Benign Environment AC-DC Converters >100 W VRW-Family 150/200/300/450 W AC-DC Converters VRW-Family Single output * Universal AC input (VRW 200, VRW 300, VRW 450) * 3000 Vrms input to output isolation * Compact design * Excellent line/load regulation * High efficiency Safety according to IEC 950 Table of Contents Page Type Survey ............................................................ 11 - 99 Description .............................................................. 11 - 99 Safety and Installation Instructions ....................... 11 - 100 Electromagnetic compatibility EMC ....................... 11 - 100 Electrical Input and Output Data ........................... 11 - 101 Operation Instructions ........................................... 11 - 104 Mounting Instructions ............................................ 11 - 105 Immunity to Environmental Conditions .................. 11 - 106 Type Key and Product Marking ............................. 11 - 106 Mechanical Data, Input and Output Terminals ...... 11 - 107 Type Survey Table 1: Type survey 3 40 60 5 30 40 60 90 12 13 19 26 40 15 10 15 21 32 Input voltage range Ui min...Ui max Rated power Po tot TA = 40 C [W] VRW 150: 85...132 V AC or 170...265 V AC 47...440 Hz 230...330 V DC jumper selectable VRW 200, VRW 300 VRW 450: 85...265 V AC 47...63 Hz PF = 0.95 Type designation Open frame Chassis cover 120 180 VRW 200-03 VRW 300-03 VRW 200-03A VRW 300-03A 150 200 300 450 VRW 150-05 VRW 200-05 VRW 300-05 VRW 450-05 VRW 150-05A VRW 200-05A VRW 300-05A VRW 450-05A 150 200 300 450 VRW 150-12 VRW 200-12 VRW 300-12 VRW 450-12 VRW 150-12A VRW 200-12A VRW 300-12A VRW 450-12A 150 200 300 450 VRW 150-15 VRW 200 -15 VRW 300-15 VRW 450-15 VRW 150-15A VRW 200-15A VRW 300-15A VRW 450-15A 150 200 300 450 VRW 150-24 VRW 200-24 VRW 300-24 VRW 450-24 VRW 150-24A VRW 200-24A VRW 300-24A VRW 450-24A 24 6.5 9 13 20 28 4.5 150 VRW 150-28 VRW 150-28A 48 3.2 150 VRW 150-48 VRW 150-48A Description The VRW family of switching power supplies is a single output family of AC-DC converters. Compact size and high reliability make the VRW family an excellent choice. Five standard single output ratings are available. All types have sense lines, the VRW 300 and VRW 450 provide also for inhibit function. The units are UL 1950 (D3), CSA 1402C und EN 60950 approved. Edition 2/96 - (c) Melcher AG Key applications Factory automation, test and measurement, point-of-sales and communications equipment. MELCHER The Power Partners. 11 - 99 11.3 Output configuration Uo nom Io nom [V DC] TA = 40 C [A] VRW-Family AC-DC Converters >100 W Benign Environment Safety and Installation Instructions Safety If the output circuit of an AC-DC converter is operator-accessible according to the IEC 950 related safety standards, it shall be an SELV circuit (Safety Extra Low Voltage circuit, i.e. a circuit, separated from mains by at least basic insulation, that is so designed and protected that under normal and single fault conditions, the voltage between any two conductors and between any conductor and earth does not exceed 60 V DC). Installation instruction Installation of the power supply must strictly follow the national safety regulations. To observe the safety requirements according to EN 60950/IEC 950, the module shall be connected via the female connector or terminal block. Other installation methods may not meet the safety requirements. At least one external fuse, installed in the wiring to the input is essential! In the following section an interpretation is provided of the IEC 950 safety standard with respect to the safety status of the output circuit. However, it is the sole responsibility of the installer or user to assure the compliance with the relevant and applicable safety standards: If the AC-DC converter is installed acoording to the relevant safety regulations, its output is considered to be an SELV circuit up to a nominal output voltage of 36 V, provided the output is connected to ground according to the relevant safety standard, a suitable input line fuse is installed