Power Conversion Systems

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1 Power Conversion Systems Innovation made in Germany Switchmode Power Supplies Converters DC/DC Rectifiers AC/DC Chargers Switchmode Inverters Inverters DC/AC Frequency converters UPS Thyristor-controllers Power supplies Chargers

people, who oversee the entire concept, design, control and manufacture of all of the SCHAEFER Product Portfolio.

Intellectual Property, which can only be gained from Designing, Manufacturing solutions after detailed and in-depth consultation with Clients.

Power Supplies & Battery Chargers. DC / DC Converters. AC / DC Rectifiers & Battery Chargers. DC / AC Inverters single & three phase.

Control and monitoring systems integrated and stand alone.

testing and customer support areas being all under the same roof.

Fruits of this labour are to be seen throughout the World, in a variety of fields such as; Rail industry Automotive industry Power Generation

design in house & manufacture in house generates a large degree of flexibility.

2 Company Profile Power Solutions designed & manufactured in Germany workforce SCHAEFER GmbH being a wholly owned, privately run and assisted by a qualified, and experienced, team of experts, SCHAEFER has grown in a controlled and sustainable manner to a dedicated workforce of over 200 people, who oversee the entire concept, design, control and manufacture of all of the SCHAEFER Product Portfolio. Stemming from experience which dates back to the founding days of the Company, SCHAEFER Personnel can tap into a rich resource, that is our Intellectual Property, which can only be gained from Designing, Manufacturing solutions after detailed and in-depth consultation with Clients. products It is as a result of this intensive depth of Engineering that the Product Portfolio has been expanded to include: THYRISTOR Controlled Power Supplies & Battery Chargers. DC / DC Converters. AC / DC Rectifiers & Battery Chargers. DC / AC Inverters single & three phase. AC / AC Frequency Converters - single & three phase. Electronic By-pass switches. DC & AC, UPS systems. Control and monitoring systems integrated and stand alone. manufacture Immediate proximity also generates the free flowing information path, which is the production and development areas, along with the testing and customer support areas being all under the same roof. This enhances the SCHAEFER Teams ability to react to exacting demands with ease. Fruits of this labour are to be seen throughout the World, in a variety of fields such as; Rail industry Automotive industry Power Generation Industry Chemical industry Oil & Gas Industry Factory Industry Military Industry Aeronautics Industry flexibility Maintaining the ability to design in house & manufacture in house generates a large degree of flexibility. The SCHAEFER Client profits from these engineering skills through an optimised solution tailored to the needs and parameters of the Project. Be they on shore, or off shore, stationary or mobile, land air or marine based. A system component or complete system, environmentally Hazardous area 1, corrosive or simply Industrial, there is a SCHAEFER Power solution to fit the parameters. Welcoming the challenge, the SCHAEFER Team offer the highest quality engineering designed and Manufactured in Germany. Innovation made in Germany 2 3

Power Supplies - Converters DC / DC, Rectifiers AC / DC &

3-Phase Output - Inverters DC / AC, Frequency Converters AC /

Customized Systems 12 Preview 14 Photo Gallery of special

Diagram C > F 4 the client available upon request The

details given. Conversion Table Height 1 HE = 44.

3 Type Test Certificates Table of contents Page Company Profile 2 Type Test Certificates 4 Table of contents 5 Switchmode Power Supplies - Converters DC / DC, Rectifiers AC / DC & Chargers 6 Design solutions 7 Switchmode Inverters 1-Phase & 3-Phase Output - Inverters DC / AC, Frequency Converters AC / AC & UPS 8 Design solutions 9 Mechanics and Accessories 10 Customized Systems 12 Preview 14 Photo Gallery of special units 15 Specific Certification in conjunction with Conversion Diagram C > F 4 the client available upon request The manufacturer reserves the right to deviate from technical details given. Conversion Table Height 1 HE = mm 1 HE = 1.75 Width 1 TE = 5.08 mm 1 TE = = 25.4 mm Weight 1 kg = 2.2 lbs F - 40 C - 20 C 55 C 75 C 85 C C 185 F 167 F 131 F 4 F 40 F 5

