Accessories Mounting Supports (R) Description Special mounting supports have been designed for the integration of power supplies into switch boards, control panels, printed circuit boards, etc., using adapters for chassis-, DIN-rail, or PCB mounting. The 19-inch cassette style DC-DC and AC-DC converters can also be chassis-mounted with frontal access by means of a special Chassis Mounting Plate, attached to the converters. The Universal Mounting Bracket also fits to most of these cassette type converters, allowing for either vertical-chassis or DIN-rail mounting. rail mounting, is available either for PCB mountable PSR and PSA Switching Regulators with option "Y" pins or for small DC-DC converters up to 15 Watt. For isolation of the PCB-mountable converters from a doublesided PCB, the use of Isolation Pads is recommended, as described below. RoHS-compliant products are available on request. Note: All dimensions are in mm, unless otherwise specified. A Bracket Kit, consisting of a PCB with screw-terminal connectors and a brackets suitable for either chassis or DIN- Table of Contents Page Page Description ............................................................................ 1 Chassis Mounting Plates ...................................................... 2 Universal Mounting Brackets ............................................... 4 DIN-Rail and Chassis-Mounting Brackets ........................... 6 Isolation Pads for PCB Mounting ....................................... 11 PCB-Tags for PCB Mounting .............................................. 11 BCD.20007 Rev AB, 04-Jun-2012 Page 1 of 11 www.power-one.com Accessories Mounting Supports (R) Chassis Mounting Plates For chassis mounting of 19" cassette-style converters, where only frontal access to the mounting screws is given, special chassis mounting plate adapters are available according to the following table and figures 1 to 3. Table 1: Mounting Plate survey Case size Converter Model type series Item no. Delivery content K02 K 1, PSK 1 S02 S 1, PSS 1, R 1 Mounting plate, 4 countersunk screws Q01 Q Q03 LPC Q04 P Q01 Q Q03 LPC Q04 P M02 M H02 H 1 Mounting plate K02 HZZ01213 Mounting plate Q HZZ01215 Mounting plate M HZZ01210 Mounting plate, 4 countersunk screws, 4 washers with Option B1 Note: The mounting plate K02 fits to K, S, PSK, or PSS converters with opt. B1. However, it is possible to order these converters directly with option B. Such converters exhibit the same mounting plate as shown in fig. 1. European Projection 7.5 6.5 11.2 12021a 13 140 125 M4 x 10 17.3 133.4 168 30 Converter S, K, PSK, or PSS with Option B1 5 Fig. 1 Mounting plate K02 Aluminium, black finish BCD.20007 Rev AB, 04-Jun-2012 Page 2 of 11 www.power-one.com Accessories Mounting Supports (R) 168 4.5 4.5 12022 European Projection M3 x 6 6 18 140 1040.1 128 3.6/7.5 x 90 115 12701 115 3 14 26 20 16.8 Fig. 2b Retention Clip [HZZ01209] 133 16.3 115 25.5 6.5 4.5 12020 6 Fig. 2a Mounting plate Q with integrated connector retention facility using the Retention Clip [HZZ01209] Aluminium, black finish 11.2 M3x 6 Washer 103.5 18.5 128 140 4.5/9 x 90 European Projection 127 166 19.5 3 Fig. 3 Mounting plate M Aluminium, black finish BCD.20007 Rev AB, 04-Jun-2012 Page 3 of 11 www.power-one.com Accessories Mounting Supports (R) Universal Mounting Brackets (DIN- and Chassis Mounting) Series H, M, Q, P, LPC, PSL A special universal mounting bracket has been designed for vertical or upright chassis and DIN-rail mounting of the 19" cassette style converters shown in table 2. 