Mechanical Accessory Products Front Panels Front Panels Description Front panels are available for 19" rack mounting of 3 U cassette type power supplies in Schroff system version (Intermas 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 HE instead of U is used.) Tolerances 0.2 mm, unless otherwise specified Schroff System for 3 U Rack 2.50.1 6.4 0.1 Q-, PC-, P-, R Series Front Panels in 4, 5 or 6 TE 9.5 12002 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 G04-Q01 HZZ 00835 P R 5 25.1 Q01 Q Q03 PC Q04 P R 6 30.2 Q01 Q Q03 PC Q04 P R G04-Q04 HZZ 00840 G05-Q01 HZZ 00836 G05-Q04 HZZ 00841 G06-Q01 HZZ 00839 G06-Q04 HZZ 00842 Note: For use of several units next to each other, we advise to pack them not too densely in order to assure good thermal management (see also relevant data sheet). Table of Contents X 9.2 0.1 Q04 Q04 only Q PC 4 13 104 0.1 Q01 Q03 50 Type Part no. 20.6 20.0 Converter series 13 4 Case size 0.2 mm 128.4 122.4 X TE Fig. 1 Front panel for Q case size Delivery contents: Front panel, grey plastic handle, three countersunk screws, set of two plastic retainers with captive screws and assembly instructions. Page Page Description ....................................................................... 1 Schroff System for 3 U Rack ............................................ 1 Intermas System for 3 U Rack ......................................... 4 Schroff System Kit for 6 U Rack ....................................... 4 Edition 5/6.2000 1/4 Mechanical Accessory Products Front Panels H- and M Series Front Panel in 8 TE 2.5 0.1 31.5 0.1 4.4 0.1 9 12003 This front panel fits to all 50 Watt DC-DC and AC-DC converters 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. 40.3 Case size Converter series Type Part no. M02 M H02 H G08-M02 HZZ 00802 4 26 94.5 0.1 8 mm 128.4 122.4 TE 50 Table 2: H02 and M02 case front panel selection 0.2 18.2 0.1 Delivery contents: Front panel with grey plastic handle, two countersunk screws, set of two plastic retainers with captive screws and assembly instructions 40.3 (8 TE) Fig. 2 Front panel for H02 and M02 case size PSL- and SR 20E Series Front Panel in 8 TE 18.4 0.1 2.5 0.1 7 12004 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 Type Part no. 8 40.3 L04 PSL 1 L01 SR20E G08-L HZZ 00805 12.2 26 100 0.1 Converter family 50.5 Case size 85 mm 128.4 122.4 Exception: PSL with option D is part no. G08-L04-D, HZZ 00816 Option D 1 Delivery contents: Front panel with grey plastic handle, two countersunk screws, set of two plastic retainers with captive screws and assembly instructions. 0.2 Note: This front panel is a compatible replacement for all earlier versions of the same size, published in any previous front panel data sheet. 40.3 (8 TE) 11.7 0.1 1 TE Fig. 3 Front panel for L01 and L04 case size Edition 5/6.2000 2/4 Mechanical Accessory Products Front Panels PSS and S Series Front Panels in 12 TE PSK and K Series Front Panels in 16 TE 2.5 0.1 27.4 0.1 12005 4.4 0.1 9 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...LSand A...LK Series with case size S02 or K02 according to the selection table below: mm Case size Converter series Type Part no. 12 60.6 S01 PSS G12-S HZZ 00845 16 81.0 S02 S K01 PSK K02 K 4 29 103 0.1 X 128.4 122.4 TE 50 Table 4: S and K case front panel selection G16-K HZZ 00831 9.7 0.1 0.2 Delivery contents: Front panel with grey plastic handle, two countersunk screws, set of four plastic retainers with captive screws and assembly instructions. X Fig. 4 Front panel for S01, S02, K01 and K02 case size T Series Front Panel in 28 and 26 TE 26.2 0.1 81.8 0.1 56.7 29 2.5 0.1 12006 This front panel fits to all 500 Watt AC-DC converters of the T Series with case size T01. 141.9 Converter series Type Part no. T01 T G28-T01 HZZ 00837 Delivery contents: Front panel with two grey plastic handles, three countersunk screws, set of four plastic retainers with captive screws and assembly instructions. 103 28 Case size 50 mm 128.4 122.4 X TE 9 Table 5: T case front panel selection X 9.7 0.1 G28-T01-blank met HZZ 00847 with metal screw retainers G28-T01-blank plas HZZ 00848 with plastic screw retainers 0.2 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. Fig. 5 Front panel for T01 case size Edition 5/6.2000 3/4 Mechanical Accessory Products Front Panels Intermas System for 3 U Rack 16.5 12007 2 0.1 The major differences between the Intermas and the Schroff system front panels are the thickness (2 mm instead 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. 0.6 The following Intermas front panels are available on request: Table 6: Intermas front panel selection TE mm Case size Converter series Type Part no. 8 40.3 H02 H M02 M F08-M02 HZZ 00702 8 40.3 L01 PSL 1 L04 SR 20E 12 60.6 S01 PSS S02 S K01 PSK K02 K 16 1 81.0 Option D1 F08-L HZZ 00705 16.5 X F12-S HZZ 00732 F16-K HZZ 00731 X Fig. 6 Intermas system front panel (various case sizes) Exception: PSL with option D is type/part no. F08-L04-D, HZZ 00716 2.5 0.1 12008 Delivery contents: Front panel with grey plastic handle, two countersunk screws and assembly instructions. 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. Table 7: 6 U assembly kit selection X TE mm 5 25.1 8 40.3 12 60.6 16 81.0 Case size Converter series Type Part no. Kit-G05-6HE-Q01 HZZ 00838 Q01 Q Q03 PC H02 H M02 M S01 PSS S02 S K01 PSK K02 K 261.8 255.8 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: Support bracket Kit-G08-6HE-M02 HZZ 00804 Kit-G12-6HE-S HZZ 00833 Kit-G16-6HE-K HZZ 00832 0.2 Delivery contents: Double height front panel with two grey plastic handles, four countersunk screws, set of two plastic retainers with captive screws, a support bracket and assembly instructions. X Fig. 7 Front panel for 6 U configuration (various case sizes) Edition 5/6.2000 4/4 Mechanical Accessory Products Mounting Supports Mounting Supports for Chassis-, DIN-Rail- and PCB Mounting 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 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 converters. The Universal Mounting Bracket also fits to most of these cassette type converters, allowing for either vertical chassis- or DIN-Rail mounting. A Bracket Kit, consisting of a PCB with screw terminal connectors and a bracket suitable for either Chassis- or DINRail 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 double sided PCB, the use of Isolation Pads is recommended, as described below. A 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. Table of Contents Page Page Description ....................................................................... 1 Chassis Mounting Plates .................................................. 2 DIN- and Chassis Mounting Brackets .............................. 4 Universal Mounting Bracket ............................................. 9 Isolation Pads for PCB Mounting ................................... 11 PCB-Tags for PCB Mounting .......................................... 11 Flexible H11 PCB ........................................................... 11 Edition 5/6.2000 1/11 Mechanical Accessory Products Mounting Supports 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 according to the following table and figures 1 to 3. Table 1: Mounting Plate survey Converter Type series Part. no. K02 K1 S02 S1 Q01 Q Q03 PC Q04 P Q01 Q Q03 PC Q04 P M02 M H02 H Delivery content Mounting plate K02 Mounting plate HZZ 01213 and 4 countersunk screws Mounting plate Q HZZ 01215 Mounting plate M HZZ 01210 Mounting plate, 4 countersunk screws and 4 washers Option B1 necessary 133 16.3 115 25.5 6.5 4.5 European Projection 12020 6 1 Case size 11.2 M3 x 6 Washer 103.5 18.5 128 140 4.5/9 x 90 127 166 19.5 3 Fig. 1 Mounting plate M Aluminium, black finish Edition 5/6.2000 2/11 Mechanical Accessory Products Mounting Supports 11.2 12021 7.5 6.5 13 140 125 M4 x 10 17.3 133.4 168 Option B1 necessary for K and S family 5 30 Fig. 2 Mounting plate K02 Aluminium, black finish 168 4.5 12022 4.5 M3 x 6 6 18 140 1040.1 128 3.6/7.5 x 90 115 12701 115 26 20 16.8 3 14 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. Edition 5/6.2000 3/11 Mechanical Accessory Products Mounting Supports 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 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 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 [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 (Ui max 40, 60, 80 V) CMBA01-iRY/80 HZZ 00607 DMB A01-iRY/80 HZZ 00606 PSA (Ui max 144 V) CMBA01-iRY/144 HZZ 00609 DMB A01-iRY/144 HZZ 00608 PCB, screw teminal blocks, 4 diodes, capacitor C1 and C- or D-bracket with screws 72.5 67.5 2"x 2" IMR 6, IMR 15 IMP 6, IMP 12 CMB2x2-BCFG HZZ 00605 DMB 2x2-BCFG HZZ 00603 50.0 45.0 DIL 24 IMP 3 IMX 4 Option K CMB3W-123 HZZ 00604 DMB 3W-123 HZZ 00602 72.5 67.5 1"x 2" IMX 7 IMS 7 CMB IMS/X 7 HZZ 00617 DMB IMS/X 7 HZZ 00613 PCB, screw teminal blocks, and C- or D-bracket See Basic Kit C/DMB IMX/S 7 A1 4 12023 4 3.2 60 83 85 11.5 12024 38 13.3 A2 12 Fig. 4 "CMB" chassis mounting bracket dimensions Bracket: Aluminium, black finish Fig. 5 "DMB" DIN-rail mounting bracket dimensions Bracket: Polycarbonate, black Edition 5/6.2000 4/11 Mechanical Accessory Products Mounting Supports 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, including 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 Exception: Input voltage for PSR 54 (PSA 55) is 20 Vrms. PSR 54 (PSA 55) and PSR 362 require an additional capacitor (C2) of at least 470 F. X1 - 1 12025 D1 1 X1 Vi Gi i 1 X2 