The TCP3500 series is a universal 3-phase AC-DC converter with
adjustable DC output and universal 3-phase AC input. Conduction
cooling (No Fans) makes this power supply series suitable for a wide
variety of Industrial Applications that can utilize conduction or liquid
cooling, negating the use of fans.
Emphasis is given on reliability and long life. Parallel operation is
possible up to 16 units (50.4 kW). Passive or active current share
system can be selected.
The PSU includes DSP which enables monitoring of electrical
parameters (including input voltage of all 3 phases) and controlling the
PSU from system controller.
An RS485 bus is used for command, monitoring and diagnostic
information that can be supplied to a system controller.
• World-Wide 3-phase Input Voltage Range
(nom. 115 - 277 V / 200 - 480 V)
• Power Factor > 0.94
• High Power Density 16 W/in3
• 94% Typical Efficiency
• Parallel Operation up to 16 Units (50.4 kW)
• Cold-Plate Cooling System
• 0 to 50°C of Cold-Plate Surface,
0 to 70°C of Ambient Air Temperature
• Possibility to Install 4 Units in 2U 19” Rack
• Advanced Performance for Fast Dynamic and Pulsed Load
up to 100 kHz (Optional)
• RS485 Interfaces
• Wide Adjustable Output Voltage Range
• Fast Output Voltage Set Response (5 ms)
• Active Current Sharing
2
TCP3500 Series
tech.support@psbel.com
MODEL
INPUT VOLTAGE
RANGE
NOMINAL
OUTPUT
VOLTAGE
OUTPUT
VOLTAGE
RANGE
MAX OUTPUT
CURRENT
MAX
OUTPUT
POWER
AVAILABILITY
TCP3500-1024G
180 – 528 Vrms,
50/60 Hz
28 V
Adjustable
10 – 32 VDC
125 ADC
3500 W
Engineering samples
available
TCP3500-H048G
180 – 528 Vrms,
50/60 Hz
48 V
Adjustable
10 – 50 VDC
73 ADC or pulse1
3500 W
Mass production
TCP3500-1048G
180 – 528 Vrms,
50/60 Hz
48 V
Adjustable
10 – 50 VDC
73 ADC
3500 W
Mass production
TCP4000-H0902
180 – 528 Vrms,
50/60 Hz
90 V
Adjustable
30 – 100 VDC
45 ADC or 39 A
pulse1
3500 / 4000 W
Mass production
1 PSU model with pulse load operation capability 0 – 100 kHz, 0 – 100% Duty, 0 A/Iout_max.
2 Output Power 4000W at Input Voltage range 340 – 528 Vrms (L-L)
PARAMETER
DESCRIPTION / CONDITION
MIN
NOM
MAX
UNIT
Input Voltage
3-phase (L-N / L-L), 3 wires + PE
115 - 277 / 200 - 480
V
Permitted variation (L-N / L-L)
104 - 305 / 180 - 528
V
Input Frequency
50/60
Hz
Permitted variation
47
63
Hz
Input Current
per Line at 3 x 180 V (line to line)
14
Arms
Input Current THDi
Typical
30
%
Power Factor
Load above 40%
94
Fuse
3 x 20 A, Fast acting
PARAMETER
DESCRIPTION / CONDITION
MIN
NOM
MAX
UNIT
Output Voltage
Adjustable or fixed (see Model Selection table)
Output Power Rating
3500
W
Output Current
Fixed or Adjustable (60 – 100%)
Efficiency
Input Voltage 400 Vrms (L-L) and load above 40%
94
%
Voltage Setting Accuracy
± 0.5
%
Line Regulation
Io = 0.5 * Io_nom
±0.5
%
Load Regulation
±0.3
%
Thermal Drift
±0.02
%/°C
Transient Response
load variation 10-100% and back:
Recovery time:
load variation 50-100% and back:
Recovery time:
±5
±3
2
0.4
%
ms
%
ms
Ripple
Vout_nom (BW 20 MHz)
1.5
%
Output Start Up
2
s
Rise Time
250
ms
TCP3500 Series
3
Asia-Pacific
+86 755 298 85888
Europe, Middle East
+353 61 225 977
North America
+1 408 785 5200