49 12031 14 4 168 84 20.5 127 158 20.5 5 4 20 14 29 5 7.5 Fig. 4 DIN-rail clamp Steel, galvanized European Projection M4 3 M4 (3) 10068a 4.5 5.5 10 5 12032a Fig. 5 Universal mounting bracket UMB-LHMQ Aluminum, untreated Series W and X Chassis mounting brackets UMB-W are available; see table 2 and fig. 6. DIN-rail mounting is possible with the built-in snap fit devices. For heavy-duty railway applications, 2 or better all 4 fixing brackets DMB-EWG should be fitted; see fig. 8. Fig. 7 W unit with chassis-mounting brackets 3 4.2 12055a 18 8 Left bracket Right bracket JM 09 5 33 0.5 49 Fig. 6 Universal mounting bracket UMB-W Fig. 8 Additional fixing brackets for railway application Table 2: Universal mounting bracket survey Converter case size Converter series Bracket Item no. Delivery content L04 H02, M02 Q01, Q03, Q04 PSL H, M Q, LPC, P UMB-LHMQ HZZ00610 Alu-profile (fig. 5), 2 screws and a DIN-rail clamp (fig. 4) with screw W01, X01 W, X UMB-W HZZ00618 2 clamps (fig. 6), 4 countersunk screws M4, washers, and spring washers DMB-EWG HZZ00624 DIN-rail clamp left and right (fig. 9), 2 screws M4, 2 washers, 2 ribbed-lock washers BCD.20007 Rev AB, 04-Jun-2012 Page 4 of 11 www.power-one.com Accessories Mounting Supports (R) DMB-K/S, DMB-MHQ By means of these DMB mounting kits, the S, K, PSS, PSK (DMB-K/S) and the M, H, Q, LPC, P (DMB-MHQ) converters can be fastened onto a DIN-rail. The kit consists of two aluminum brakets to be mounted on each side of the converter, including a clamp. The DMB-K/S kit contains two different sets of screws for the adaption of the brakets either to S/PSS or K/PSK converter types. The design of the kit is made such that the fixture is very tight, and as a result the assembly can also be used for mobile applications. Table 3: Mounting bracket survey Case Converter Type size series item no. S01 S02 K01 K02 PSS S, R PSK K DMB-K/S HZZ00615 M02 H02 Q01 Q03 Q04 M H Q1 LPC1 P1 DMB-MHQ HZZ00619 1 Not together with screw-style connectors STV-H15-FSR [HZZ00107] Fig. 9 Schematic view: Assembly of DMB-K/S CMB-S This mounting kit allows for chassis mounting of the S and PSS Series converters, if access is only possible from the front of the chassis. Note: If space conditions are very tight, option B1 or B can be used instead of the heat sink. Refer to the data sheets of the respective converters. This kit uses parts of the DMB-K/S kit, since it consists of the same two brakets but without the clamps and fitted the other way round on the heat sink. Table 4: Mounting bracket survey Case Converter Type size series Part no. S01 S02 PSS S, R CMB-S HZZ00616 BCD.20007 Rev AB, 04-Jun-2012 Page 5 of 11 www.power-one.com Accessories Mounting Supports (R) DIN-Rail and Chassis-Mounting Brackets PCB mounting as well as cassette style converters can be chassis- or DIN-Rail mounted by means of mounting bracket adapters. For selection and part numbers refer to table 5 ! Note: Customized adapters for other case sizes are available upon request. Each part number gives a direct indication of the kind of mounting, the type of converter, i.e. the case size, or the output power as well as the possible pin-out and the options according to the relevant converter data. The adaptors are divided into two mechanical types: CMB and DMB. Table 5: Mounting Bracket survey 1 A1 [mm] A2 [mm] Converter case size 95.0 90.0 A01 Converter series Chassis-mounting Part no. DIN-mounting Part no. Delivery content PSR, PSA (Vi max = 40, 60, 80 V) CMBA01-iRY/80 HZZ00607 DMBA01-iRY/80 HZZ00606 PSA (Vi max = 144 V) CMBA01-iRY/144 HZZ00609 DMBA01-iRY/144 HZZ00608 PCB, screw teminal blocks, 4 diodes, capacitor C1 and C- or D-bracket with screws 50.0 45.0 DIL 24 IMX4 with Option K IMS6 with Option