G R Go Vo R1 Fig. 6b C/DMBA01- .. print layout D3 Vo Go Gi D2 Input - AC-input: The recommended transformer secondary voltage is 48 Vrms for PSR and 72 Vrms for PSA (Ui max 144 V) + C2 + C1 D3 D4 D1 D2 Output - DC-input: Consider the forward voltage drop across the rectifier diodes (also providing reverse polarity protection). Capacitor C1 compensates the negative converter input impedance in case of long connection wires to the module. MB A01-iRY 12026 This bracket is designed for non-isolated Switching Regulators 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 voltage 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 device can be driven either from a DC-source or from a transformer secondary voltage. D4 C2 + C1 X1 - 4 PSR/PSA A01-iRY + Vi X2 - 3 X2 - 2 R1 R i X2 - 1 X1 - 3 X1 - 2 Fig. 6a C/DMBA01- .. circuit diagram Edition 5/6.2000 5/11 Mechanical Accessory Products Mounting Supports C/DMB2x2-BCFG Electrical Description 12029 This bracket allows the mounting of isolated DC-DC converters 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. Gi Output X1 2 SD 4 Vi 3 X2 Depending on the application input transient protection may be incorporated (e.g. an appropriately dimensioned Transzorb diode D1). MB 2x2 BCFG Input 2 1 12027 X1 - 4 Vo (Vo+) Vi D1 IMR 6 IMR 15 IMP 6 Gi IMP 12 (Go) X1 - 1 X1 - 2 X1 - 3 SD Go (Vo-) X2 - 1 D1 X2 - 2 X2 - 3 X2 - 4 Fig. 7b C/DMB2x2-BCFG print layout Fig. 7a C/DMB2x2-BCFG circuit diagram C/DMB3W-123 Electrical Description 12030 Depending on the application input transient protection may be incorporated (e.g. an appropriately dimensioned Transzorb diode D1) . X1 - 2 X1 - 4 20 1 2 IMP 1 IMP 3 IXP 3 D1 X1 - 1 SD Vi+ Vi+ 23 24 ViVi- Vo+ Vo13 Vo2 Vo+ 15 Go2 16 com com Go+ 11 10 9 Vo1/Vo- 12 12028 X2 - 4 MB 3W-123 Input Output 1 3 4 X2 2 X1 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. D1 1 4 3 2 1 Fig. 8b C/DMB3W-123 print layout X2 - 3 X2 - 2 X2 - 1 Fig. 8a C/DMB3W-123 circuit diagram for all pin configurations Basic Kit CMB IMX/S 7 Basic Kit DMB IMX/S 7 For use with 1"x 2" DC-DC converter types: IML 10, IMS 7 and IMX 7 Part No.: HZZ 00617 For use with 1"x 2" DC-DC converter types: IML 10, IMS 7 and IMX 7 Part No.: HZZ 00613 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 (2x 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. YSK 25300 S3 01 The basic kit contains the following: - DIN-mounting support for 35 mm DIN-rail systems - PCB ZGN 09601 A - Three 2-pole terminal blocks (2x 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. YSK 25300 S3 01 Edition 5/6.2000 6/11 Mechanical Accessory Products Mounting Supports Mounting Instructions for Basic Kit Application specific circuitry Single output units IML 10, IMS 7 and IMX 7 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. - 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 Uo adjustment by e.g. an external voltage source) 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: - Solder the selected DC-DC converter a) Uo - adjustment in the range of 70/75...100% of Uo nom by resistors RX3 or RX4 or combinations of RX3/RX4. - Mount PCB onto rails by using the 4 screws and nuts or snap PCB onto the DIN mounting support. b) Uo - adjustment in the range of 100...105% of Uo nom by resistors RX1 or RX2 or combinations of RX1/RX2. - Perform function test Double output units: Double output units IML 10, IMS 7 and IMX 7 a) Uo - trimming by resistor R2 in the range of 100...105% of Uo nom - 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) - Reduced output ripple (by approx. factor 5) by using chokes L3/L5 together with electrolytic capacitors C8/ C9. - For applications with the 2 outputs in parallel: 4. Place/solder jumpers B4 and B5, (5.08mm) - Improved electromagnetic emission EN 55022, level B, lead length to load 1 m. (Level A for 110 IMX 7 types) - 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 b) Uo - trimming in the range of 70/75...100% of Uo nom by a current diode together with a Zener diode D2 applicable for 24/48 IMS 7 and 20/40 IMX 7 types. This requires all capacitors and output chokes as per circuit diagram YSK 25300 S3 /01 whereby the coupling capacitor C10 connected to Vi- via jumper B2 is foreseen 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 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 SELV Application specific assemblies are available on request. Edition 5/6.2000 7/11 Mechanical Accessory Products Mounting Supports IMX 7 IMS 7 12036 X1 D1 BYV27-200 L1 + L2 - A nc 1 + Vi X1 i X1 C3 470n 63V Vo2+ 12 [Vo-] 3 R2 R D2 ZPD 16V 4 C4 1u 63V i Vo1+ 11 [Vo+] R [nc] B2 B3 L4 - A C5 470n 63V RX4 + R1 B5 RX3 D3 E - 2025N B1 Vi - RX2 2 L2 - B L3 Vo2+ 13 [R] RX1 X1 - 100 100 V 14 Vi + C2 150n 250V C11 X2 C6 1u 63V L4 - B Vo1- 10 [Vo-] X2 - L5 L6 - A C7 470n 63V B4 X2 + C8 + 180u Vo2 50V L6 - B X3 + C9 + 180u 50V Vo1 X3 - [ ] = Single Output Version C10 Ker Y2 4n7 250V C11 Y2 47n 250V C12 Y2 60n 250V 1 Fig. 9a C/DMB IMX/S 7 circuit diagram Valid for 24/48 IMS/IML and 20/40 IMX for 70 IMX use 150 V type for 110 IMX use 200 V type 12037 Input X1 IMS/X 7 Output X3 Vo1- (Vo-) R (n.c.) Vo1+ (Vo+) i Vo2- (Vo-) Vi- Vo2+ (R) Vi+ n.c. X2 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. Edition 5/6.2000 8/11 Mechanical Accessory Products Mounting Supports 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 case size Converter series L01, L04 SR, PSL H02, M02 H, M Q01, Q03, Q04 Q, PC, P Chassis-mounting DIN-mounting Delivery content Part number UMB-LHMQ UMB-LHMQ Alu-profile, two screws and HZZ00610 a DIN-rail clamp with screw 12031 49 4 7.5 14 M4 Fig. 10 DIN-rail clamp Steel, galvanized 12032 168 84 127 158 20.5 5 20 29 20.5 5 Fig. 11 "UMB" universal mounting bracket dimensions Aluminium, untreated Edition 5/6.2000 4.5 5.5 10 5 4 3 14 M4 (3x) 9/11 Mechanical Accessory Products Mounting Supports UMB-W... (Shock resistant, DIN- and Wall Mounting) 8 4.2 18 12055 For the DIN-rail snap-fit "Convert" Front End Line, two different mounting bracket sets are available on request. One set for wall mounting, the other for an additional shock resistant fixing to the DIN-rail in applications with higher vibration levels. 3 33 0.5 49 Fig. 12 Table 4: Mounting Bracket survey Converter case Converter series Wall-mounting W01 W UMB-W DIN-mounting Shock resistant UMB-WDIN Delivery content Part number Two clamps, four countersunk screws M4, washers and spring washers HZZ 00618 in preparation 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, 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 5: Mounting bracket survey Case size Converter Type series Part number S01 S02 K01 K02 PSS S PSK K DMB-K/S HZZ 00615 M02 H02 Q01 M H Q DBM-MHQ HZZ 00619 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 size Converter Type series Part number S01 S02 PSS S HZZ 00616 Edition 5/6.2000 CMB-S 10/11 Mechanical Accessory Products Mounting Supports Isolation Pads for PCB Mounting Table 7 : Isolation Pad survey 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. Case size Converter Isolation pad series Dimensions [mm] Part number A01 PSR, PSA Isolation A 70 x 50 x 0.3 HZZ 01203 B02 PSB Isolation B 107 x 71 x 0.3 HZZ 01205 C01 C03 xSR 20 PSC Isolation C 152 x 86 x 0.3 HZZ 01206 2"x 2" IMR 6/15 Isolation 2"x 2" 53 x 53 x 0.3 PCB-Tags for PCB Mounting 12035 1 17 5 7 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. PCB Tag 10 pieces HZZ01204 1 5 Type: Delivery content: Part number: HZZ 01207 5.08 Fig. 13 PCB-Tag 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: Part number: H11 Flexi-PCB HZZ01208 3.81 24,5 21.3 5.08 12034 7.62 83.82 Fig. 14 H11 Flexi-PCB Edition 5/6.2000 11/11 Mechanical Accessory Products Rack Systems 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 19" and 23" (IEC 60297-1, -2 and -3) 485 mm (for 19") 465.1 mm (for 19") 450 mm (for 19") 19" = 482.6 mm 23" = 584.2 mm 6.35 mm 6.35 mm n * U, U = 13/4" = 44.45 mm 1U 1U 12056 1 TE 1 TE = 2/10" = 5.08 mm 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 HE instead of U is used.) Tolerances 0.2 mm, unless otherwise specified Edition 5/6.2000 1/2 Mechanical Accessory Products Rack Systems Metric (IEC 60917) 485 mm 465 mm 450 mm 482.6 mm (19") n * 25 mm 1 SU = 25 mm 12057 5 mm 5 mm Fig. 2 Metric rack systems Edition 5/6.2000 2/2 Electrical Accessory Products Mating Connectors Mating Connectors H11 H15 H15 S4 Description All 19" cassette type converters are equipped with either H11-, H15-, H15 S2 or H15 S4 male connectors. Mating female 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 possibilities. Modules with high output current normally use two contacts in parallel to keep the voltage drop across the connector as low as possible. H11 Connector This connector has eleven contacts in one vertical column marked 2 to 32. Mating and mounting conditions are according to DIN 41612. The connector contacts are hardsilver-plated and correspond to quality class 1, with respect to electrical and mechanical life time. Table 1: H11 Connector Survey Female connector type Part no. Description of terminals STV-H11-F/CO HZZ 00101 Faston straight 6.3 x 0.8 mm yes STV-H11-FS/CO HZZ 00104 Faston straight 6.3 x 0.8 mm, solderable (short moulding) yes STV-H11-FSR/CO HZZ 00102 Screw terminals, 90, 2.5 mm2 (AWG 13) max, yes 1 HZZ 00103 Solder pin 5.2 mm, 1.6 mm yes HZZ 00113 Solder pin 4.3 mm, 1.0 mm yes STV-H11-FB/CO STV-H11-FBER/CO 2 STV-H11-FP/CO 2 STV-H11-FBG/CO 2 1 2 Integrated coding HZZ 00111 Press fit 6.5 mm, 1.0 mm yes HZZ 00199 Solder pin 5.2 mm, 1.6 mm, gold-plated contacts yes See also matching Flexi-PCB for PCB mounting of converters (see Mounting Supports) Available on request This connector type (male version) is used in the following converter series (case size): H (H02), M (M02), SR (L01) and PSL (L04). Table of Contents Page Page Description ....................................................................... 