BEL LBM Series - Battery Charger Installation guide

Brand: BEL

Model: LBM Series - Battery Charger

Type: Installation guide

MODELS:

LBM10000-1110Sxxx

LBM12000-1110Sxxx

LBM15000-1110Sxxx

AC INPUT:

3 PHASE

VOLTAGE: 230-277 / 400-480 Vac 3W + PE

CURRENT: 18-12 A (LBM10000)

CURRENT: 21-14 A (LBM12000)

CURRENT: 26-18 A (LBM15000)

FREQUENCY: 50 / 60 Hz

DC OUTPUT:

VOLTAGE: adjustable 80 – 140 Vdc

CURRENT: max. 91 A @ 110 V (10000 W)

CURRENT: max. 110 A @ 110 V (12000 W)

CURRENT: max. 137 A @ 110 V (15000 W)

SAFETY APPROVALS

▪ CE Mark

▪ RoHS

▪ UL/CSA

pending

CAUTION

These component level power supplies are intended exclusively for installation within other equipment by an industrial assembly operation or by

professional installers. These are Class 1 power supplies; the unit must be properly connected to earth ground in end use. A component power supply

should be installed in end-use equipment according to the requirements of the safety standard used for that equipment. This power supply is not designed

to be operated outside of an enclosure which provides a means of mechanical, electrical, and fire protection.

PROTECTIVE EARTHING

The Power Supply must be properly grounded to mains protective earth termination at end use.

ENVIRONMENTAL CONDITIONS:

TRANSPORTATION & STORAGE:

Ambient Temperature Range -40 °C to +85 °C

Relative Humidity Range: 0% to 95% RH Non-Condensing

Altitude: to 12192 m asl (40 000 ft)

OPERATION:

Ambient Temp. Range -25°C to +55°C (at 100% load), to +70°C (at 75% load)

Relative Humidity Range: 0% to 95% RH Non-Condensing

Altitude (asl): to 2500 m (8200 ft) full power, to 5000 m (16 400 ft) derating 80% of full power

DISCLAIMER

It is the customer’s responsibility to check the suitability and qualify the product in their application. If any queries, please contact Bel

(at tech.support@psbel.com or website belfuse.com/home/contact-bel) to ensure product remains within specification at all time.

Supplier shall in no way be liable for use or installation of the product outside of the parameters of the specification.

INSTALLATION REQUIREMENTS

Hardware:

Recommended power wires dimensions you can find in charts below. The mate parts of connectors are also described below. For the air inlet

there is required to maintain a minimum open space 15 cm, for the output min. 10 cm. For chassis fastening you will need 4x screws M10. The preferred

mounting position is vertical, with connectors on top. The AC input line shall be fused by: Breaker ABB, S203MT, C30/C25, or similar. The output Battery

must be protected by following fusing: Breaker ABB 1SDA066809R1 (160/125/100 Adc), or similar. We highly recommend using fuses, e.g. 1 A / F, in series

with inputs 1, 2, 3, 4 of connector X3 (battery sections sensing).

Software:

In case the standard units are delivered to the customer with the Configuration file (.csv) in default (factory) settings, it is necessary for the

customer to upgrade the Configuration file (by the help of GUI – graphical user interface) to the version, which corresponds with their specific project. The

same needs to be done, if the units are returned from the repair (RMA), since the units are shipped back to the customer with default Configuration setting.

WARNING

1. The equipment is for business use (Class A) and has acquired electromagnetic conformity registration. This product may cause interference if used

in residential areas. Such use must be avoided unless the user takes special measures to reduce electromagnetic emissions to prevent interference

to the reception of radio and television broadcasts.

2. Maximal Touch current measured according to IEC 62368-1 is 6.5 mA.

Except of connector X1 ground wire use also an additional grounding wire connected on the grounding screw on the chassis.

3. Maximal value of the Protective conductor current (leakage current) is 9.9 mA.

4. Do not touch the Output connector X2 during the operation. There is a hazard voltage present, up to 140 Vdc.

5. Caution, this is a heavy equipment, weight 17.5 kg.

SAFETY INSTRUCTIONS

Switch off the input power and disconnect battery (X2) together with connector X3, X1 and wait min. 2 minutes before doing any maintenance on the unit!

Do not turn-on the unit with removed mate part of the X2 connector!

