BPF1007 - BEL POWER SOLUTIONS

Mechanical Accessory Products Front Panels

Edition 5/6.2000 1/4

Front Panels

Table of Contents Page

Description ....................................................................... 1

Schroff

System for 3 U Rack ............................................ 1

Description

Front panels are available for 19" rack mounting of 3 U cas-

sette type power supplies in

Schroff

system version (

Inter-

mas

on request) and may be attached to the converter by

means of countersunk screws.

An assembly kit, consisting of a front panel and a support

bracket, enables arrangement of two standard cassettes

with up to six output voltages in 6 U configuration.

All front panels are of colourless anodised aluminium and

delivered with one or two grey plastic handles of 3 TE for

easy pull-out and two or four hand-press insertable plastic

retainers with captive screws for fixing to the rack.

Note: Front panel mounting or custom specific front panels

are available on request.

Dimensions in accordance to DIN 41494-1 (IEC 60297):

Width: 1 TE = 5.08 mm (0.20")

Height: 1 U = 44.45 mm (1.750")

(In Europa often

instead of

is used.)

Tolerances ±0.2 mm, unless otherwise specified

Schroff

System for 3 U Rack

Q-, PC-, P-, R Series Front Panels in 4, 5 or 6 TE

This front panel available in three versions fits to all DC-DC

converters of the Q-, P- and R-Families and to the AC-DC

converters of the PC Series with case size Q.

Table 1: Q01 case front panel selection

X Case Converter Type

TE mm size series Part no.

4 20.0 Q01 Q G04-Q01

Q03 PC HZZ 00835

Q04 P G04-Q04

RHZZ 00840

5 25.1 Q01 Q G05-Q01

Q03 PC HZZ 00836

Q04 P G05-Q04

RHZZ 00841

6 30.2 Q01 Q G06-Q01

Q03 PC HZZ 00839

Q04 P G06-Q04

RHZZ 00842

Note: For use of several units next to each other, we advise

to pack them not too densely in order to assure good ther-

mal management (see also relevant data sheet).

2.5

±0.1

128.4

6.4

±0.1

9.2

±0.1

104

±0.1

0.2 122.4

413

9.5

20.6

12002

Q04 only

Fig. 1

Front panel for Q case size

Page

Intermas

System for 3 U Rack ......................................... 4

Schroff

System Kit for 6 U Rack....................................... 4

Delivery contents:

Front panel, grey plastic handle, three countersunk screws,

set of two plastic retainers with captive screws and assem-

bly instructions.

Mechanical Accessory Products Front Panels

Edition 5/6.2000 2/4

H- and M Series Front Panel in 8 TE

This front panel fits to all 50 Watt DC-DC and AC-DC con-

verters of the 12...LH Series with case size H02 as well as

to all AM...LM- and CMZ...LMZ Series versions with case

size M02.

Table 2: H02 and M02 case front panel selection

TE mm Case Converter Type

size series Part no.

8 40.3 M02 M G08-M02

H02 H HZZ 00802

Delivery contents:

Front panel with grey plastic handle, two countersunk

screws, set of two plastic retainers with captive screws and

assembly instructions

128.4

4.4 ±0.1 31.5 ±0.1 2.5 ±0.1

18.2 ±0.1 94.5 ±0.1

40.3 (8 TE)

0.2 122.4

426

12003

Fig. 2

Front panel for H02 and M02 case size

PSL- and SR 20E Series Front Panel in 8 TE

This front panel fits to all Switching Regulators of the PSL

Series with case size L04 and to all 20 Watt DC-DC and

AC-DC converters of the B...LSR Series with case size L01.

Table 3: L case front panel selection

TE mm Case Converter Type

size family Part no.

8 40.3 L04 PSL 1 G08-L

L01 SR20E HZZ 00805

1Exception: PSL with option D is part no. G08-L04-D, HZZ 00816

Note: This front panel is a compatible replacement for all

earlier versions of the same size, published in any previous

front panel data sheet.

Delivery contents:

Front panel with grey plastic handle, two countersunk

screws, set of two plastic retainers with captive screws and

assembly instructions.

Fig. 3

Front panel for L01 and L04 case size

128.4

18.4 ±0.1 2.5 ±0.1

11.7 ±0.1 100 ±0.1

40.3 (8 TE)

0.2 122.4

12.2

50.5

Option D 1

12004

Mechanical Accessory Products Front Panels

Edition 5/6.2000 3/4

PSS and S Series Front Panels in 12 TE

PSK and K Series Front Panels in 16 TE

This front panel fits to all Switching Regulators of the PSS

and PSK Series with case size S01 or K01 as well as to all

100...150 Watt DC-DC and AC-DC converters of the A...LS-

and A...LK Series with case size S02 or K02 according to

the selection table below:

Table 4: S and K case front panel selection

X Case Converter Type

TE mm size series Part no.

12 60.6 S01 PSS G12-S

S02 S HZZ 00845

16 81.0 K01 PSK G16-K

K02 K HZZ 00831

Delivery contents:

Front panel with grey plastic handle, two countersunk

screws, set of four plastic retainers with captive screws and

assembly instructions.

128.4

4.4 ±0.1 27.4 ±0.1 2.5 ±0.1

9.7 ±0.1 103 ±0.1

0.2 122.4

429

12005

Fig. 4

Front panel for S01, S02, K01 and K02 case size

T Series Front Panel in 28 and 26 TE

This front panel fits to all 500 Watt AC-DC converters of the

T Series with case size T01.

Table 5: T case front panel selection

X Case Converter Type

TE mm size series Part no.

28 141.9 T01 T G28-T01

HZZ 00837

Delivery contents:

Front panel with two grey plastic handles, three counter-

sunk screws, set of four plastic retainers with captive

screws and assembly instructions.

Blind plates: to close a non fully equipped 19" rack (only

one or two LTs mounted). Power-One offers 28 TE wide

blind plates without hole.

G28-T01-blank met HZZ 00847 with metal screw retainers

G28-T01-blank plas HZZ 00848 with plastic screw retainers

Fig. 5

Front panel for T01 case size

128.4

26.2

±0.1

2.5

±0.1

9.7

±0.1

103

0.2 122.4

56.7 29

81.8

±0.1

12006

Mechanical Accessory Products Front Panels

Edition 5/6.2000 4/4

Intermas

System for 3 U Rack

The major differences between the Intermas and the

Schroff system front panels are the thickness (2 mm in-

stead of 2.5 mm), the hole size for the plastic retainers and

a small cut-out on each side (see figure:

Intermas system

front panel

). All other dimensions are given in the relevant

Schroff front panel drawings.

The following Intermas front panels are available on re-

quest:

Table 6: Intermas front panel selection

X Case Converter Type

TE mm size series Part no.

8 40.3 H02 H F08-M02

M02 M HZZ 00702

8 40.3 L01 PSL 1 F08-L

L04 SR 20E HZZ 00705

12 60.6 S01 PSS F12-S

S02 S HZZ 00732

16 81.0 K01 PSK F16-K

K02 K HZZ 00731

1Exception: PSL with option D is type/part no. F08-L04-D,

HZZ 00716

Delivery contents:

Front panel with grey plastic handle, two countersunk

screws and assembly instructions.

2 ±0.1

16.5

0.6

Option D1

12007

Fig. 6

Intermas system front panel (various case sizes)

Fig. 7

Front panel for 6 U configuration (various case sizes)

261.8

2.5 ±0.1

0.2 255.8

Support

bracket

12008

Schroff

System Kit for 6 U Rack

To configure Power-One Power Supplies for use in 6 U

racks a special assembly kit has been created consisting of

a double height front panel together with a support bracket

for two converters as shown in figure 7.

All other dimensions are given in the relevant 3 U front

panel drawings according to their case size. The assembly

kit is available with the type designation according to the

following table:

Table 7: 6 U assembly kit selection

X Case Converter Type

TE mm size series Part no.

5 25.1 Q01 Q Kit-G05-6HE-Q01

Q03 PC HZZ 00838

8 40.3 H02 H Kit-G08-6HE-M02

M02 M HZZ 00804

12 60.6 S01 PSS Kit-G12-6HE-S

S02 S HZZ 00833

16 81.0 K01 PSK Kit-G16-6HE-K

K02 K HZZ 00832

Delivery contents:

Double height front panel with two grey plastic handles, four

countersunk screws, set of two plastic retainers with cap-

tive screws, a support bracket and assembly instructions.

Mechanical Accessory Products Mounting Supports

Edition 5/6.2000 1/11

Mounting Supports

for Chassis-, DIN-Rail- and PCB Mounting

Table of Contents Page

Description ....................................................................... 1

Chassis Mounting Plates.................................................. 2

DIN- and Chassis Mounting Brackets .............................. 4

Universal Mounting Bracket ............................................. 9

Description

Special mounting supports have been designed for the in-

tegration of power supplies into switch boards, control pan-

els, printed circuit boards, etc. using adapters for Chassis-,

DIN-Rail or PCB mounting.

The 19 inch cassette type 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 con-

verters.

The

Universal Mounting Bracket

also fits to most of these

cassette type converters, allowing for either vertical chas-

sis- or DIN-Rail mounting.

Bracket Kit

, consisting of a PCB with screw terminal con-

nectors and a bracket suitable for either Chassis- or DIN-

Rail mounting, is available either for PCB mountable PSR

and PSA Switching Regulators with option "Y" pins or for

small DC-DC converters 1...15 Watt.

For isolation of the PCB-mountable converters from a dou-

ble sided PCB, the use of

Isolation Pads

is recommended,

as described below.

Flexible H11 PCB

allows for connection of casette type

converters with H11 connector mounted on a printed circuit

board to this board.

Note: All dimensions are in mm, with tolerances of ±0.2 mm

unless otherwise specified.

Page

Isolation Pads for PCB Mounting ................................... 11

PCB-Tags for PCB Mounting.......................................... 11

Flexible H11 PCB ........................................................... 11

Mechanical Accessory Products Mounting Supports

Edition 5/6.2000 2/11

Chassis Mounting Plates

For chassis mounting of 19" cassette type converters

where only frontal access to the mounting screws is given,

special chassis mounting plate adapters are available ac-

cording to the following table and figures 1 to 3.