1 H11 Connector ................................................................. 1 H15 Connector ................................................................. 3 H15 S2, H15 S4 Connector ............................................. 4 Technical Data .................................................................. 5 Code Key System ............................................................ 6 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 Edition 5/6.2000 1/7 Electrical Accessory Products Mating Connectors Mechanical Dimensions All dimensions in mm, tolerances 0.2 mm unless otherwise specified European Projection 95 90 10 x 7.62 = 76.2 7.62 8.5 10.7 12042 Fig. 1 H11 frontal view, relating to figures below 84.8 Coding wedge 4 2 5 I 8 H 11 14 17 G 20 23 F 26 Fig. 2 STV-H11-F/CO, Faston cable terminals 6.3 x 0.8 mm 5.5 7.4 11.5 6.3 x 0.8 31.3 6.5 K 2.90.3 12038 H G F 2.90.3 Fig. 3 STV-H11-FS/CO, Faston cable terminals 6.3 x 0.8 mm, solderable (short moulding) 7.3 I 25.8 K 6.3 x 0.8 11.5 12043 11.5 12044 17 20 23 26 29 32 Fig. 4 STV-H11-FSR/CO, screw terminals (max. 2.6 mm 2/AWG 13) X 12045 14 2.9 0.3 11 F 2.90.3 8 G 19.8 5 H 11.5 2 I 10.9 K 8 11 14 17 20 23 26 29 32 10 x 7.62 = 76.2 900.1 Y 5.08 5 0.3 2 5.08 2.80.1 5.63 Fig. 5 STV-H11-FB/CO, soldering pins X = 5.2 Y = O 1.6 STV-H11-FBG/CO, soldering pins X = 5.2 Y = O 1.6 STV-H11-FBER/CO, soldering pins X = 4.3 Y = O 1.0 STV-H11-FP/CO, press insert pins X = 6.5 Y = O 1.0 Footprint for PCB-layout Edition 5/6.2000 2/7 Electrical Accessory Products Mating Connectors H15 Connector This connector type (male version) is used in the following converter series (case size): 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. PSS (S01), S (S02), Q (Q01) and for PSK (K01) and K (K02) only for output current 18 A. Table 2: H15 Connector Survey Female connector type Part no. Integrated coding STV-H15-F/CO HZZ 00106 Faston straight 6.3 x 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 1 HZZ 00117 Press fit 4.5 mm, 1.0 mm (double pin version) yes HZZ 00197 Solder pin 4.0 mm, 1.6 mm, gold-plated contacts yes HZZ 00114 Solder pin 10.1 mm, 1.6 mm, 90 bent contacts yes STV-H15-FBG/CO 1 STV-H15-FWS/CO 1 Description of terminals Available on request Mechanical Dimensions All dimensions in mm, tolerances 0.2 mm unless otherwise specified European Projection 95 90 12046 12.4 14.8 Fig. 6 H15 frontal view, relating to figures below 84.9 10.1 12039 3.3 8.0 301 Fig. 7 STV-H15-FSR, Screw terminals, no coding STV-H15-F/CO, Faston cable terminals 6.3 x 0.8 mm (identical dimensions, but not shown) 84 14.8 1.6 5.08 10.16 0.3 2.8 Fig. 8 STV-H15-FB/CO, soldering pins 3.5 3 10.1 12047 14 x 5.08 = 71.12 8.17 90 Footprint for PCB-layout Edition 5/6.2000 3/7 Electrical Accessory Products Mating Connectors 3 3 14.9 12053 14 x 5.08 min. 10.1 2.54 7.62 3.5 88.9 6 Fig. 9 STV-H15-FWS/CO Solder pins for pcb mounting 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 designed to handle currents from 20 A up to 40 A. They correspond to quality class 1, with respect to electrical and mechanical life time. The contact material is high quality Beryllium-Copper (CuBe treated) with a gold-plated surface. circuits between the cable terminals, especially in applications 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 contacts for replacement (see: Extraction Tool). Caution: The use of an adequate cable strain relief device (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. To install the high current contacts carefully follow the assembly instructions. It is extremely important to solder cables, 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. This connector type (male version) is used in the following converter series (case size): Using screw versions, the two outer high current jacks may be inserted at a 90 angle in order to prevent possible short PSK (K01), K (K02) and P with output current 20 A. Table 3: H15 S2/S4 Connector Survey Female connector type Part no. Description of terminals coding STV-H15 S2-F/CO HZZ 00115 11 Faston straight 6.3 x 0.8 mm, set of 2 solder jacks 1 yes STV-H15 S2-FSF/CO HZZ 00116 11 Faston straight 6.3 x 0.8 mm, set of 2 screw yes STV-H15 S4-F/CO HZZ 00105 7 Faston straight 6.3 x 0.8 mm, set of 4 solder jacks 1 yes HZZ 00110 7 Faston straight 6.3 x 0.8 mm, set of 4 screw yes STV-H15 S4-FSF/CO 1 Integrated mm2, jacks 1 jacks 1 set of 4 solder jacks 1 yes yes STV-H15 S4-FLS/CO HZZ 00109 7 screw terminals, 90, 2.5 STV-H15 S4-FSR/CO HZZ 00108 7 screw terminals, 90, 2.5 mm2, set of 4 screw jacks 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. Mechanical Dimensions All dimensions in mm, tolerances 0.2 mm unless otherwise specified European Projection 95 90 14.8 12.4 12054 30.3 10.1 84.9 Fig. 10 STV-H15 S2-FSF/CO Faston cable terminals and two high current screw terminals (solder terminals see H15 S4) 13 Edition 5/6.2000 4/7 Electrical Accessory Products Mating Connectors 95 90 12048 14.8 Fig. 11 H15 S4 frontal view, relating to figures below 84.9 12.4 10.1 3 12040 30.6 Fig. 12 STV-H15 S4-FLS/CO, screw terminals and four high current soldering terminals O 3.5 40.5 14.8 84.9 12.4 STV-H15 S4-FSR/CO, screw terminals and four high current screw terminals (not shown) 10.1 3 12049 8 30.3 Fig. 13 STV-H15 S4-FSF/CO, Faston cable terminals and four high current screw terminals 4 STV-H15 S4-F/CO Faston cable terminals and four high current soldering terminals (not shown) 7.6 41.6 13 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 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 3100 3100 3100 Electrical data Test voltage Vrms Operation voltage V AC Operation current per contact TA 20C TA 70C TA 95C 500 500 20 A 17 A 14 A 15 A 12 A 9A 15 A 12 A 9A 8 m Contact resistance 8 m 8 m Isolation resistance at 100 V DC 1012 1012 -55...125C -55...125C 6 m Ag 6 m Ag 500 40 A 35 A 25 A 1 m 1012 Miscellaneous data Operating temperature Contact surface Moulding material Flammability -55...125C 6 m Ag 1.3 m Au PBTP/PC PBTP/PC PBTP UL 94V-0/UL 94 V-1 UL 94 V-0/UL 94 V-1 UL 94 V-0 Approvals Edition 5/6.2000 5/7 Electrical Accessory Products Mating Connectors Code Key System 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) respectively 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 12041 2 8 5 11 14 17 I K 20 26 23 H 32 29 G F Coding tab Coding wedge 4 6.5 An efficient coding system is of great importance and cannot be valued highly enough in complex electronic systems. Since power supplies handle high currents and voltages any false connection could not only be extremely dangerous but also quite costly. K 2 5 I 8 11 H 14 17 G 20 23 F 26 29 32 Fig. 14 Integrated code key system 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 moulding 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 damage the tool and/or connector. Fig. 15 Extraction tool This tool is available as an accessory for both screw or solder high current contacts. Note: In order to avoid damage never manipulate high current contacts when plugged-in! Description: Part Number: Extraction Tool HZZ 00150 Connector retention clips (unlocked) 12050 Connector Retention Clip V The retention clip V is an accessory which guarantees secure connection even under severe vibration, as for example in mobile applications. One connector retention system fits to almost all units and all of the aforementioned connector types. The following converter series are delivered with prepunched 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 (locked) Fig. 16 Connector retention clip Edition 5/6.2000 6/7 Electrical Accessory Products Mating Connectors 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 series Type Part number Delivery content H, M K, PSK S, PSS T CRB-HKMS HZZ 01216 2 brackets 2 screws 2 washers Q, P PC CRB-Q HZZ 01217 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. If using the cable hood together with retention clips a special 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 withstand 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 68 Description: KSG-H15/H15 S4 Delivery content: Housing shell, cable duct with covers, cable clip, cable boot and screws Part number: HZZ 00141 20.2 12051 Cable Hood Modification for use with Retension Clip 110 Fig. 17 Cable hood for H15 and H15 S4 connectors 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 Edition 5/6.2000 7/7 Electrical Accessory Products Temperature Sensors 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 batteries) 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 temperature coefficient of the battery (e.g. -3.0 mV/K/cell) and the nominal floating charge voltage per cell of the battery at 20C (e.g. 2.27 V/cell). The latter two are defined in the specifications of the battery given by the respective battery manufacturer. Vi+ Vi- Power supply 03099 Vo+ Vo- R /UCR input Load Battery + - Temperature sensor Fig. 1 Functional description 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 20C directly at the unit. If this Z switch is used the 2.23 V/cell sensor 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. Table of Contents Page Page Description ....................................................................... 