INSTALLATION INSTRUCTIONS

[email protected]om

SERVICING

In case of failure, the unit must be returned to the Bel Power Solutions Authorized Service Center. There are no user serviceable parts inside, except of the

fan replacement. In case of failure of the fan this can be replaced without the whole chassis opening. The procedure is described below.

CORROSION PROTECTION

The unit outside is protected by painting with Durpol epoxide 6L series, RAL9005. Inside all PC boards are protected by lacquering with AVR 80.

LIMITED WARRANTY

Bel Power Solutions warrants each power supply of its manufacture for a period of two years from the date of original shipment. This warranty applies to

defects in materials and workmanship that result in non-performance to published specifications. The product(s) must be returned to a Bel Power Solutions

Authorized Service Center for repair with a Bel Power Solutions pre-assigned RMA number.

Bel Power Solutions assumes no liabilities for consequential damages of any kind through the use or misuse of its products by any user. No other obligations

are expressed or implied. Please note that the specifications, terms, and conditions stated are subject to change without notice.

MAINTENANCE - FAN REPLACEMENT PROCEDURE

In the unit there are no user replaceable parts, except of the fans. Fan failure is reported in data sent to the train control unit.

In case of regular maintenance or fan failure, the front panel with fans (Bel order Nr. YGA.F0G03.0, 1.2kg) can be simply removed for cleaning / replacement:

1) Turn-off the charger (disconnect AC and battery), wait min. 2 minutes after the unit completely shuts down. By the hand simply unscrew the six

screws holding the panel (signed by the red circles – see Fig. 1 below) and pull out the panel from the chassis.

2) Replace the whole panel with the original part YGA.F0G03.0. Contact our Sales Center for the part order.

3) Proceed with the mounting in reverse order. Gently push the new panel straight in the chassis. By screws tightening first push on the screws

and at the same time twist them clockwise (by hand).

The panel with fans contains also the addresses for power modules, so do not exchange the positions of fans.

Life expectance: 70 000 hours @ 40 °C, continuous operation (8.0 years or 2.4 mil km, whichever occurs first). This value can be added in the regular

maintenance scheduler of the vehicle (W-class C). For cleaning and checking (outside the chassis) use a shorter period, depending on the pollution of the

flowing air and if Tamb > 40°C.

Figure 1: Area of maintenance and Fans replacement – screws to release at YGA.F0G03.0

NUCLEAR AND MEDICAL APPLICATIONS

Bel Power Solutions products are not designed, intended for use in, or authorized for use as critical components in life support systems, equipment used in

hazardous environments, or nuclear control systems without the express written consent of the respective divisional president of Bel Power Solutions.

TECHNICAL REVISIONS

The appearance of products, including safety agency certifications pictured on labels, may change depending on the date manufactured. Specifications are

subject to change without notice.

OPERATION

Before turning-on the charger make sure the pins 7, 8 of connector X3 are outside reconnected (by a wire jumper >0.5mm², or by a switch / relay). This

jumper can be used for a complete disconnection of the charger controller from battery (if AC is not present and the battery breaker remains still in ON

position), to minimize the battery discharging when the train is out of service for a long time, more than one week. Note that only the controller power

supply will be disconnected, not the battery power input. So, in this case battery will be still connected to consumers, but the charger controller will not

work. In the case pins 7, 8 are disconnected, the AC must not be present, because the power modules would deliver power (in Safe mode), but the battery

charging current would be not controlled!

It is recommended first turn-on the battery breaker and only then turn-on the AC input voltage breaker. The charger will start in a Safe mode = constant

voltage, e. g. 105 Vdc, the value is configurable. In this state the current into Consumer output will flow either from charger or from battery, which one of

the voltages will be higher.

30 seconds after the first AC start-up the charger performs the battery test, by decreasing the output voltage. During battery test the output voltage can go

down to 80 V, if the battery is not connected. In this case, after the test, the charger will remain in the Safe mode. In the other case (battery connected /

OK), or if the battery will be connected afterwards, the charger will start to work in a Charge mode, to keep the maximal charging current and to supply the

consumers. The voltage will be set to value which corresponds to the measured battery temperature (battery charge curve). The actual state can be seen

by LED-s on the connector panel or by communication SW / GUI. For the LED-s meaning and for details see the Datasheet BCD.20200.