Table 1: Mounting Plate survey

Case Converter Type Delivery content

size series Part. no.

K02 K 1 Mounting plate K02 Mounting plate

S02 S 1 HZZ 01213 and 4 countersunk

Q01 Q Mounting plate Q screws

Q03 PC HZZ 01215

Q04 P

Q01 Q Mounting plate M Mounting plate,

Q03 PC HZZ 01210 4 countersunk

Q04 P screws and

M02 M

4 washers

H02 H

1Option B1 necessary

6.5

11.2

140

16.3

133

166

128 6

115 25.5

19.5

103.5

18.5

127

4.5

M3 × 6

Washer

∅ 4.5/9 × 90°

12020

Fig. 1

Mounting plate M

Aluminium, black finish

European

Projection

Mechanical Accessory Products Mounting Supports

Edition 5/6.2000 3/11

115

127±01

115

16.8

168

4.5

140

104±0.1

128

M3 × 6

∅ 3.6/7.5 × 90°

4.5

12022

Fig. 3

Mounting plate Q with integrated connector retention facility

Aluminium, black finish

Note: Details on Connector Retention Clip V are given in section:

Mating Connectors

6.5

11.2

140

17.3 133.4 30°

168

125 7.5

Option B1 necessary

for K and S family

M4 x 10

12021

Fig. 2

Mounting plate K02

Aluminium, black finish

Mechanical Accessory Products Mounting Supports

Edition 5/6.2000 4/11

11.5

3.2

13.3

12024

Fig. 4

"CMB" chassis mounting bracket dimensions

Bracket: Aluminium, black finish

DIN- and Chassis Mounting Brackets

PCB mounting as well as cassette type converters can be

chassis- and/or DIN-Rail mounted by means of Mounting

Bracket adapters. For selection and part numbers refer to

table below.

Note: Customized adapters for other case sizes are avail-

able 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 pinnings and options

according to the relevant converter data. The adaptors are

divided into two mechanical types:

CMB

and

DMB

Table 2: Mounting Bracket survey

A1 A2 Converter Converter Chassis-mounting DIN-mounting Delivery

[mm] [mm] case size series Part no. Part no. content

95.0 90.0 A01 PSR, PSA CMBA01-iRY/80 DMB A01-iRY/80 PCB, screw teminal blocks,

(

i max 40, 60, 80 V) HZZ 00607 HZZ 00606 4 diodes, capacitor C1 and

PSA CMBA01-iRY/144 DMB A01-iRY/144 C- or D-bracket with screws

(

i max 144 V) HZZ 00609 HZZ 00608

72.5 67.5 2"×2" IMR 6, IMR 15 CMB2×2-BCFG DMB 2×2-BCFG PCB, screw teminal blocks,

IMP 6, IMP 12 HZZ 00605 HZZ 00603 and C- or D-bracket

50.0 45.0 DIL 24 IMP 3 CMB3W-123 DMB 3W-123

IMX 4 Option K HZZ 00604 HZZ 00602

72.5 67.5 1"×2" IMX 7 CMB IMS/X 7 DMB IMS/X 7 See Basic Kit C/DMB IMX/S 7

IMS 7 HZZ 00617 HZZ 00613

12023

Fig. 5

"DMB" DIN-rail mounting bracket dimensions

Bracket: Polycarbonate, black

Mechanical Accessory Products Mounting Supports

Edition 5/6.2000 5/11

Fig. 6a

C/DMBA01- .. circuit diagram

MB A01-iRY

D1 D2

D3 D4 C1 C2

X1 X2

Input

Output

Vi Gi iR

GGo Vo

12026

Fig. 6b

C/DMBA01- .. print layout

PSR/PSA

A01-iRY

X2 - 3

X2 - 2

X1 - 4

X2 - 1

X1 - 3

X1 - 1

X1 - 2

D4 C2 C1

12025

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 PCB's 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 (according to EN 50022, in-

cluding Hat- and C-rail). The black plastic body of the

bracket holds the PCB by means of a snap-in device. Four

different versions according to table 2 are available.

Details on the layout of the PCB's and diagrams are given

in the description below.

C/DMBA01-.. Electrical Description

This bracket is designed for non-isolated Switching Regula-

tors of the PSR and PSA series in the A01 case size,

equipped with "Option Y" pins and giving output voltages

between 5 V and 48 V. Technical details, i.e. max. input volt-

age etc. are described in the relevant PSR and PSA data

and further information is given in the application notes.

The use of the optional inhibit- and R-functions (external

output voltage adjustment with R1) is possible and the de-

vice can be driven either from a DC-source or from a trans-

former secondary voltage.

– DC-input: Consider the forward voltage drop across the

rectifier diodes (also providing reverse polarity protec-

tion). Capacitor C1 compensates the negative converter

input impedance in case of long connection wires to the

module.

– AC-input: The recommended transformer secondary vol-

tage is 48 Vrms for PSR and 72 Vrms for PSA (

i max 144 V)

Exception: Input voltage for PSR 54 (PSA 55) is 20 Vrms.

PSR 54 (PSA 55) and PSR 362 require an addi-

tional capacitor (C2) of at least 470 µF.

Mechanical Accessory Products Mounting Supports

Edition 5/6.2000 6/11

C/DMB2×2-BCFG Electrical Description

This bracket allows the mounting of isolated DC-DC con-

verters of series IMR 6, IMR 15, IMP 6 and IMP 12 in 2" by

2" cases with either one or two output voltages of 5, 12 or

15 V. The technical details are given in the relevant IMR 6,

IMR 15, IMP 6, IMP 12.

Depending on the application input transient protection

may be incorporated (e.g. an appropriately dimensioned

Transzorb diode D1).

MB 2×2 BCFG

Input

Output

12029

Fig. 7b

C/DMB2

2-BCFG print layout

(Vo+)

(Go)

(Vo–)

X2 - 1

X2 - 2

X2 - 4

X2 - 3

X1 - 2

X1 - 4

X1 - 1

X1 - 3

IMR 6

IMR 15

IMP 6

IMP 12

12027

Fig. 7a

C/DMB2

2-BCFG circuit diagram

C/DMB3W-123 Electrical Description

This bracket is designed for galvanically isolated DC-DC

converters of the IMP 1, IMP 3 and IXP 3 series in DIL 24

cases with one or two output voltages of 5, 12 or 15 V. The

pin configuration of the converter groups single, double,

and dual and all technical converter details are described in

the relevant data.

Depending on the application input transient protection

may be incorporated (e.g. an appropriately dimensioned

Transzorb diode D1) .

IMP 1

IMP 3

IXP 3

Vi+

Vi-

X1 - 2

X1 - 4

X1 - 1

Vo+

Vo-

Vo2 X2 - 4

Vo+ X2 - 3

Vo1/Vo- X2 - 1

Go2

X2 - 2

com

Go+

12028

Fig. 8a

C/DMB3W-123 circuit diagram for all pin configurations

Basic Kit CMB IMX/S 7

For use with 1"×2" DC-DC converter types:

IML 10, IMS 7 and IMX 7

Part No.: HZZ 00617

The basic kit contains the following:

–Two mounting rails, 83 mm

–Four screws M 2.5 x 6

–Four nuts M 2.5

–PCB ZGN 09601 A

–Three 2-pole terminal blocks

(2× for X1 terminal, 1× 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. YSK 25300 S3 01

Fig. 8b

C/DMB3W-123 print layout

MB 3W-123

Input Output

12030

Basic Kit DMB IMX/S 7

For use with 1"×2" DC-DC converter types:

IML 10, IMS 7 and IMX 7

Part No.: HZZ 00613

The basic kit contains the following:

–DIN-mounting support for 35 mm DIN-rail systems

–PCB ZGN 09601 A

–Three 2-pole terminal blocks

(2× for X1 terminal, 1× 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. YSK 25300 S3 01

Mechanical Accessory Products Mounting Supports

Edition 5/6.2000 7/11

Mounting Instructions for Basic Kit

Single output units IML 10, IMS 7 and IMX 7

–Solder the wire jumpers into positions as below:

1. D1 (10.16mm)

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 (6.8mm)

4. L4-A and L4-B (6.8mm), only necessary if remote

R-input is used.

–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 remote

o adjust-

ment by e.g. an external voltage source)

–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

Double output units IML 10, IMS 7 and IMX 7

–Solder the wire jumpers into positions as below:

1. D1 (10.16mm)

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 6.8mm)

–For applications with the 2 outputs in parallel:

4. Place/solder jumpers B4 and B5, (5.08mm)

–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

–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/DMB IMX/S 7 offers a variety of additional

external circuitries which may be implemented onto the

PCB ZGN 09601 A. See circuit diagram YSK 25300 S3 /01.

Please also consult the IMS/X 7 data sheet.

Depending upon the application the following pheripheral

additions can be made:

–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.

–Remote inhibit.

Note: If the inhibit is not actively used the inhibit has to

be connected to Vi– by jumper B1.

–External output voltage trimming/adjustment

Single output units:

o – adjustment in the range of 70/75...100% of

o nom

by resistors RX3 or RX4 or combinations of RX3/RX4.

o – adjustment in the range of 100...105% of

o nom

by resistors RX1 or RX2 or combinations of RX1/RX2.

Double output units:

o – trimming by resistor R2 in the range of

100...105% of

o nom

o – trimming in the range of 70/75...100% of

o nom by

a current diode together with a Zener diode D2 appli-

cable for 24/48 IMS 7 and 20/40 IMX 7 types.

–Reduced output ripple (by approx. factor 5) by using

chokes L3/L5 together with electrolytic capacitors C8/

C9.