and an adequate voltage limiting device is connected across the output. Electromagnetic compatibility EMC Immunity A metal oxide VDR together with an input fuse and an input filter form an effective protection against high input transient voltages which typically occur in most installations, but especially in battery driven mobile applications. The VRW family has been successfully tested to the following specifications: Table 2: Immunity type tests 1 2 11.3 3 Phenomenon Standard Class Level Coupling mode 3 Electrostatic discharge IEC 801-2 (1991-04) 4 air discharge to frame Fast transient/ burst IEC 801-4 (1988) 3 Transient IEC 801-5 (Draft 1993-01) 4 Value applied Waveform Source Imped. Test procedure In Peroper. form. 15 kVp 1/50 ns 330 10 positive and 10 negative discharges yes 1 i/c, +i/-i 2000 Vp 5/50 ns 50 1 min positive 1 min negative bursts per coupling mode yes 1 i/c 4000 Vp 1.2/50 s 12 5 pos. and 5 neg. impulses per coupling mode yes 2 1 Normal operation, no deviation from specifications No load i = input, o = output, c = case Emission Suitable input filtering keeps the conducted noise of the units within the frequency range of 10 kHz to 30 MHz below level B according to EN 55011 and EN 55022 standards (CISPR 11/22 respectively). In some applications, it may be necessary to add an external input filter to reach level B. Refer also to table "Input Data". 11 - 100 MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Benign Environment AC-DC Converters >100 W VRW-Family Electrical Input and Output Data General Condition: TA = 25C unless otherwise specified Table 3: Input data Characteristics VRW 150-.. VRW 200-.. VRW 300-.. Ui rated Rated input voltage 100-120/200-240 100-120/200-240 Ui Input voltage range 85...132/170...265 1 85...265 fi Line frequency current 3 Ii Input linr Inrush current 3 PF Power Factor 3 I i leak Leakage current 3 Ui RFI Input RFI level VRW 450-.. Unit V AC 230...330 2 - V DC 47...440 47...63 Hz 100/200 V AC 3.2/1.7 3.0/1.5 4.0/2.0 6.2/3.1 100/200 V AC 15/30 14.0/28.0 14/28 14/28 100/200 V AC 0.25/0.40 0.6/0.4 0.6/0.4 0.8/0.4 EN 55011/22 B B B B - A 0.95 mA 1 Jumper selectable. 2 Terminals A and B not connected. 3 At rated input and output. General Condition: TA = 25C unless otherwise specified Table 4a: Output data 150 W types Type VRW 150-05 VRW 150-12 VRW 150-15 Characteristics Unit Uo nom Output voltage Uo adj Adjustable voltage range Io nom Rated output current Io Output current range uo Ripple-noise 1 Uo U Line regulation Uo I Load regulation uo Temperature coefficient Io L Overcurrent protection 2 Uo L Overvoltage protection 3 nom. 5 12 15 10 30 min./max. max. 13 150 Ui min...Ui max 0.4 0...100% 0.8 1 10 A 150 mVpp 0...100 120 V % % % 1 max. 105 5.75...6.75 13.8...16.2 t Uo r Rise time typ. 20 th Hold-up time 1 typ. 20 Effciency 1 typ. 78 Output indicator 80 17.3...20.3 V ms 82 % not provided Outputs connected in series possible Outputs connnected in parallel not possible Remote sensing possible Remote shut-down not possible 1 At rated input and output. Operating in foldback method, automatic recovery. Overload for more than 30 seconds should be avoided. 3 Shut down of output. Turn-on by brief removal of the input voltage. Overvoltage protection is not adjustable. 11.3 2 Edition 2/96 - (c) Melcher AG MELCHER The Power Partners. 11 - 101 VRW-Family AC-DC Converters >100 W Benign Environment General Condition: TA = 25C unless otherwise specified Table 4b: Output data 150 W types Type VRW 150-24 VRW 150-28 VRW 150-48 Characteristics Unit Uo nom Output voltage Uo adj Adjustable voltage range I o nom Rated output current Io Output current range uo Ripple-noise 1 nom. 24 28 48 V 10 6.5 % 4.5 min./max. 3.2 A 0...100 max. 150 % 150 Uo U Line regulation Uo I Load regulation Ui min...Ui max 0.4 0...100% 0.8 uo Temperature coefficient Io L Overcurrent protection 2 Uo L Overvoltage protection 3 t Uo r Rise time 1 typ. 20 th Hold-up time 1 typ. 20 Effciency 1 typ. 200 mVpp % 1 max. 105 27.6...32.4 32.2...37.8 84 55.2...64.8 84 Output indicator V ms 84 % not provided Outputs connected in series possible Outputs connnected in parallel not possible Remote sensing possible Remote shut-down not possible 1 At rated input and output. Operating in foldback method, automatic recovery. Overload for more than 30 seconds should be avoided. 