1 Temperature Sensors for T and U units ........................... 1 Mechanical Dimensions ................................................... 2 Temperature Sensors for M, H, S, K, KP, PSx, LW, OK Units .................................. 3 Mechanical Dimensions ................................................... 3 Fail Safe Operation .......................................................... 4 Edition 2/5.2000 1/4 Electrical Accessory Products Temperature Sensors Table 1: Type survey T sensors Nominal battery voltage [V] Sensor type Part no. Cell voltage [mV] Temp. coefficient [mV/K/cell] Cable length [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. 05064 + i/Ucr Vo+ Vo-- -- Sensor wires 05148 + Sensor Temperature sensor cable U 28 white Ucr 12 Vo+ brown 22 green Battery 9 green Fig. 2: Connection to the T unit. Sensor Temperature sensor cable 1 -- Vo- Sensor wires 2 white brown + - + - Battery Fig. 3: Connection to the U unit. Mechanical Dimensions All dimensions in mm, tolerances 0.3 mm unless otherwise specified. European Projection 15 12 14.5 25 0.2 09044 l 60 adhesive tape l: 2 m standard length other cable lengths on request Fig. 4 T and U temperature sensor with mounting fixture. Edition 2/5.2000 2/4 Electrical Accessory Products Temperature Sensors 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 criteria is in every case both the cell voltage and the temperature 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 voltage [V] Sensor type Part no. Cell voltage [mV] Temp. coefficient [mV/K/cell] Cable length [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. 05163 + R Vo+ Vo- - Sensor wires Sensor Temperature sensor cable white brown green + - Battery Fig. 5 Connection to a M, H, S, K, KP, LW or OK unit. Mechanical Dimensions All dimensions in mm, tolerances 0.3 mm unless otherwise specified. European Projection 55 (2.17") Fig. 6 S-KSMH temperature sensor. Edition 2/5.2000 26 (1.02") 9.8 (0.4") S90051 3/4 Electrical Accessory Products Temperature Sensors Fail Safe Operation To prevent overcharging of the battery but still maintain a minimum charging in case of interruption of the sensor signal 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 [V] Output voltage setting (20C) [V] 12 12.84 24 25.68 36 38.52 48 51.36 60 64.2 Tabel 4: Special units for battery charging Ubatt [V] Po 50 Watt Po 70 Watt Po 100 Watt Po 150 Watt Po 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 Higher power requirements can be covered by paralleling of these units. Complete microprocessor controlled systems of un-interuptable power suplies (UPS) are realized by our Applications Center. Please consult your local Power-One representant. Edition 2/5.2000 4/4 Electrical Accessory Products Filter & Ring Core Chokes Filters and Ring Core Chokes FP Series L Series LP Series Description These Filters and chokes are designed to reduce input interference and/or output ripple voltages occurring in applications 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 magnetisation 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 considerably exceed the rated current, by accepting a corresponding gradual loss of inductance (unlike ferrite core chokes where inductance rapidly decreases above a certain DC magnetising level). In applications where switching regulators have long supply lines, filters and chokes are used in order to prevent oscillations caused by their negative input impedance. For further information refer also to switching regulator data for "Option L", and to section: Technical Information: Installation & Application. Table 1a: Type survey of FP filter blocks Table 1b: Type survey ring core chokes Filter type Part number Matching switching regulator type 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 Inductivity ILn LP 34-3 34 H 3A * HZZ 00501 L 20-7 20 H 7A * HZZ 00502 LP 20-7 20 H 7A * LP 183 2 x 183 H 8A Single Symm. coil coil Part number HZZ 00503 * 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 regulators. This forms a complete external filter system optimised to prevent oscillations and to reduce superimposed Table of Contents 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. Page Page Description ....................................................................... 1 Filter Blocks FP Types ..................................................... 1 Low-Loss Ring Core Chokes L/LP-Series ........................ 3 Mechanical Dimensions ................................................... 5 Edition 5/6.2000 1/5 Electrical Accessory Products Filter & Ring Core Chokes Electrical Data Filter Blocks General Condition: TA = 25C unless otherwise specified Table 2: Filter blocks FP Characteristics Conditions min FP 38 typ max min FP 80 typ max min FP 144 typ max IFn Rated current L = 0.75 Lo UFn Rated voltage TC min...TC max 5 RF Ohmic resistance 18 20 22 18 20 22 90 Lo No load inductance IL = 0, TC min...TC max 30 34 38 30 34 38 88 TA Ambient temperature IF = IFn -40 80 -40 80 -40 TC Case temperature -40 92 -40 92 -40 98 TS Storage temperature -40 100 -40 100 -55 100 4 4 40 5 2 80 15 Unit A DC 144 V DC 95 100 m 100 112 H 95 C For currents IF > 4 A the following derating takes place: TA max = 100 - 1.3 * IF2 [C], TC max = 100 - 0.49 * IF2 [C] Input Interference Reduction Reduction of Output Ripple 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. Even though switching regulators have an inherently low output ripple, certain sensitive applications need even further 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 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 (ZLine). The interference currents are therefore practically independent of their source impedance. The filter 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 increase (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). inductive resistive capacitive Interference voltage reduction Att. [dB] 40 12009 The output ripple can be reduced by the use of filter blocks by about 24 dB. The formula for the ripple uR at the load RL is as follows: uR = 0.063 * uo (Ripple voltage uo is given for specific regulators in the corresponding data section). Vo+ Vi+ U Uo PSR Gi- Uii Filter Uio Gi 12010 UR RL Go- Fig. 2 Reduction of voltage interference by FP filters Consider, that the filter not only affects the output ripple but can also influence the voltage across the load RL 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. 30 20 10 Z Line [] 0 0 1 3 2 4 Source impedance 5 6 Fig. 1 Interference voltage reduction with FP filters at f = 150 kHz Edition 5/6.2000 2/5 Electrical Accessory Products Filter & Ring Core Chokes Typical Application The example in figure Reduction of voltage interference by FP filters shows a switching regulator operating from a battery (Ri < 0.5 ) with long supply lines (e.g. 2 m). The resulting superimposed interference voltage USL may be measured at the regulators input. The connection of a filter in front of the power supply will reduce this interference accordingly: 1. The regulator's source impedance is mainly inductive because of the low battery impedance and the long supply lines. It can be calculated as follows: ZLine 2 * fS * LLine * 2 l ZLine 2 * (150 * 103) * 10-6 * 2 * 2 3.8 fS : Switching frequency (150 kHz) LLine : Supply line inductance (typically 1H/m) l: Length of single supply line (twice for positive and negative path) 2. This example shows, that with an inductive source impedance of 3.8 , 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: USF = USL * 10 -18/20 [V] 2*l Uii Uio Filter Us ZLine U 12011 Vo+ Vi+ Gi- RL Uo PSR Gi Go- Fig. 3 Reduction of voltage interference by FP filters Low-Loss Ring Core Chokes L/LP-Series 12012 LP 183 80 75 LP 34-3 60 L/LP 20-7 ILn Series L/LP 20-7 and LP 34-3 are intended for use as differential mode filters and the current compensated choke LP 183 enables attenuation of common mode interference. L /Lo [%] 100 ILn 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 isolation pad. 40 20 Fig. 4 Choke inductance versus current 0 0 2 3 4 6 7 8 10 12 14 IL [A] Electrical Data Ring Core Chokes General Condition: TA = 25C unless otherwise specified Table 3: Ring core chokes Characteristics current 1 Conditions L 20-7/LP 20-7 min typ max L = 0.75 Lo min LP 34-3 typ max min LP 183 typ max ILn Rated RL Ohmic resistance Lo No load inductance D TI Current specific case temp. increase 1 TA Amb. temperature 1 -40 106 -40 104 -40 98 TC Case temperature -40 110 -40 110 -40 110 TS Storage temperature -40 110 -40 110 -40 110 IL = 0, TC min...TC max 7 3 8 A DC 5 5.5 6 18 20 22 2x2.9 2x4.2 2x5.5 m 18 20 22 30 34 38 2x95 2x183 2x245 H 0.19 K/A2 0.082 IL = ILn Unit 0.68 C 1 If the choke is not operating at the rated current ILn, the maximum ambient temperature TA max and the maximum direct current IL max change according to the following equations: TC max -TA max IL max = TA max = TC max - IL2 max * D TI D TI Edition 5/6.2000 3/5 Electrical Accessory Products Filter & Ring Core Chokes Input Interference Reduction Reduction of Output Ripple 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 oscillations caused by the negative input impedance of the regulator. 