–Improved electromagnetic emission EN 55022, level B,

lead length to load 1 m. (Level A for 110 IMX 7 types)

This requires all capacitors and output chokes as per cir-

cuit diagram YSK 25300 S3 /01 whereby the coupling

capacitor C10 connected to Vi– via jumper B2 is fore-

seen for 24/48 IMS/L types and 20/40/70 IMX 7 types.

For 110 IMX 7 types the coupling capacitor C11 or C12

should be used connected to Vo+ via jumper B3.

Note:

–For single output units or double output units with the 2

outputs in parallel one filter set (L5 or L6-A/L6-B)

together with C7 and C9 is sufficient.

–Wire jumpers B2 and B3 should not be mounted to-

gether onto the PCB as this would cause a short cir-

cuit.

–The coupling capacitors C10 or C11/12 should be Y2

ceramic types to maintain the outputs SELV

Application specific assemblies are available on request.

Mechanical Accessory Products Mounting Supports

Edition 5/6.2000 8/11

+C11

100 µ

100 V

L2 - A

L2 - B +

470n

63V

E - 2025N

150n

250V

BYV27-200

B2 B3

R2 D2

ZPD

16V

RX1

RX2

RX3

RX4

L4 - A

L4 - B

L6 - A

L6 - B

Vo2+

[R]

Vi +

Vi -

[nc]

Vo2+

[Vo-]

Vo1+

[Vo+]

Vo1-

[Vo-]

IMX 7

IMS 7

[ ] = Single Output Version

C10

Ker Y2

4n7

250V

C11

47n

250V

C12

60n

250V

63V

470n

63V

470n

63V

180u

50V

180u

50V

Vo2

Vo1

12036

Fig. 9a

C/DMB IMX/S 7 circuit diagram

Fig. 9b

C/DMB IMX/S 7 arrangement of the terminals on the PCB

Note: Where the pin/terminal designations for single output

units deviate from double output units they are shown in

brakets.

1Valid for 24/48 IMS/IML and 20/40 IMX

for 70 IMX use 150 V type

for 110 IMX use 200 V type

12037

IMS/X 7

Input

Output

R (n.c.)

Vi–

Vi+

Vo1– (Vo–)

Vo1+ (Vo+)

Vo2– (Vo–)

Vo2+ (R)

n.c.

Mechanical Accessory Products Mounting Supports

Edition 5/6.2000 9/11

Universal Mounting Bracket

(DIN- and Chassis Mounting)

UMB-LHMQ

A special Universal Mounting Bracket has been designed

for vertical or upright chassis- and DIN-Rail mounting of the

19" cassette type converters shown in table below.

Table 3: Mounting Bracket survey

Converter Converter Chassis-mounting DIN-mounting Delivery Part

case size series content number

L01, L04 SR, PSL UMB-LHMQ UMB-LHMQ Alu-profile, two screws and HZZ00610

H02, M02 H, M a DIN-rail clamp with screw

Q01, Q03, Q04 Q, PC, P

Fig. 10

DIN-rail clamp

Steel, galvanized

7.5

12031

20.5

168

127

158

20.5

4.5

5.5

M4 (3×)

12032

Fig. 11

"UMB" universal mounting bracket dimensions

Aluminium, untreated

Mechanical Accessory Products Mounting Supports

Edition 5/6.2000 10/11

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 (DMB-MHQ) converters can be

adapted to the DIN rail. The kit consists of two aluminium

brakets to be mounted on each side of the converter, in-

cluding 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 5: Mounting bracket survey

Case Converter Type Part

size series number

S01 PSS DMB-K/S HZZ 00615

S02 S

K01 PSK

K02 K

M02 M DBM-MHQ HZZ 00619

H02 H

Q01 Q

CMB-S

This mounting kit allows for chassis mounting of the S and

PSS converters, if access is only possible from the front of

the chassis. (If space conditions are very tight, option B1 or

B can be used in place of the heat sink. Please refer to the

description of the respective converter.)

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 6: Mounting bracket survey

Case Converter Type Part

size series number

S01 PSS CMB-S HZZ 00616

S02 S

UMB-W... (Shock resistant, DIN- and Wall Mounting)

For the DIN-rail snap-fit "Convert" Front End Line, two dif-

ferent mounting bracket sets are available on request. One

set for wall mounting, the other for an additional shock re-

sistant fixing to the DIN-rail in applications with higher vi-

bration levels.

Table 4: Mounting Bracket survey

Converter Converter Wall-mounting DIN-mounting Delivery Part

case series Shock resistant content number

W01 W UMB-W Two clamps, four countersunk screws M4, HZZ 00618

washers and spring washers

UMB-WDIN in preparation

33 ±0.5

4.2

12055

Fig. 12

Mechanical Accessory Products Mounting Supports

Edition 5/6.2000 11/11

Isolation Pads 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 part numbers refer to table below.

Flexible H11 PCB

If cassette type converters with male H11 connectors (used

for example in H or M series) are mounted on wiring

boards, the connection between the wiring board and the

male converter connector may be made using the special

H11 Flexi-PCB together with the female STV-H11-FB/CO

connector (see also:

Female connector

data).

Type: H11 Flexi-PCB

Part number: HZZ01208

3.81 7.62

83.82

5.08

21.3

24,5

12034

PCB-Tags for PCB Mounting

DC-DC and AC-DC converters in C01 case and Switching

Regulators either in B02 or C03 cases may also be

mounted directly onto PCB’s. The connection between the

converters' fast-on pins and the PCB can be easily made by

means of PCB-Tags.

Type: PCB Tag

Delivery content: 10 pieces

Part number: HZZ01204

5.08

12035

Fig. 13

PCB-Tag

Table 7 : Isolation Pad survey

Case Converter Isolation pad Dimensions Part

size series [mm] number

A01 PSR, PSA Isolation A 70 × 50 × 0.3 HZZ 01203

B02 PSB Isolation B 107 × 71 × 0.3 HZZ 01205

C01 xSR 20 Isolation C 152 × 86 × 0.3 HZZ 01206

C03 PSC

2"×2" IMR 6/15 Isolation 2"×2" 53 × 53 × 0.3 HZZ 01207

Fig. 14

H11 Flexi-PCB

Mechanical Accessory Products Rack Systems

Edition 5/6.2000 1/2

Rack Systems

Complete 19" rack with side walls, transversal rails and

mounting flanges. Six guiding rails are included for set up of

a system with up to three T units together with a back plane,

BPF or BPD type (T units and back plane not included).

The guiding rails shall be fixed to the rack by the delivered

screws (12 screws M2.5 x 12 and 12 nuts).

The rack can also be used for different 19" cassette type

converters like Q, M, K ect. (additional guiding rails may be

necessary).

Part no.: MQB 02002

Size: 19"/3 U/84 TE

485 mm (for 19")

465.1 mm (for 19")

450 mm (for 19")

1 TE = 2/10" = 5.08 mm

1 TE

19" = 482.6 mm

23" = 584.2 mm

6.35 mm

1 U

n • U, U = 13/4" = 44.45 mm

12056

Fig. 1

19" and 23" rack systems

Dimensions in accordance to DIN 41494-1 (IEC 60297):

Width: 1 TE = 5.08 mm (0.20")

Height: 1 U = 44.45 mm (1.750")

(In Europa often

instead of

is used.)

Tolerances ±0.2 mm, unless otherwise specified

19" and 23" (IEC 60297-1, -2 and -3)

Mechanical Accessory Products Rack Systems

Edition 5/6.2000 2/2

Fig. 2

Metric rack systems

Metric (IEC 60917)

485 mm

465 mm

450 mm

5 mm

482.6 mm (19")

1 SU = 25 mm

n • 25 mm

12057

Electrical Accessory Products Mating Connectors

Edition 5/6.2000 1/7

Table 1: H11 Connector Survey

Female connector Part no. Description of terminals Integrated

type coding

STV-H11-F/CO HZZ 00101 Faston straight 6.3 × 0.8 mm yes

STV-H11-FS/CO HZZ 00104 Faston straight 6.3 × 0.8 mm, solderable (short moulding) yes

STV-H11-FSR/CO HZZ 00102 Screw terminals, 90°, 2.5 mm2 (AWG 13) max, yes

STV-H11-FB/CO 1HZZ 00103 Solder pin 5.2 mm, ∅ 1.6 mm yes

STV-H11-FBER/CO 2 HZZ 00113 Solder pin 4.3 mm, ∅ 1.0 mm yes

STV-H11-FP/CO 2HZZ 00111 Press fit 6.5 mm, ∅ 1.0 mm yes

STV-H11-FBG/CO 2HZZ 00199 Solder pin 5.2 mm, ∅ 1.6 mm, gold-plated contacts yes

1 See also matching Flexi-PCB for PCB mounting of converters (see

Mounting Supports

)

2 Available on request

Mating Connectors H11

H15

H15 S4

Table of Contents Page

Description ....................................................................... 1

H11 Connector ................................................................. 1

H15 Connector ................................................................. 3

H15 S2, H15 S4 Connector ............................................. 4

Technical Data.................................................................. 5

Code Key System ............................................................ 6

Description

All 19" cassette type converters are equipped with either

H11-, H15-, H15 S2 or H15 S4 male connectors. Mating fe-

male connectors are available as accessories according to

the following tables. The four H-type connector versions are

specially designed for power supply applications, capable

of handling high operating currents. The connectors have

an integrated code key system allowing many coding possi-

bilities. Modules with high output current normally use two

contacts in parallel to keep the voltage drop across the con-

nector as low as possible.

H11 Connector

This connector has eleven contacts in one vertical column

marked 2 to 32. Mating and mounting conditions are ac-

cording to DIN 41612. The connector contacts are hard-

silver-plated and correspond to quality class 1, with respect

to electrical and mechanical life time.

This connector type (male version) is used in the following

converter series (case size):

H (H02), M (M02), SR (L01) and PSL (L04).

