(CURVE_CV)
stage 1stage 2stage 3
Color of LED
OrangeGreen
Note: By factory default, PIN10 and PIN14 on CN1 are connected.
◎ Embedded 3 stage charging curve
MODEL
24V
48V
Description
Default, programmable
#1 Pre-defined, gel batter
#2 Pre-defined, flooded battery
#3 Pre-defined,AGM battery
Default, programmable
#1 Pre-defined, gel batter
#2 Pre-defined, flooded battery
#3 Pre-defined,AGM battery
V
28.8
28.4
57.6
56.8
boost
28
29
56
58
float
V
27.6
27.2
26.8
27
55.2
54.4
53.6
54
Float
(CURVE_FV)
CC
(default)
110A
55A
boost
V
float
V
100% CC
10% CC
4
Page 7
8.&PMBusCommunication InterfaceCANBus
DBU 3200it-is compliant with PMBus Rev.1.1, the maximum communication speed is 100KHz and
has the capability of identifying up to 8 addressed units.
◎ PMBus communication interface is able to provide the current operating status and information
follow :ass
1. Output voltage, current and internal temperature
Alarm and status2.
. Msanufacturer' and model data3
4 Read/write of charge curve settings
For further CANBus information Please contact MEAN WELL for detail.,
PMBus DeviceAddre sing and Charge Mode Selections
◎ Each-unit should have their unique and own device address to communicate over theDBU 3200
PMbus. This 7-bit address is defined as follows:
MSB
1
000A2A1A0
LSB
A0-A2 allow users to designate the address for each DBU-3200 unit; these three bits are defined
through PIN7 (A0), PIN8 (A1) and PIN9 (A2) on CN1. There are up to 8 different addresses are
available to be assigned. When connecting one of these pins, for example, PIN8, with PIN14
(-V(Signal)), the corresponding bit, A1, is set to logic “0”; when it is kept open, for example, PIN7, the
corresponding bit,A0, is set to logic “1”. Please refer to Figure 8-1(left) for the detailed setup advice.
◎ The charging operation can be determined by the setup over D0, PIN10 on CN1. When D0 is logic
“0”, connecting PIN10 with PIN14(-V(Signal)), DBU-3200 follows a built charging curve to charge the
batteries; when D0 is logic “1”, PIN10 kept open, the charging operation is completely defined by the
control over PMBus, PV/PC or SVR. Please refer to Figure 8-1(right).
Module
No.
0
1
2
Device address
A0
0
1
0
A1A2
0
0
1
D0Description
0
0
0
0Charging curve
1PMBus or V PC or SVR controlP/
3
4
5
6
7
1
0
1
0
1
1
0
0
1
1
0
1
1
1
1
Figure 8-1
5
Page 8
Charging Curve
When it is opted for charging curve, D0 set to 0, charging curve function is enabled with additional
PMBus commands. There are 4 built-in charging curves, “default” curve, one pre-defined curve for “gel
battery”, one pre-defined curve for “flooded battery” and one pre-defined curve for “AGM battery”.
Each curve can be selected by Command B4h CURVE_CONFIG.
In addition, users are able to customize their own charge curves, which will be stored to “default” after
modification. CV can be set by Command B1h CURVE_CV; FV can be set by Command B2h
CURVE_FV; Charge current level of stage1 can be set by Command B0h CURVE_CC; Taper current
level from stage 2 to stage 3 can be set by Command B3h CURVE_TC. Please refer to the following
PMBus Command List in table 8-2 for detailed information on commands and parameters.
NOTE: 1. The updated charging parameters is saved into EEPROM. The updated charging curve
takes effect after DBU-3200 is restarted.
2. When charging curve is enabled, the following commands will be invalid while other PMBus
commands are effective: Command 01h OPERATION (regarding Remote ON-OFF function),
command 22h VOUT_TRIM (regarding Output voltage programming function) and
command 46h IOUT_OC_FAULT_LIMIT (regarding Output current programming function).