LBM Series

Asia-Pacific

+86 755 298 85888

Europe, Middle East

+353 61 49 8941

North America

+1 866 513 2839

BCM.20061_2

When no temperature sensor is connected to the connector X7 (and no temp. value from the superior system will be available), or any other fail will be

detected, the charger will remain to work in the Safe mode. In this mode the output voltage is set below the value allowed for Tmax (specific charging

curve dependent), e. g. to 105 Vdc. If this mode will remain for longer time, please note that the battery will be not fully charged. When no battery voltage

sensing is connected to the connector X3, the charger will also stay in the Safe mode and the battery voltage symmetry cannot be evaluated and reported

by communication. All error conditions are reported to the parent system.

The charger does not have the possibility to disconnect the battery if battery undervoltage occurs (e. g. without AC, when the load is supplied from battery

only). So, the battery undervoltage must be controlled externally and when it happens, the consumers must be disconnected (the typical turn-off should be

under 80 V, the value depends on battery type).

Inside, in series with the Consumer output, there is connected an OR-ing diode (MOSFET), so two or more LBM systems (preferably each one with his own

separate battery pack) can be at these outputs connected in parallel (to supply the load in redundancy, if the size of the load was chosen appropriately).

In the case more BC are working in parallel in one battery or when the connection to battery is long (more than 3m), please contact the Bel support to

agree the details of the installation.

This equipment can be (AC) powered by a generator in the vehicle, or by public grid while train in the depot. The charger complies with IEC 61000-3-12

provided that the short-circuit power Ssc is greater than or equal to 2,9x106 at the interface point between the user’s supply and the public system. It is the

responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is

connected only to a supply with a short-circuit power Ssc greater than or equal to 2,9x106.

Figure 2: Connectors placement

INPUT AC CONNECTOR X1 – PINOUT

SIGNAL NAME

PIN #

TYPE

RECOMMENDED WIRES

V MAX

I MAX

Earth

Earth / Chassis

6 mm2

528 Vrms (line to line)

26/21/18 Arms (per line)

AC Line 1

Input Power AC Fused

6 mm2

AC Line 2

Input Power AC Fused

6 mm2

AC Line 3

Input Power AC Fused

6 mm2

Connector type:

DFK-PC16/4-STF-10,16 - 1703470 (Phoenix Contact)

Mating part:

PC16/4-STF-10,16 - 1967472 (Phoenix Contact), torque 1.7-1.8 Nm

Nr. of cycles: 50

OUTPUT and BATTERY CONNECTOR X2 - PINOUT

SIGNAL NAME

PIN #

TYPE

RECOMMENDED WIRES

V MAX

I MAX

CONSUMER +

1, 2

Output Power DC

2x 16 mm2

140 VDC,

137/110/91 A

BATTERY +

3, 4

Output Power DC

2x 16 mm2

COMMON -

5, 6

Output Power DC_return

Isolated from Earth

2x 16 mm2

Connector type:

PC35HC/6-GF-15,00 - 1762783 (Phoenix Contact)

Mating part:

PC35HC/6-STF-15,00 - 1762631(Phoenix Contact), torque ≤25mm² = 2.5 Nm; >25mm² = 4.5 Nm

Nr. of cycles: 50

NOTE: Do not apply excessive forces on the connector, do not bend the wires close to the connector, keep the required torque!

INSTALLATION INSTRUCTIONS

[email protected]om

SIGNAL CONNECTOR X3 – PINOUT

SIGNAL NAME

PIN #

TYPE

SIGNAL

REFERENCE

LOW LEVEL

HIGH LEVEL

V MAX

I MAX

VBsense1

Battery Voltage Sense 1 ***

GRD

0 - 140 V

140 V

VBsense2

Battery Voltage Sense 2 ***

GRD

0 - 105 V

140 V

VBsense3

Battery Voltage Sense 3 ***

GRD

0 - 70 V

140 V

VBsense4

Battery Voltage Sense 4 ***

GRD

0 - 35 V

140 V

GRD

Return

Isolated from Common -

N.C.