Page

Extraction Tool for High Current Contacts ........................ 6

Connector Retention Clip V.............................................. 6

Connector Retention Braket CRB .................................... 7

Cable Hood ...................................................................... 7

Cable Hood Retention Bracket CHRB ............................. 7

Electrical Accessory Products Mating Connectors

Edition 5/6.2000 2/7

Mechanical Dimensions

All dimensions in mm, tolerances ±0.2 mm unless otherwise specified

84.8

7.62

10 x 7.62 = 76.2

10.7

8.5

12042

Fig. 1

H11 frontal view, relating to figures below

11.5

31.3

2.9

±0.3

7.4

6.3 x 0.8

6.5

Coding wedge

K I H G F

2 5 8 11 14 17 20 23 26

5.5

12038

11.5

25.8

2.9±0.3

7.3

6.3 x 0.8

K I H G F

12043

Fig. 3

STV-H11-FS/CO,

Faston cable terminals 6.3

0.8 mm,

solderable (short moulding)

Fig. 2

STV-H11-F/CO,

Faston cable terminals 6.3

0.8 mm

Fig. 4

STV-H11-FSR/CO,

screw terminals (max. 2.6 mm2/AWG 13)

Fig. 5

STV-H11-FB/CO,

soldering pins X = 5.2 Y = Ø 1.6

STV-H11-FBG/CO,

soldering pins X = 5.2 Y = Ø 1.6

STV-H11-FBER/CO,

soldering pins X = 4.3 Y = Ø 1.0

STV-H11-FP/CO,

press insert pins X = 6.5 Y = Ø 1.0

11.5

2 5 8 1114172023262932

2.9

±0.3

19.8

K I H G F

10.9

12044

5.63

10 x 7.62 = 76.2 Y

0.3

2.8

±0.1

2 5 8 1114172023262932

11.5

5.08

2.9

±0.3

5.08

±0.1

Footprint for PCB-layout

12045

European

Projection

Electrical Accessory Products Mating Connectors

Edition 5/6.2000 3/7

H15 Connector

This connector has fifteen contacts in two vertical columns

marked 4 to 32 and is designed to meet DIN 41612. The

connector contacts are hardsilver-plated and correspond to

quality class 1, with respect to electrical and mechanical life

time.

This connector type (male version) is used in the following

converter series (case size):

PSS (S01), S (S02), Q (Q01) and for PSK (K01) and K

(K02) only for output current ≤18 A.

Fig. 8

STV-H15-FB/CO,

soldering pins

3.5

14 × 5.08 = 71.12 8.17

10.16

0.3

1.6

2.8

10.1

5.08

Footprint for PCB-layout

12047

Mechanical Dimensions

All dimensions in mm, tolerances ±0.2 mm unless otherwise specified

Fig. 6

H15 frontal view,

relating to figures below

14.8

12.4

12046

±1

10.1

14.8

84.9

8.0

3.3

12039

Fig. 7

STV-H15-FSR,

Screw terminals, no coding

STV-H15-F/CO,

Faston cable terminals 6.3

0.8 mm

(identical dimensions, but not shown)

Table 2: H15 Connector Survey

Female connector Part no. Description of terminals Integrated

type coding

STV-H15-F/CO HZZ 00106 Faston straight 6.3 × 0.8 mm yes

STV-H15-FSR HZZ 00107 Screw terminals, 90°, 2.5 mm2 (AWG 13) max. no

STV-H15-FB/CO HZZ 00112 Solder pin 4.0 mm, ∅ 1.6 mm yes

STV-H15-FP/CO 1HZZ 00117 Press fit 4.5 mm, ∅ 1.0 mm (double pin version) yes

STV-H15-FBG/CO 1HZZ 00197 Solder pin 4.0 mm, ∅ 1.6 mm, gold-plated contacts yes

STV-H15-FWS/CO HZZ 00114 Solder pin 10.1 mm, ∅ 1.6 mm, 90° bent contacts yes

1 Available on request

European

Projection

Electrical Accessory Products Mating Connectors

Edition 5/6.2000 4/7

H15 S2, H15 S4 Connector

This special connector is a derivative of the H15 having

seven standard contacts as above, combined with two

(H15 S2) or four (H15 S4) high current contacts according

to DIN 41626. The high current contacts are specially de-

signed to handle currents from 20 A up to 40 A. They corre-

spond to quality class 1, with respect to electrical and me-

chanical life time. The contact material is high quality Beryl-

lium-Copper (CuBe treated) with a gold-plated surface.

To install the high current contacts carefully follow the as-

sembly instructions. It is extremely important to solder ca-

bles, screw cable terminals or heat shrink sleeves to high

current jacks first, before inserting them into the moulding.

Paralleled converters should preferably be interconnected

on current bars or at a star point.

Using screw versions, the two outer high current jacks may

be inserted at a 90° angle in order to prevent possible short

circuits between the cable terminals, especially in applica-

tions with high vibration environment. Heat shrink sleeves

might be necessary for further isolation purposes or to keep

clearance and creepage distances at specified levels.

An Extraction Tool allows removal of the high current con-

tacts for replacement (see:

Extraction Tool

Caution: The use of an adequate cable strain relief de-

vice (e.g. Cable Hood etc.) is essential in order to protect

the high current contact jacks from damage. Never

screw, solder or manipulate these contacts when the

connector is plugged into the male connector! The use

of highly flexible cables is strongly recommended.

This connector type (male version) is used in the following

converter series (case size):

PSK (K01), K (K02) and P with output current ≥20 A.

Table 3: H15 S2/S4 Connector Survey

Female connector Part no. Description of terminals Integrated

type coding

STV-H15 S2-F/CO HZZ 00115 11 Faston straight 6.3 × 0.8 mm, set of 2 solder jacks 1 yes

STV-H15 S2-FSF/CO HZZ 00116 11 Faston straight 6.3 × 0.8 mm, set of 2 screw jacks 1 yes

STV-H15 S4-F/CO HZZ 00105 7 Faston straight 6.3 × 0.8 mm, set of 4 solder jacks 1 yes

STV-H15 S4-FSF/CO HZZ 00110 7 Faston straight 6.3 × 0.8 mm, set of 4 screw jacks 1 yes

STV-H15 S4-FLS/CO HZZ 00109 7 screw terminals, 90°, 2.5 mm2, set of 4 solder jacks 1 yes

STV-H15 S4-FSR/CO HZZ 00108 7 screw terminals, 90°, 2.5 mm2, set of 4 screw jacks 1 yes

1 Spare set of high current jacks are available on request

Delivery content: H15 S2 (S4) moulding, two (four) high current jacks and assembly instructions. Screw versions also

include four M4 screws with washers and heat shrink sleeves.

14 x 5.08

2.54

7.62

88.9

14.9

12053

3.5 6

min.

10.1

Fig. 9

STV-H15-FWS/CO

Solder pins for pcb mounting

14.8

12.4

12054

10.1

84.9

30.3

Fig. 10

STV-H15 S2-FSF/CO

Faston cable terminals and two high

current screw terminals (solder termi-

nals see H15 S4)

Mechanical Dimensions

All dimensions in mm, tolerances ±0.2 mm unless otherwise specified

European

Projection

Electrical Accessory Products Mating Connectors

Edition 5/6.2000 5/7

Technical Data

Table 4: Connector data

Type H11 H15 H15 S2/H15 S4

Standard High current

Mechanical data

Number of poles 11 15 11/ 7 2/4

Mating cycles 500 500 500 500

Insertion/withdrawal forces max. 80 N 90 N 90 N 10/1.6 N

Electrical data

Clearance distance contact/ground ≥4.5 mm ≥4.5 mm ≥4.5 mm

Creepage distance contact/contact ≥8.0 mm ≥8.0 mm ≥8.0 mm

Test voltage Vrms 3100 3100 3100

Operation voltage V AC 500 500 500

Operation current

A 20°C 20 A 15 A 15 A 40 A

per contact

A 70°C 17 A 12 A 12 A 35 A

A 95°C 14 A 9 A 9 A 25 A

Contact resistance ≤8 mΩ≤8 mΩ≤8 mΩ≤1 mΩ

Isolation resistance at 100 V DC ≥1012 Ω≥1012 Ω≥1012 Ω

Miscellaneous data

Operating temperature –55...125°C–55...125°C–55...125°C

Contact surface 6 µm Ag 6 µm Ag 6 µm Ag 1.3 µm Au

Moulding material PBTP/PC PBTP/PC PBTP

Flammability UL 94V-0/UL 94 V-1 UL 94 V-0/UL 94 V-1 UL 94 V-0

Approvals

Fig. 13

STV-H15 S4-FSF/CO,

Faston cable terminals and four high

current screw terminals

STV-H15 S4-F/CO

Faston cable terminals and four high

current soldering terminals (not shown)

84.9

30.3

41.6

12.4

10.1

7.6

12049

84.9

30.6

40.5

12.4

10.1

14.8

Ø 3.5

12040

Fig. 12

STV-H15 S4-FLS/CO,

screw terminals and four high current

soldering terminals

STV-H15 S4-FSR/CO,

screw terminals and four high current

screw terminals (not shown)

14.8

12048

Fig. 11

H15 S4 frontal view,

relating to figures below

Electrical Accessory Products Mating Connectors

Edition 5/6.2000 6/7

Extraction Tool

for High Current Contacts

High current plugs and jacks can be disassembled from the

moulding by means of a special Extraction Tool (H15 S2,

H15 S4). Holding the extraction tool over the centre of the

connector's female contact the outer part of the extraction

tool should be fed between the moulding and the outside of

the female contact itself. This releases the spring clip fixing

the contacts, in order to pull the contacts out of their mould-

ing for replacement. If the operation is performed correctly

very little force is required. Extreme care should be taken

since incorrect procedure and excessive force could dam-

age the tool and/or connector.

This tool is available as an accessory for both screw or sol-

der high current contacts.

Note: In order to avoid damage never manipulate high cur-

rent contacts when plugged-in!

Description: Extraction Tool

Part Number: HZZ 00150

Connector Retention Clip V

The retention clip V is an accessory which guarantees se-

cure connection even under severe vibration, as for exam-

ple in mobile applications. One connector retention system

fits to almost all units and all of the aforementioned connec-

tor types.