Switchmode Power Supplies - Converters DC / DC, Rectifiers AC / DC & Chargers Design Solutions Input voltage DC/DC converters: 10-800V DC Input

DC ; additional outputs: 5 / 12 / 15 / 24V DC upon request : 50W - 40kW The flexibility of the SCHAEFER SMPS Modules is shown through the

The ease through which SCHAEFER GmbH can supply such a solution results from the in house design of all electrical and mechnical elements that

Features Specifications: Rail application - on board Continuous short circuit protection High degree of shock and vibration compliant

grade components Compact and robust design Frequence Immunity - Fast transients - Surges 47-100 Hz acc. to EN 61000-4-4 level 3 acc.

modules for 19 sub-racks with natural convection Output DC output voltage 5 9 12 15 24 28 48 60 110 200 220 400 from 50 W up to 5 kw Line

2% (10-90%) Load regulation (10-90%) ± 1 % Ripple and noise < 1% + 30 mv pk-pk High power modules in 19 format with fan cooling DC output

.., 400 V, 600 V, 800 V from 5 up to 30 kw High power modules in 19 format with water/ liquid cooling Overload protection Overvoltage protection

Efficiency 80-95% typical for low input / output voltage: 75% typical Operating temperature -20 to +75 C optional: -40 to +75 C above + 55 C

5%/ C High power density Environmentally adapted to 97% non condensing humidity Client interface and signals at the front 19 design, vertical

.., 400 V, 600 V, 800 V from 8 up to 40 kw 19 = 482.

to EN 60950, class 1 EMI acc. to EN 55022, class A optional: class B Connector H15 acc.

4 Switchmode Power Supplies - Converters DC / DC, Rectifiers AC / DC & Chargers Design Solutions Input voltage DC/DC converters: V DC Input voltage AC/DC power supplies: 115 / 230V AC, single phase (with or without PFC) or 200 / 400 / 480V AC, three phases Output voltage: up to 800V DC ; additional outputs: 5 / 12 / 15 / 24V DC upon request : 50W - 40kW The flexibility of the SCHAEFER SMPS Modules is shown through the versatility to be either a stand alone solution or integrated as a system element within Client specific applications. The ease through which SCHAEFER GmbH can supply such a solution results from the in house design of all electrical and mechnical elements that create the SCHAEFER GmbH solution. Features Specifications: Rail application - on board Continuous short circuit protection High degree of shock and vibration compliant Overvoltage protection Input External environmental thermal discharge thermal shutdown with auto-restart operational from 40 to +75 C Industrial grade components Compact and robust design Frequence Immunity - Fast transients - Surges Hz acc. to EN level 3 acc. to EN level 3 Completely autonomous design, turn key solution 3rd Rail power sourced Client specific customized interface Plug-in modules for 19 sub-racks with natural convection Output DC output voltage from 50 W up to 5 kw Line regulation (±10%) 0.1% Load regulation 0.2% (10-90%) Load regulation (10-90%) ± 1 % Ripple and noise < 1% + 30 mv pk-pk High power modules in 19 format with fan cooling DC output voltage 5 V, 9 V,..., 400 V, 600 V, 800 V from 5 up to 30 kw High power modules in 19 format with water/ liquid cooling Overload protection Overvoltage protection Remote sense current limited to % of full load OVP switches off module with automatic return to operation up to 3 V per wire General Efficiency 80-95% typical for low input / output voltage: 75% typical Operating temperature -20 to +75 C optional: -40 to +75 C above + 55 C derating 2.5%/ C High power density Environmentally adapted to 97% non condensing humidity Client interface and signals at the front 19 design, vertical convectional cooling Programmable output through an SPS controller DC output voltage 12 V, 15 V,..., 400 V, 600 V, 800 V from 8 up to 40 kw 19 = mm Storage temperature -40 to + 85 C I/O isolation voltage 2100 VDC (Vin < 60 VDC) 3500 VDC (Vin > 60 VDC) Safety acc. to EN 60950, class 1 EMI acc. to EN 55022, class A optional: class B Connector H15 acc. to DIN or terminals / bolts / bars Military grade solution Flexible orientation Options Capable of populating a 5U RACK with three units Capable of populating a 3U RACK with two units 5kW Modules ensuring a high power density Inrush current limiting Automatic / manual selection of charging characteristic Being impervious to both the 99% humidity, shock and Automatic selection of 115 / 230V AC input Temperature compensated charging voltage vibration, the flexibility in both mechanics and electrical Power factor correction for single phase input Monitoring of input and output voltage design were fundamental to the Client specifications. DC Input polarity protection RS232 or IEEE488 interface Output decoupling diode for redundant / parallel operation Wall mount, chassis mount or DIN rail mount Active current sharing for parallel operation Increased mechanical strength Remote on / off (inhibit) Tropical protection 6 7