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 Information: Installation & Application. Even though switching regulators have an inherently low output ripple, certain sensitive applications need even further 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 regard to the ripple and dynamic regulation. The current compensated choke LP 183 has a high permeability ring core with two identical separate windings. The normal operating current will only see the small stray inductance between the windings. However common mode interference will be blocked by the full inductance of the choke. LP 183 LP 34-3 or L/LP 20-7 Vo+ Vi+ U Uo PSR Cext 1 Cext 2 Cext 3 Gi- 12013 RL Go- Fig. 5 L/LP type chokes and capacitors used as input filter Typical Application A voltage drop UrGo = rGo * (Io - Ii) is produced across the ground loop resistance rGo. It is superimposed upon the regulators output voltage Uo and generates the voltage UR = Uo - Ur Go across the load resistance RL. Without an input inductance Le the current Ii in the input circuit has a relatively high AC component with a basic frequency fs (regulator's switching frequency of approx. 150 kHz). This alternating current produces an AC voltage component across rGo which is superimposed upon URL. To prevent this phenomenon, an inductance Le can be inserted into the input circuit. This causes the AC component of the input current to be supplied entirely from the input capacitor Ce; thus, Ii is a pure direct current. Ce should be wired as close as possible to the regulator's input terminals Vi+ and Gi-. The formula for the remaining output ripple at the load RL is calculated as follows: UR = uo * ZCex/ZLD uo: Output ripple of the regulator ZCex: The impedance of the capacitor at the regulator's switching frequency (150 kHz) corresponds to the equivalent series resistance (ESR) of the capacitor (please refer to the corresponding data sheet). ZLD = 2 * fS * LD fS: 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 reduced. Consider that the filter not only affects the output ripple but can also influence the voltage UR across the load RL 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 capacitor. Generally, the bigger Cex the smaller is the dynamic, however, recovery will be slower. RD PSR Gi- ZLD ZC ext 12014 Vo+ Vi+ U LD Uo Ce UR RL Go- Fig. 7 Low-loss ring core choke with external capacitor (Cex approx. 1000 F) used as output filter Le and Ce additionally provide protection against input transients and reduce radio interference voltages. External connection of Gi- and Go- or connection via a common ground is not recommended. The internal voltage drop UrG in the regulator would be superimposed on the output voltage. 12015 Le U PSR Ur G Ce Gi- Io Vo+ Vi+ rG Uo RL URL Go- rGo Ur Go Fig. 6 Reduction of superimposed interference voltages in grounded power supply systems, caused by ground loops Edition 5/6.2000 4/5 Electrical Accessory Products Filter & Ring Core Chokes Mechanical Dimensions 7.5 1 o 3.8 3.6 30 6 (3.22) 4 13.7 b 3.66 b b 15.24 12017 0.9 x 0.56 3.22 0.5 10.16 1 4 Legend: b = 5.08 mm 1 1 = Uii (input) 2 = Uio (output) 3 = Gi (ground) 4 = Positioning pins 22 1 3 2 o1.3 1 37.8 0.5 min. 4.5 4 European Projection 12016 16.6 1 6.8 1 M 2.5 25 0.5 (3.66) Dimensions in mm. Tolerances 0.2 mm unless otherwise specified 0.8 Fig. 8 Filter blocks FP weight 30 g 27 38.1 47.5 Fig. 9 Differential mode choke L 20-7, weight 30 g max 8 5.08 max 14.5 o1 12019 o 0.8 5 1 1 10 12018 M 2.5 2 x 5.08 17.5 Fig. 10 Differential mode choke LP 34-3, weight 7 g Edition 5/6.2000 3 -0.5 o 0.9 7.6 13.2 5.08 7.5 Fig. 11 Common mode choke LP 183, weight 7 g 5/5 Electrical Accessory Products Back Planes for the T Series Back Planes 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 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 terminals 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 available 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 further 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. Table of Contents 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 output 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 maintenance, depends on the final installation as well as on the applicable safety requirements. However, it is the responsibility of the installer or user to provide such a safety cover to assure the compliance with the relevant and applicable safety standards. Page Page Summary .......................................................................... 1 Type Survey and Key Data .............................................. 2 Functional Description ...................................................... 2 Mains Input Section .......................................................... 4 Output Section ................................................................. 5 Electromagnetic Compatibility (EMC) .............................. 7 System Integration ........................................................... 8 Mechanical Data ............................................................ 10 Safety and Installation Instructions ................................ 10 Edition 5/6.2000 1/14 Electrical Accessory Products Back Planes Type Survey and Key Data Table 1: Type survey Input filters 1 Output capacitors (reduced 100 Hz output ripple) 2 Preload BPD 1002 BPD 1003 x x - 90 mF - - Front-end, fitted with diodes BPF 1004 BPF 1007 BPF 1006 x x x - 50 mF 90 mF x x x Battery charger, fitted with fuses BPF 1037 () 3 x 50 mF x BPF 1007 in configuration AC Input 85...255 V AC 1 or 3 phase (Y) 19" Rack, 3 U 1 2 3 Application Rack for systems with up to 3 T units See also: Electromagnetic Compatibility. Please refer to: Dimensioning Example of a Battery Charger System in Single Phase Connection Only 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 jumpers 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 input 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 Edition 5/6.2000 each) further reduce the low frequency output ripple and provide enhanced hold-up time. All relevant monitoring signals as well as control signal inputs 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 circuit (protected by a fuse F1, rated T1A, 250 V, 5 x 20 mm) allows a relay to be directly driven for system specific control 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 Dset (R13/14, R23/24 and R33/34). Note: If a power system is operated with 3 T units per backplane, 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. 2/14 Electrical Accessory Products Back Planes Signal terminal strip X5 Connector H15 for T unit Mains input connector X1 X4 3 2 Input filter Input filter Y Input filter Y B20 B30 Y + D31 D21 D11 F31 F21 F11 - R33 R23 R34 R24 R25 Output capacitor (10 mF, each) B10 R14 R13 Dset T1 Jumper strip X3 Bus bar system L1 L2 L3 N 1 03012 Fuse F1(auxiliary circuit) Preload (<10 W) Output fuse Decoupling diode Fig. 1 Back plane, view from the rear Vo+ (BUS) F Y P Vo+ N Vo- L1 F Y P N F Y P N + + RPT C C C DC-Bus Vo+ (BUS) D21 Vo+ F21 Vo- R24 R23 + + Vo+ + C + + R25 RPT C C - D2 Vo- Sys In 2 Vo+ (BUS) T unit 3 B30 + Sys In 1 D set D i Sys out Sys In N R13 D1 T unit 2 B20 L2 L3 F11 R14 D set D i Sys out Sys In X1 D11 03013 T unit 1 B10 - D31 Vo+ F31 Vo- R34 D set D i Sys out Sys In R33 + C + C C + RPT D3 Sys In 3 Fig. 2 Block diagram of back plane F11, 21, 31 fitted to BPF types. D11, 21, 31 fitted to BPD types. Edition 5/6.2000 3/14 Electrical Accessory Products Back Planes 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 Phase-Earth/Phase-Phase 230/400 V Single phase L, N, 3-phase (Y) L1, L2, L3, N, LT types 120/208 V Phase - phase () L1, L2, 3-phase () L1, L2, L3, LT types Not allowed Not allowed LT types UT types LT types only External fuses required With special back plane BPF 1037 and LT types only Single-phase/3-phase (Y) Configuration Standard back plane version (Y-configuration) Phase to Phase Configuration With 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) configuration. 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. 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, providing 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. Connection to the ground is mandatory. 03019 03017 Ii Input Filter Input Filter Option P Go+ Gi+ Ui i (option) Control circuit -U i Ce Vo+ 17 26 Control circuit Ce -U o Uo 2 R (option) 20 8 23 11 Vo- 32 Io Ii R Go- Gi- Vi- Io 14 29 Vi+ Fig. 3 Single phase configuration L, N 230 V mains: LT-types Fig. 5 Phase to phase configuration L1, L2 120/208 V mains (e.g. USA): LT types only. Not applicable for UT types. 