The following converter series are delivered with pre-

punched holes in the back plate for fast field-mounting of

retention clips:

H, M, K, PSK, S, PSS and T (Q series only in combination

with Mounting Plate Q, see Mounting Supports)

Description: Retention Clips V

Delivery content: 2 pcs.

Part Number: HZZ 01209

Connector retention clips (unlocked)

Connector retention clips (locked)

12050

Fig. 16

Connector retention clip

Fig. 15

Extraction tool

Code Key System

An efficient coding system is of great importance and can-

not be valued highly enough in complex electronic systems.

Since power supplies handle high currents and voltages

any false connection could not only be extremely danger-

ous but also quite costly.

This integrated polarizing system allows effortless coding

by the simple insertion of Coding Wedges into the female

connector mouldings. The corresponding counter-parts, i.e.

the coding tabs of the male moulding just have to be broken

off to match the right female part. Major advantages are

high mechanical stability and ease of handling. The H11

connectors have 10 and the H15 connectors have 8 coding

positions. Using 4 coding wedges results in 210 (H11) re-

spectively 70 (H15) different coding possibilities. Coding

wedges are available as accessories to female connectors

with the following part number:

Description: Coding wedge (Codierkeil)

Delivery content: 5 pcs.

Part Number: HZZ 00202

232

5811 14 17 20 23 26 29

KIHGF

K I H G F

2 5 8 11 14 17 20 23 26 29 32

Coding tab

Coding wedge

6.5

12041

Fig. 14

Integrated code key system

Electrical Accessory Products Mating Connectors

Edition 5/6.2000 7/7

110

20.2

Modification for use with Retension Clip

12051

Fig. 17

Cable hood for H15 and H15 S4 connectors

Cable Hood

A cable connector housing or Cable Hood is available for all

female H15, H15 S2 and H15 S4 type connectors with

faston connectors (Not suited for screw terminals). It serves

as a strain relief, isolates connections and protects cables.

Description: KSG-H15/H15 S4

Delivery content: Housing shell, cable duct with covers,

cable clip, cable boot and screws

Part number: HZZ 00141

If using the cable hood together with retention clips a spe-

cial version is available, where both sides of the hood are

slightly modified in order to allow for insertion of the clips.

The cable hood with retention clips has been tested to with-

stand vibrations according to IEC 86-2-6: 5 g, 6 directions,

2.5 hours per axis.

Description: KSG-H15/H15 S4-V

Delivery content: Housing shell, cable duct with covers,

cable clip, cable boot and screws

Part Number: HZZ 00142

Cable Hood Retention Bracket CHRB

The cable hood can also be fixed to the converter case

with two U-shaped cable hood retention brackets.

Description: CHRB-KSG

Delivery content: Two brackets with two screws

Part number: HZZ 01218

Connector Retention Bracket CRB

An alternative to the above mentioned retention clip V is the

connector retention bracket. They are attached to the back

plate by one screw each with a torque of 20 to

30 Ncm.

Table 5: Connector Retention Bracket Survey

Connector Type Delivery

series Part number content

H, M CRB-HKMS 2 brackets

K, PSK HZZ 01216 2 screws

S, PSS 2 washers

Q, P CRB-Q

PC HZZ 01217

Electrical Accessory Products Temperature Sensors

Edition 2/5.2000 1/4

Temperature Sensors

Description

Power-One offers a wide range of battery charger systems

for power requirements of 50 Watt up to 8000 Watt.

For this purpose Power-One supplies temperature sensors

and adapted power supplies. The batteries (lead acid bat-

teries) are charged according to the battery temperature

and the ambient temerature. If the battery is fully charged it

is maintained at the ﬂoat charge voltage which represents

the optimum point for maximum available energy in case of

need and optimum life expectancy of the battery. The type

of sensor needed is defined mainly by three parameters:

The nominal battery voltage (e.g. 24 V or 48 V), the tempe-

rature coefficient of the battery (e.g. –3.0 mV/K/cell) and the

nominal floating charge voltage per cell of the battery

at 20°C (e.g. 2.27 V/cell). The latter two are defined in the

specifications of the battery given by the respective battery

manufacturer.

Table of Contents Page

Description ....................................................................... 1

Temperature Sensors for T and U units ........................... 1

Mechanical Dimensions ................................................... 2

Page

Temperature Sensors for

M, H, S, K, KP, PSx, LW, OK Units .................................. 3

Mechanical Dimensions ................................................... 3

Fail Safe Operation .......................................................... 4

Temperature Sensors for T and U units

T and U units feature a cell voltage selector switch (feature

Z) to set the required floating charge voltage at 20°C di-

rectly at the unit. If this Z switch is used the 2.23 V/cell sen-

sor types should be selected in any case as a basis and the

selection criteria are only the temperature coefficient of the

battery and the nominal battery voltage. If for example a

24 V battery is used which has a cell voltage of 2.27 V/cell

and a temperature coefficient of –3.5 mV/K/cell, the sensor

type is S24-2.23-35-02. The setting on the Z switch of the T

or U unit should be 2.27.

For units without the Z selector switch a sensor according

to both criteria should be selected. In our example it would

be S24-2.27-35-02.

For further details please consult the T or U datasheet.

Power

supply Load

–

Vo+

Vi+

Vo–Vi–

input

Temperature sensor

03099

Battery

Fig. 1

Functional description

Electrical Accessory Products Temperature Sensors

Edition 2/5.2000 2/4

Table 1: Type survey T sensors

Nominal battery Sensor type Part no. Cell voltage Temp. coefficient Cable length

voltage [V] [mV] [mV/K/cell] [m]

24 S24-2.23-30-02 MQC02052 2.23 –3.0 2

24 S24-2.23-35-02 MQC02053 2.23 –3.5 2

24 S24-2.23-45-02 MQC02051 2.23 –4.5 2

36 S36-2.23-30-02 MQC02081 2.23 –3.0 2

36 S36-2.23-35-02 MQC02082 2.23 –3.5 2

36 S36-2.27-35-02 MQC02083 2.27 –3.5 2

48 S48-2.23-30-02 MQC02008 2.23 –3.0 2

48 S48-2.23-35-02 MQC02009 2.23 –3.5 2

48 S48-2.23-40-02 MQC02013 2.23 –4.0 2

48 S48-2.23-45-02 MQC02012 2.23 –4.5 2

48 S48-2.27-30-02 MQC02010 2.27 –3.0 2

48 S48-2.27-35-02 MQC02007 2.27 –3.5 2

48 S48-2.27-45-02 MQC02006 2.27 –4.5 2

Other types for different cell voltages or temperature coefficients are available upon request.

+—

Battery

Vo+

i/Ucr

Vo—

Temperature

sensor

Sensor

cable

Sensor

wires

+—

05064

green

brown

white

+–

Battery

Vo+

Ucr

Vo–

Temperature

sensor

Sensor

cable

Sensor

wires

+–

05148

green

brown

white

Fig. 2:

Connection to the T unit.

Fig. 3:

Connection to the U unit.

Mechanical Dimensions

All dimensions in mm, tolerances ±0.3 mm unless otherwise specified.

≤60

l: 2 m standard length

other cable lengths on request

± 0.2

adhesive tape

14.5

09044

European

Projection

Fig. 4

T and U temperature sensor with mounting fixture.

Electrical Accessory Products Temperature Sensors

Edition 2/5.2000 3/4

Temperature Sensors for

M, H, S, K, KP, PSx, W, OK Units

With M, H, S, K, KP, PSx, W and OK units the sensor signal

acts on the R pin to adjust the output voltage relative to the

battery temperature and the ambient temperature. As these

units in contrast to the T and U units do not feature a cell

voltage selector switch (Z switch) the sensor selection crite-

ria is in every case both the cell voltage and the tempera-

ture coefficient (beside the nominal battery voltage).

If the application uses for example a 48 V battery with a cell

voltage of 2.23 V/cell and a temperature coefficient of

–3.0mV/K/cell the sensor S-KSMH48-2.23-30-2 should be

selected.

Table 2: Type survey S-KSMH sensors

Nominal battery Sensor type Part no. Cell voltage Temp. coefficient Cable length

voltage [V] [mV] [mV/K/cell] [m]

12 S-KSMH12-2.27-30-2 MQC03005 2.27 -3.0 2

24 S-KSMH24-2.27-35-2 MQC03002 2.27 -3.5 2

24 S-KSMH24-2.27-30-2 MQC03004 2.27 -3.0 2

48 S-KSMH48-2.27-35-2 MQC03001 2.27 -3.5 2

48 S-KSMH48-2-27-30-2 MQC03003 2.27 -3.0 2

Other types for different cell voltages or temperature coefficients are available upon request.

Mechanical Dimensions

All dimensions in mm, tolerances ±0.3 mm unless otherwise specified.

European

Projection

+–

Battery

Vo+

Vo–

Temperature

sensor

Sensor

cable

Sensor

wires

+–

05163

green

brown

white

Fig. 5

Connection to a M, H, S, K, KP, LW or OK unit.

Fig. 6

S-KSMH temperature sensor.

9.8 (0.4")

55 (2.17") 26 (1.02")

S90051

Electrical Accessory Products Temperature Sensors

Edition 2/5.2000 4/4

Tabel 4: Special units for battery charging

batt [V]

o 50 Watt

o 70 Watt

o 100 Watt

o 150 Watt

o 250 Watt

12 LM 1781-7R LH 1781-2R LS 4740-7R LK 4740-7R

24 LM 1782-7R LH 1782-2R LS 5740-7R LK 5740-7R LKP 5740-6R

36 LM 1783-7R LH 1783-2R

48 LM 1784-7R LH 1784-2R LS 5740-7R LK 5740-7R LKP 5740-6R

60 LM 1785-7R LH 1785-2R

Fail Safe Operation

To prevent overcharging of the battery but still maintain a

minimum charging in case of interruption of the sensor sig-

nal cable to the power supply, Power-One has designed

units with a special nominal output voltage setting. These

units differ from the respective standard units described in

the datasheet in the nominal output voltage and output

current settings. Without the sensor connected to the R pin

the output voltage will be higher than the nominal battery

voltage to avoid a discharging of the battery but still lower

than the theoretically needed float charge voltage. As soon

as the sensor is connected to the R pin the output voltage

will be set to the correct value.