PMBus, PV/PC or SVR Functions:
Users are able to fully control and design the entire charging behavior, without the charging curve,
by one of the following means- PMBus command, PV/PC function or SVR adjustment. The operating
priority is, PMBus > PV/PC > SVR.
NOTE: When operating in this mode, PMBus commands B0h/B1h…B8h can be set but there will
be no response whereas other PMBus commands and functions work normally.
6
Page 9
Command
Code
01h
02h
19h
20h
21h
22h2
46h
47h
79h
7Ah
7Bh
7Ch
7Dh
7Eh1
80h
81h
88h
8Bh
8Ch
90h
91h
98h
99h
9Ah
9Bh
9Ch
9Dh
9Eh
Command
Name
OPERATION
ON_OFF_CONFIG
CAPABILITY
VOUT_MODE
VOUT_COMMAND
VOUT_TRIMR/W Word
IOUT_OC_FAULT_LIMITR/W Word
IOUT_OC_FAULT_RESPONSE
STATUS_WORD
STATUS_VOUT
STATUS_IOUT
STATUS_INPUT
STATUS_TEMPERATURE
STATUS_CMLR Byte
STATUS_MFR_SPECIFIC
STATUS_FANS_1_2
READ_VIN
READ_VOUT
READ_IOUT
READ_FAN_SPEED_1
READ_FAN_SPEED_2
PMBUS_REVISION
MFR_ID
MFR_MODEL
MFR_REVISION
MFR_LOCATION
MFR_DATE
MFR_SERIAL
Transaction
Type
R/W Byte
Read Byte
Read Byte
R Byte
R Word
R Byte
R Word
R Byte
R Byte
R Byte
R Byte
R Byte
R Byte
R Word
R Word
R Word
R Word
R Word
R Byte
Block Read
Block Read
Block Read
Block R/W
Block R/W
Block R/W
# of data
Bytes
1
1
1
1
2
2
1
2
1
1
1
1
1
1
2
2
2
2
2
1
12
12
6
3
6
12
Description
Remote ON/OFF control
ON/OFF function configuration
Capabilities of a PMBus device
Define data format for output voltage
(format: Linear, N= -9)
Output voltage setting value
(format: Linear, N= -9)
Output voltage trimmed value
(format: Linear, N= -9)
Output overcurrent setting value
(format: Linear, N= -2)
Define protection and response when an
output overcurrent fault occurred
Summary status reporting
Output voltage status reporting
Output current status reporting
AC inpit voltage statusreporting
Temperature status reporting
Communication, logic,
Memory status reporting
Manufacture specific status reporting
Fan1 and 2 status reporting
AC input voltage reading value
(format: Linear, N=-1)
Output voltage reading value
(format: Linear, N= -9)
Output current reading value
(format: Linear, N= -2)
Fan speed 1 reading value
(format: Linear, N= 5)
Fan speed 2 reading value
(format: Linear, N= 5)
The compliant revision of the PMBus
(default: 11h for Rev. 1.1)
Manufacturer's name
Manufacturer's model name
Firmware revision
Manufacturer's factory location
Manufacture date. (format: YYMMDD)
Product serial number
Table 8-2
7
Page 10
Command
Code
B0h
B1h
B2h
B3h
B4h
B5h
B6h
B7h
Valid when charging according to charge curve (D0=0)
B8h
Command
Name
CURVE_CC
CURVE_CV
CURVE_FV
CURVE_TC
CURVE_CONFIG
CURVE_CC_TIMEOUT
CURVE_CV_TIMEOUT
CURVE_FLOAT_TIMEOUT
CHG_STATUS
Transaction
Type
R/W Word
R/W Word
R/W Word
R/W Word
R/W Word
R/W Word
R/W Word
R/W Word
READ Word
Note:
◎Definition of Command B4h CURVE_CONFIG:
Bit7Bit6Bit5Bit4Bit3Bit2Bit1Bit0
# of data
Bytes
2
2
2
2
2
2
2
2
2
Description
Constant current settingvalue of chargingcurve
(format: Linear, N= - )2
Constant voltage settingvalue of chargingcurve
(format: Linear, N= -9)
Constant voltage settingvalue of chargingcurve
(format: Linear, N= -9)
Taper current setting valueof chargingcurve
(format: Linear, N= - )2
Configuration setting of chargingcurve
CC stage timeoutsetting value ofcharging curve
(format: Linear, N= 0)
CV stage timeoutsetting value ofcharging curve
(format: Linear, N= 0)
Floating timeout settingvalue of chargingcurve
(format: Linear, N= 0)
Bit 1 CCM:Constant Current Mode Status