K CMB3W-123 HZZ00604 DMB3W -123 HZZ00602 72.5 67.5 1" x 2" IMX7, IMS7 IML101 CMBIMS/X7 HZZ00617 DMBIMS/X7 HZZ00613 See Basic Kit C/DMBIMX/S7 Obsolete model 12023 A1 4 4 3.2 60 83 85 11.5 12024 13.3 38 A2 12 Fig. 10 CMB chassis mounting bracket dimensions Bracket: Aluminum, black finish BCD.20007 Rev AB, 04-Jun-2012 Fig. 11 DMB DIN-rail mounting bracket dimensions Bracket: Polycarbonate, black Page 6 of 11 www.power-one.com Accessories Mounting Supports (R) CMB: Chassis Mounting Bracket The kit consists of a PCB for the converter, a set of screw terminals allowing for easy electrical connection and two aluminium profiles, attached to the PCB by means of four screws, which serve as the chassis mounting bracket. Four different versions according to table 2 are available. Details on the layout of the PCBs and diagrams are given in the description below. DMB: DIN-Rail Mounting Bracket The DMB kit differs from the CMB version by a bracket suited for DIN-rail mounting. The black plastic body of the bracket holds the PCB by means of a snap-in device. Four different versions according to table 5 are available. Details on the layout of the PCB's and diagrams are given in the description below. 12026a C/DMBA01-... Electrical Description This bracket is designed for non-isolated switching regulators of the PSR and PSA Series in the A01 case size, equipped with option Y. Technical details and further information, e.g. max. input voltage etc., are described in the PSR/PSA data sheet. The use of the optional inhibit - and R-function (external output voltage adjustment with R1) is possible, and the device can be driven either from a DC-source or from a transformer secondary voltage. CMB/DMBA01 PSR01/PSA-...iRY Input - AC-input: The recommended transformer secondary voltage is 48 VAC for PSR/PSA (with Vi max = 80 V) and 72 VAC for PSA (with Vi max = 144 V) Exception: Input voltage for PSA55 is 20 VAC. Vi Gi Note: PSA55 and PSR362 require an additional capacitor (C2) of at least 470 F. X1 - 1 D1 X2 X1 1 1 i + C2 + C1 D3 D4 D1 D2 G R Go Vo Output - DC-input: Consider the forward voltage drop across the rectifier diodes (also providing reverse polarity protection). Capacitor C1 compensates for the negative input impedance of the converter in case of long connection wires. R1 Fig. 13 C/DMBA01- .. PCB layout 12025a D3 Gi- Vo+ Go- X2 - 3 X2 - 2 D2 D4 C2 + C1 X1 - 4 PSR/PSA A01-iRY + Vi+ R1 R i X2 - 1 X1 - 3 X1 - 2 Fig. 12 C/DMBA01-... circuit diagram BCD.20007 Rev AB, 04-Jun-2012 Page 7 of 11 www.power-one.com Accessories Mounting Supports (R) C/DMB3W-123 Electrical Description This bracket is designed for galvanically isolated DC-DC converters of the IMX4 and IMS6 Series (both with option K) in DIL 24 cases with one or two output voltages. The pin configuration of the converter groups single, double, and dual, and all technical converter details are described in the data sheets. Depending on the application input transient protection may be incorporated (e.g. an appropriate Transzorb diode D1) . - Four nuts M 2.5 - PCB - Three 2-pole terminal blocks (2 x for X1 terminal, 1 x for X3 terminal) - One 3-pole terminal block for X2 terminal - Three wire jumpers 5.08 mm (positions B1, B4, B5) - One wire jumper 10.16 mm (position D1) - Six wire jumpers 6.8 mm (positions L2, L4, L6) - Circuit diagram no. YSK25300 S3 01 Basic Kit DM BIMX/S7 12028b 20 1 2 X1 - 2 X1 - 4 Vo+2 15 16 For use with 1"x2" DC-DC converter types: IML10, IMS7 and IMX7 X2 - 4 The basic kit contains the following: - DIN-mounting support for 35 mm DIN-rail systems - PCB - Three 2-pole terminal blocks (2 x for X1 terminal, 1x for