Table 3:

Nominal battery voltage Output voltage setting

[V] (20°C) [V]

12 12.84

24 25.68

36 38.52

48 51.36

60 64.2

Higher power requirements can be covered by paralleling

of these units. Complete microprocessor controlled sys-

tems of un-interuptable power suplies (UPS) are realized

by our Applications Center. Please consult your local

Power-One representant.

Electrical Accessory Products Filter & Ring Core Chokes

Edition 5/6.2000 1/5

Filters and Ring Core Chokes FP Series

L Series

LP SeriesDescription

These Filters and chokes are designed to reduce input in-

terference and/or output ripple voltages occurring in appli-

cations with switched mode power supplies. Since all our

filters contain a Moly Permalloy Powder (MPP) ring core

they feature very low DC losses as well as high DC mag-

netisation and operate perfectly at the input and/or output

of switching regulators ensuring effective filtering even at

elevated DC current levels. These special characteristics

allow the chokes to be operated at DC currents which con-

siderably exceed the rated current, by accepting a corre-

sponding gradual loss of inductance (unlike ferrite core

chokes where inductance rapidly decreases above a cer-

tain DC magnetising level).

In applications where switching regulators have long supply

lines, filters and chokes are used in order to prevent oscilla-

tions caused by their negative input impedance. For further

information refer also to switching regulator data for "Option

L", and to section:

Technical Information: Installation & Ap-

plication

Table 1a: Type survey of FP filter blocks

Filter type Part number Matching switching

regulator type

FP 38 HZZ 00903 PSR 54

PSA 55

PSA 5A2

PSA 5A5

PSA 123

PSA 153

FP 80 HZZ 00904 PSR 53

PSR 122.5

PSR 152.5

PSR 242

PSR 362

PSA 242.5

FP 144 HZZ 00905 PSA 121.5

PSA 151.5

PSA 241.5

PSA 361

PSA 481

Table 1b: Type survey ring core chokes

Type Inductivity

Ln Single Symm. Part

coil coil number

LP 34-3 34 µH 3 A • HZZ 00501

L 20-7 20 µH 7 A • HZZ 00502

LP 20-7 20 µH 7 A • HZZ 00503

LP 183 2 × 183 µH 8 A • HZZ 00504

Filter Blocks FP Types

The filter blocks contain, in addition to a MPP ring core, a

capacitor and an attenuation resistor, capable of handling

the high ripple currents seen at the input of switching regu-

lators. This forms a complete external filter system opti-

mised to prevent oscillations and to reduce superimposed

interference voltages and currents, specially designed for

use in PCB applications together with switching regulators

in an A01 case size. For selection of filters refer to the type

survey.

Table of Contents Page

Description ....................................................................... 1

Filter Blocks FP Types ..................................................... 1

Page

Low-Loss Ring Core Chokes L/LP-Series........................ 3

Mechanical Dimensions ................................................... 5

Electrical Accessory Products Filter & Ring Core Chokes

Edition 5/6.2000 2/5

Electrical Data Filter Blocks

General Condition:

A = 25°C unless otherwise specified

Table 2: Filter blocks FP

Characteristics Conditions FP 38 FP 80 FP 144

min typ max min typ max min typ max Unit

Fn Rated current

= 0.75

o4 4 2 A DC

Fn Rated voltage

C min...

C max 5 40 5 80 15 144 V DC

FOhmic resistance 18 20 22 18 20 22 90 95 100 mΩ

oNo load inductance

L = 0,

C min...

C max 30 34 38 30 34 38 88 100 112 µH

AAmbient temperature

F =

Fn –40 80 –40 80 –40 95 °C

CCase temperature –40 92 –40 92 –40 98

SStorage temperature –40 100 –40 100 –55 100

For currents

F > 4 A the following derating takes place:

A max = 100 – 1.3 •

F2 [°C],

C max = 100 – 0.49 •

F2 [°C]

Reduction of Output Ripple

Even though switching regulators have an inherently low

output ripple, certain sensitive applications need even fur-

ther reduction. In such cases, the filters designed to reduce

disturbances at the input, can also be used for reducing the

ripple on the output voltage (even better results with regard

to the ripple and dynamic control deviation can be achieved

by using low-loss ring core chokes in combination with an

external capacitor, see below).

The output ripple can be reduced by the use of filter blocks

by about 24 dB. The formula for the ripple

R at the load

is as follows:

R = 0.063 •

(Ripple voltage

o is given for specific regulators in the cor-

responding data section).

Consider, that the filter not only affects the output ripple but

can also influence the voltage across the load

L in the

event of load changes. The static load regulation increases

with the ohmic resistance of the choke i.e. 24 mV/A for the

FP 38 and FP 80 filters and 95 mV/A for the FP 144 filter.

Vi+

Gi–

Vo+

Go–

PSR RL

Filter Uio

Uii

12010

Fig. 2

Reduction of voltage interference by FP filters

Input Interference Reduction

An AC ripple current can be measured at the input of any

switching regulator, even if they are equipped with an input

filter. Depending on the types of filters used, common and/

or differential mode interferences can be reduced. They will

also help to further increase the surge and burst immunity

of the power supplies.

The FP filters considerably increase the source impedance

of the regulators superimposed interference, to a value

which is normally high in comparison to the impedance of

the source (

Line). The interference currents are therefore

practically independent of their source impedance. The fil-

ter will reduce these currents by approximately 25 dB at a

frequency of 150 kHz.

The interference voltages at the filter input are due to the

remaining interference currents flowing through the source

impedance. The resulting interference voltage reduction

can be seen in the following figure. For frequencies above

the regulator switching frequency the attenuation will in-

crease (up to 2 MHz approx.).

Parallel operation: When several switching regulator inputs

are connected in parallel, each regulator should be

equipped with a separate input filter. Interconnections

should only be made in front of the filter or at its input Uii

(i. e. the central ground point should be before or at the filter

and under no circumstances at the regulator input).

0123456

ZLine [Ω]

Source impedance

Interference voltage reduction

Att. [dB] inductive

resistive

capacitive 12009

Fig. 1

Interference voltage reduction with FP filters at f = 150 kHz

Electrical Accessory Products Filter & Ring Core Chokes

Edition 5/6.2000 3/5

Typical Application

The example in figure

Reduction of voltage interference by

FP filters

shows a switching regulator operating from a bat-

tery (

i < 0.5 Ω) with long supply lines (e.g. 2 m). The result-

ing superimposed interference voltage

SL may be meas-

ured at the regulators input. The connection of a filter in

front of the power supply will reduce this interference ac-

cordingly:

1. The regulator's source impedance is mainly inductive be-

cause of the low battery impedance and the long supply

lines. It can be calculated as follows:



Line ≅ 2 π•

S •

Line • 2 l



Line ≅ 2 π•(150 • 103) • 10-6 • 2 • 2 ≅ 3.8 Ω

S: Switching frequency (150 kHz)

Line : Supply line inductance (typically 1µH/m)

l : Length of single supply line (twice for posi-

tive and negative path)

Fig. 3

Reduction of voltage interference by FP filters

Vi+

Gi–

Vo+

Go–

PSR RL

Filter Uio

Uii

2 • l

ZLine

12011

2. This example shows, that with an inductive source im-

pedance of 3.8 Ω, the insertion of the filter results in an

interference voltage reduction of approx. 18 dB (see

fig.:

Interference voltage reduction with FP filters at f =

150 kHz

3. The original superimposed interference voltage will be

reduced by a factor of approx. 8:

SF =

SL • 10–18/20 [V]

Electrical Data Ring Core Chokes

General Condition:

A = 25°C unless otherwise specified

Table 3: Ring core chokes

Characteristics Conditions L 20-7/LP 20-7 LP 34-3 LP 183

min typ max min typ max min typ max Unit

Ln Rated current 1

= 0.75

o738A DC

LOhmic resistance 5 5.5 6 18 20 22 2×2.9 2×4.2 2×5.5 mΩ

oNo load inductance

L = 0,

C min...

C max 18 20 22 30 34 38 2×95 2×183 2×245 µH

DTI Current specific case 0.082 0.68 0.19 K/A2

temp. increase 1

AAmb. temperature 1

L =

Ln –40 106 –40 104 –40 98 °C

CCase temperature –40 110 –40 110 –40 110

SStorage temperature –40 110 –40 110 –40 110

1 If the choke is not operating at the rated current

Ln, the maximum ambient temperature

A max and the maximum direct current

L max

change according to the following equations:

L max =

C max –

A max

A max =

C max –

L2 max • DTI

DTI

Low-Loss Ring Core Chokes L/LP-Series

The ring core chokes, in combination with a capacitor, may

easily be used for application specific LC filters at the input

or output of switched mode power supplies. All chokes are

suitable for PCB mounting. They are either moulded into

plastic cases or isolated from the PCB by means of an iso-

lation pad.

Series L/LP 20-7 and LP 34-3 are intended for use as differ-

ential mode filters and the current compensated choke

LP 183 enables attenuation of common mode interference.

02 6412

8 10 14

100

LP 34-3

LP 183

L/LP 20-7

12012

L/Lo [%]

ILn

IL [A]

Fig. 4

Choke inductance versus current

Electrical Accessory Products Filter & Ring Core Chokes

Edition 5/6.2000 4/5

Input Interference Reduction

Using L- or LP-series chokes together with an additional

external capacitor a similar attenuation can be achieved as

with filter blocks. The capacitor between the choke and the

converter input is necessary in order to avoid possible oscil-

lations caused by the negative input impedance of the regu-

lator. This phenomenon could cause the input voltage to

leave the specified regulator input range. The relatively

high ripple current flowing through the capacitor must be

considered for the design. Refer also to:

Technical Informa-

tion: Installation & Application

The current compensated choke LP 183 has a high perme-

ability ring core with two identical separate windings. The

normal operating current will only see the small stray in-

ductance between the windings. However common mode

interference will be blocked by the full inductance of the

choke.