03018 Io Ii Option C Vo+ Input Filter Option L Vi+ D (option) i Control circuit Ui Uo Option C R G Go- Gi- Option D Option P 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 Edition 5/6.2000 4/14 Electrical Accessory Products Back Planes 3-phase () Configuration With special back plane version BPF 1037 (-configuration) for LT units exclusively Low mains 120/208 V The input section of the 3 LT units is wired in a -connection 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 (D) 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. X1 L1 L2 L3 04020 L1 L2 L3 N LT 1 LT 2 LT 3 Fig. 6 3-phase (D) configuration, L1, L2, L3 120/208 V mains (e.g. USA) LT types only. Not applicable for UT types. Output Section Power Bus Power Down Signal (D1, D2, D3) The back plane is fitted with a generously dimensioned bus bar system. Each bus bar (4 mm thick Alu alloy profile, identified with its polarity) is fitted with 2 captive nuts (M 6) serving 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. The power down signal monitors the voltage level of the bus bar system. Depending upon the application it may be advantageous to use the power down signal D1 and D2 in a redundant configuration and the third signal (D3) as a separate warning signal at a higher threshold level. For such a configuration the jumpers of X3 should be set in the positions D - D1 and D - D2. (See fig.: Jumper strip (X3), Signal meshing.) For application specific requirements such as reduced ripple current, reduced low frequency ripple voltage, enhanced 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 functions 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 diode allows a small reverse current from the DC bus supplying the control functions of the affected T unit. Battery Charger Version Direct battery charging or powering battery buffered systems 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 x 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, interrupting the reverse short circuit current supplied by the battery and the remaining T units. Edition 5/6.2000 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 system status monitoring jumpers should be set in the positions 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.) 5/14 Electrical Accessory Products Back Planes Table 3: Terminal strip X5 Interface for Remote Signalling and Control 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+ D - D2 D - D3 D - Si3 i - i1 i - i2 i - i3 Si1 - So2 Si2 - So3 - Si1 - Si2 - Si3 Signal allocation Description Sys In 3 Sys In 2 Sys In 1 05029 Vo+ F1 T1A, 250 V X3 D - D1 Sys Out 3 Sys Good input T2 Sys In 1 Sys Out 2 Sys In 2 4 Sys Out 1 3 i3/Ucr Sys Good input T3 i2/Ucr Supply Vo- Sys In 3 i1/Ucr Vo- 2 D3 1 Each of the signals can be made available as an individual signal or as a combined signal. D2 Connector X5 D1 A signal terminal strip (X5) allows interfacing with the customer`s control system. X5 14 13 1 13 14 2 12 15 3 11 16 4 10 17 5 9 18 6 8 19 7 7 20 8 6 21 9 5 22 10 4 23 11 3 24 12 2 1 Vo- Vo+ D1 D2 D3 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- Vo- Fig. 7 Jumper strip (X3), signal meshing Edition 5/6.2000 6/14 Electrical Accessory Products Back Planes Electromagnetic Compatibility (EMC) Conducted Emission Radiated 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 To keep the radiated noise of the T units as low as possible they should be mounted into a conductive chromatized 19" rack, fitted with front panels and the back plane earth connected to the rack. See also data sheet: T series. In output voltage regulation mode, the conducted noise at the input of the T units is below level B according to CISPR 11/22/EN 55011/55022. In output power and output current limitation mode, e.g. in the case of charging heavily discharged batteries, the conducted noise may be above level B, but below level A For integration into non-conductive 19" racks, special front panels with conductive nuts are available on request. [dB pW] 07010 90 80 70 60 [dBV] 90 07009 EN 55014 50 80 40 70 30 60 20 30 50 100 150 200 250 [MHz] 300 50 Fig. 9 Typical radiated electromagnetic power (quasi peak) at system input and output of a back plane fitted with 3 LT units, input filters and 5 additional output capacitors (10 mF each) according to CISPR 14 and EN 55014, measured at Ui nom and Io nom. 40 30 20 10 20 30 10 5 2 1 0.5 0.1 0.05 MHz 0.02 0.01 0 Fig. 8 Typical disturbance voltage (quasi-peak) at the input of a back plane fittet with 3 LT units, input filters and 5 additional output capacitors (10 mF each) according to CISPR11/22 and EN 55011/22, measured at Ui nom and Io nom. Edition 5/6.2000 7/14 Electrical Accessory Products Back Planes System Integration Mains Input Voltage Monitoring Battery Selection The T unit interprets a mains failure as a system error, indicated by the red Error LED together with a System Good failure signal. Should a dedicated mains failure identification be required this signal would have to be established externally. When selecting a battery, the following aspects should be considered: Available signals/signal combinations (Please also refer to the: T series data sheet): The T unit provides two open collector signals, System Good and Power Down. The System Good signal monitors the operational function of a single T unit. In case of reduced available output power due to a mains failure, a T unit failure or inhibit, the signal changes from low to high impedance. In systems with battery back-up or with n+1 redundancy the failure of one single unit does not cause a failure of the system as the required output power is still available either from the battery or from the remaining T units. To indicate the status of the whole system, the System Good signals of all 3 units should be connected in series on the back plane. 1. Batteries are normally specified at 20C. Steady operation at higher temperatures will shorten the life time of a battery. For every 10 K temperature increase the battery lifetime is halved. 2. Worst case considerations with regard to the necessary battery capacity should include operation at the lowest possible temperature and highest possible discharge current, since under such conditions a substantial capacity drop has to be expected. 3. The capacity of a battery deteriorates with time. Therefore decisions on battery capacity should be based upon 20% ageing loss. 4. Consult the battery manufacturer for correct layout of the battery system. Selecting the Right Battery and Back Plane Configuration The System Good output can be combined with similar outputs of other DC-DC converters such as CQ units, integrating the additional information into the overall system status signal. As mentioned in the T series data sheet the power factor correction at the input of the T unit generates a ripple voltage at the output of twice the input frequency, causing a ripple current into the connected battery. If only the system status of the T unit is to be monitored, Sys In should be wired to Vo-. For most battery types the low frequency ripple current should not exceed 5 Arms per 100 Ah (0.05 C). Some manufacturers (with newer battery technology) specify 10 Arms per 100 Ah (0.1 C). The Power Down signal monitors the output voltage level of the bus bar system. The threshold levels of the 3 possible signals can be individually adjusted by means of resistors R 13/14...R 33/34 (see: T series data sheet) and be used for: * Save data * Disconnecting the load or part of it * Performing a battery test In systems with battery back-up it may be desirable to extend system operation in case of long term mains failures by disconnecting an uncritical part of the load at a certain bus voltage level, triggered by one of the 3 possible power down signals. The 2 remaining signals can be set to the low battery discharge level to get a redundant signal (wired AND) for finally disconnecting the critical part of the load. Excessive ripple current can increase the battery temperature and reduces the battery lifetime. For a single phase system additional output capacitors may be necessary depending upon the selected battery type. Note: With the T units symmetrically connected to a 3-phase (Y) mains supply the low frequency output ripple is virtually zero, only a high frequency ripple and noise of <100 mVpp at the switching frequency of 65.5 kHz remains. Note: The Power Down signal has an enlarged hysteresis of approximately 6 V for T 1740 units and 3.5 V for T 1240 units. The Power Down signal(s) can be combined with the System Good signal to give a wired AND (see: T series data sheet). In such cases the resulting alarm only becomes active as a result of a mains failure or a converter failure together with a heavily discharged battery. Edition 5/6.2000 8/14 Electrical Accessory Products Dimensioning Example of a Battery Charger System in Single Phase Connection Battery charger system in single phase connection: 230 V, 50 Hz, load: 1 kW, battery back-up: 3 h Conditions: TA = -10...40C for both, charger and battery 06039 Rtot supply lines + - 16 m LT 1 Additional capacitance on the back plane not only reduces the AC ripple on the battery, but stabilizes the output voltage during fast load changes. Where the ripple current should be reduced even more, the system resistance RSys could be increased with a special choke set into the battery supply line. For further information please contact Power-One. Battery charger: 3 LT 1740 , n+1 redundant configuration, 1.6 kW Rback plane 1 Back Planes Ri AC bat factor y (Irms bat /Iload) 06037 0.6 + LT 2 - LT 3 1 1.5 m 0.4 The resistance on the back plane (Rback plane) is already taken into account in the following two graphs. Fig. 10 System set-up Battery specification (at 20C): * 24 cells, 2.23 V/cell, float charge voltage 53.5 V * Permissible ripple current Irms bat: 0.05 C (5% of battery capacity) * Temperature coefficient -3 mV/K per cell * Max. discharge current 20 A * Capacity at -10C and 0.2 C discharge: 70% Calculation of battery size: Load 20 A, back-up 3 h, ageing loss 20% therefore ageing factor 0.8, derating factor for temperature and discharge current 0.7 Qbat [Ah] = Iload * tback-up / (fageing * fTAI discharge) = 20 [A] * 3 [h] /(0.8 * 0.7) = 107 [Ah] next closest battery configuration::120 Ah or 95 Ah Decision: Battery with 95 Ah (Ri DC: 28 m) Calculation of the ripple current: The ripple current to the battery can either be measured