INSTALLATION & MAINTENANCE A53106 SERIES DC-TO-DC CONVERTER AUGUST 2011, REVISED AUGUST 2014 DOCUMENT NO. COM-00-04-20 VERSION C.1 Siemens Industry, Inc., Rail Automation 9568 Archibald Ave., Suite 100, Rancho Cucamonga, California 91730 1-800-793-7233 Copyright 2014 Siemens Industry, Inc., Rail Automation All rights reserved PRINTED IN U.S.A.
PROPRIETARY INFORMATION Siemens Industry, Inc., Rail Automation (Siemens) has a proprietary interest in the information contained herein and, in some instances, has patent rights in the systems and components described. It is requested that you distribute this information only to those responsible people within your organization who have an official interest. This document, or the information disclosed herein, shall not be reproduced or transferred to other documents or used or disclosed for manufacturing or for any other purpose except as specifically authorized in writing by Siemens. TRANSLATIONS The manuals and product information of Siemens are intended to be produced and read in English. Any translation of the manuals and product information are unofficial and can be imprecise and inaccurate in whole or in part. Siemens does not warrant the accuracy, reliability, or timeliness of any information contained in any translation of manual or product information from its original official released version in English and shall not be liable for any losses caused by such reliance on the accuracy, reliability, or timeliness of such information. Any person or entity who relies on translated information does so at his or her own risk. WARRANTY INFORMATION Siemens Industry, Inc., Rail Automation warranty policy is as stated in the current Terms and Conditions of Sale document. Warranty adjustments will not be allowed for products or components which have been subjected to abuse, alteration, improper handling or installation, or which have not been operated in accordance with Seller's instructions. Alteration or removal of any serial number or identification mark voids the warranty. SALES AND SERVICE LOCATIONS Technical assistance and sales information on Siemens Industry, Inc., Rail Automation products may be obtained at the following locations: Siemens Industry, Inc., Rail Automation Siemens Industry, Inc., Rail Automation 2400 NELSON MILLER PARKWAY 939 S. MAIN STREET LOUISVILLE, KENTUCKY 40223 MARION, KENTUCKY 42064 TELEPHONE: (502) 618-8800 TELEPHONE: (270) 918-7800 FAX: (502) 618-8810 CUSTOMER SERVICE: (800) 626-2710 SALES & SERVICE: (800) 626-2710 TECHNICAL SUPPORT: (800) 793-7233 WEB SITE: http://www.rail-automation.com/ FAX: (270) 918-7830 FCC RULES COMPLIANCE The equipment covered in this manual has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his/her own expense. ii
DOCUMENT HISTORY Version Release Sections Details of Change Date Changed A 11/16/2004 Initial release A.1 10/31/2005 1 Pages 1-1, 1-2: Changed Input to Output isolation to 2000 VRMS. B 12/17/2007 1.2 2.1.1 2.1.2 2.3.1 2.3.2 Page 1-2: Clarified and expanded specifications, expanded operating/storage temperature range. Page 2-1: Changed input current to 14.0 amps for -04 version, stipulated that converter must be connected to battery source and not the battery charger. Page 2-3: Added part number for Safetran primary arrester Page 2-4: Added Cycle converter input circuit breaker to Loss of input causes. Page 2-4: Added Over temperature condition to Loss of output causes C Aug 2011 1.1 1.2 2.1.1 2.1.2 Update front material Page 1-1: list all five A53106 models, Replace Figure 1-1 Page 1-2: Replace specifications table Page 2-1: add grounding options, add Figure 2-1, add Warning Page 2-2: add all models to minimum voltage information, add Warning Page 2-3: Replace Figure 2-2 Page 2-4: Add Caution C.1 August 2014 all Siemens rebranding iii