Fig. 7

Low-loss ring core choke with external capacitor (Cex

approx. 1000

F) used as output filter

Reduction of Output Ripple

Even though switching regulators have an inherently low

output ripple, certain sensitive applications need even fur-

ther reduction. In such cases, the low-loss ring core chokes

designed to reduce disturbances at the input can also be

used for reducing the ripple on the output voltage. The

chokes in combination with an external capacitor can

achieve even better results than the Filter Blocks with re-

gard to the ripple and dynamic regulation.

The formula for the remaining output ripple at the load

L is

calculated as follows:

R =

o •

Cex/

o: Output ripple of the regulator

Cex: The impedance of the capacitor at the regu-

lator's switching frequency (150 kHz) corre-

sponds to the equivalent series resistance

(ESR) of the capacitor (please refer to the

corresponding data sheet).

LD =2 π •

S •

S: 150 kHz (regulator switching frequency)

Through the use of a common mode choke LP 183, the

common mode noise at the output can also be further re-

duced.

Consider that the filter not only affects the output ripple but

can also influence the voltage

R across the load

L in the

event of load changes. The static regulation increases with

the ohmic resistance of the choke, i.e. 6 mV/A for the choke

L/LP 20-7 and 20 mV/A for the LP 34-3.

The dynamic regulation is dependent on the size of the ca-

pacitor. Generally, the bigger

ex the smaller is the dy-

namic, however, recovery will be slower.

Typical Application

A voltage drop

rGo =

Go • (

o –

i) is produced across the

ground loop resistance

Go. It is superimposed upon the

regulators output voltage

o and generates the voltage

o –

r Go across the load resistance

L. Without an input

inductance

e the current

i in the input circuit has a rela-

tively high AC component with a basic frequency

s (regula-

tor's switching frequency of approx. 150 kHz). This alternat-

ing current produces an AC voltage component across

which is superimposed upon

RL.

To prevent this phenomenon, an inductance

e can be in-

serted into the input circuit. This causes the AC component

of the input current to be supplied entirely from the input

capacitor

e; thus,

i is a pure direct current.

e should be

wired as close as possible to the regulator's input terminals

Vi+ and Gi–.

e and

e additionally provide protection against input tran-

sients and reduce radio interference voltages.

External connection of Gi– and Go– or connection via a

common ground is not recommended. The internal voltage

drop

rG in the regulator would be superimposed on the

output voltage.

Vi+

Gi–

Vo+

Go–

PSR C

12014

C ext

Fig. 5

L/LP type chokes and capacitors used as input filter

Vi+

Gi–

Vo+

Go–

PSR

Cext 1 Cext 2 Cext 3

LP 34-3 or

L/LP 20-7

LP 183 12013

UoRL

Vi+

Gi–

Vo+

Go–

PSR R

r G

r Go

12015

Fig. 6

Reduction of superimposed interference voltages in

grounded power supply systems, caused by ground loops

Electrical Accessory Products Filter & Ring Core Chokes

Edition 5/6.2000 5/5

Mechanical Dimensions

Dimensions in mm. Tolerances ±0.2 mm unless otherwise specified

Fig. 10

Differential mode choke LP 34-3, weight 7 g

Fig. 9

Differential mode choke L 20-7, weight 30 g

Fig. 11

Common mode choke LP 183, weight 7 g

38.1

47.5

13.7

22 ±1

3.6

7.5 ±1

ø 3.8

0.8

12017

2 x 5.08

17.5

±1

ø 1

5.08

M 2.5

ø 0.8

12018

–0.5

5.08

max 14.5

7.6

13.2 7.5

max 8

ø 0.9

12019

37.8

±0.5

ø1.3

±1

M 2.5

0.9 x 0.56

±0.5

min. 4.5

13.22

±0.5

(3.22)

3.66 10.16 15.24 (3.66)

16.6

±1

6.8

±1

Legend: b = 5.08 mm

1 = Uii (input)

2 = Uio (output)

3 = Gi (ground)

4 = Positioning pins

12016

Fig. 8

Filter blocks FP weight 30 g

European

Projection

Electrical Accessory Products Back Planes

Edition 5/6.2000 1/14

Back Planes for the T Series BPD Series

BPF Series

19"/3U Rack-Systems

•Easy configuration of telecom rectifiers, battery

chargers and power bus systems

•Provides controller function

• 1.6 kW maximum power

•Single or triple phase connection

•Redundant configuration possible

Table of Contents Page

Summary .......................................................................... 1

Type Survey and Key Data .............................................. 2

Functional Description...................................................... 2

Mains Input Section.......................................................... 4

Output Section ................................................................. 5

Summary

The back plane types BPF 1000 and BPD 1000 have been

designed for fast and simple set-up of 19" rack mounted

power supply systems powered by AC-DC converters of

the T series. Battery charger systems, telecom rectifiers

and modular power bus systems can easily be configured

with n+1 redundancy if required. Three T units can be

plugged into one back plane providing up to 1.6 kW output

power.

Since for such applications the status of the power bus is of

importance rather than the output status of a single AC-DC

converter, T units with option D should be choosen enabling

remote bus voltage sensing.

The back plane concept allows system assembly in next to

no time. When fitted in the rack all input and output termi-

nals are readily accessible from the rear. The AC input is

designed for single or 3-phase operation. The monitoring

signals and the control signal inputs and outputs are avail-

able from a screw terminal strip. System specific signal

combination is possible with different jumper settings. The

back plane fulfills in this way the function of a controller unit.

The layout of the back plane and the hot plug-in capability

of the AC-DC converters allow system expansion under

load (e.g. from 550 W up to 1.6 kW) by simply inserting fur-

ther T units into the rack. Larger system power extension is

just a matter of interlinking the DC output rails and signal

outputs of two or more racks.

The back planes are available in 2 basic versions:

– BPD 1000

A front-end version, fitted with decoupling diodes in each

positive line to the DC bus, for systems with 2 or more

T units in parallel or n+1 redundancy.

– BPF 1000

A battery charger version, in which each output is fitted

with a fuse in the positive line to the DC bus, for battery

charging or rectifier systems with two or more T units in

parallel or n+1 redundancy.

For minimum electromagnetic emission at the input, both

the BPD and the BPF versions are fitted with input filters.

Should project specific requirements demand enhanced

hold-up time or lower output ripple (low frequency ripple)

than specified for the individual AC-DC converters, both

basic back plane versions are available with additional out-

put capacitors.

Important: The neccessity to provide a cover over the

live parts at the mains input (High Voltage) or over the

DC bus bars (Energy Danger), preventing accidental

contact during installation, start-up of a system or main-

tenance, depends on the final installation as well as on

the applicable safety requirements. However, it is the re-

sponsibility of the installer or user to provide such a

safety cover to assure the compliance with the relevant

and applicable safety standards.

Page

Electromagnetic Compatibility (EMC) .............................. 7

System Integration ........................................................... 8

Mechanical Data ............................................................ 10

Safety and Installation Instructions ................................ 10

Electrical Accessory Products Back Planes

Edition 5/6.2000 2/14

Type Survey and Key Data

Table 1: Type survey

AC Input Input filters 1 Output capacitors Preload Application

85...255 V AC (reduced 100 Hz

1 or 3 phase (Y) output ripple) 2

BPD 1002 x ––Front-end, fitted with diodes

BPD 1003 x 90 mF –

BPF 1004 x –x Battery charger, fitted with fuses

BPF 1007 x 50 mF x

BPF 1006 x 90 mF x

BPF 1037 (∆) 3 x 50 mF x BPF 1007 in ∆ configuration

19” Rack, 3 U Rack for systems with up to 3 T units

1See also:

Electromagnetic Compatibility

2Please refer to:

Dimensioning Example of a Battery Charger System in Single Phase Connection

3Only for LT units and 120/208 V mains. See fig.:

Mains input arrangement

Functional Description

The back plane is divided into 3 sections, each one fitted

with an H15 female connector for one T unit, with the mains

input section and the DC output section separated from

each other.

The layout of the standard back planes gives the user the

flexibility to operate the system either in single phase or

in 3-phase (Y) configuration. Connection to the mains is

achieved via the 6-pole connector (X1). With the wire jump-

ers B10/20/30 in Y-position (standard configuration) each

T unit is connected between its defined input line and the

neutral. (Changing of the configuration by the customer is

not recommended.) An input filter, provided in the supply

line to each T unit minimizes the conducted noise at the in-

put of the system. The positive output of each T unit is

separately fed to the common power bus and is decoupled

depending upon the back plane type, either by a fuse (F11/

21/31) or by a decoupling diode (D11/21/31). The fuses

(cartridge type) are externally accessible from the frontside.

The BPF versions are fitted with a common preload (R25).

Additional output capacitors (up to 3 per output,10 mF

each) further reduce the low frequency output ripple and

provide enhanced hold-up time.

All relevant monitoring signals as well as control signal in-

puts and outputs are accessible at the signal terminal strip

(X5). The jumper strip (X3) allows system specific signals

according to different jumper settings. An auxilliary cir-

cuit (protected by a fuse F1, rated T1A, 250 V, 5 × 20 mm)

allows a relay to be directly driven for system specific con-

trol functions.

Each T unit provides an individually adjustable power down

signal enabling bus status monitoring at different voltage

levels. The threshold values can be set at the soldering tabs

set (R13/14, R23/24 and R33/34).

Note: If a power system is operated with 3 T units per back-

plane, connection to the mains in a 3-phase configuration

(Y or ∆) will provide equal load distribution on the input

lines. Furthermore the low frequency ripple at the output of

the T units is compensated to zero as long as all 3 T units

are in operation.