or calculated. The diagrams allow a good estimation of the relationship between the ripple current to the battery Irms bat and the load current I Load of a given system resistance RSys. The system resistance is the sum of the resistance of the supply and the AC resistance of the battery. The AC resistance is defined as the relationship between the AC voltage and the AC current to the battery measured with a capacitively coupled 100 Hz AC source. In the example the system resistance is: RSys = Rsupply rms + Ri AC bat = 16 m + 16 m = 32 m Permissible ripple current: Irms bat = 0.05 * 95 Ah = 4.75 Arms Calculated ripple current: With 3 LT 1740 without capacitance on the back plane Irms bat = Iload * factor y = 19 A * 0.198 = 3.76 Arms = 0.04 C With 3 LT 1740 and 50 mF on the back plane Irms bat = 19 A * 0.16 = 3.04 Arms = 0.032 C With 3 LT 1740 and 90 mF on the back plane Irms bat = 19 A * 0.13 = 2.47 Arms = 0.026 C All three examples give a value below the permissible ripple current. Edition 5/6.2000 0.2 0 1.0 10 Number of LT units: 1 2 Rsys [m] 100 300 5 6 3 4 Fig. 11 Irms bat/Iload versus system resistance (Rsys). Up to 6 T units in parallel, without additional output capacitors factor y (Irms bat /Iload) 06038 0.6 0.4 0.2 0.16 0 1.0 Rsys [m] 10 32 100 300 Number of LT units plus additional output capacitance 3 units + 50 mF 2 units + 50 mF 3 units + 90 mF 2 units + 90 mF Fig. 12 Irms bat/Iload versus system resistance (Rsys). 2 and 3 T units in parallel, with additional output capacitors 9/14 Electrical Accessory Products Back Planes Mechanical Data Dimensions in mm. Tolerances 0.3 mm unless otherwise indicated. European Projection 60 09108 142.24 35.56 7.62 142.24 101.6 101.6 101.6 101.68 129.54 3.5 Safety cover 426.72 Fig. 13 Back plane for 19" rack, weight: 1.7 kg Safety and Installation Instructions Table 5: Pin allocation of the signal terminal strip X5 Transportation For transportation use standard Power-One packaging material. Racks fitted with back planes are not designed for transportation with the T series AC-DC converters fitted into the racks. Connector Pin Allocation The power output is provided via the two bus bars, the positive one designated Vo+, the negative one Vo-. The following pin allocation tables define the electrical potentials and the physical pin positions on the connectors of the back planes. Table 4: Pin allocation of the mains input connector X1 Pin no. Electrical determination Pin designation Pin no. Electrical determination Pin designation 1 Supply negative (return potential) Vo- 2 Sys good input of T unit no. 3 Sys In 3 3 Sys good input of T unit no. 2 Sys In 2 4 Sys good input of T unit no. 1 5 Sys good output of T unit no. 3 Sys Out 3 6 Sys good output of T unit no. 2 Sys Out 2 7 Sys good output of T unit no. 1 Sys Out 1 8 Inhibit or Ucr of T unit no. 3 Sys In 1 i3/Ucr 9 Inhibit or Ucr of T unit no. 2 i2/Ucr 10 Inhibit or Ucr of T unit no. 1 i3/Ucr 11 Power down of T unit no. 3 D3 12 Power down of T unit no. 2 D2 13 Power down of T unit no. 1 D1 14 Supply positive Vo+ 1 Input phase 1 L1 2 Input phase 2 L2 3 Input phase 3 L3 4 Input neutral N 5 Protective earth The signal terminal strip X5 is provided with a matching female connector at delivery. 6 Protective earth The jumper strip X3 is provided with 7 jumpers at delivery. Input connector X1 is provided with a matching male connector at delivery. Standard configuration: Pins 1, 2 and 3 are interconnected (for single phase operation). Edition 5/6.2000 The pin allocation of the jumper strip is described in fig. Jumper strip (X3), signal meshing. 10/14 Electrical Accessory Products Back Planes Installation Instruction The BPD/BPF series back planes are components, intended exclusively for inclusion within other equipment by an industrial assembly operation or by professional installers. Installation must strictly follow the national safety regulations in compliance with the enclosure, mounting, creepage, clearance, casualty, markings and segregation requirements of the end-use application. See also: Technical Information: Installation and Application. Caution: It is the responsibility of the design engineer and of the installer to define and apply a safety concept for the whole system which is provided with a PowerOne back plane. The following are under the aspects which have to be considered: * Consult the T-series AC-DC converters data sheet prior to connecting the system to the mains. * The necessity to provide a cover over the live parts at the mains input (hazardous voltage) or over the DC-bus bars (energy hazard), preventing accidental contact during installation, start-up of a system or maintenance, depends on the final installation as well as on the applicable safety requirements. * Service should be carried out by qualified personnel only. * Fuses should be replaced with the same types only. * The earth terminal on the back plane must be connected to safety ground. * 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. * The maximum nominal input voltage is 230 Vrms +10%. Higher input voltages may damage the T series AC-DC converters as well as the back plane. * Empty spaces in a rack should be covered by a dummy front panel. Caution: Prior to handling, the back plane must be disconnected from mains and from other sources (e.g. batteries). Check for hazardous voltages and hazardous energy before and after altering any connections. Hazardous energy levels may be present at the output terminals even after the mains input voltage has been disconnected from the unit. This is indicated by the red error LEDs of the T series AC-DC converters. It is the responsibility of the installer to prevent an unwanted short-circuit across the output of the back plane, of the battery and of each T series AC-DC converter. In case of a short circuit across the output of a T unit, all LEDs will be off, although the mains may be present. The back planes are intended for stationary applications. They shall be installed in 19'' racks according to DIN 41494. Install the back planes vertically, the mains input connector X1 being on the right hand side of the back plane (view from the back) and make sure that there is sufficient air flow available for convection cooling of the T-series AC-DC converters. Mechanical fixing shall be made via 10 screws M2.5 x 10 and 10 nuts M2.5. When mounting a back plane to a rack, fit two T units into the H 15 female connectors on the back plane prior to fixing the back plane to the rack. This ensures correct positioning of the female connectors on the back plane with respect to the given position of the male connec- Edition 5/6.2000 tors of the T units in the rack. With the back plane improperly positioned, the connectors of the T units and the female connectors on the back plane may be damaged. In order to maintain correct positioning, use all the available mounting holes. Connection to the supply system shall be made via the 6pole screw terminal connector X1 according to: Connector Pin Allocation and Mechanical Data. The connector X1 of the back planes (class I equipment) is provided with two protective earth terminals ( ), which are reliably connected with the protective earth pins of the connectors for the T units. For safety reasons it is essential to connect at minimum one of these terminals with the protective earth of the supply system. Since the earth leakage current exceeds 3.5 mA, the system must be permanently connected or it must be pluggable equipment type B according to IEC/EN 60950. The earth connection must be performed before connecting the supply. To maintain good electrical connection, the AC input, earth and signal to the terminal strip wiring should be secured, using tie wraps, to prevent stress upon the wires and the connectors. Refer to Mains Input Section to ensure that phase and neutral configuration matches with the back plane and T series AC-DC converter types. Wrong connection at the input may damage the T series AC-DC converters as well as the back plane. Standard back planes are designed for a 3-phase system in Y connection with a phase to neutral voltage of 230 V or 120 V where connection to neutral is mandatory. Integration into a 3-phase system in configuration (120/ 208 V and without connection to neutral) is only possible with LT AC-DC converters together with the special back plane BPF 1037. For safety reasons, a mains switch for line interruption is required. The back plane does not provide any input fuses. The input fuses of the T series AC-DC converters in the connection from the L terminal are designed to protect the units in case of overcurrent and may not be able to satisfy all customer requirements. An external input fuse suitable for the application and in compliance with the local requirements in the wiring to each phase and to the neutral terminal may therefore be necessary to ensure compliance with local requirements. A second fuse in the wiring to each input terminal is needed if: * Standard back planes are used in phase to phase configuration * Local requirements demand an individual fuse in each source line * Neutral to earth impedance is high or undefined * Phase and neutral of the mains are not defined or cannot be assigned to the corresponding terminals (L to phase and N to neutral). Important: Do not open the modules, or guarantee will be invalidated. 