250 Watt AC-DC Converters with PFC KP Series

Transcription

1 Rugged Environmen AC-DC Converers > Wa KP Series 25 Wa AC-DC Converers wih PFC KP Series Inpu o oupu isolaion Double oupu Power facor >.95, harmonics <IEC/EN6-3-2 Oupu power up o 28 Wa Inpu over- and undervolage lock-ou Efficien inpu filer and buil-in surge and ransien suppression circuiry V rms inpu o oupu elecric srengh es Fully isolaed oupus Oupus open- and shor-circui proof Safey according o IEC/EN 695 LGA Summary C The KP series is an exension of he K series of AC-DC converers wih an increased oupu power level of up o 28 W depending on he operaing ambien emperaure requiremens. The KP converers are opimized for use in 23 V AC mains applicaions and feaure high efficiency, high reliabiliy, low oupu volage noise and excellen dynamic response o load/line changes. The converer inpus are proeced agains surges and ransiens occuring a he source lines. An inpu over- and undervolage lock-ou curcuiry disables he oupus if he inpu volage is ouside he specified range. The LKP ypes include an inrush curren limiaion prevening circui breakers and fuses from being damaged a swich-on. The oupus are open- and shor-circui proof and are proeced agains overvolages by means of a buil-in suppressor diode. The oupus can be inhibied by a logic signal applied o he connecor pin 8 (i). If he inhibi funcion is no used pin 8 mus be conneced wih pin o enable he oupus (fail safe). LED indicaors display he saus of he converer and allow visual monioring of he sysem a any ime " 6 TE "." 3 U Full inpu o oupu, inpu o case, oupu o case and oupu o oupu isolaion is provided. The modules are designed and buil according o he inernaional safey sandards IEC/EN 695. The case design allows operaion up o an operaing ambien emperaur of 7 C wih reduced oupu power. Depending on he ambien emperaure requiremens, however, he oupu power can be up o 28 W. An inernal emperaure sensor generaes an inhibi signal which disables he oupus if he case emperaure T C exceeds he specified limi. The oupus are auomaically reenabled when he emperaure drops below he limi. Various opions are available o adap he converers o individual applicaions. Especially for baery charger applicaions an exernal emperaure sensor has been designed o allow for emperaure compensaed baery charging. The modules may eiher be plugged ino 9" rack sysems according o DIN 9 or be chassis mouned. Table of Conens Page Summary... Type Survey and Key Daa... 2 Type Key... 2 Funcional Descripion... 3 Elecrical Inpu Daa... Elecrical Oupu Daa... 6 Auxiliary Funcions... Page Elecromagneic Compaibiliy (EMC)... Immuniy o Environmenal Condiions... 5 Mechanical Daa... 6 Safey and Insallaion Insrucions... 7 Descripion of Opions... 2 Accessories /23

2 KP Series AC-DC Converers > Wa Rugged Environmen Type Survey and Key Daa Non sandard inpu/oupu configuraions or special cusom adapaions are available on reques. See also: Commercial Informaion: Inquiry Form for Cusomized Power Supply. Table : Type survey Oupu Oupu curren,inpu volage and efficiency Op. volage T A = 5 C U i min...u i max h min T A = 6 C U i min...u i max h min T A = 7 C U i min...u i max h min U o [V DC] I o nom [A] V AC [%] I o nom [A] V AC [%] I o nom [A] V AC [%] LKP 566-5R 85. LKP 566-6R LKP R 85 E LKP 57-5R 85 9 LKP 57-6R 86 8 LKP 572-7R 85 D P 5 2, 2 5.8, 5.8 LKP 566-5R , 5.2 LKP 566-6R 86.8,.8 LKP R 85 T LKP 566-5R LKP 566-6R 86.8 LKP R 85 B LKP 57-5R 85.5 LKP 57-6R 86 LKP 572-7R 85 Efficiency a U i nom and I o nom. 2 Parallel connecion of U o and U o2. 3 Series connecion of U o and U o2. Designed for baery charging. Needs exernal emperaure sensor. 5 Opion P no available for LKP 57-5R, LKP 57-6R, LKP 572-7R. Type Key Type Key Inpu volage range U i : V AC, Hz... L Series... KP Number of oupus (5 for double oupus)... 5 Nominal volage oupu Recifier version... 6 Baery charger version... 7 Oher specificaions Symmerical double oupu unis: Nominal volage oupu /oupu 2, U o/2 nom 2 V/2 V (8 V series connecion) V ( V ser. conn.)... oher symmerical volages Operaional ambien emperaure range T A : 25 5 C C C Cusomer specific Auxiliary funcions and opions: Oupu volage conrol inpu... R 2 Inrush curren limiaion... E Poeniomeer (oupu volage adjusmen)... P 2 Save daa signal (D...DD, o be specified)... D Curren sharing... T Cooling plae... B L KP E R P D T B Exernal wiring of main and second oupu depending upon he desired oupu configuraion (see: R-Funcion for differen oupu configuraions). 2 Feaure R excludes opion P and vice versa. Opion P no available for LKP 57-6R. Example: LKP 57-6RD3: Power facor correced AC-DC converer, inpu volage range V AC, double oupu, each providing V/.5 A, equipped wih feaure R, undervolage monioring opion, operaional ambien emperaure range C. 2/23