3 Shut down of output. Turn-on by brief removal of the input voltage. Overvoltage protection is not adjustable. 2 General Condition: TA = 25 C unless otherwise specified Table 4c: Output data 200 W types Type VRW 200-05 VRW 200-12 VRW 200-15 VRW 200-24 5 12 15 24 40 19 15 9 A 150 180 180 240 mVpp Characteristics Unit Uo nom Output voltage Uo adj Adjustable voltage range Io nom Rated output current Io Output current range uo Ripple-noise 1 Uo U Line regulation Uo I Load regulation uo Temperature coefficient Io L Overcurrent protection 2 Uo L Overvoltage protection 3 t Uo r Rise time 1 typ. 20 th Hold-up time 1 typ. 20 Effciency 1 typ. nom. 10 min./max. max. 0.4 0...100% 0.8 19.9...23.7 15.7...18.7 9.4...11.2 A 6.0...7.0 14.4...16.8 18.0...21.0 28.0...32.0 V 75 77 11.3 ms 78 81 % not provided possible Outputs connnected in parallel 3 % 42.0...50.0 Outputs connected in series 2 % 1 max. Output indicator 1 % 0...100 Ui min...Ui max V not possible Remote sensing possible Remote shut-down possible At rated input and output. Operating in foldback method, automatic recovery. Overload for more than 30 seconds should be avoided. Shut down of output. Turn-on by brief removal of the input voltage. Overvoltage protection is not adjustable. 11 - 102 MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Benign Environment AC-DC Converters >100 W VRW-Family General Condition: TA = 25 C unless otherwise specified Table 4d: Output data 300 W types Type VRW 300-05 VRW 300-12 VRW 300-15 VRW 300-24 Characteristics Unit Uo nom Output voltage Uo adj Adjustable voltage range Io nom Rated output current Io Output current range uo Ripple-noise 1 Uo U Line regulation Uo I Load regulation uo Temperature coefficient Io L Overcurrent protection 2 nom. 5 12 15 60 max. 21 180 0.4 0...100% 0.8 63.0...75.0 27.3...32.5 6.0...7.0 14.4...16.8 Uo L Overvoltage t Uo r Rise time 1 typ. 50 th Hold-up time 1 typ. 20 Effciency 1 typ. 76 mVpp % 22.1...26.2 13.7...16.2 18.0...21.0 28.0...32.0 A V ms 78 78 82 % not provided possible Outputs connnected in parallel 3 240 1 max. Outputs connected in series 2 A % 180 Ui min...Ui max protection 3 13 0...100 150 V % 26 min./max. Output indicator 1 24 10 not possible Remote sensing possible Remote shut-down possible At rated input and output. Operating in foldback method, automatic recovery. Overload for more than 30 seconds should be avoided. Shut down of output. Turn-on by brief removal of the input voltage. Overvoltage protection is not adjustable. General Condition: TA = 25 C unless otherwise specified Table 4e: Output data 450 W types Type VRW 450-05 VRW 450-12 VRW 450-15 VRW 450-24 5 12 15 24 90 40 32 20 A 150 180 300 400 mVpp Characteristics Unit Uo nom Output voltage Uo adj Adjustable voltage range I o nom Rated output current Io Output current range uo Ripple-noise 1 U o U Line regulation U o I Load regulation uo Temperature coefficient Io L Overcurrent protection 2 Uo L Overvoltage protection 3 t Uo r Rise time 1 typ. 50 th Hold-up time 1 typ. 20 Effciency 1 typ. 10 min./max. max. % 0...100 Ui min...Ui max 0.4 0...100% 0.8 V % % 1 max. 94.5...103.5 42.0...46.0 33.6...36.8 21.0...23.0 A 6.0...7.0 14.4...16.8 18.0...21.0 28.0...32.0 V 76 78 Output indicator ms 78 82 % not provided Outputs connected in series 11.3 nom. possible Outputs connnected in parallel not possible Remote sensing possible Remote shut-down possible 1 At rated input and output. 2 Operating in foldback method, automatic recovery. Overload for more than 30 seconds should be avoided. 3 Shut down of output. Turn-on by brief removal of the input voltage. Overvoltage protection is not adjustable. Edition 2/96 - (c) Melcher AG MELCHER The Power Partners. 