0=the charger NOT in constant current mode
1=the charger in constant current mode
Bit 2 CVM:Constant Voltage Mode Status
0=the charger NOT in constant voltage mode
1=the charger in constant voltage mode
Bit 3 FVM:Float Mode Status
0=the charger NOT in float mode
1=the charger in float mode
Bit1Bit0
-
CVMFVM
CCM
EEPER
FULLM
High byte
Bit 0 EEPER: EEPROM Charge Parameter Error
=0data of charge parameter correct
1=data of charge parameter error
Bit 2 NTCER: Temperature Compensation Status
0=NO short-circuit in the circuitry of temperature compensation
1=the circuitry of temperature compensation has short-circuited
Bit 3 BTNC: Battery Detection
0=battery detected
1=NO battery detected
Bit 5 CCTOF:Time-out Flag of Constant Current Mode
0time-out=NOin constant current mode
1=constant current mode timed out
:Bit 6 CVTOFTime-out Flag of Constant Voltage Mode
0time-out=NOin constant voltage mode
1=constant voltage mode timed out
:Bit 7 FTTOFTime-out Flag of Float Mode
0=NO time-out in float mode
1=float mode timed out
9
Page 12
Note:
EEPER When EEPROM Charge Parameter Error occurs, the charger stops charging the battery and
:
the LED indicator turns red. The charger needs to re-power on to re-start charging the battery.
NTCER: When Temperature Compensation Short occurs, the charger output will shut down and the
LED indicator will turn red. The charger will automatically restart after the Temperature
Compensation Short condition is removed.
BTNC When there is no battery detected, the charger stops charging the battery and the LED
:
indicator turns red. The charger needs to re-power on to re-start charging the battery.
CCTOF When timeout arises in the Constant Current stage, the charger stops charging the battery
:
and the LED indicator turns red. The charger needs to re-power on to re-start charging the
battery.
CVTOF When timeout arises in the Constant Voltage stage, the charger stops charging the battery
:
and the LED indicator turns red. The charger needs to re-power on to re-start charging the
battery.
FVTOF: When timeout arises in the Float stage, the charger stops charging the battery and the LED
indicator turns green. This charging flow is finished; the charger needs to re-power on to
start charging a different battery.
1.will display ZERO amp when output current is less than values in the table below:READ_IOUT
Minimum readable currentModel
24V5.3A 1A±
48V2.7A 1A±
Figure 8-5
When using PMBus to adjust output voltage, VOUT_COMMAND only can be used to display the
2.
rated voltage of the unit and cannot be written. It is VOUT_TRIM that sets up the amount of
trimmed voltage. Taking DBU-3200-24 as an example, to get a 18V output, please set value of
VOUT_TRIM to -6V.Adjustable voltage range for each model is shown as below:
Adjustable voltage rangeModel
24V18 ~ 30V
48V36 ~ 60V
Figure 8-6
3.
The value of CURVE_FV should be set less or equal to CURVE_CV,If CURVE_FV is greater than
CURVE_CV, it will be saved as CURVE_FV = CURVE_CV in EEPROM.
11
Page 14
4.
Insert an at least 35msec delay between commands.
5.
When there is no any PMBus command detected for 10 sec, the charger restores to the factory
default settings, that is operation = ON…etc. please refer to Tabel 8-4.
6.
Data format of IOUT_OC_FAULT_LIMIT(46h), CURVE_ICHG(B0h), CURVE_ITAPER(B3h) is as
below: (Please refer to PMBus_Specification_Part_II_Rev_1-1 for detailed information)
Data format of VOUT_MODE, VOUT_MODE, VOUT_COMMAND, VOUT_TRIM, READ_VIN,
7.
