TDK-Lambda Americas 3055 Del Sol Blvd. San Diego, CA. 92154 TEL. 619.575.4400 FAX 619.429.1011 Toll Free-1.800.LAMBDA4 http://www.us.tdk-lambda.com/lp CSS500 SERIES USER MANUAL August 9, 2011 General Safety Instructions This is an open type switch mode power supply for use in applications meeting Pollution Degree 2 environment. A suitable mechanical and fire enclosure must be provided by the end use equipment for shock hazard protection, fire protection and protection from hazardous energy levels. READ SAFETY INSTRUCTIONS carefully before working on the unit. HIGH VOLTAGE WARNING: Dangerous voltages are present in the power supply. 1. Do not install, test or operate this unit near water and do not spill any liquid on it. 2. Do not operate this unit unless it is in a secure position. This unit must be installed and put into service by authorized competent personnel only who are fully conversant with the hazards of AC line operated equipment and with the particular dangers associated with switch mode power supplies. The output power taken from the power supply must not exceed the rating stated on the power supply label. Refer to typical rating on power supply label for product's real output. In case of defect, this unit must be returned to the manufacturer. Safety Agency Certifications CSS500-xx, /S, /T versions These units are approved to UL 60601-1 1st Edition, CSA 601.1-M90, IEC 60601-1:1988+A1+A2 and EN 60601-1:1990+A1+A2. EMC should be evaluated to IEC/EN 60601-1-2 in the final system. CSS500-xx/I, /SI, /TI versions These units are approved to UL 60950-1 2nd Edition, CSA 60950-1-07 and EN 60950-1:2006+A11. Environmental Specifications Storage and Transportation: -10C to 85C, 10% to 95%RH Operating: 70C max ambient, IPX0, Continuous, Class I, NOT evaluated as AP/APG equipment. Input Rating 100-240 VAC, 6-2.5 A, 50/60 Hz Output Rating Model Output Voltage Maximum Current Convection Maximum Power Convection Maximum Current Forced Air Maximum Power Forced Air CSS500-12 CSS500-24 CSS500-30 CSS500-36 CSS500-48 CSS500-54 CSS500-57 12V 24V 30V 36V 48V 54V 57V 30A 15A 12A 10A 7.5A 6.67A 6.32A 360W 360W 360W 360W 360W 360W 360W 41.67A 20.84A 16.67A 13.89A 10.42A 9.26A 8.78A 500W 500W 500W 500W 500W 500W 500W Connections CN1 See outline drawings CN2 Mates with J.S.T. housing XHP-2, terminals: SXH-001T-P0.6; 28-22 AWG Pin 1 Pin 2 5Vsb Common 0V (V-) CN3 Mates with J.S.T. housing XHP-6, terminals SXH-001T-P0.6; 28-22 AWG Pin 1 Pin 2 Pin 3 Pin 4 Pin 3 Pin 6 CN4 Current Share Remote On/Off Common 0V (V-) +5Vsb - Sense + Sense See outline drawings CN5 Mates with Molex housing 90142-0006 & terminals: 90119-0109. (The 2 pin version 90123-0102 can also used) Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Fan Fault Power Good Fan Full Speed Common 0V Fan Full Speed Common 0V (V-) FAN 1 (Fixed Voltage) Mates with J.S.T. housing XHP-2, terminals: SXH-001T-P0.6; 28-22 AWG Pin 1 Pin 2 +12V fan Common 0V (V-) FAN 2 (Speed controlled) Mates with J.S.T. housing XHP-2, terminals: SXH-001T-P0.6; 28-22 AWG Pin 1 Pin 2 +12V fan Common 0V (V-) 5Vsb (StandBy Output) The 5Vsb is always "ON", even when the power supply inhibit is activated. Note that when the supply is inhibited or is used with convection cooling, the output must be de-rated to 5V 0.25A. The 5Vsb return is via Common 0V (V-) terminal. Remote On/Off The CSS500 can be remotely turned on or off with either an external voltage (Vext) or closed contact. Output inhibited (OFF) Short pin 2 to pin 3 or 0 < Vext < 0.5V Output enabled (ON) Open circuit (floating) or 3.5 < Vext < 5.25V The Remote On/Off return is via the Common 0V (V-) terminal. Power Good Signal An open collector signal indicates if the DC output of the CSS500 is good. An internal pull up resistor is fitted, tied to the 5Vsb. The maximum sink current is 0.5mA. The Power Good Signal return is via the Common 0V (V-) terminal. High = Output good Low = Output faulty Fan Fault Signal An open collector signal indicates if the fan is operating normally. An internal pull up resistor is fitted, tied to the 5Vsb. The maximum sink current is 0.5mA. The Fan Fault Signal return is via the Common 0V (V-) terminal. High = Fan operating normally Low = Fan faulty Fan Connection & Fan Speed Control The FAN 1 or FAN 2 connectors can be used to power an external 12VDC fan and supply up to 1A. FAN 1 provides a fixed 12V output. FAN 2 provides a variable voltage derived from a sophisticated fan controller turning on the fan as needed and adjusting its speed according to the cooling requirements. The FAN 2 speed controller can be over-ridden by applying a short on CN5. Current Share (Parallel Operation) Up to four units may be connected in parallel for either increased output power or for redundant operation and will share within 10% at full load. For best performance, the output voltages should all be set to the same value. Connect the current share pins together, and ensure that the output cables to the load are the same wire gauge and length. Remote Sense To compensate for up to 0.25V voltage drop in each of the output cables, connect + sense to + load and - sense to - load. Twist sense wires together to reduce noise pick up. If remote sense is not used, connect + sense to V+ and - sense to V-. Output Potentiometer The output potentiometer is fitted for factory adjustment only. Operating Temperature and Cooling If the internal fan is specified (/T or /S option) or forced air is applied, then the CSS500 will operate as per the blue line. If the CSS500 is used without the internal fan option and in still air (U channel version), then derate the unit according to the pink line. The recommended direction of the external air should be over the input terminal block, exiting over the output terminal block. The minimum recommended air volume for the correct cooling is 15CFM. If the internal fan is fitted, leave a minimum of 2" (50mm) clearance on intake and exhaust to avoid restricting airflow. To ensure unit reliability and to avoid over temperature shutdown, monitor temperature at the following locations: Dielectric Withstand (hipot) Before applying a test voltage, ensure the following connections are jumpered: L to N, + Output to - Output /I version (non medical) Primary to Secondary Primary to Chassis Secondary to Chassis 4,242VDC 2,121VDC 707VDC Medical version Primary to Secondary Primary to Chassis Secondary to Chassis 5,656VDC 2,121VDC 707VDC Outline Drawing - U channel version Outline Drawing - End fan channel version (/S) Outline Drawing - Top Fan Version (/T)