11/14 Electrical Accessory Products Additional Information for Installation of Battery Charger Systems: Reverse polarity connection of the battery may damage the battery, the back plane(s) and the battery chargers. Prior to putting a system into operation, check whether the position of the cell voltage selector switch of each T series AC-DC converter corresponds to the required battery cell voltage. For battery maintenance please contact the battery manufacturer. Exchanging a battery should always include the whole battery bank. New batteries should be of the same type, with the same cell voltage and temperature coefficient. For expansion of battery systems contact the battery manufacturer. For battery location and connection please refer to VDE 0510, part 2. In battery charger systems, safety standards demand that a battery can be completely disconnected from the power system including the battery system ground. Depending upon the project specific requirements, disconnecting may either occur by a manually operated switch with fuses, or automatically by means of a circuit breaker. Caution: Care should be taken during system set-up or after maintenance when connecting a battery to the power bus of a back plane (BPF types) fitted with fuses. The T series AC-DC converter system with the back planes should be switched to the mains prior to connecting the battery to the power bus, since the reverse current from the battery into the uncharged output capacitors of the T units and the back plane may damage the fuses. Make sure that there is sufficient air flow available for convection cooling. This should be verified by measuring the case temperature of each T series AC-DC converter when the complete back plane is installed and operated in the end-use application. The maximum specified case temperature TC max of the T series AC-DC converters must not be exceeded. Ensure that a unit failure (e.g. by an internal short-circuit) does not result in a hazardous condition. See also: Safety of operator accessible output circuit. Standards and approvals All back planes correspond to class I equipment. They have been designed in accordance with UL 1950, CAN/CSA C22.2 No. 950-95 and IEC/EN 60950 standards. Safety approvals are not provided. The units have been evaluated for: * Building in * Basic insulation between input and earth, based on 250 V AC * Double or reinforced insulation between input and output, based on 250 V AC * Operational insulation between output and earth * The use in a pollution degree 2 environment * Connecting the input to a primary circuit with a maximum transient rating of 2500 V (overvoltage class III based on a 110 V primary circuit, overvoltage class II based on a 230 V primary circuit). Edition 5/6.2000 Back Planes Troubleshooting See also: T series AC-DC converters data sheet Functional Features. * All T-series AC-DC converters are operating, all Sys OK LEDs are OFF. - Sys In is not referenced to Vo- * 3-phase AC input, Y-configuration. One T unit indicates Error. - single T unit failure or - single T unit inhibit or - single phase mains failure * All System OK LEDs are OFF, all T units indicate Error. - mains failure or - all T units inhibited, e.g. battery test or less likely - all T units have a failure * The red Error LED of one of the T units is ON. - T unit with Error LED ON has an overtemperature, the output is automatically re-enabled when the temperature drops below the limit. * The red Error LED flickers. - overvoltage disturbance from the mains. * One of the T units has all LEDs OFF. - short circuit across output of a T unit. * All Sys OK LEDs ON, at one T unit the Uo OK LED is ON. The remaining T unit are below the threshold level of the power down signal with the LED Uo OK OFF. - a fuse on the back plane damaged, relevant T unit with Uo OK ON. * All LEDs at the T units are OFF, mains is apparent. - short circuit across the power bus * Single phase AC input. Only one T unit is in operation. - wire jumpers on mains input connector X1 not connected to L2/ L3 input terminals * All Sys Good and Uo OK LEDs are ON, no output power. - output not connected to the system * All T units are operating. One or several T units indicate Error with the Uo OK LEDs OFF although the bus voltage is present. - Dset not referenced to Vo+ Protection Degree The protection degree of the back planes is IP 00. Isolation The electric strength test is performed as factory test in accordance with IEC/EN 60950 and UL 1950 and should not be repeated in the field. Power-One will not honour any guarantee claims resulting from electric strength field tests. The electric strength test is performed as factory test in accordance with IEC/EN 60950 and UL 1950. Nor this test nor the insulation resistance measuring should be repeated in the field. Power-One will not honour any guarantee claims resulting from field tests with high voltages. Important: The backplane must carry the safety covers, which prevent from touching conductive parts. Such covers are mounted on both sides of the printed circuit board and over the bus bars. Removing the protection covers will provoke danger of high voltage or high energy impact! Testing by applying AC voltages will result in high and dangerous leakage currents flowing through the Y-capacitors (see fig.: Block diagram of back plane). 12/14 Electrical Accessory Products Back Planes Table 6: Isolation Characteristic Electric strength test voltage Input to earth Input to output Output to earth Unit Required according to IEC/EN 60950 1.5 3.0 0.5 kVrms 2.1 4.2 0.7 kV DC Actual factory test 1 s 2.8 4.2 1.4 AC test voltage equivalent to actual factory test 2.0 3.0 1.0 kVrms >300 >300 >300 M Insulation resistance at 500 V DC For creepage distances and clearances refer to: Technical Information: Safety. Leakage Currents in AC-DC operation 10077 Leakage currents flow due to internal leakage capacitance and RFI suppression Y-capacitors. The current values are proportional to the mains voltage and nearly proportional to the mains frequency. They are specified at the maximum operating input voltage, where phase, neutral and protective earth are correctly connected as required for class I equipment. Under test conditions, the leakage current flows through a measuring instrument (MI) as described in fig.: Measuring instrument for earth leakage current tests, which takes into account impedance and sensitivity of a person touching unearthed accessible parts. The current value is calculated by dividing the measured voltage by 500 . If inputs and/or outputs of back planes are connected in parallel, their individual leakage currents are added. 10078 L1 L1 L2 L2 L3 N L3 N Back Plane Vo+ Vo- Vo+ L N Vo- S1 S4 Back Plane MI for earth leakage current S2 S3 MI for output leakage current Fig. 14 Test set-up for leakage current tests on class I equipment in single phase configuration. S1 is used to simulate the interchanging of phase and neutral, S2/3 select either the earth or output leakage current measurements, S4 selects the leakage current measurement of either the positive or negative output. MI for earth leakage current 1500 MI 10061 S4 S2 S3 L N 500 10 k 220 nF MI for output leakage current 22 nF Fig. 15 Test set-up for leakage current tests on class I equipment in phase to phase or 3-phase configuration of back planes fitted with LT units. S2/3 select either the earth or output leakage current measurements, S4 selects the leakage current measurements of either the positive or negative output. Edition 5/6.2000 V Fig. 16 Measuring instrument (MI) for earth leakage current tests according to IEC/EN 60950, Annex D. 13/14 Electrical Accessory Products Back Planes Table 7: Leakage currents in single phase configuration (= worst case) Characteristic Back plane Back plane with without T unit one T unit Earth Permissible according to IEC/EN 60950 leakage Specified value at 255 V, 50 Hz 2 current Specified value at 127 V, 60 Hz 2 Output Permissible according to IEC/EN 60950 leakage Specified value at 255 V, 50 Hz current Specified value at 127 V, 60 Hz 1 2 Back plane with two T units Back plane with three T units 5% of the input current per phase 1 Unit - 2.6 4.4 6.2 7.9 1.6 2.6 3.7 4.7 0.25 0.25 0.25 0.25 - <0.1 <0.1 <0.1 - <0.1 <0.1 <0.1 mA If the value exceeds 3.5 mA, equipment must be pluggable equipment type B or permanently connected, according to IEC/EN 60950. In best case configuration (3-phase), earth leakage currents compensate to 0 mA. Safety of operator accessible output circuit If the output circuit of an AC-DC converter is operator accessible, it shall be an SELV circuit according to IEC/EN 60950 related safety standards. The following table shows a possible installation configuration, compliance with which causes the output circuit of the AC-DC converter to be an SELV circuit according to IEC/ EN 60950 up to a configured output voltage of 56.5 V. However, it is the sole responsibility of the installer to assure the compliance with the relevant and applicable safety regulations. More information is given in: Technical Information: Safety. Table 8: Safety concept leading to an SELV circuit Conditions AC-DC converter Installation Result Supply voltage Grade of isolation between input and output, provided by the AC-DC converter Measures to achieve the resulting safety status of the output circuit Safety status of the AC-DC converter output circuit Mains 250 V AC Double or reinforced Installation according to the applicable standards SELV circuit Edition 5/6.2000 14/14