Vaux_in

Controller supplying

Common -

140 V

+110Vdc

Battery voltage input – connected internally

Common -

140 V

Common -

Return ****

ADR0

Unit Address 0 *, floating = 0 **

Common -

< 12 V / > 80 V

140 V

ADR1

Unit Address 1 *, floating = 0 **

Common -

< 12 V / > 80 V

140 V

INH_IN

Inhibit input *, floating = 0 **

Common -

< 12 V / > 80 V

140 V

P_LIM

Power Limitation *, floating = 0 **

Common -

< 12 V / > 80 V

140 V

Output floating relay contact (normally open)

Open when in fault condition *

0.4A@140Vdc

Connector type: MSTB2.5/15-GF - 1776825 (Phoenix Contact)

Mating part: MSTB2.5/15-STF - 1786967 or FKCN2.5/15-STF - 1733084 (Phoenix Contact), wires max. 2.5 mm2, torque max. 0.6 Nm

* defined by the Configuration file (a part of the firmware)

** for log.1 connect by a jumper/relay the relevant pin to pin 1, VBsense1 (where the BAT+ is connected)

*** for a description of the connection to battery see Fig.8 in the Datasheet BCD.20200

**** connected internally to Common- via a PTC resistor, not necessary to connect externally

ETHERNET CONNECTOR X4 – PINOUT

SIGNAL NAME

PIN #

TYPE

SIGNAL REFERENCE

NOTE

V MAX

I MAX

TxData+

Communication Data

10/100 Mbit

RxData+

Communication Data

10/100 Mbit

TxData-

Communication Data

10/100 Mbit

RxData-

Communication Data

10/100 Mbit

Connector type:

4-pin M12 D-coded - 1534630 (Phoenix Contact)

Mating part:

4-pin M12 D-coded - 1521258 (Phoenix Contact)

CAN-BUS CONNECTOR X5, X6 – PINOUT

SIGNAL NAME

PIN #

TYPE

SIGNAL REFERENCE

NOTE

V MAX

I MAX

CAN +

Communication Data

CAN-

250 kbit *

CAN -

Communication Data

CAN+

250 kbit *

GRC

Power Supply_Return

Isolated from Common -

Do not use-only for servicing

+5V

Power Supply

GRC

Do not use-only for servicing

5.5V / 100 mA

Connector type:

X5: 9-pin D-SUB male (Amphenol) X6: 9-pin D-SUB female (Amphenol)

Mating part:

9-pin D-SUB female / male

* defined by the Configuration file

NOTE: CAN and Ethernet (TRDP) communication commands are described in a separate document Communication Interface.

LBM Series

Asia-Pacific

+86 755 298 85888

Europe, Middle East

+353 61 49 8941

North America

+1 866 513 2839

BCM.20061_2

SIGNAL CONNECTOR X7 – PINOUT

SIGNAL NAME

PIN #

TYPE

SIGNAL REFERENCE

NOTE

V MAX

I MAX

TB1H

Temperature sensor 1 High

TB1L

For 103AT-11, Semitec *

3.3 V

TB1L

Temperature sensor 1 Low

3.3 V

TB2H

Temperature sensor 2 High

TB2L

For 103AT-11, Semitec *

3.3 V

TB2L

Temperature sensor 2 Low

3.3 V

N.C.

Common -

Can be used to connect the

cable shielding

Do not connect the cable

shielding to earth (chassis)

Figure 3: Output voltage characteristic (model 12/15kW)

INSTALLATION INSTRUCTIONS

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MECHANICAL DIMENSIONS

Figure 4: Main dimensions with bent holders (standard)

Figure 5: Main dimensions with flat holders (optional). The second fixation option requires to unmount the BC before replacing the fans

LBM Series

Asia-Pacific

+86 755 298 85888

Europe, Middle East

+353 61 49 8941

North America

+1 866 513 2839

BCM.20061_2

MOUNTING REQUIREMENTS

The four holders and related screws are placed separately in the package. Please, mount them on the chassis, to the desired position as shown in Fig. 4

or 5 above. It is necessary to use only the original screws (or new screws of the same length as the original !)

Recommended tightening torque min. 40 Nm.

Charger shall be mounted securely on the supporting frame by all 4pcs of holders, by self-locking screws. Mounting holders are designed to support

charger only and cannot be used to support other assemblies. The charger can be installed vertically on the wall or horizontally, by keeping minimal 10

cm of free space around all ventilation openings and at least 15 cm of free space for fans panel replacement. It can be mounted also in a 19” rack, size

3U. Recommended mounting screws are M10 with washer, Bossard 1001361 and 1729314 (not included). Recommended tightening torque 40 Nm.

BC weight: 17.5 kg

Figure 6: The possible mounting positions and distances from the surroundings