Switchmode Inverters 1-Phase & 3-Phase Output - Inverters DC/AC, Frequency Converters AC/AC & UPS Design Solutions Input voltage 10-800VDC or 1-Phase / 3-Phase, 47-400Hz Output 115 / 230 VAC,

standard SCHAEFER GmbH design and manufacture may be adapted in a myriad of Forms.

Some examples here show how a singular Inverter module may be used in several fundamentally different solutions.

Compact and robust design Additional features for 3-Phase Output Unsymmetrical load permissible Modular system with interchangeable inverters Inverters or Frequency Converters with 1-Phase

400 / 480V or any other output voltage (to be specified) from 600VA to 45kVA Specifications: Input Voltage 10-800 V No-load input power 10 30 W Frequency 40 400 Hz or fi xed frequency

to DIN / EN 61000-4-5 level 3 Output Line regulation (±10 %) Load regulation (10 90 %) Turn-on rise time Waveform 0.1 % for series CI, 2 % for series IT and IV 1 % typical, 3 % max.

) Soft-start, 100 ms typical sine wave or any wave shape programmable by external signal Frequency 40 400 Hz: adjustable / programmable or any fixed frequency (crystal stabilized) Distortion

05 x Inom 2 x Pnom for 1 s electronically limited to 3 x Inom, unit switches off after 1 s Crest factor approx. 3 Power factor cos 0.

5 % / C from + 55 C Storage temperature 40 to + 85 C Humidity up to 95 % RH, non-condensing Safety / Construction acc.

to EN 55022, class A, optionally class B Marking CE Rail application Rolling Stock mounted High degree of shock & vibration protection IP66 Client specific interface connection Anchored to

environmental temperature Full power ability, across a phase shifted load, capacitive & inductive load tolerant of ± 0.7cos ϕ Military grade design.