X3 terminal) - One 3-pole terminal block for X2 terminal - Three wire jumpers 5.08 mm (positions B1, B4, B5) - One wire jumper 10.16 mm (position D1) - Six wire jumpers 6.8 mm (positions L2, L4, L6) - Circuit diagram no. YSK25300 S3 01 Vi+ IMX4...K IMS6...K D1 23 24 X2 - 3 11 Go2 10 9 X2 - 2 Vo-1 12 Vi- X1 - 1 Vo+ Vo-2 13 1 X2 - 1 C1 C2 C3 1 2 Single-output models Double-output models Fig. 14 C/DMB3W-123 circuit diagram 12030 MB 3W-123 Input Output 1 C2 D1 C1 C3 3 X2 4 X1 2 3 2 1 4 1 Fig. 15 C/DMB3W-123 print layout Basic Kit CM BIMX/S7 For use with 1" x 2" DC-DC converter types: IMX7, IMS7, IML10 Part no. HZZ00617 The basic kit contains the following: - Two mounting rails, 83 mm - Four screws M 2.5 x 6 BCD.20007 Rev AB, 04-Jun-2012 Page 8 of 11 www.power-one.com Accessories Mounting Supports (R) Mounting Instructions for Basic Kit - Reverse polarity protection by a series diode D1. - Improved input transient protection according to IEC/EN 61000-4-5, level 2, by chokes L1 or L2-A, L2-B (EMC version) and capacitor C1. Single-output models IMX7, IMS7, IML10: - Solder the wire jumpers into positions as below: 1. D1 (10.16 mm) 2. B1 (5.08 mm), inhibit. - Remote inhibit. Note: This jumper should be fitted, if the inhibit is not actively used. An open inhibit disables the converter. Note: If the inhibit is not actively used the inhibit has to be connected to Vi- by jumper B1. - External output voltage trimming/adjustment 3. L2-A and L2-B, L6-A and L6-B (6.8 mm) 4. L4-A and L4-B (6.8 mm), only necessary, if the R-input is used. Single-output models: a) Vo - adjustment in the range of 70/75 - 100% of Vo nom by resistors RX3 or RX4 or combinations of RX3/RX4. - Solder terminal blocks 5. X1: Position Vi+/ Vi-, 2-pole terminal block 6. X1: Position i/n.c., 2-pole terminal block (only necessary in the case of remote inhibit) 7. X3: Position Vo+/ Vo-, 2-pole terminal block 8. X2: Position n.c., R, Vo-, 3-pole terminal block only necessary in the case of Vo adjustment by e.g. an external voltage source) b) Vo - adjustment in the range of 100 - 105% of Vo nom by resistors RX1 or RX2 or combinations of RX1/RX2. Double-output models: a) Vo - trimming by resistor R2 in the range of 100 - 105% of Vo nom - Solder the selected DC-DC converter - Mount PCB onto rails by using the 4 screws and nuts or snap PCB onto the DIN mounting support. - Perform function test b) Vo - trimming in the range of 70/75 - 100% of Vo nom by a current diode together with a Zener diode D2 applicable for 24/48 IMS7 and 20/40IMX7 types. - Reduced output ripple (by approx. factor 5) by using chokes L3/L5 together with electrolytic capacitors C8/C9. - Improved electromagnetic emission EN 55022, class B, lead length to load 1 m (class A for 110IMX7 types). Double-output models IMX7, IMS7, IML10: - Solder the wire jumpers into positions as below: 1. D1 (10.16 mm) 2. B1 (5.08 mm), inhibit Note: This jumper should be fitted, if the inhibit is not actively used. An open inhibit disables the converter. 3. L2-A and L2-B, L6-A and L6-B, L4-A and L4-B (all 6.8 mm) - For applications with both outputs in parallel: 4. Place/solder jumpers B4 and B5, (5.08 mm) This requires all capacitors and output chokes as per circuit diagram fig. 16, whereby the coupling capacitor C10 connected to Vi- via jumper B2 is foreseen for 24/48IMS/L types and 20/40/70IMX7 models. For 110IMX7 types the coupling capacitor C11 or C12 should be used connected to Vo+ via jumper B3. Notes: - For single-output models or double-output models with both outputs in parallel, one filter set (L5 or L6-A/L6-B) together with C7 and C9 is sufficient. - Solder terminal