INSTALLATION MANUAL ULTRAFLEX POWER SUPPLY. UF1500 Series

Transcription

1 INSTALLATION MANUAL ULTRAFLEX POWER SUPPLY UF1500 Series 3055 Del Sol Blvd. San Diego, CA Phone: (619) Fax: (619) P/N: IMUE1500 Rev. C DATE: February 2002

2 TABLE OF CONTENTS INTRODUCTION 4 CERTIFICATION 4 WARRANTY 4 APPLICABILITY 4 INSTALLATION MANUAL 4 SAFETY AGENCY APPROVALS 4 GENERAL SAFETY INSTRUCTIONS 5 INPUT FUSE 6 RECEIPT AND UNPACKING 6 MOUNTING REQUIREMENTS AND COOLING 7 INPUT POWER CONNECTIONS 7 AC INPUT AND OUTPUT POWER RATINGS 7 EMI 8 INPUT TRANSIENT/ESD PROTECTION 8 REMOTE SENSE 8 OUTPUT VOLTAGE ADJUSTMENT (TRIMMING) 9 CURRENT LIMIT PROTECTION 9 OVERVOLTAGE PROTECTION (OVP) 9 OUTPUT LOAD REGULATION 9 OUTPUT LINE REGULATION 9 HOLD UP TIME AFTER POWER LOSS 9 REV C Page 2 of 17

3 TURN-OFF/TURN-ON 9 TURN ON TIME 9 NOISE AND RIPPLE 9 DYNAMIC LOAD TRANSIENT RESPONSE 10 DYNAMIC CROSS REGULATION 10 TEMPERATURE COEFFICIENT 10 NO LOAD OPERATION 10 OVER TEMPERATURE SHUTDOWN 10 OPERATING ENVIRONMENT 10 SIZE AND WEIGHT 10 COOLING 11 SHOCK & VIBRATION 11 PACKAGE DROP 11 RELIABILITY PREDICTION 11 MATING SIGNAL & CONTROL CONNECTOR INFORMATION 11 GLOBAL SIGNALS 11 OUTPUT MODULE SIGNALS & FEATURES 12 MODULE RATING WITH MODEL NUMBERS: UE Z 1 - X X X X X X 14 NOTE: ENERGY HAZARDS 15 THERMAL DERATING GUIDELINE 15 MAXIMUM POWER VS. AC LINE 15 LABEL / CONNECTION DIAGRAM 17 REV C Page 3 of 17

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 UltraFlex UF1500 Series power supply. Manual part no. IMUE1500. PART NUMBER CONFIGURATION U E Z 1- _ UltraFlex Case Code Global Signals Output Module Codes [SEE PAGE 14] EN55022 Level B, FCC20780 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. SAFETY AGENCY APPROVALS The UltraFlex power supply series complies with the following regulatory specifications: UL1950, IEC950, CSA 22.2 No.950, EN This product is certified and allowed to carry UL combined Canada/U.S. Recognized Component Mark, 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. PLEASE READ THE SAFETY AND INSTALLATION INSTRUCTIONS BEFORE INSTALLATION OR USE OF THIS PRODUCT. REV C Page 4 of 17

5 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. GENERAL SAFETY INSTRUCTIONS The UltraFlex power supply series is designed for use within other equipment or enclosures. Access is restricted to authorized personnel only. For safe installation and operation of this product, carefully follow the instructions below: 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, since, under full load conditions, parts of the unit chassis may reach temperatures in excess of those considered safe for operator access. 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 with 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 REV C Page 5 of 17

6 M. A protective earth must be provided for safety in accordance with EN WARNING: It is essential that the earth grounding terminal of this product be securely connected to earth (hard-wired) by the end user. N. PREVENTION OF ACCESS BY THE USER: This apparatus is intended to be accessible to authorized personnel only. Ensure that user access to this product, when installed in a host equipment, complies with EN Failure to do this will invalidate the approval given to this apparatus. O. WARNING: All outputs used are SELV as defined in EN60950 Clause 2.3. As such, all outputs must only be connected to circuits compliant with the requirements of SELV complying EN60950 Clause 2.3. circuits. 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 UltraFlex 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. INPUT FUSE The AC power source line is protected by an internal ceramic body fuse contained within the power supply enclosure located in the neutral side. Only qualified service personnel should replace the internal fuse (no user access). Notes: 1. Replace the input fuse in the unit with same type and rating. Fusing requirements are shown in Table #1. Caution: Primary fuse is located in the neutral side. 2. Additional customer supplied fuse is required in the Line side, same as in Table #1. 3. Internal fuses (no user access) F506, F601, rated 4A/250v Very Fast-Acting Type. TABLE #1 MODEL OUTPUT FUSE VALUE NOTES POWER UF W 25A/600V Bussmann fast acting KTK-25 or equivalent RECEIPT AND UNPACKING On receipt, the unit should be unpacked carefully and checked for transit damage. If the unit is damaged, do not apply power or 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 REV C Page 6 of 17