Electrical Accessory Products Back Planes

Edition 5/6.2000 3/14

Input filter Input filter Input filter

Fuse F1(auxiliary circuit)

Bus bar system Output capacitor (10 mF, each)

set

Preload (<10 W)

Signal terminal strip X5

Jumper strip X3

Mains input connector X1

Connector H15 for T unit

–

Output fuse

B30

B20

B10

03012

R33 R34

F31

R23 R24 R25

F21

R13 R14

F11

D31 D21 D11

Decoupling

diode

Fig. 1

Back plane, view from the rear

++ +

Vo+

Vo–

D set

Sys In

Sys out

F11

F31

CCC

D31

D21

D11

RPT

–

Vo+

Vo–

Vo+ (BUS)

Sys In 2

Sys In 3

Sys In 1

F21

Vo+

Vo–

D set

Sys In

Sys out

Vo+

Vo–

D set

Sys In

Sys out

R13

R23

R33

R14

R24

R34

03013

DC-Bus

B10

B20

B30

T unit 1

T unit 2

T unit 3

R25

Fig. 2

Block diagram of back plane

F11, 21, 31 fitted to BPF types. D11, 21, 31 fitted to BPD types.

Electrical Accessory Products Back Planes

Edition 5/6.2000 4/14

Phase to Phase Configuration

With standard back plane version (Y-configuration)

For LT units exclusively

The layout of the standard back planes also allows phase to

phase connection at low mains voltage 208 V e.g. USA, pro-

viding full output power from the LT units. In such cases one

of the two input lines (L1 or L2) should be connected to the

N-terminal at the AC input connector instead of the neutral

line. The neutral line is not connected. For safety reasons

an external fuse should be fitted in each input line. Connec-

tion to the ground is mandatory.

Fig. 5

Phase to phase configuration L1, L2

120/208 V mains (e.g. USA): LT types only.

Not applicable for UT types.

Control circuit

Go–

Vo+

Gi–

Vi+

Input Filter

03019

Mains Input Section

Connection to the Mains

Connection to the mains shall be made via the 6-pole screw

terminal connector (X1), located on the right hand side of

the back plane (view from the rear).

For single phase operation the terminals (L1, L2 and L3) at

the female connector X1 should be connected together.

The T-series has two AC input voltage ranges. The LT units

are optimized for the 230 V mains, the UT units for the

120 V mains. (See also:

T series

)

Table 2: Mains input arrangement

Mains voltage Single phase 3-phase (Y) Phase - phase (∆) 3-phase (∆)

Phase-Earth/Phase-Phase L, N, L1, L2, L3, N, L1, L2, L1, L2, L3,

230/400 V LT types LT types Not allowed Not allowed

120/208 V LT types LT types only With special back plane

UT types External fuses required BPF 1037 and

LT types only

Single-phase/3-phase (Y) Configuration

Standard back plane version (Y-configuration)

The layout of the standard back planes allows operation of

the system either in single phase or in 3-phase (Y) configu-

ration. In both configurations each T unit on the back plane

is connected between its defined phase and neutral. For

single phase operation the AC-input terminals (L1, L2 and

L3) should be connected together at the female connector.

Connections to neutral and to ground are mandatory. (See

also fig.:

Single phase configuration

as well as fig.:

3-phase

(Y) configuration

.) Equal load distribution on the input lines

at 3-phase configuration will compensate the low frequency

ripple at the output to zero.

Control circuit

Vo–

Go+

Vi–

Gi+

Input Filter

R (option)

i (option)

–U

03017

Option P

Control circuit

Option P

Go–

Vo+

Gi–

Vi+

Input Filter

Option L

D (option)

I i

Option C

03018

Option D

Fig. 3

Single phase configuration L, N

230 V mains: LT-types

Fig. 4

3-phase (Y) configuration L1, L2, L3, N

230/400V mains: LT-types

120/208V mains: UT-types, LT-types 1

1 Reduced output power with LT types

Electrical Accessory Products Back Planes

Edition 5/6.2000 5/14

3-phase (∆) Configuration

With special back plane version BPF 1037 (∆-configura-

tion) for LT units exclusively

Low mains 120/208 V

The input section of the 3 LT units is wired in a ∆-connec-

tion enabling full output power of the LT units at low mains

input voltage 120/208 V.

Back planes in 3-phase (∆) configuration are available on

request. Modifications to the back plane in the field from "Y"

to "∆"-configuration (and vice versa) are not recommended.

Maximum nominal input voltage: 230 Vrms + 10%, phase to

phase. Higher input voltages may damage the LTs as well

as the back plane. Connection to the mains should strictly

be done according to fig.:

3-phase (

) configuration

. Wrong

connection at the input may damage the LT units as well as

the back plane. An external fuse needs to be installed into

each input line.

Fig. 6

3-phase (

) configuration, L1, L2, L3

120/208 V mains (e.g. USA) LT types only.

Not applicable for UT types.

04020

∆

Output Section

Power Bus

The back plane is fitted with a generously dimensioned bus

bar system. Each bus bar (4 mm thick Alu alloy profile, iden-

tified with its polarity) is fitted with 2 captive nuts (M 6) serv-

ing as connection points to the load as well as to the battery

system. Depending upon the application either the positive

or the negative pole of the battery may be earthed.

For application specific requirements such as reduced rip-

ple current, reduced low frequency ripple voltage, enhan-

ced hold-up time or heavy pulse loads, the back planes are

available with additional output capacitors (see table:

Type

Survey)

. The output capacitors are mounted between the

positive and the negative bus rails.

Front-end Version

To provide maximum system reliability especially with n+1

redundant systems, each positive output path is fitted with a

decoupling diode mounted onto the positive bus rail. The

diodes D11, D21 and D31 prevent a possible Power Down

on the power bus in the case of a short-circuit across the

output of one of the T units. To maintain the signalling func-

tions of the T unit(s) in the case of a single inhibit or a single

mains phase failure, a PTC in parallel to the decoupling di-

ode allows a small reverse current from the DC bus supply-

ing the control functions of the affected T unit.

Battery Charger Version

Direct battery charging or powering battery buffered sys-

tems require an adequate float charge voltage over the

specified temperature range. Decoupling diodes should be

avoided due to their voltage drop, affecting the float charge

voltage of the battery. To maintain system redundancy

adequatedly rated fuses (F11, F21 and F31, rated F20A

minimum, 250 V, 6.3 × 32 mm each) are mounted in each

positive output line. In the case of a short circuit across the

output of one of the T units the relevant fuse will blow, inter-

rupting the reverse short circuit current supplied by the bat-

tery and the remaining T units.

Power Down Signal (D1, D2, D3)

The power down signal monitors the voltage level of the bus

bar system. Depending upon the application it may be ad-

vantageous to use the power down signal D1 and D2 in a

redundant configuration and the third signal (D3) as a sepa-

rate warning signal at a higher threshold level. For such a

configuration the jumpers of X3 should be set in the posi-

tions ∑D - D1 and ∑D - D2. (See fig.:

Jumper strip (X3), Sig-

nal meshing.

)

For individual adjustment of the power down level see also:

System Integration

Inhibit

The output of a T unit may be enabled or disabled by the

inhibit input signal. Moreover the output voltage can be

controlled with an external temperature sensor connected

to this input. If just the inhibit function is used, the units can

be individually inhibited. If the output voltage is temperature

controlled the same sensor signal should control all units in

the rack and the jumpers of X3 should be set in all 3 inhibit

positions, ∑i – i1, ∑i – i2 and ∑i – i3 (See fig.:

Jumper strip

(X3), Signal meshing

System Good Signal (Sys In 1, 2, 3/Sys Out 1, 2, 3)

The System Good signal can be used either for status

monitoring of each individual T unit or as a combined signal

for status monitoring of the whole system. For overall sys-

tem status monitoring jumpers should be set in the posi-

tions Si1-So2, Si2-So3 (See fig.

Jumper strip (X3), Signal

meshing

The System Good input of the first T unit in a system (T3)

should be referenced to the negative output. This can be

done either on the jumper strip X3 with a jumper in position

⊥-Si3 (See fig.:

Jumper strip (X3), Signal meshing.

) or

directly at the terminal strip X5, by connecting Sys In 3 to

Vo–. (See also:

System Integration

Electrical Accessory Products Back Planes

Edition 5/6.2000 6/14

F 1

T1A, 250 V

Vo+

Vo–

∑D - D1

∑D - D2

∑D - D3

∑D - Si3

∑i - i1

∑i - i2

∑i - i3

Si1 - So2

Si2 - So3

- Si1

- Si2

- Si3

Vo+

i1/Ucr

i2/Ucr

i3/Ucr

Sys Out 1

Sys Out 2

Sys Out 3

Sys In 1

Sys In 2

Sys In 3

Vo–

i1/Ucr

i2/Ucr

i3/Ucr

Sys Out 1

Sys Out 2

Sys Out 3

Sys In 1

Sys In 2

Sys In 3

05029

Vo–

Fig. 7

Jumper strip (X3), signal meshing

Table 3: Terminal strip X5

Connector X5 Signal allocation Description

1Vo–Supply Vo-

2 Sys In 3 Sys Good input T3

3 Sys In 2 Sys Good input T2

4 Sys In 1 Sys Good input T1

5 Sys Out 3 Sys Good output T3

6 Sys Out 2 Sys Good output T2

7 Sys Out 1 Sys Good output T1

8 i3/Ucr Inhibit T3/Ucr

9 i2/Ucr Inhibit T2/Ucr

10 i1/Ucr Inhibit T1/Ucr

11 D3 Power Down T3

12 D2 Power Down T2

13 D1 Power Down T1

14 Vo+ Supply Vo+

Interface for Remote Signalling and Control

A signal terminal strip (X5) allows interfacing with the cus-

tomer‘s control system.

Each of the signals can be made available as an individual

signal or as a combined signal.

Electrical Accessory Products Back Planes

Edition 5/6.2000 7/14

Electromagnetic Compatibility (EMC)

Conducted Emission

The battery charger units can be operated in 3 different

modes, depending on the load:

–Output voltage regulation

–Output power limitation

–Output current limitation