11 - 103 VRW-Family AC-DC Converters >100 W Operation Instructions Benign Environment PO [%] VRW 150: AC Input Voltage Range Selection The AC input voltage range can be selected by means of wiring at the connector barrier as per the following table: 100 Table 5: Input voltage range selection Input voltage range Terminals A and B 85...132 V AC interconnected 170...265 V AC 230...330 V DC open (not connected) 60 50 VRW 150 VRW 200/VRW 300/VRW 450 Output Power Rating The relation between the rated output power Po and the ambient temperature TA is shown in fig. 1. Output Voltage Adjustment The output voltage may be adjusted within 10% of Uo nom by means of the internal potentiometer. If the output voltage setting should be excessively high, the overvoltage protection circuit may shut-down the output. Output Overvoltage Protection If the built-in overvoltage protection circuit becomes active, the output is shut down and a reset can only be achieved by brief removal of the input voltage after a minimum interval time. The overvoltage threshold level is not adjustable. Output Overload Protection An overload condition at the output should not last for more than 30 seconds. After removal of the overload, the overload protection circuit will automatically recover. 0 -20 -10 0 10 20 30 TA 70 [C] 60 Outputs Connected in Parallel Parallel connection of several identical modules is not possible. Inhibit (R, VRW 200, VRW 300 and VRW 450 series) The output may be enabled or disabled by means of a logic signal (TTL, CMOS etc.) or a mechanical contact applied to the inhibit input which is isolated from input and output by means of an opto-coupler. This provides independency from other voltages polarity. If the inhibit function is not required, connect the inhibit input +R to return pin -R to enable the output (active low logic, fail safe). L +R I inh U inh N -R Fig. 2 Definition of inhibit voltage and current Table 6: Inhibit characteristics Characteristic Uinh Inhibit Iinh Conditions min Uo = on Ui min...Ui max -0.7 voltage Uo = off 2.0 Inhibit sink curr. Uinh = 0 typ max Unit 0.8 V 7 6 mA 11.3 Outputs Connected in Series Two or more units supplying the same or different output voltages may be connected in series. The value of the maximum output current to be taken is defined by that unit providing the lowest current limiting value. It should be assured that the outputs do not feed backwards into each other caused by their different rise/fall times at switch-on/off cycles by adding reverse polarity diodes across each output. 50 Fig. 1: Output power vs. ambient temperature Sense Lines (S, VRW 200, VRW 300, VRW 450 series) Remote sensing provides compensation of voltage drops between power supply and load, caused by connectors and load feeding wires. The sense lines should consist of shielded cables or be twisted. If remote sensing is not reqiured, the +S should be connected to the +V and the -S to the -V terminals respectively applying shortest possible links. The compensation range is 10 % of Uo nom. 40 11 - 104 MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Benign Environment AC-DC Converters >100 W VRW-Family Mounting Instructions VRW 150 Mounting B Mounting A Mounting C Mounting D standard Fig. 3 Mounting instruction for VRW 150 Table 7: Output derating without chassis cover for VRW 150 TA [C] Mounting A Mounting B Mounting C Mounting D 30 100% 100 % 100% 100% 40 100% 100 % 100% 80 % 50 100% 80% 80% 60 % 60 50% 40% 40% 40 % Load Table 8: Output derating with chassis cover for VRW 150 TA [C] Mounting A Mounting B Mounting C Mounting D 30 100% 100% 100% 100 % 40 100% 70 % 70% 70% 50 80% 60 % 60% 60% 60 40% 40 % 40% 40% Load VRW 200, VRW 300 and VRW 450 Mounting B without cover Mounting A without cover Mounting B with cover Mounting A with cover Fig. 4 Mounting instruction for VRW 200, VRW 300, VRW 450 TA [C] Convection cooling Forced air cooling Table 10: Output derating with chassis cover for VRW 200, VRW 300 and VRW 450 40 100% 90% 50 80% 70% 60 60% 50% 50 100% 90 % 60 80% 70% 70 60% 50% Edition 2/96 - (c) Melcher AG TA [C] Load Mounting A Mounting B Convection