7 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 pamphlet, provides the necessary installation dimensions required for customer mounting and space allocation. IMPORTANT: Use M4 screws for mounting. Screws must not penetrate more than 1/8 (3 MM) into the power supply. The UF1500 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 air flow. Furthermore, the power supply air intakes 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. AC INPUT Line: Neutral: Ground: Black White Green The ground connection must be made to a well defined, low impedance ground (protective ground). 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. AC INPUT AND OUTPUT POWER RATINGS Vac, Hz. The input current will be limited to 20A max. Output Power 85 Ambient Temp. 0 to 50 o C; Vac 60 o C derate output power to 75% Vac 70 o C derate output power to 50% Note: Refer to Table 3 and Graphs 1 & 2 on pages 13 and 14 respectively. REV C Page 7 of 17

8 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 s Application Engineering Staff. INPUT TRANSIENT/ESD PROTECTION The UltraFlex is designed to withstand surges, line 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 Transients: EN , Level 3, Criterion B. ESD: EN , Level 3, Criterion B. Input Dips and Variations: IEC , Criterion B. Radiated Immunity: EN , Level 3, 10 V/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 and output voltage set point of the output modules, 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 Table 2 below for the appropriate pin numbers. Table 2 Single Output Modules Dual Output Modules J1 pin 1 + Positive Remote Sense J2 pin 2 - Negative Remote Sense Output 1 J1 pin 10 Negative Remote Sense 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 power supply output power connections with the remote sense still connected to the load. This may damage the internal remote sense pick-up resistors. 4) The total voltage drop on the output cables must be limited to less that 0.5V. REV C Page 8 of 17

9 OUTPUT VOLTAGE ADJUSTMENT (TRIMMING) Voltage adjust potentiometers are provided for all outputs. The potentiometers are located adjacent to the output connections of the power supply. Use a non-conductive trim-pot adjustment tool. Turn clockwise to increase the voltage. NOTE: Always monitor the corresponding output voltage while turning the potentiometer. CURRENT LIMIT PROTECTION All outputs are protected by constant-current limiting circuitry. The overcurrent limits are set at the factory between % for single outputs. 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, that channel will shut down. When any dual output module reaches % of nominal voltage, both outputs of the dual module will shut down. 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 until the AC input power is recycled OFF to ON to clear the latch and resume normal operation, once the OVP problem has been corrected. OUTPUT LOAD REGULATION (NO LOAD/FULL LOAD/NO LOAD) OUTPUT LINE REGULATION (85-265VAC Hertz) Single output modules 0.4% maximum. Dual output modules 0.8% maximum. Single output modules 0.1% maximum. Dual output modules 0.2% maximum. HOLD UP TIME AFTER POWER LOSS (AC INPUT) The UltraFlex output voltages will remain within specified regulation for a minimum of 16msec after loss of applied power on the AC input 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 the application or removal of input voltage under any condition of turn-on, turn-off, including inhibit or enable. TURN ON TIME All outputs shall be within voltage regulation limits within 1 second of application of AC power. NOISE AND RIPPLE UltraFlex output modules meet the following specifications with a 20MHz bandwidth. Care must be taken when conducting the following measurements: Single output modules: 2-5V, <1000W: <50mV pk pk. </= 5V, 1000W: <200mV pk-pk directly on the output terminals; <50mV pk-pk measured 5 inches away from the output terminals with two 2700 uf capacitors located at this point. > 5V: <1% pk pk. REV C Page 9 of 17

10 Dual output modules: <1% pk-pk. DYNAMIC LOAD TRANSIENT RESPONSE A 25% step load change will result in an output deviation (overshoot or undershoot) of less than 3% of nominal output voltage (150mV for <5V outputs, 400mV for the </= 5V 1000W module). Output voltage will recover to within 1% of set value within 300 s (500us for the </=5V 1000W module.) Slew rate not to exceed 1A/us. DYNAMIC CROSS REGULATION The effect of dynamic cross regulation on any fully loaded auxiliary channel for a load step change of 25% from a 75% base value on the highest rated channel, at a slew rate not to exceed 1A/us, shall be less than 0.1% for single output modules and less than 3% for dual output modules. The summation of the individual module powers must not exceed the total rated power of the UF1500. This measurement is to be performed with all other channels loaded to 50% of rated load. TEMPERATURE COEFFICIENT The output voltage will change less than.02% per o C over the ambient temperature range of 0-50 o C. (After 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 1 Ampere preload 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: Humidity: Altitude: 0 to 50 o C; -20 o C Start-Up, 30 Minutes to perform within specifications. 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 conditions: Temperature: -40 o C to +85 o C Humidity: 90% Non-condensing Altitude: 40,000 ft. (12Km) SIZE AND WEIGHT H" x W" x L": 5 x5.125 x11 WEIGHT: 5.7lbs lbs. / used slot; maximum # of slots = 10. REV C Page 10 of 17

11 COOLING Integral fans provide forced-air cooling to ensure safe operation under all environmental conditions. Care must be taken not to obstruct intake and exhaust ports. SHOCK & VIBRATION The UltraFlex power supply meets the performance requirements of IEC ; 15g, 11ms half-sine pulses. The UltraFlex power supply meets the performance requirements of IEC with a frequency range of Hz and acceleration of 6 Grms for a minimum of 30 minutes. 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 =/> hours MTBF (e.g. 5V/12V/12V/5V). MATING SIGNAL & CONTROL CONNECTOR INFORMATION Lambda Kit Part # (J3) Input Connector Kit (J1) Output Connector Kit (J2) Dual Output Connector Kit TO ORDER CONNECTORS DIRECT FROM AMP: Single Output & Input Connector: AMP P/N (holds 10 Pins) Dual Output Connector: AMP P/N (holds 6 Pins) Pin For Above Connectors: AMP P/N GLOBAL SIGNALS The following signals are provided as a standard feature on the UF1500 via J3. Logic level signal outputs are via open drain Mosfets (60VDC/100mA max ratings). Pull up resistors are 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 5%. Global Output Good LED Drive (J3 pin 2): An open drain output to light an external LED indicator. If any output equipped with a DC output good option fails, this signal goes low. An internal 390 ohm series resistor limits the current through the LED. Global Output Good (J3 pin 4): When all output modules which have Output Good signals are within specification, this signal is high. If any output fails, this signal goes low. REV C Page 11 of 17

12 Fan Stop/Thermal Alarm (J3 pin 5): Logic signal goes low if the fan stops; or in the event of overheating, at least 10mS prior to a thermal shutdown of the supply. Signal remains low until fault is cleared. If a thermal shutdown has occurred, the input power must be re-cycled to restore output. 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 it's regulation band when adjusted to Vo nominal at full load. The signal goes "Low" when input power is lost. Signal "High" on fault available as a special option. Global Inhibit (J3 pin 8): A TTL compatible signal will turn off all output modules, depending upon the setting of the Inhibit/Select function (See below.) The outputs are less than 0.5V while inhibited at no load. Inhibit/Select (J3 pin 10): When open circuit, Global Inhibit is Active Low. When this input is shorted to signal common (Pin 3), Global Inhibit 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. Signals are referenced to the -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 the +/- 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 a 2% capture window. Refer to Lambda application note AN-018 for additional details. High Module Signal (J1 pin 5): When outputs are connected in parallel and the current share option is employed, only the module with the highest output voltage will have a logic high signal (useful for system diagnostics). This is an open collector output signal. REV C Page 12 of 17

13 Inhibit Module (J1 pin 6 - single output module, J2 pin 1 - dual output module): A TTL "low" level signal can be applied to disable outputs to <0.5V 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 20V/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 C Page 13 of 17

14 MODULE RATING WITH MODEL NUMBERS: UE Z 1 - X X X X X X Module Code TABLE 3 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 C Page 14 of 17

15 NOTE: ENERGY HAZARDS Modules Overcurrent Protection are 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 THERMAL DERATING GUIDELINE for UltraFlex UF1500 Power Supply Series Derating UF1500 Series 120 % Output Power Temperature [C] MAXIMUM POWER VS. AC LINE for UltraFlex UF1500 Power Supply Continuous Output Power Derating REV C Page 15 of 17 watts)

16 OUTLINE DRAWING REV C Page 16 of 17

17 LABEL / CONNECTION DIAGRAM REV C Page 17 of 17