© 2019 Bel Power Solutions & Protection
BCD.00509_AA
PARAMETER
DESCRIPTION / CONDITION
MIN
NOM
MAX
UNIT
Over Temperature Protection
Cooling Plate surface (PSU bottom side)
55
°C
Input Under Voltage Protection
3-phase (L-N / L-L)
104 / 180
V
Input Over Voltage Protection
3-phase (L-N / L-L)
305 / 528
V
Reversed Sense Output Protection
Latch type
Output Under Voltage Protection
Latch type – Fixed SW, based on Minimal Output
Voltage
50
85
%
Output Over Voltage Protection
Latch type – Fixed HW, based on Nominal Output
Voltage
Resettable – Floating SW, based on Output Voltage
Set Point (configurable)
115
+4
125
+6
%
V
Output Over Current
Short Circuit Protection
PSU starts operating as a current source, based on
Maximal Output Current
Latch type – Fixed SW, based on Maximal
Measured Output Current
Fast Acting Fuse for min. 120% of Rated Output
Current
104
114
112
122
%
%
Alarms
Input under and over voltage
Output under and over voltage
Output overload
Over temperature
PARAMETER
DESCRIPTION / CONDITION
SPECIFICATION
Insulation (Factory tested)
Input to output:
Input to chassis:
Output to chassis:
Signals to chassis:
2122 VDC
2122 VDC
500 VDC
500 VDC
Safety Standards
UL/CSA60950-1 2nd, EN60950-1 2nd and IEC60950-1 2nd
UL/CSA62368-1, IEC 62368-1
Emission Requirements
Radiated Emission
EN55011
Class A
Conducted Emissions
EN55011
Class A
Immunity Requirements
Electrostatic Discharge (ESD)
EN IEC 61204-3
±8 kV contact, ±15 kV air
Criterion A
Radiated Electromagnetic Field
EN IEC 61204-3
Criterion A
Electrical Fast Transients (EFT)/Burst
EN IEC 61204-3
Criterion A
Surge Immunity
EN IEC 61204-3
Criterion A
RF Conducted Immunity
EN IEC 61204-3
Criterion A
Useful Life Assessment
>5 years life at ambient temperature of +70°C and case temperature 55°C
>10 years of predicted electrolytic capacitor life at 55°C of case temperature and 100% load.
4
TCP3500 Series
tech.support@psbel.com
PARAMETER
DESCRIPTION / CONDITION
MIN
NOM
MAX
UNIT
Humidity
Operating range according IEC 60068-2-78
10
90
RH
Operating Temperature
Cold-plate cooling: of base plate (Tc - ref. point)
of ambient air temperature
0
0
+55
+70
°C
Storage Temperature
-40
+85
°C
LED NAME
COLOR
STATUS
OPERATING CONDITIONS
AC-OK
Green
ON
AC Input Voltage is within operation range
DC-OK
Green
ON
Output is Enabled and Operational
OT/FAIL
Orange
ON
Blinking
Over Temperature conditions inside the unit or FAIL appeared (e.g. Overload)
FW upgrade via RS485-1
PARAMETER
DESCRIPTION / CONDITION
Input Connector
4-pin, Pitch 7.62 mm (Weidmüller 1081850000, see Figure 1)
Output Connector
Bus bars, screw size M4, see Fig.1
Signal Input Connector
15-pin D-SUB Male (Würth Elektronik, 61801529221, see Figure 1)
Signal Output Connector
15-pin D-SUB Female (Würth Elektronik, 61801529321, see Figure 1)
Figure 1a. Rear View of TCP3500-1048G – Detail of Signal Connectors Pin Position
7.1 GUI (GRAPHIC USER INTERFACE) AND RS485 COMMUNICATION PROTOCOL
Bel Power Solutions provides a Windows® XP/Vista/Win7 compatible Graphical User Interface SW for TCP/TXP3500/4000
PSU’s program, control and monitor via Serial Communication Interface – RS485.
The SW GUI can be downloaded from: belfuse.com/power-solutions.
For detailed information please see Communication Manual (BCA.00140) or contact Bel Power Solutions sales representative.
7.2 LED SIGNALING
TCP3500 Series
5
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Europe, Middle East
+353 61 225 977
North America
+1 408 785 5200
© 2019 Bel Power Solutions & Protection
BCD.00509_AA
Figure 1b. Rear View of TCP3500-1024G (left) and TCP4000-H090 (right) - Connectors Position
SIGNAL NAME
PIN #
TYPE
RECOMMENDED WIRES
V MAX
I MAX
Earth
Earth / Chassis
Min. 2.5 mm2
AC Line 1
L1
Input Power AC Fused
Min. 2.5 mm2
528 Vrms (L-L)
16 Arms (per line)
AC Line 2
L2
Input Power AC Fused
Min. 2.5 mm2
AC Line 3
L3
Input Power AC Fused
Min. 2.5 mm2
Connector type:
Weidmüller 1081850000
Mating part:
Weidmüller 1173520000
SIGNAL NAME
PIN #
TYPE
SIGNAL REFERENCE
LOW LEVEL
HIGH LEVEL
V MAX
I MAX
Vout+
+
Output Power DC
Vout-
see Model Selection table
Vout-
-
Output Power DC
-
see Model Selection table
Connector type: Busbar see Figure 1
Mating part: Ring terminal for M4 screw, with appropriate cross section for wire.
8.1 INPUT POWER CONNECTOR: PINOUT
8.2 POWER OUTPUTS CONNECTOR: +/- BUSBARS
6
TCP3500 Series
tech.support@psbel.com
SIGNAL NAME
PIN #
TYPE
SIGNAL
REFERENCE
LOW LEVEL
HIGH LEVEL
V MAX
I MAX
RS485-1A
1
RS485 Half Duplex, Differential pair 1
RS485-1B
+/-60 mA
@ 60 Ω, 0 pF2
-7 to 12 VDC
8 mA
RS485-2A
2
RS485 Half Duplex, Differential pair 2
RS485-2B
+/-60 mA
@ 60 Ω, 50 pF2
-7 to 12 VDC
8 mA
ADDR-INIT IN
3
The unit’s address change required
SRTN
<0.4 VDC
>2.5 VDC
3.6 VDC
0.2 mA
IN OK
4
AC Power Fail Warning - open collector,
external pull-up needed to max. 7 V
SRTN
<0.4 VDC
Pull up
7 VDC
20 mA
OUT OK
5
Output Voltage Fault - open collector,
external pull-up needed to max. 7 V
SRTN
<0.4 VDC
Pull up
7 VDC
20 mA
INHIBIT
6
Output Inhibit - Open circuit or “High” to SRTN
shuts OFF Vout
SRTN
<0.4 VDC
>2.5 VDC
3.6 VDC
0.2 mA
ENABLE
7
Power Supply Enable pin – for unit enable short
this pin to SRTN
SRTN
<0.4 VDC
>2.5 VDC
3.6 VDC
0.2 mA
SRTN1
8
Signal Return
-
-
-
RS485-1B
9
RS485 Half Duplex, Differential pair 1
RS485-1B
+/-60 mA
@ 60 Ω, 50 pF2
-7 to 12 VDC
8 mA
RS485-2B
10
RS485 Half Duplex, Differential pair 2
RS485-2B
+/-60 mA
@ 60 Ω,50 pF2
-7 to 12 VDC
8 mA
Not Connected
11
-
-
-
-
OT/FAIL
12
Over Temperature /PSU Fail, open collector,
external pull-up needed to max. 7 VDC
SRTN
<0.4 VDC
Pull up
7 VDC
20 mA
PS-PRESENT
13
Power Supply Seated – signal internally
connected through 10 Ohm resistor to SRTN
SRTN
-
1 VDC
100 mA
ACSH
143
Active Current Share
SRTN
0.2 VDC
5.0 VDC
7 VDC
0.7 mA
Margin
15
Optional – analog signal for Output Voltage
adjustment – Not connected
-
-
-
Connector type: Würth Elektronik, 61801529221
Mating part: Würth Elektronik, 61801529321
1 SRTN and Vout- are connected together inside the power supply (not valid for TCP4000-H090). The power supplies with
maximal output voltage >60V have all signals on 15-pin DSUB connector galvanically isolated from main output (including
SENSE +/- and ACSH).