cooling Forced air cooling MELCHER The Power Partners. Load Mounting A Mounting B 30 80% 80% 40 80% 80% 50 60% 60% 40 100% 90 % 50 80% 70% 60 60% 50% 11 - 105 11.3 Table 9: Output derating without chassis cover for VRW 200, VRW 300 and VRW 450 VRW-Family AC-DC Converters >100 W Benign Environment Immunity to Environmental Conditions Table 11: Mechanical stress Test Method Test conditions Damp heat steady state Temperature: Relative humidity: 40 2 C 30...90 -3/+2 % Status Operating Shock (half-sinusoidal) Acceleration amplitude: 20 gn = 196.2 m/s2 Operating Vibration (sinusoidal) Frequency (1 Oct/min): Maximum vibration amplitude: Acceleration amplitude: Test duration: 10...55 Hz 0.83 mm (55 Hz) 2 gn = 19.6 m/s2 3 h (1 h each axis) Operating Table 5: Temperature specifications Characteristic min max Unit TA Operating ambient temperature range without derating -10 40 C TA Operating ambient temperature range with derating (see fig. 1) -10 60 TS Storage temperature range -30 85 Table 13: MTBF values MTBF MTBF according to MIL-HDBK-217D Ground Benign TC = 40C VRW 150 types 121'830 h VRW 200 types 75'789 h VRW 300 types 60'334 h VRW 450 types 52'347 h Table 14: Isolation Test Input to output Input to case Output to case Unit Electric strenght test voltage (1 min) 3000 2000 500 V AC Isolation resistance (500 V DC) >100 >100 >100 M Table 15: Safety approvals UL 1950 CSA 1402C TUV 1 VRW 150 x x x VRW 200 x x x VRW 300 x x x VRW 450 x x x Safety Approvals 1 EN 60950 Type Key and Product Marking Type Key Family ........................................................................ VRW Blank .................................................................................. VRW 450 - 12 A 11.3 Nominal output power [W] .................... 150, 200, 300, 450 Dash ................................................................................ Nominal output voltage [V] ....................................... 5...48 Structure and connectors: - Open frame .......................................................... - With chassis cover ............................................. A Example: VRW 450-12A = AC-DC converter providing 12 V/40 A, 480 W output, module with chassis cover Produkt Marking Label: Type designation, applicable safety approvals and recognition marks, specific type designation, input voltage range, nominal output voltage and current and pin allocation. 11 - 106 MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Benign Environment AC-DC Converters >100 W VRW-Family Mechanical Data, Input and Output Terminals European Projection 8 Dimensions in mm. Tolerances 1 mm unless otherwise indicated 37.5 3 - M3 11.6 100 0.5 25 0.5 25 33 4.5 4.5 O 7.5 80 65 LED (on) 21 50 0.5 125 0.5 40 Uo adjustment (Potentiometer) Output: +V Output: +V Sense: +S Output: -V Output: -V Frame ground: FG Sense: -S AC input: L AC input: N 230 V AC: open A 110 V AC short B 5 4 - M4 16.5 11- M4 83 93 198 7.36.7 10 19 12 24.5 Fig. 5 VRW 150, weight 890 g 152.5 48.5 50 1.0 8.5 24 2 3 - M4 +V 2 - 5.5 O -V 9.5 5.5 11 13.6 +V 11 -V 14.7 10.5 Uo adjustment (Potentiometer) 90 0.5 2 - M4 121 5.5 62 3 - M4 17 11.3 M4 +SSense -S Sense +RInhibit -R Return for +R L AC input N AC input 45 28 152 0.5 5 233 Fig. 6 VRW 200, weight 1500 g, with cover 1610 g Edition 2/96 - (c) Melcher AG MELCHER The Power Partners. 11 - 107 AC-DC Converters >100 W Benign Environment 63 8.3 3 24.5 14 3 - M4 27 175 50 1.0 VRW-Family +V 2 - 5.5 O -V 9.5 5.5 11 13.6 14.5 9.3 Uo adjustment (Potentiometer) +V 11 -V 96 0.5 2 - M4 121 5.5 53 3 - M4 14 M4 +SSense -S Sense +RInhibit -R Return for +R L AC input N AC input 45 4 5 247 0.5 298 Fig. 7: VRW 300, weight 2200 g, with cover 2450 g 266.7 0.5 19 50 8.3 3 - M4 3 24 12.7 139 0.5 +V -V 121 100 0.5 2 - M4 2 - 8.3 O 6.5 +V -V 42 10 11.3 5 6.5 2 - 14.3 +SSense -S Sense +RInhibit -R Return for +R L AC input N AC input 3 - M4 M4 9.7 25.4 12.3 14.5 Uo adjustment (Potentiometer) 9 324 0.5 394 5 Fig. 8: VRW 450, weight 2800 g, with cover 3060 g 11 - 108 MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG