Charger for EDLC Capacitors (Ultra-Caps) Prepared: Michael Raspotnig, PULS GmbH 2013/01/19 2 Typical Wiring Scheme 3 8 LEDs and Relay Contacts Pattern 8 10 Dielectric Strength, Isolation, Leakage Current 9 This document is proprietary. Any dispatch or disclosure of content is authorized only after written authorization by PULS GmbH. All parameters are specified at 400V, 2.5A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

Functional Description - The charger is designed to charge EDLC (electrical double layer capacitors commonly known as Ultracaps, Supercaps or Greencaps) with a constant current – constant voltage characteristic (float charge mode). The charger is suitable to be used in a permanently spinning rotor-hub of a wind turbine. The charger is suitable for flange mounting. Any mounting orientation is allowed. Most of the heat will be conducted through the base-plate of the charger. A good thermal connection to the cabinet or an external heatsink can improve the MTBF and life time expectancy. The charger...

Typical Wiring Scheme Functional Diagram Input Fuses Input Filter Input Rectifier Inrush Limiter Over Voltage Output Voltage disable/ enable Fully charged This document is proprietary. Any dispatch or disclosure of content is authorized only after written authorization by PULS GmbH. All parameters are specified at 400V, 2.5A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

Performance Description Input Voltage: Turn-on Voltage Shut-down Voltage Input Current: Input Frequency: Power Factor: Inrush Current: < 10A peak (active limited, temperature independent) End-of-Charge Voltage: Adjustable: 360-460Vdc (output voltage) Factory setting: 410Vdc 370-470Vdc; auto setting (OVP = Output over-voltage protection) The OVP voltage automatically adjusts to 10V higher then the endof-charge voltage after following the procedure for setting the endof-charge voltage. Testing the OVP level: Tune the end-of charge-voltage potentiometer clockwise until the “Fully Charged” LED starts...

Output Ripple-Voltage: Without connected capacitor bank: With connected capacitor bank: Output Current Ripple: Output Return Current: Max. 1mA (discharge current when charger is not working) Procedure for Setting the End-of-Charge” Voltage: Setting the end-of-charge voltage shall be done in a laboratory. The output shall be open (not loaded, no capacitor needed). The output voltage (end-of-charge voltage) shall be measured with a digital voltmeter. Factory setting of the end-of-charge voltage is 410Vdc and the OVP level is 10V higher. Changing of these values can be done according to the following...

General Data at 400Vdc output voltage, 2.6A output current and 230Vac input Full-load Power Losses: typ. 60.8W at 400Vdc output voltage and 2.6A output current No-load Power Losses: The charger is suitable to charge capacitors up to 5F. The typical capacitance is considered to be 2F. Therefore, most of the following curves and investigations apply for this size of capacitor unless otherwise stated. Voltage on Output Terminals for a 2F EDLC, typ This document is proprietary. Any dispatch or disclosure of content is authorized only after written authorization by PULS GmbH. All parameters are specified...

/j\ Installation by professional personnel « ' Do not use without protective earth ADo not open, risk of electrical shock Read PAS395 instruction manual Assembled in Czech Republic Factory settings: Electronically protected End-of -Charge Voltage o Signals, LEDs Inhibit Input: A signal voltage of at least 18V on the inhibit input terminal stops the charging mode. Safety features are not included. The input is galvanically isolated by an optocoupler. Output-OK Relay Contact: This relay contact closes (normally-open-contact) when the charger works properly and no internal faults or abnormal The...

8 LEDs and Relay Contacts Pattern Input-OK Output-OK Fully charged Output OK Fully charged Capacitors in charging mode ON ON OFF closed open Capacitors fully charged ON ON ON closed closed Inhibit input activated ON OFF OFF***) open open***) Capacitor does not permit charging ON typ. ON 130s OFF typ. ON 130s open (e.g. short circuit across output) OFFHOs... OFFHOs... No capacitor connected ON ON ON closed closed Over-temperature shut-down (OTP) ON OFF according to the open according to the state-of-charge state of charge Over-voltage protection activated (OVP) ON OFF **) flashing open **) closed...

Dielectric Strength, Isolation, Leakage Current The output is floating and has no ohmic connection to the ground. The following type and factory tests are conducted by the manufacturer. The test duration is 60s for type tests and 5s for the factory tests. Type- & Factory Tests Input Signal Pins Field tests may be conducted in the field using the appropriate test equipment which applies the voltage with a slow ramp (2s up and 2s down). Prior to the field test, special treatment of the unit may be necessary. Connect all input-terminals together as well as all output poles before conducting the...

Electrostatic discharge Contact discharge Air discharge Fast transients (Burst) Input lines Output lines Signal lines Criterion A Criterion A Criterion A Surge voltage on input Surge voltage on signals Conducted disturbance Mains voltage dips Criterion A Criterion C *) Criterion A Voltage interruptions Powerful transients over entire load range Surge voltage on output Criterions: A: Power supply shows normal operation behavior within the defined limits. C: Temporary loss of function is possible. Power supply may shut-down and restarts by itself. No damage or hazards for the power supply will...

Protection Features The output is short-circuit, overload and no-load proof. After removing the fault, an auto-restart will be performed. Over- temperature protection: A temperature sensor monitors the internal temperature of a semiconductor. If the temperature rises above a certain level, the fan will be turned on. If the temperature keeps rising, the output will switch off in order to protect the charger. The output will automatically turn on again as soon as the temperature decreases by 5°C. The “Output-OK” LED will be off and the “Output-OK” contact will be open when the over-temperature...