blocks 5. X1: Position Vi+/ Vi-, 2-pole terminal block 6. X1: Position i/R (Trim), 2-pole terminal block (only necessary in the case of remote inhibit or output voltage trimming by an external voltage source) 7. X3: Position Vo1+/ Vo1-, 2-pole terminal block 8. X2: Position n.c/Vo2+/Vo2-, 3-pole terminal block - Wire jumpers B2 and B3 should not be mounted together onto the PCB as this would cause a short circuit. - The coupling capacitors C10 or C11/12 should be Y2 ceramic types to maintain the outputs being SELV. - Application specific assemblies are available on request: MK001-xxx and MK002-xxx. - Solder the selected DC-DC converter - Mount PCB onto rails by using the 4 screws and nuts or snap PCB onto the DIN mounting support. - Perform function test Application-Specific Circuitry The assembly C/DMBIMX/S7 offers a variety of additional external circuitries which may be implemented onto the PCB. See circuit diagram and consult the IMS/X7 data sheet. Depending upon the application the following pheripheral additions can be made: BCD.20007 Rev AB, 04-Jun-2012 Page 9 of 11 www.power-one.com Accessories Mounting Supports (R) IMX7, IMS7, IML10 X2 14 D1 BYV27-200 L1 + L2 - A 12036a n.c. X1 1 + Vi + L3 Vi Vo2+ 13 [R] R1 X1 B5 Vo2+ 12 [Vo-] D2 ZPD 16 V 4 R2 C6 1 63 V R [n.c.] L6 - A X3 + C9 + 180 Vo1 50 V B2 B3 L6 - B X3 C7 470 n 63 V B4 Vo1- 10 [Vo-] X2 L5 Vo1+ 11 [Vo+] R X2 + C8 + 180 Vo2 50 V - i C3 470 n 63 V L4 - A L4 - B C4 1 63 V 3 i X1 C5 470 n 63 V RX4 + B1 Vi- D3 E - 2025N L2 - B RX3 2 - RX2 C11 100 100 V RX1 X1 C2 150 n 250 V - 1 for 70IMX7 use 160 V, for 110IMX7 use 220 V C10 Ker Y2, 4.7 n, 250 V C11, Y2, 47 n, 250 V [ ] = single-output models C12, Y2, 60 n, 250 V Fig. 16 C/DMB circuit diagram with IMX7, IMS7, IML10 12037 Input IMS/X 7 C12 C11 B3 B1 R2 D2 C3 D3 R1 B2 Output B4 C10 C9 x X3 Vo1- (Vo-) R (n.c.) C7 i L5 L6 Vo1+ (Vo+) X1 Vo2- (Vo-) Vi- C6 C4 Vo2+ (R) Vi+ C5 C2 L2 L1 Fig. 17 C/DMB arrangement of the terminals on the PCB for IMX7, IMS7, IML10 BCD.20007 Rev AB, 04-Jun-2012 x C2 RX4 RX3 RX2 RX1 B5 L3 L4 n.c. X2 C8 x Note: Where the pin/terminal designations for single-output models deviate from double-output models, they are shown in brakets. Page 10 of 11 www.power-one.com Accessories Mounting Supports (R) Isolation Pads for PCB Mounting PCB-Tags for PCB Mounting In applications, where PCB mounting converters are placed on top of double sided boards, the use of Isolation Pads is recommended. These fibre pads avoid short circuits and provide excellent protection against possible damage to tracks. For selection and item numbers refer to table below. Switching Regulators in B02 or C03 cases may also be mounted directly onto PCBs. The connection between the converters' faston pins and the PCB can be easily made by means of PCB-Tags. Table 6 : Isolation Pad survey Case size Series Isolation pad Dimensions [mm] A01 PSA PSR Isolation A 70 x 50 x 0.3 B02 PSB Isolation B 107 x 71 x 0.3 ISLOATIONB,B02 HZZ01205 C01 PSC Isolation C C03 xSR201 152 x 86 x 0.3 ISOLATIONC,C03 HZZ01206 Obsolete models 10 pieces LOETGABEL(10x) HZZ10204 Part no. 1 ISOLATIONA,A01 HZZ01203 17 5 7 12035 1 Delivery content: Part number: 1 5 Fig. 18 PCB-Tag 5.08 NUCLEAR AND MEDICAL APPLICATIONS - Power-One products are not designed, intended for use in, or authorized for use as critical components in life support systems, equipment used in hazardous environments, or nuclear control systems without the express written consent of the respective divisional president of Power-One, Inc. 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. BCD.20007 Rev AB, 04-Jun-2012 Page 11 of 11 www.power-one.com