2 120Ω resistors connection required between RS485-xA and RS485-xB on both sides externally.
3 The pin 14 on TCP4000-H090 is not internally connected to ACSH signal (see capture 8.6).
8.3 SIGNAL INPUT CONNECTOR: PINOUT
TCP3500 Series
7
Asia-Pacific
+86 755 298 85888
Europe, Middle East
+353 61 225 977
North America
+1 408 785 5200
© 2019 Bel Power Solutions & Protection
BCD.00509_AA
SIGNAL NAME
PIN #
TYPE
SIGNAL
REFERENCE
LOW LEVEL
HIGH LEVEL
V MAX
I MAX
RS485-1A
1
RS485 Half Duplex, Differential pair 1
RS485-1B
+/-60 mA
@ 60 Ω, 50 pF2
-7 to 12 VDC
8 mA
RS485-2A
2
RS485 Half Duplex, Differential pair 2
RS485-2B
+/-60 mA
@ 60 Ω, 50 pF2
-7 to 12 VDC
8 mA
ADDR-INIT OUT
3
The unit’s address change accepted
SRTN
<0.4 VDC
Pull up
7 VDC
20 mA
IN OK
4
AC Power Fail Warning - open collector,
external pull-up needed to max. 7 V
SRTN
<0.4 VDC
Pull up
7 VDC
20 mA
OUT OK
5
Output Voltage Fault - open collector, external
pull-up needed to max. 7 V
SRTN
<0.4 VDC
Pull up
7 VDC
20 mA
INHIBIT
6
Output Inhibit - Open circuit or “High” to SRTN
shuts OFF Vout
SRTN
<0.4 VDC
>2.5 VDC
3.6 VDC
0.2 mA
ENABLE
7
Power Supply Enable pin – for unit enable
short this pin to SRTN
SRTN
<0.4 VDC
>2.5 VDC
3.6 VDC
0.2 mA
SRTN1
8
Signal Return
-
-
-
RS485-1B
9
RS485 Half Duplex, Differential pair 1
RS485-1B
+/-60 mA
@ 60 Ω, 50 pF2
-7 to 12 VDC
8 mA
RS485-2B
10
RS485 Half Duplex, Differential pair 2
RS485-2B
+/-60 mA
@ 60 Ω, 50 pF2
-7 to 12 VDC
8 mA
Not Connected
11
-
-
-
-
OT/FAIL
12
Over Temperature /PSU Fail, open collector,
external pull-up needed to max.7 VDC
SRTN
<0.4 VDC
Pull up
7 VDC
20 mA
PS-PRESENT OUT
13
Power Supply Seated – last unit in string will
pull down this signal (external short to SRTN)
and informs Master Controller that all units in
string are seated and connected
SRTN
<0.4 VDC
>2.5 VDC
3.6 VDC
0.2 mA
ACSH
143
Active Current Share
SRTN
0.2 VDC
5.0 VDC
7 VDC
0.7 mA
Margin
15
Optional – analog signal for Output Voltage
adjustment - Not Connected
SRTN
-
-
Connector type: Würth Elektronik, 61801529321
Mating part: Würth Elektronik, 61801529221
SIGNAL NAME
PIN #
TYPE
SIGNAL
REFERENCE
LOW LEVEL
HIGH LEVEL
V MAX
I MAX
SENSE+
1
Sense line for Vout+ – voltage drop
compensation for positive pole
Vout+
-
-
SENSE-
2
Sense line for Vout- – voltage drop
compensation for negative pole
Vout-
-
-
Connector type: Phoenix Contact, MC 1.5/ 2-G-3.81
Mating part: Phoenix Contact, MC 1.5/ 2-ST-3.81
SIGNAL NAME
PIN #
TYPE
SIGNAL
REFERENCE
LOW LEVEL
HIGH LEVEL
V MAX
I MAX
ACSH
1
Active Current Share
SRTN
-
-
SRTN
2
Signal Return
-
-
-
SENSE+
3
Sense line for Vout+ – voltage drop
compensation for positive pole
Vout+
-
-
SENSE-
4