NOTES, CAUTIONS, AND WARNINGS Throughout this manual, notes, cautions, and warnings are frequently used to direct the reader s attention to specific information. Use of the three terms is defined as follows: WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY. WARNINGS ALWAYS TAKE PRECEDENCE OVER NOTES, CAUTIONS, AND ALL OTHER INFORMATION. CAUTION REFERS TO PROPER PROCEDURES OR PRACTICES WHICH IF NOT STRICTLY OBSERVED, COULD RESULT IN A POTENTIALLY HAZARDOUS SITUATION AND/OR POSSIBLE DAMAGE TO EQUIPMENT. CAUTIONS TAKE PRECEDENCE OVER NOTES AND ALL OTHER INFORMATION, EXCEPT WARNINGS. NOTE Generally used to highlight certain information relating to the topic under discussion. If there are any questions, contact Siemens Industry Inc., Rail Automation Application Engineering. iv
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS Static electricity can damage electronic circuitry, particularly low voltage components such as the integrated circuits commonly used throughout the electronics industry. Therefore, procedures have been adopted industry-wide which make it possible to avoid the sometimes invisible damage caused by electrostatic discharge (ESD) during the handling, shipping, and storage of electronic modules and components. Siemens Industry, Inc., Rail Automation has instituted these practices at its manufacturing facility and encourages its customers to adopt them as well to lessen the likelihood of equipment damage in the field due to ESD. Some of the basic protective practices include the following: Ground yourself before touching card cages, assemblies, modules, or components. Remove power from card cages and assemblies before removing or installing modules. Remove circuit boards (modules) from card cages by the ejector lever only. If an ejector lever is not provided, grasp the edge of the circuit board but avoid touching circuit traces or components. Handle circuit boards by the edges only. Never physically touch circuit board or connector contact fingers or allow these fingers to come in contact with an insulator (e.g., plastic, rubber, etc.). When not in use, place circuit boards in approved static-shielding bags, contact fingers first. Remove circuit boards from static-shielding bags by grasping the ejector lever or the edge of the board only. Each bag should include a caution label on the outside indicating static-sensitive contents. Cover workbench surfaces used for repair of electronic equipment with static dissipative workbench matting. Use integrated circuit extractor/inserter tools designed to remove and install electrostaticsensitive integrated circuit devices such as PROM s (OK Industries, Inc., Model EX-2 Extractor and Model MOS-40 Inserter (or equivalent) are highly recommended). Utilize only anti-static cushioning material in equipment shipping and storage containers. For information concerning ESD material applications, please contact the Technical Support Staff at 1-800-793-7233. ESD Awareness Classes and additional ESD product information are also available through the Technical Support Staff. v
TABLE OF CONTENTS Section Title Page PROPRIETARY INFORMATION... ii TRANSLATIONS... ii WARRANTY INFORMATION... ii SALES AND SERVICE LOCATIONS... ii FCC RULES COMPLIANCE... ii DOCUMENT HISTORY... iii NOTES, CAUTIONS, AND WARNINGS... iv ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS... v 1.0 INTRODUCTION... 1-1 1.1 General Description... 1-1 1.2 Specifications... 1-2 2.0 INSTALLATION & MAINTENANCE... 2-1 2.1 Installation for Best Performance... 2-1 2.1.1 Grounding... 2-1 2.1.2 Installation for Converter Used with WCP Radio... 2-2 2.1.3 Installation of Converter to Track Switch Motor Battery... 2-4 2.2 Maintenance... 2-4 2.3 Troubleshooting... 2-4 2.3.1 Loss of Input... 2-5 2.3.2 Loss of Output... 2-5 TABLE OF FIGURES Figure No. Title Page Figure 1-1 A53106-1, A53106-4, and A53106-5 DC-to-DC Converters... 1-1 Figure 1-2 Case Dimensions (All Models)... 1-3 Figure 2-1 Grounding Options... 2-1 Figure 2-2 A53106 Used With WCP... 2-3 vi
INTRODUCTION SECTION 1 INTRODUCTION 1.0 INTRODUCTION 1.1 GENERAL DESCRIPTION The Siemens A53106 DC to DC converters (see figure 1-1) are used in Railroad applications requiring isolated and regulated DC/DC conversion. Five converter models: The A53106-01 converts 12 volts to 12.5 volts @ 150 Watts The A53106-02 converts 24 volts to 12.5 volts @ 144 Watts The A53106-03 converts 12 volts to 12.5 volts @ 75 Watts The A53106-04 converts 24 volts to 12.5 volts @ 220 Watts The A53106-05 converts 10 to 36 volts to 13.8 volts @ 200 Watts Each model provides: 2000 VRMS of Isolation from input to output. Front-end filter with Surge protection WARNING ALL CONVERTERS ARE SHIPPED WITH THE OUTPUT NEGATIVE BONDED TO CHASSIS GROUND. REFER TO SECTION 2.1.1 FOR CHASSIS GROUND AND FLOATING GROUND OPTIONS BEFORE CONNECTING CONVERTER. Figure 1-1 A53106-1, A53106-4, and A53106-5 DC-to-DC Converters 1-1
INTRODUCTION 1.2 SPECIFICATIONS Part Number: A53106-01 A53106-02 A53106-03 A53106-04 A53106-05 Input Voltage Range: 10-20-VDC 18-36 VDC 10-20 VDC 18-36 VDC 10-36 VDC** Nominal Input Voltage: 12 VDC 24 VDC 12 VDC 24 VDC 28 VDC Maximum Input Current: 19 A @ 10 VDC 9 A @ 18 VDC 9.5 A @ 10 VDC 14 A @ 18 VDC 19 A @ 10 VDC Output Voltage: 12.5 VDC 12.5 VDC 12.5 VDC 12.5 VDC 13.8 VDC Output Power @ 25 C 15% Duty Cycle: 150 Watts 144 Watts 75 watts 220 watts 200 Watts Maximum Continuous Current: 4.5 Amps 5.0 Amps 2.25 Amps 8.0 Amps 4.5 Amps Maximum Current 15% Duty Cycle (Pulsed): 12 Amps 10 Amps 6 Amps 17 Amps 14 Amps Max Intermittent Peak Output (Pulsed): 15% above rated output (pulsed) 15% above rated output (pulsed) 15% above rated output (pulsed) 15% above rated output (pulsed) 15% above rated output (pulsed) Output Ripple P-P Typical 360 mv Typical 360 mv Typical 370 mv Typical 360 mv Typical 220 mv Efficiency: Up to 90% Up to 90% Up to 90% Up to 90% Up to 85% Isolation Input to Output: 2000V RMS 2000V RMS 2000V RMS 2000V RMS 2000V RMS Temperature (Operating): -40 to +160 F -40 to +160 F (-40 to +70 C) (-40 to +70 C) Temperature (Storage): -40 to +185 F -40 to +185 F (-40 to +85 C) (-40 to +85 C) -40 to +160 F (-40 to +70 C) -40 to +185 F (-40 to +85 C) -40 to +160 F (-40 to +70 C) -40 to +185 F (-40 to +85 C) -40 to +160 F (-40 to +70 C) -40 to +185 F (-40 to +85 C) Dimensions: See Figure 1-2 See Figure 1-2 See Figure 1-2 See Figure 1-2 See Figure 1-2 ** 9-36 VDC input is available with output power reduced to 75% (150 Watts). 1-2
INTRODUCTION R101904_0121 10-19-04 Figure 1-2 Case Dimensions (All Models) 1-3
INTRODUCTION This Page Intentionally Left Blank 1-4
INSTALLATION & MAINTENANCE SECTION 2 INSTALLATION 2.0 INSTALLATION & MAINTENANCE 2.1 INSTALLATION FOR BEST PERFORMANCE The A53106 DC to DC converter may be either rack or wall mounted. For each application, the A53106 must be installed with attention to the size and length of the input feed wire. The input wire should be as short as practical. AWG 6 or double AWG 10 size wire is recommended for most applications 2.1.1 Grounding The A53106 DC-to-DC Converters have a chassis ground or floating ground option. Units are shipped with the chassis ground connected. If floating ground is required (e.g. powering signals) remove the left cover to expose the circuit board and switch the chassis ground from J1 to J2. The negative will now be floating in reference to the chassis and earth ground. Figure 2-1 shows the ground connections. Chassis Ground Floating Ground Figure 2-1 Grounding Options 2-1
INSTALLATION & MAINTENANCE WARNING ALL CONVERTERS ARE SHIPPED WITH THE OUTPUT NEGATIVE BONDED TO CHASSIS GROUND. IF POWERING SIGNALS, A FLOATING GROUND MAY BE REQUIRED. VERIFY THE TYPE OF GROUND REQUIRED PER RAILROAD AND/OR AGENCY DRAWINGS AND PROCEDURES BEFORE CONNECTING THE DC TO DC CONVERTER TO THE SYSTEM. 2.1.2 Installation for Converter Used with WCP Radio The 30-Watt A53412 radio draws approximately 11 Amps while transmitting. To insure that the radio will transmit properly at all battery levels the following cabling requirements must be followed. The recommended feed wire size (AWG 6 or double AWG 10) is used to prevent excessive voltage drop between the battery and the A53106 input, i.e., to produce the lowest voltage drop across the feed wire when the A53106 DC/DC Converter is pulling maximum current at the minimum input voltage level. Minimum input voltage levels: A53106-01 or -03 12V to 12.5V converter 10 Volts @ 19 Amps A53106-02 or -04 24V to 12.5V converter 18 Volts @ 14 Amps A53106-05 10-36V to 13.8 converter 10 Volts @ 19 Amps The recommended feed wire size is used between the A53106 and the battery. The feed wire can be terminated at the DCV Bus Bar (see Figure 2-2) on the Wall of the house, as long as: 1. It's the shortest route 2. AWG #6 or double AWG #10 is used on both sides of the Bus Bar. 3. Converter is to be connected to the battery source, not at the charger. Proper wire size insures that the DC to DC converter input voltage will remain above the required minimum voltage when the charger is down and the unit is running solely off the battery. Proper wire size also minimizes the feed-wire voltage drop that may drop the input voltage below the minimum level as output current increases. 2-2
INSTALLATION & MAINTENANCE Figure 2-2 A53106 Used With WCP 2-3
INSTALLATION & MAINTENANCE 2.1.3 Installation of Converter to Track Switch Motor Battery The A53106 can run directly from the same Signal battery that powers the Switch Motor, as long as: 1. The AWG #6 input wire to the A53106 is connected directly to the Battery via a Clearview Primary Surge Arrester, Siemens Part Number 022485-33X 2. The input wire is not routed via the Wall Bus strip 3. When the proper feed wire size and routing is observed the battery will provide enough current for both the Radio and the Switch motor. 4. The A53106 will: a. Provide the power required by Radio to Transmit at full power, even while a Track Switch move is in progress b. Supply the current without the surge causing a drop at the A53106 input below minimum input level CAUTION A SURGE VOLTAGE DROP WILL CAUSE THE A53106 TO RESET, AND THUS CAUSE AN INTERRUPTION OF DC POWER TO THE RADIO. NOTE The use of incorrect feed wire size, length, or routing may cause the current drawn by the Radio and/or the Switch Motor to drop the A53106 input voltage below the minimum operating level. 2.2 MAINTENANCE No routine or preventive maintenance is necessary to the converter. 2.3 TROUBLESHOOTING In general, any trouble encountered with the unit will result from low output, or no output. The steps outlined below provide a general guideline for isolating the cause of trouble. 2-4
INSTALLATION & MAINTENANCE 2.3.1 Loss of Input Loss of converter input may result from: Defective battery. Check battery voltages under load conditions. Loose connection. Check wiring and terminations. Defective wiring or component(s) between the battery and the converter input. Replace or repair wiring and/or component(s). Tripped input circuit breaker. Check circuit breakers and reset as required. 2.3.2 Loss of Output Loss of output may result from: Tripped front-panel circuit breaker. Check circuit breakers and reset as required. Input voltage is below minimum input-voltage level (see paragraph 2.1.2). Check battery voltages under load conditions. Replace or repair as required. Check wiring as described in paragraphs 2.1.2 and 2.1.3. Repair as required. Excessive output load. Remove the loads and measure the no-load voltage output. If the no-load output voltage is consistent with the specification, connect each load through an arrester to see if the drain is excessive. If a load fault is indicated, the condition should be corrected. Over temperature condition. 2-5
Siemens Industry, Inc., Rail Automation 2400 Nelson Miller Parkway Louisville, Kentucky 40223 (502) 618-8800 Siemens Industry, Inc., Rail Automation California R&D Division 9568 Archibald Ave., Suite 100 Rancho Cucamonga, California 91730 (909) 532-5300