INSTALLATION MANUAL ULTRAFLEX POWER SUPPLY. UF2500 Series

Transcription

1 INSTALLATION MANUAL ULTRAFLEX POWER SUPPLY UF2500 Series 3055 Del Sol Blvd. San Diego, CA Phone: (619) Fax: (619) P/N: IMUG2500 Rev. B DATE:February 2002

2 TABLE OF CONTENTS INTRODUCTION 4 CERTIFICATION 4 WARRANTY 4 APPLICABILITY 4 PART NUMBER CONFIGURATION 4 INSTALLATION MANUAL 4 SAFETY AGENCY APPROVALS 4 GENERAL SAFETY INSTRUCTIONS 5 FUSE REPLACEMENT 6 RECEIPT AND UNPACKING 6 MOUNTING REQUIREMENTS AND COOLING 6 INPUT POWER CONNECTIONS 7 INPUT VOLTAGE RANGE 7 OUTPUT POWER AND DERATING GUIDELINES 7 EMI (CONDUCTED) 9 ELECTROMAGNETIC COMPATIBILITY 9 REMOTE SENSE 9 OUTPUT VOLTAGE ADJUSTMENT (TRIMMING) 9 CURRENT LIMIT PROTECTION 10 OVERVOLTAGE PROTECTION (OVP) 10 OUTPUT LOAD REGULATION 10 OUTPUT LINE REGULATION 10 HOLD UP TIME: (AC INPUT) 10 TURN-OFF/TURN-ON 10 TURN ON TIME 10 NOISE AND RIPPLE 10 REV B Page 2 of 18

3 DYNAMIC LOAD TRANSIENT RESPONSE 11 DYNAMIC CROSS REGULATION 11 TEMPERATURE COEFFICIENT 11 NO LOAD OPERATION 11 OVER TEMPERATURE SHUTDOWN 11 OPERATING ENVIRONMENT 11 COOLING 12 SHOCK (OPERATING) 12 VIBRATION (OPERATING) 12 PACKAGE DROP 12 RELIABILITY PREDICTION 12 GLOBAL SIGNALS 12 OUTPUT MODULE SIGNALS & FEATURES 13 MODULE RATING WITH MODEL NUMBERS: UGZ1-XXXXXX 15 NOTE: ENERGY HAZARDS 16 OUTLINE DRAWING 17 LABEL / CONNECTION DIAGRAM 18 REV B Page 3 of 18

4 LAMBDA Power Supply Installation Manual INTRODUCTION The UltraFlex is a product family of fan-cooled, multi-output, power factor corrected, switch mode power supplies. The flexible design offers a high quality, cost-effective solution for the high volume OEM market. CERTIFICATION Lambda certifies that this product meets published specifications at the time of shipment from the factory. WARRANTY This power supply is warranted against defects in material and workmanship for a period of three years from date of shipment. During this period Lambda will either repair or replace this product at the discretion of Lambda. No other warranty is implied or given. APPLICABILITY This manual applies to the UF2500 Series power supply. Manual part no. IMUG2500. PART NUMBER CONFIGURATION U G Z 1- _ - _ UltraFlex Case Code Global Signals Output Module Codes [See table on Page 15] EN55022 Level B, FCC Class A Cond. EMI INSTALLATION MANUAL This manual contains important information regarding the proper installation and operation of the power supply mounted inside the host equipment. PLEASE READ THE SAFETY AND INSTALLATION INSTRUCTIONS BEFORE INSTALLATION OR USE OF THIS PRODUCT. SAFETY AGENCY APPROVALS The UltraFlex power supply series complies with the following regulatory specifications: UL1950, IEC 950, CSA 22.2 No. 950, EN This product is Certified and allowed to carry the UL combined Canada/U.S. Recognized Component Mark and Demko. CE Marked in accordance with the Low Voltage directive (73,23/EEC) as amended by the CE Marking directive (93/68/EEC). NOTE: CE Mark does not include compliance to either EMC or medical device directives. REV B Page 4 of 18