Sense line for Vout- – voltage drop
compensation for negative pole
Vout-
-
-
Connector type: Phoenix Contact, MC 1.5/ 4-G-3.81
Mating part: Phoenix Contact, MC 1.5/ 4-ST-3.81
8.4 SIGNAL OUTPUT CONNECTOR: PINOUT
8.5 SIGNAL OUTPUT CONNECTOR: PINOUT
8.6 SIGNAL OUTPUT CONNECTOR TCP4000-H090: PINOUT
8
TCP3500 Series
tech.support@psbel.com
PARAMETER
DESCRIPTION / CONDITION
MIN
NOM
MAX
UNIT
Dimensions (W x D x H)
See Figure 2
400 x 103 x 85
15.7 x 4 x 3.3
mm
in
Weight
Single PSU
6.5
kg
Cooling
Liquid cooled cold-plate, power dissipation ~300 W/PSU
Recommended water flow rate: 2 – 4 liters/min.
(depends on the cooling plate design)
Insulation
Input to Output:
Input to Chassis:
3.0
1.5
kVAC
Enclosure
IP20
Figure 2. Mechanical Dimensions
Main heatsink surface - bottom side (good thermal
connection to the cold plate is required, ∆T ≤ 5°C)
Tc – reference point
TCP3500 Series
9
Asia-Pacific
+86 755 298 85888
Europe, Middle East
+353 61 225 977
North America
+1 408 785 5200
© 2019 Bel Power Solutions & Protection
BCD.00509_AA
ITEM
DESCRIPTION
ORDERING
PART
NUMBER
SOURCE
SW GUI
Bel Power Solutions
Graphical User Interface
Windows XP/Vista/7 compatible GUI to
program, control and monitor TCP3500
PSU (and other Serial Communication
units)
N/A
belfuse.com/power-solutions
Mounting Screws
M4 x 80mm, Hex socket
XFM.00183.0
BOSSARD: 3186737
AC Input connector
4-pin Straight Cable Receptacle (Female)
ZES.00962
Weidmüller: 1173520000
Signal Connector
2-pin Straight Cable Receptacle,
pitch 3.81 mm (SENSE+/-)
1-111890-G
PHOENIXCONTACT:
1803578
2 4-pin Straight Cable Receptacle,
pitch 3.81 mm (SENSE+/- and ACSH)
1-114261-G
PHOENIXCONTACT:
1803594
Adapter USB to RS485
USB 2.0 compatible adapter to dual
RS485 with jumpers for signals:
ENABLE, INHIBIT and ADDR-INIT_IN
VKA.00489.0
Bel Power Solutions
Signal End Board
PCB (ZGN.00383) with 15-pin DSUB
connector and 6 jumpers: two for
setting-up of 120Ω resistors for RS485-1
and -2, and signals ADDR-INIT_OUT,
ENABLE, INHIBIT, PS PRESENT OUT
VKA.00488.0
Bel Power Solutions
Signal Connection Board
PCB (ZGN.00382) with two 15-pin DSUB
connectors. This PCB makes practical
and space saving solution for parallel
signals connection.
VKA.00487.0
Bel Power Solutions
2 For TCP4000-H090 only
NUCLEAR AND MEDICAL APPLICATIONS - Products are not designed or intended for use as critical components in life support systems,
equipment used in hazardous environments, or nuclear control systems.
TECHNICAL REVISIONS - The appearance of products, including safety agency certifications pictured on labels, may change depending on
the date manufactured. Specifications are subject to change without notice.