5 Switchmode Inverters 1-Phase & 3-Phase Output - Inverters DC/AC, Frequency Converters AC/AC & UPS Design Solutions Input voltage VDC or 1-Phase / 3-Phase, Hz Output 115 / 230 VAC, 200 / 400 / 480 VAC, 1-Phase / 3-Phase Hz fixed or variable frequency (crystal stabilized) Continuous short circuit protection; Surge power capability, Industrial grade components The standard SCHAEFER GmbH design and manufacture may be adapted in a myriad of Forms. In conjunction with the Clients Engineering Department, the SCHAEFER Team of Engineers can offer untold variations both mechanically and electrically to suit almost any application. Some examples here show how a singular Inverter module may be used in several fundamentally different solutions. Features Sine Wave Continuous short circuit protection thermal shutdown with auto-restart for inverters >1kVA Suitable for complex load Surge power capability Industrial grade components Compact and robust design Additional features for 3-Phase Output Unsymmetrical load permissible Modular system with interchangeable inverters Inverters or Frequency Converters with 1-Phase Output 1-phase AC output voltage 115 or 230V or any other voltage (to be specified) from 200VA to 15kVA Inverters or Frequency Converters with 3-Phase Output 3-phase AC output voltage 200 / 400 / 480V or any other output voltage (to be specified) from 600VA to 45kVA Specifications: Input Voltage V No-load input power W Frequency Hz or fi xed frequency Immunity- ESD acc. to DIN / EN level 3 Fast transients acc. to DIN / EN level 3 Surges acc. to DIN / EN level 3 Output Line regulation (±10 %) Load regulation (10 90 %) Turn-on rise time Waveform 0.1 % for series CI, 2 % for series IT and IV 1 % typical, 3 % max. (400 Hz: 3 % typical, 5 % max.) Soft-start, 100 ms typical sine wave or any wave shape programmable by external signal Frequency Hz: adjustable / programmable or any fixed frequency (crystal stabilized) Distortion 3 % typical, Hz, Hz Overload protection (steady state) Surge power Short circuit protection current limited to approx x Inom 2 x Pnom for 1 s electronically limited to 3 x Inom, unit switches off after 1 s Crest factor approx. 3 Power factor cos 0.7 inductive / capacitive General Efficiency % Operating temperature 20 to + 75 C Load derating 2.5 % / C from + 55 C Storage temperature 40 to + 85 C Humidity up to 95 % RH, non-condensing Safety / Construction acc. to DIN / EN : 2003 Protection category IP 20, others or NEMA upon request EMI acc. to EN 55022, class A, optionally class B Marking CE Rail application Rolling Stock mounted High degree of shock & vibration protection IP66 Client specific interface connection Anchored to the RAIL Car floor 600mm 600mm foot print Impervious to both impulses and spikes across the input, this module delivers the full output range with a crest factor of 3, up to +75 C environmental temperature Full power ability, across a phase shifted load, capacitive & inductive load tolerant of ± 0.7cos ϕ Military grade design. Integrated Inverter, Static Switch and Battery Charger Configured both dual redundant & fault tolerant SCHAEFER GmbH electronic Static Switch Supplied form multiple independent DC and an AC source Both automatically and manually operational by-pass system. N+2 design. The indication panel reflects the operational status, while multiple stage monitoring is both locally and remotely communicated. With an integrated & isolated AC by-pass, placed behind the user interface panel, the design both fits the criteria and surpasses the basic specification requirements in its standard configuration. The electronic elements of this solution are extracted through the removal of 4 screws, without the need to take the system off-line, making the perfect solution for critical Sub Station applications. This 6U mm deep solution is an integral part of multiple applications. Through these applications the robust and reliable design comes to the fore as a repeated example of high quality engineering resulting in design excellence, mated to the application parameters. 8 9

Mechanics and Accessories Standard 19 Sub-Racks Plug-in module for

typically equipped with one or two H15 connectors at the rear.

For inverters with a transformer at the output a F24H7 connector is

F48 connector is fi tted in addition to the H15 connector.

High power module with fan cooling The high power modules are

Depending on the current, bolts or bars may also be available for

Typically, these modules are cooled through air supply entering

modules whose airflow is from front to back.

modules are designed and manufactured for insertion into 19

Higher power modules are already constructed in 19 format.

units and can be upgraded in accordance to the customers

mating connectors wired to a terminal block fuses or circuit

digital meters switches fans filters decoupling diodes provisions

Alternatively, the racks can be provided in 23 format.