5 GENERAL SAFETY INSTRUCTIONS For safe installation and operation of this product, carefully follow the instructions below. SAFETY SYMBOL This symbol indicates dangerous voltages present within the power supply. Isolation transformers should be used between the AC mains and the power supply if work is to be carried out with the safety covers removed. A. Do not install, operate or test this product near water and do not spill any liquid on it. B. Do not touch the product when the input supply is connected. C. Do not operate this product unless it is in a secure position. D. When cleaning the product, make sure the input supply is disconnected and use only a damp cloth. E. Never push objects of any kind into the product through slots in its case, as this could result in electric shock or a fire hazard. F. Slots in the product case are designed for ventilation and must not be obstructed when the product is installed and/or operated. G. Make sure the unit is supplied only by a power source of the type indicated on its label. H. When securing the product, do not use screws that infringe the maximum penetration depth specified on the mechanical drawing within this handbook. I. The unit covers are designed only to protect skilled personnel from hazards. They must not be used as part of the external covers of any equipment where they may be accessible to operators. J. All servicing, repair and testing of this product must be carried out by competent personnel who are familiar with the hazards of AC/DC line operated equipment and the particular dangers associated with switched mode power supplies. K. AFTER DISCONNECTING THE AC SOURCE, ALLOW 5 MINUTES BEFORE TOUCHING THE UNIT TO ALLOW CAPACITORS WITHIN THE UNIT TO DISCHARGE. L. The low-voltage output from the power supply unit shall not be user-accessible as defined in EN M. A protective earth must be provided for safety in accordance with EN WARNING: It is essential that the ground terminal of this product be securely connected to earth (hard-wired) by the end user. REV B Page 5 of 18

6 N. PREVENTION OF ACCESS BY THE USER: The UltraFlex power supply series is designed for use within other equipment or enclosures. This apparatus is intended to be accessible to authorized personnel only. Ensure that user access to this product, when installed in host equipment, complies with EN Failure to do this will invalidate the approval given to this apparatus. O. WARNING: All outputs are SELV and must be connected to loads compliant with the requirements indicated in EN60950 Clause 2.3. Other usage will invalidate any approval given to this apparatus. P. EARTH TERMINAL MARKING: IMPORTANT: If in the end use equipment the incoming mains cable earth wire connects directly to the "GND" connection on the Ultra-Flex unit without being interrupted or junctioned on its way to that connection, then this connection is the main protective earth of the system. To comply with EN60950, UL1950, and CSA requirements, this terminal must be marked with as defined in IEC417 No. 5019a. The customer should therefore affix an adhesive label which will pass the 15 second rub test (IEC950 section ) showing the above symbol adjacent to the earth connection. This symbol must only be used at the first interruption/connection of the incoming earth wire. FUSE REPLACEMENT The AC power line is protected by an internal ceramic body fuse contained within the power supply enclosure. Only qualified service personnel should replace the internal fuse (no user access). Notes: 1. Input fuse, F101, is a 35A/300VAC (Fast-Acting HBC) Class T fuse. Replace with Littlefuse JLLN-35 or equivalent. Caution: Primary fuse is located in the neutral. Additional customer supplied fuse is required in the Line side, same fuse as in note Internal fuse (no user access) F301 is rated at 15A/ 250 V (Fast-Acting HBC). 3. Internal fuse (no user access) F501 is rated at 1A/ 250 V (Fast-Acting HBC). RECEIPT AND UNPACKING On receipt, a unit should be unpacked carefully and checked for transit damage. If the unit is damaged, do not apply power. Do not install the unit. Seek specialist advice. Read the rating label located on the power supply to verify that the unit has the correct input and output ratings and part number. All electrical tests performed on the unit prior to installation must be carried out by a qualified person familiar with AC/DC powered equipment and having the specialized knowledge required of the hazards associated with switched mode power supplies. This is particularly essential if the unit covers are removed, which exposes many devices operating at line voltage and some operating at peak voltages of up to 400 volts. MOUNTING REQUIREMENTS AND COOLING The mechanical outline drawing, contained within this manual, provides the necessary dimensions required for customer mounting and space allocation. Use M4 screws for mounting. Screws must not penetrate more than 1/8 (3 mm) into the power supply. The UF2500 units have integral cooling fans and can be mounted in any position. However mounting orientation should not oppose the system forced air direction, the natural convection, or system cooling draft airflow. Furthermore, the power supply air intake REV B Page 6 of 18

7 and exhaust slots must not be obstructed. The intake air temperature should be limited to allow the unit to operate in accordance with the thermal derating envelope of the electrical specifications. INPUT POWER CONNECTIONS The input power terminal block is located on the chassis end that also includes the fans. Safety earth ground is to be connected to the grounding post adjacent to the input power terminal block. The terminal functions are clearly shown on the top label of the unit. Connections should be made using correctly sized wire gauges and colors as per applicable electrical codes. The UF2500 units may also be installed from line to line, where the neutral terminal is connected to the second phase. Connections must not have loose strands and the insulation must cover the wire up to the block itself. Interface terminal lugs must be fastened properly. INPUT VOLTAGE RANGE VAC, 47-63Hz; Input current is limited to 20A max. OUTPUT POWER AND DERATING GUIDELINES 2500 Watts at ambient temperature 0 to 50 C and at sea level. Power derating is required under various conditions. To derate the product properly, refer to the graphs on the next page and the equation below. All output channels should be derated equally to insure proper temperature distribution. Max Output Power = 2500 Watts x Temp multiplier x Altitude multiplier x Voltage multiplier If the input voltage 200 Volts AC, the Voltage multiplier is 1. If the input voltage > 200 Volts AC, the Voltage multiplier is REV B Page 7 of 18

8 Altitude Multiplier Multiplier Altitude (Feet) Temp Multiplier Multiplier Temperature Celsius REV B Page 8 of 18

9 EMI (Conducted) The UltraFlex power supply has internal EMI filtering, and complies with EN55022 level B, as well as FCC Docket Part 15, Subpart J Class A. The end system wiring and grounding can influence the conducted and radiated EMI pattern. The customer may require additional EMI filtering to meet system requirements. If problems are encountered, the customer should contact Lambda Electronics Application Engineering Staff. ELECTROMAGNETIC COMPATIBILITY The UltraFlex is designed to withstand surges, transients, and ESD as specified in the following documents. Surge IEEE-C62.41, Category A3, EN , Class 4, L-L: 2kV, L-Gnd: 4kV Criterion B Fast Transient EN , Level 3, Criterion B ESD EN , Level 3, Criterion B Input Dips, Variations IEC , Criterion B Radiated Immunity EN , Level 3, 10V/M REMOTE SENSE Remote sense is provided for each output to compensate for load cable drops from the power supply to the sense points. To meet specifications, the sense lines must be connected to the load or locally to the power supply output terminals. The remote sense connections are available on the signal connector. See the table below for the appropriate pin numbers. Single Output Modules J1 pin 1 + Positive Remote Sense J1 pin 10 Negative Remote Sense Dual Output Modules J2 pin 2 - Negative Remote Sense Output 1 J2 pin 3 +Positive Remote Sense Output 1 J2 pin 4 +Positive Remote Sense Output 2 J2 pin 5 - Negative Remote Sense Output 2 The following rules should be observed when using remote sense: 1. Use a twisted pair of AWG wires for remote sense leads. 2. Route the sense leads away from any high current conductors or devices (motors, transformers, etc.) to avoid pick-up, as this may cause ripple or stability problems on the power supply. 3. Never disconnect the output power cables while maintaining remote sense connections to the load. This may damage the internal remote sense protection resistors. 4. The total voltage drop on the output cables must be limited to less than 0.5V. OUTPUT VOLTAGE ADJUSTMENT (TRIMMING) Voltage adjust potentiometers are provided for all outputs. The potentiometers are located adjacent to the output connectors of the power supply. Use a non-conductive trim-pot adjustment tool. Turn clockwise to increase the voltage. Always monitor the corresponding output voltage while turning the potentiometer. REV B Page 9 of 18

10 CURRENT LIMIT PROTECTION All outputs are protected by constant-current limiting circuitry. The overcurrent limits are set at the factory between % of maximum rated load for single outputs on both single wide and double wide modules. The overcurrent limit settings for the dual output modules are as follows: Output #1: % of rated load; Output #2: % of rated load. Removing the overload automatically restores the output voltage. On Dual Output Modules, if output #1 is in current limit, output #2 voltage will also decrease. OVERVOLTAGE PROTECTION (OVP) When any single output module voltage reaches % of nominal voltage, the channel will shut down. When any dual output module reaches % of nominal voltage, both outputs of the dual module will shutdown. OVP on 2V outputs is factory set to 3-3.5V, and OVP on 3.3V outputs is set to V. OVP activates the internal shutdown latch of the module. The latch remains in effect until the AC input power has been recycled OFF to ON and the cause of the OVP shutdown has been corrected. OUTPUT LOAD REGULATION Single output modules 0.4% maximum. Dual output modules 0.8% maximum. NO LOAD/FULL LOAD/NO LOAD OUTPUT LINE REGULATION Single output modules 0.1% maximum. Dual output modules 0.2% maximum VAC Hertz HOLD UP TIME: (AC INPUT) The UltraFlex output voltages will remain within specified regulation for a minimum of 16 msec after loss of applied power on the AC input [220 VAC] at full load and nominal output voltage. TURN-OFF/TURN-ON Turn-off/turn-on output voltage - transient overshoot is less than 3% of nominal voltage during applied power or removal of input voltage under any condition of turn-on, turn-off, to include inhibit or enable. TURN ON TIME All outputs shall be in voltage regulation within 1 second of application of AC power. NOISE AND RIPPLE UltraFlex output modules meet the following specifications. Care must be taken when conducting the following measurements: Single output modules Single output modules Dual output modules 2-5V, <50mV pk -pk 20MHz BW. <1000W >5V <1% pk -pk 20MHz BW. All <1% pk-pk, 20MHz BW. REV B Page 10 of 18

11 Single output modules 1000W, </= 5V <200mV pk-pk directly on the output terminals. 20 MHz BW. <50mV pk-pk measured 5 inches away from the output terminals with two uF capacitors located at this point. DYNAMIC LOAD TRANSIENT RESPONSE A 25% step load change will result in an output deviation (overshoot or undershoot) of less than: 1. 3% of nominal output voltage for all models >/= 5V except 1000W, mV for models < 5V, mV for </= 5V 1000Watt module. For slew rates not exceeding 1 Amp/ S, output voltage regulation band recovery is: 1. 1% of nominal within 300 S for all models except the 5V 1000W module. 2. 1% of nominal within 500 S for the </= 5V 1000W module. DYNAMIC CROSS REGULATION The effect of dynamic cross regulation shall be less than 0.1% for single output modules and less than 3% for dual output modules under the following conditions: 1. Auxiliary channels are fully loaded. 2. A load step change of 25% from the 75% base on the highest rated channel. 3. The slew rate does not exceed 1A/ S. 4. The total power of all modules added together must not exceed the total rated power of the UltraFlex. 5. All other channels are loaded to 50% of rated load. TEMPERATURE COEFFICIENT The output voltage will change less than 0.02%/ C over the ambient temperature range of 0 to 50 C, after a 30 minute warm-up. NO LOAD OPERATION Operation at no load will not cause damage to the UltraFlex supply. However the output voltages may be outside the regulation band. A 1Amp pre-load is required on the highest rated output for a dual output module. OVER TEMPERATURE SHUTDOWN The power supply is self-protected against over-temperature conditions. A thermal shutdown requires re-cycling of the input voltage to restore output. The fan will continue to operate during thermal shutdown. OPERATING ENVIRONMENT The power supply is designed to meet the performance parameters defined above when operated within the following conditions: Temperature: specifications. Humidity: Altitude: 0 to 50 C ; -20 C Start-Up, 30 minutes to perform within 10% - 90% Non condensing 0 10,000 ft. Operating. The power supply will not be damaged during transit and storage when subjected to the following limits: REV B Page 11 of 18

12 Temperature: Humidity: Altitude: -40 C to +85 C 90% Non condensing 40,000 ft. (12Km) Size H" x W" x L" 5.0 x 8.0 x 11.0 Weight (shipping) 9.5 lbs lbs. / Used Slot (Maximum Slots=14) COOLING Embedded cooling fans, within the power supply, direct airflow distribution to ensure safe operation under all environmental conditions. Care must be taken not to obstruct intake and exhaust ports. SHOCK (OPERATING) The UltraFlex power supply meets the performance requirements of IEC g, 11 ms, half sine pulses. VIBRATION (OPERATING) The UltraFlex power supply meets the performance requirements of IEC , frequency range Hz, 30 min. 6g rms. PACKAGE DROP The UltraFlex packaging has been tested per National Safe Transit Association Project 1A. RELIABILITY PREDICTION Reliability prediction MTBF by stress method per Bellcore TR-NWT Issue 4 (reliability prediction procedure for electronic equipment). Typical Quad output supply --> 70,000 hours MTBF (e.g. 5V/12V/12V/5V). Typical Single output --> 100,000 hours (e.g. 5V). GLOBAL SIGNALS The following signals are provided as a standard feature on the Ultra-Flex 2500 via J3. Logic level signal outputs are via open drain MOSFETS (60VDC/100mA max ratings). Pull up resistor required. Signals are referenced to the signal common terminal (J3 Pin 3) on the interface connector. 5V DC Standby Output (J3 pin 1): Isolated 5VDC/0.3A output available whenever the input power is applied. This output is not affected by inhibit signals. Load regulation less than or equal to 4%. Global Output Good LED Drive (J3 pin 2): An open collector output to light an external LED indicator. If any output equipped with a DC output good option fails, this signal goes low. An internal 400 ohm series resistor limits the current through the LED. Global Output Good (J3 pin 4): When all output modules that have output good signals are within specification, this signal is high. If any output fails, this signal goes low. Fan Stop/Thermal Alarm (J3 pin 5): Logic signal goes low if the fan stops. Signal remains low until fault is cleared. Logic signal will REV B Page 12 of 18

13 also transition low at least 10mS prior to overheating and thermal shutdown of the supply. If a thermal shutdown has occurred, the input power must be re-cycled. Input Power Fail Signal (J3 pin 6): Following the loss of input power, this signal provides at least 5mS warning prior to any output going outside of its regulation band when adjusted to Vo nominal with 100% load applied. The signal goes "Low" when input power is lost. Signal "High" on fault available as a special option. Global Inhibit (J3 pin 8): An active low or an active high will turn off all output modules. The logic is dependent on the state of the inhibit select pin (see below.) The outputs are less than 0.5V while inhibited at no load. Inhibit/Select (J3 pin 10): When open circuit, Global Inhibit (Pin 8) is Active Low. When this input is shorted to signal common (Pin 3), Global Inhibit (Pin 8) is active high. OUTPUT MODULE SIGNALS & FEATURES Output module options are available only with single output modules. Logic level signal outputs are via open collector NPN transistors (40VDC/10mA max ratings) except the Module Inverter OK signal which is 20vdc/4mA. Pull-up resistors are required. All signals are referenced to -Remote Sense terminal. (J1 pin 10) +Remote Sense (J1 pin 1- single output module, J2 pin 3 & 4 dual output module): Compensates for load cable drop from power supply to sense point (.25V per terminal.) To meet regulation, the remote sense must be connected to the load or locally to the power supply. Remote Voltage Adjust (J1 pin 2): This input signal may be used for remote adjustment of the output +/- 10% of nominal via external resistive or current input. Requires external potentiometer (10K ohms) between +/- remote sense terminals with the wiper to remote voltage adjust pin. Margin (J1 pin 3): Margining +/- 5% of nominal output voltage. Requires an external switch (normally open, SPDT) connected to +/- remote sense terminals with switch common connected to Margin input. Current Sharing (J1 pin 4): Active current sharing provides Load Sharing between two or more similar output modules to within 10% of each output s rated current. The current share node automatically disconnects if a module inverter fault is detected. Modules with this option share current proportionally to their maximum current ratings. Current sharing between modules is accomplished by connecting J1 pin 4 of each module together. A single remote sense point must be used. The individual output voltages must be set to within 1% of each other to ensure the outputs are within the 2% capture window. Refer to Lambda application notes for additional details. High Module Signal (J1 pin 5): When outputs are connected in parallel and the current share option is employed, only the REV B Page 13 of 18

14 module with the highest output voltage will have a logic high signal (useful for system diagnostics). This is an open collector output signal. Inhibit Module (J1 pin 6 - single output module, J2 pin 1 - dual output module): A TTL "low" level signal applied to this pin will disable the output to <.5V at no load. Output Good Signal (J1 pin 7): This signal goes low if output deviates by -4% from factory settings. Module Inverter O.K. Signal (J1 pin 8): If an output module inverter fault is detected this output goes high. This signal causes the current-share node to disconnect. Maximum ratings for the output transistor are 20vdc/4mA. Current Monitor (J1 pin 9): This is an analog signal proportional to the output current, 0-2VDC (2VDC at max output current). From 20%-100% of current rating, the accuracy will be within 10% of the max rated current value. -Remote Sense (J1 pin 10 single output module, J2 pin 2 & 5 dual output module): Compensates for load cable drop from power supply to sense point (.25V per terminal.) To meet module specifications the remote sense must be connected to the load or locally to the power supply. REV B Page 14 of 18

15 MODULE RATING WITH MODEL NUMBERS: UGZ1-XXXXXX Module Code Module Code Output Voltage DC (range) Current Max Output 50 C Max Slot Width A 2 V( ) 30A 66W 1 B 2 V( ) 60A 132W 2 C 2 V( ) 100A 200W 3 D 3.3 V( ) 30A 108W 1 E 3.3 V( ) 60A 216W 2 F 3.3 V( ) 100A 330W 3 G 5 V( ) 30A 150W 1 H 5 V( ) 60A 300W 2 I 5 V( ) 100A 500W 3 J 12 V( ) 17A 204W 1 K 12 V( ) 30A 360W 2 L 12 V( ) 50A 600W 3 M 15 V( ) 14A 210W 1 N 15 V( ) 24A 396W 2 P 24 V( ) 8.5A 204W 1 Q 24 V( ) 15A 396W 2 R 24 V( ) 25A 600W 3 S 48 V( ) 4A 211W 1 T 48 V( ) 8A 384W 2 U 48 V( ) W 3 V 12/5 V( / 10/4A 120/20W ) W 5/12 V( / 10/4A 50/48W ) Y 12/12 V( / 10/4A 120/48W 1 ( ) Z 15/15 V( / 8/3A 120/45W 1 ( ) 3 36 V( ) 11A 396W 2 5Q 20V( ) 15A 300W 2 7B 2.0V( ) 15A 38W 1 7E 3.3V( ) 15A 54W 1 7H 5.0V( ) 15A 90W 1 7K 12.0V( ) 7A 92W 1 7N 15.0V( ) 6A 99W 1 7Q 24.0V( ) 4A 105W 1 7T 48.0V( ) 2A 105W V( ) 12A 369W 2 9E 3.3V( ) 200A 660W 5 9H 5V ( ) 200A 1000W 5 9Q 24V( ) 41.7A 1000W 5 9T 48V ( ) 20.8A 1000W 5 REV B Page 15 OF 18

16 NOTE: ENERGY HAZARDS Module Overcurrent Protection is set between % of max current. Certain modules are capable of providing hazardous energy (>240VA) according to output voltage setting. Therefore, consideration should be given to electrical energy hazards from these outputs. REV B Page 16 of 18

17 OUTLINE DRAWING REV B Page 17 of 18

18 LABEL / CONNECTION DIAGRAM REV B Page 18 of 18