READ_VOUT, READ_IOUT, READ_TEMPERATURE_1, READ_FAN_SPEED_1,
READ_FAN_SPEED_2, CURVE_VBST, CURVE_VFLOAT, CURVE_CC_TIMEOUT,
CURVE_CV_TIMEOUT, CURVE_FLOAT_TIMEOUT is as below: (Please refer to
PMBus_Specification_Part_II_Rev_1-1 for detailed information)
7.1DIRECT Data Format
DIRECT format data is a two byte, two’s complement binary integer. IRECT format data may
be used with any command that sends or reads a arametric value. If a PMBus device uses
DIRECT form data, this shall be clearly described in the product literature.
12
Page 15
7.1.1 Interpreting Received Values
The host system uses the following equation to convert the value received from the
PMBus device into a reading of volts, amperes, degrees Celsius or other units as
appropriate:
7.1.2 Sending A Value
◎ Please refer to our specifications about PV/PC or SVR Function.
9.Function description
9.1 Input voltage
◎TheAC90~264VDC127~370Vinput voltage range isor.
◎The provided input voltage must fall within the specified range; otherwise, the unit may
be non-functional.Also the active PFC circuit may fail or get damaged.
◎The efficiency will be lower and the output current should be reduced according to the
Derating Curve when the unit is applied with an input voltage belowAC180V.
9.2 Power factor correction (PFC)
◎Built-in active PFC circuit: PF>0.95 when input voltage is between 90-230Vac with full load at the
output. On the other hand, if the input voltage is > 230V or output is not at full load, the PF will
drop below 0.95
13
Page 16
93.Temperature Compensation
Temperature sensor which comes with the charger can be connected to the unit to allow
temperature compensation of the charging voltage. If the temperature sensor is not used, the
charger can still work normally.
PIN15 RTH+
NTC
PIN16 RTH-
CN1
+V
-V
10.Wiring for battery
Select suitable wire guage based on rated charging current. Refer to the following table for
minimum wire gauge. It is highly recommended using RED wire for (+) connection and BLACK wire
for (-) connection
AWG
Cross section(mm )
142.112
123.322
105.335
71046
61660
4
2
11.SuggestedatteryapacityBC
Model
DPU-3200-24
DPU-3200-48
Battery capacity
330-1000AH
180-550AH
25
43
2
Maximum current(A)
UL1015(600V 105)℃
80
110
Note:1.Using battery capacity larger than the suggested value will not lead to damage of the battery.
The main drawback is it may take longer to fully charge the battery.
2.If you're unsure about max allowable charging current of your battery, please refer to the
battery's technical specification or consult its manufacturer.
14
Page 17
1.2 Series and Parallel Connection of Batteries
1.Batteries in series
Voltage can be doubled when 2 batteries are connected in series However the capacity Ah will.,()
.,=.remain the same For example 2 x 12V 100Ah batteries connected in series24V 100A
++
--
BatteriesBatteries
2.Batteries in parallel
When 2 batteries are connected in parallel, voltage remains the same and the capacity (Ah) doubles.
For example, 2 x 12V 100Ah batteries connected in parallel = 12V 200Ah.
+
-
Batteries
+
-
Batteries
1.3 Troubleshooting
Failure State
Unable to charge
the battery
LED indicator does
not turn Green after
a long charging
period
Possible Cause
Input voltage too low
Battery is over lifetime or damaged
Output cables are too thin
Make sure input source is
between 90~264VAC
Replace with a new battery
Replace with suitable wire gauge
Suggested Solutions
If you are unable to clarify the problem you are facing, please contact MEAN WELL or any of
our distributors for repair service.
15
Page 18
No.28, Wuquan 3rd Rd., Wugu Dist., New Taipei City 248, Taiwan
Loading...
+ hidden pages
You need points to download manuals.
1 point = 1 manual.
You can buy points or you can get point for every manual you upload.