with liquid cooling are also constructed in 19 format, having bolts

The connections for the liquid inlet / outlet are also located at

rear view with terminal block rear view Options w wall mount

Should the application not require a pluggable module / rack

6 Mechanics and Accessories Standard 19 Sub-Racks Plug-in module for 19 sub-rack with natural convection The standard modules are typically equipped with one or two H15 connectors at the rear. For currents > 50 A high current connectors are used. For inverters with a transformer at the output a F24H7 connector is fi tted in addition to the H15 connector and for static switches a F48 connector is fi tted in addition to the H15 connector. All these modules are designed for insertion into a 19 sub-rack. High power module with fan cooling The high power modules are constructed in 19 format, having a terminal block at the rear. Depending on the current, bolts or bars may also be available for connection. Typically, these modules are cooled through air supply entering below and exiting above (see photo), with the exception of some modules whose airflow is from front to back. H15 F48 High Current F24H7 Connector As standard, all of the modules are designed and manufactured for insertion into 19 sub-racks. Higher power modules are already constructed in 19 format. 19 sub-racks can be confi gured as 3U or 6U allowing any mix of units and can be upgraded in accordance to the customers requirements, e.g. mating connectors wired to a terminal block fuses or circuit breakers hot swappable confi guration upon request analog or digital meters switches fans filters decoupling diodes provisions for keying the modules to ensure module / slot designation Alternatively, the racks can be provided in 23 format. front view High power module with liquid cooling High power modules with liquid cooling are also constructed in 19 format, having bolts or bars and eventually Sub D connectors at the rear. The connections for the liquid inlet / outlet are also located at the rear. rear view with terminal block rear view Options w wall mount Modules, which have the wall mount option, are typically fixed to a structure or within a cabinet. Depending on the size of the module, this may be done with a fl at or angled plate (see photo). The load connections are typically a terminal block. Should the application not require a pluggable module / rack solution, wall mounting presents an alternative for the customer to choose from. internal front view showing various mating connectors cha chassis mount Module is designed for installation to a structure or within a cabinet. Screw type mating connectors are supplied with the module. Due to the limited number of connector pins this option is not available for modules with dual AC input or for multi-output converters with output 4 supplying more than 10 A. din DIN rail mount Module is designed for DIN rail mounting to a structure or within a cabinet. Screw type mating connectors are supplied with the module. Due to the limited number of connector pins this option is not available for modules with dual AC input or for multi-output converters with output 4 supplying more than 10 A. rear view showing high current mating connectors 10 11

Customized Systems Sub Sea Mineral Exploration Integrated

Integrated Switch Mode Power Supply Extreme Environmental

design to integrate into the titanium pipe / tube Enhanced

Redundant fault tolerant capability KTA 3507 Certified

reliability, Redundant fault tolerant capability 19

design Programmable output parameters through Client

Supply Military Application Multi input/output Converter

industry highly demanding environment extreme load

heat exchange re-capture Programmable output parameters

multiple sources Integrated Charger / Inverter Expansion

Micro Controller and monitoring function Elemental design

a high degree of shock & vibration Rail Application 40 kw

Support Inverter System for Aircraft Mains Simulation

Battery charger & DC Bus supply multi output Challenging

of shock & vibration Self protecting, autonomous

Input Frequency Wide input voltage range Programmable

7 Customized Systems Sub Sea Mineral Exploration Integrated Switch Mode Power Supply Nuclear Power Generation Integrated Switch Mode Power Supply Extreme Environmental Challenges Wide range of AC input supply Robust heat sink design to integrate into the titanium pipe / tube Enhanced mechanical integration High level of reliability, Redundant fault tolerant capability KTA 3507 Certified Reactor Core temperature evaluation High level of reliability, Redundant fault tolerant capability 19 Designed RACK mechanical solution Enhanced mechanical design Programmable output parameters through Client Interface Industry Automation 40 kw Liquid cooled Power Supply Military Application Multi input/output Converter for Marine Environment for semiconductor manufacturing industry highly demanding environment extreme load variations transfer of thermal energy into a fluid for heat exchange re-capture Programmable output parameters through Client Interface Wide range input voltage from multiple sources Integrated Charger / Inverter Expansion through direct Parallel Configuration on DC and AC bus Micro Controller and monitoring function Elemental design for maximum Client Integration Flexibility Engineered for a high degree of shock & vibration Rail Application 40 kw Multi input / output On-board Power System Aircraft Ground Support Inverter System for Aircraft Mains Simulation Hermetically sealed enclosure Controlled air management Battery charger & DC Bus supply multi output Challenging environmental specification Engineered for a high degree of shock & vibration Self protecting, autonomous assessment of thermal and electrical parameters 400Hz Input Frequency Wide input voltage range Programmable output parameters through Client Interface Remote or Local control 19 Designed RACK mechanical solution Proprietary designed electrical solution 12 13

communication Optimized topologies through

Support Continued availability to contact the

support through focused seminars with the

field / Closing evaluation New investment in

optimum communication Active training and

internally Exploration Expansion Founded 1969

This continues today and is taken forward

The initial establishment was, and continues

Further expansion of the German Production

8 Preview Photo Gallery of special units Research & Design DSP design Software communication Optimized topologies through new generation components Testing Client Support Continued availability to contact the dedicated support team per phone Enhanced support through focused seminars with the direct SCHAEFER Clientele Projected support to the End Client when required by the Client, theoretical or practical Transport Production Expanded to encompass direct feedback between Project / Production / Test field / Closing evaluation New investment in control technologies through direct linkage to the SCHAEFER PCB design Streamlined dedicated hierarchy in close proximity for optimum communication Active training and education Programs to advance Personnel internally Exploration Expansion Founded 1969 by Dr Johannes Schäfer, the Company has been built on a solid belief in technical excellence and service to the Marketplace. This continues today and is taken forward into the future as a fundamental philosophy. The initial establishment was, and continues to be, expanded upon in a controlled and sustainable fashion. Expansion Phase 1. Enlargement of the Production facility in Germany Establishment of support centre Expansion Phase 2. Further expansion of the German Production facility Founding of SCHAEFER Inc. Expansion Phase 3. Further expansion of the Germany Production facility Establishment of SCHAEFER GmbH Ireland Expansion Phase 4. Further expansion of the Germany Production facility Establishment of SCHAEFER GmbH Middle East. Expansion Phase 5. Establishment of SCHAEFER GmbH Middle Service & Maintenance Centre Expansion Phase 6. Further expansion of the Germany Production facility Military UPS 14 15

Represented by: Schäfer Elektronik GmbH Oststrasse 17,

Fax +49 (0)7841-2052-52 mail@schaeferpower.

4-204 5831 Fax (+971) 4-204 5832 mail@schaeferpower-me.

200 Butterfield Drive Ashland, MA 01721 United States of

9 Represented by: Schäfer Elektronik GmbH Oststrasse 17, Gamshurst Achern Germany Phone +49 (0) Fax +49 (0) Schaefer GmbH - Middle East 5EA-528, Dubai Airport Freezone P.O.Box: , Dubai United Arab Emirates Phone (+971) Fax (+971) mail@schaeferpower-me.com Schaefer, Inc. 200 Butterfield Drive Ashland, MA United States of America Phone Fax sales@schaeferpower.com - RAILROAD INDUSTRY - MILITARY APPLICATIONS - INDUSTRIAL AUTOMATION - AIRCRAFT TEST SYSTEMS - POWER GENERATION SOLUTIONS - MINERAL EXPLORATION APPLICATIONS BOTH LAND & OFF SHORE BASED edition SE8.1

Power Conversion Systems. SCHAEFER International. Switchmode Power Supplies, Chargers & Inverters. Thyristor-controlled Power Supplies & Chargers

Power Conversion Systems. SCHAEFER International. Switchmode Power Supplies, Chargers & Inverters. Thyristor-controlled Power Supplies & Chargers SCHAEFER International Power Conversion Systems Innovation made in Germany SCHÄFER Elektronik GmbH Oststrasse 17, Gamshurst 77855 Achern Germany Phone +49 (0)7841-2052-0 Fax +49 (0)7841-2052-52 mail@schaeferpower.de