3 Rugged Environmen AC-DC Converers > Wa KP Series Funcional Descripion The inpu volage is fed via an inpu fuse, an inpu filer, a recifier and an inrush curren limier o a single ransisor boos converer. This converer provides a sinusoidal inpu curren (IEC/EN 6-3-2, class D equipmen) and sources a capacior wih a volage of VDC. This capacior sources a single ransisor forward converer. Each oupu is powered by a separae secondary winding on he main ransformer. The resulan volages are recified and heir ripples smoohed by a power choke and an oupu filer. The conrol logic senses he main oupu volage U o and generaes, wih respec o he maximum admissible oupu currens, he conrol signal for he primary swiching ransisor. The second oupu is conrolled by he main oupu bu has independen curren limiing. If he main oupu is driven ino curren limiaion, he second oupu volage will fall as well and vice versa. P 32 N~ P~ Inpu filer Y Y 2 Boos converer (PFC) C i + 36 V DC Forward converer (approx. 8 khz) Y Y Y Conrol circui Y Oupu filer Oupu 2 filer Vo+ 6 8 R i D T Vo Transien suppressor (VDR). 2 Inrush curren limier (NTC or opion E). 3 Inpu fuse. Hold-up capacior. + Fig. Block diagram of symmerical double oupu converers LKP 5 3/23

4 KP Series AC-DC Converers > Wa Rugged Environmen Elecrical Inpu Daa General Condiions T A = 25 C, unless T C is specified. Pin 8 conneced o pin, U o adjused o U o nom (opion P); R inpu no conneced. Table 2: Inpu daa Inpu LKP Characerisics Condiions min yp max Uni U i Operaing inpu volage I o = I o nom V AC 3 Nominal inpu volage T C min T C max 23 U i nom I i Inpu curren U i nom, I o nom.25 A rms P i o No-load inpu power U i min U i max 7 W P i inh Idle inpu power uni inhibied 2 3 R i Inpu resisance T C = 25 C 8 mω R NTC NTC resisance 2 32 C i Inpu capaciance µf U i RFI Conduced inpu RFI EN 5522 B Radiaed inpu RFI U i nom, I o nom B U i abs Inpu volage limis V DC (wihou damage) V P Wih double oupu modules, boh oupus loaded wih I o nom. 2 Iniial swich-on cycle. Subsequen swich-on/off cycles increase he inrush curren peak value. 3 AC frequency range Hz. Inpu Fuse A fuse mouned inside he converer proecs he module agains severe defecs. Table 3: Fuse Specificaion Module Fuse ype Fuse raing LKP 5 slow-blow SP T A, 25 V Fuse size 5 2 mm Inpu Under-/Overvolage Lock-ou If he inpu volage remains below approx. V AC or exceeds approx. 28 V AC an inernally generaed inhibi signal disables he oupu(s). When checking his funcion he absolue maximum inpu volage raing U i abs should be considered! Beween U i min and he undervolage lock-ou level he oupu volage may be below he value defined in able: Oupu daa (see: Technical Informaion: Measuring and Tesing). Inpu Transien Proecion A VDR ogeher wih he inpu fuse and a symmerical inpu filer form an effecive proecion agains high inpu ransien volages. Inrush Curren Limiaion The modules of he versions -5, -6, -7 incorporae an NTC resisor in he inpu circuiry which - a iniial urn on - reduces he peak inrush curren value by a facor of 5... o proec connecors and swiching devices from damage. Subsequen swich-on cycles wihin shor periods will cause an increase of he peak inrush curren value due o he warming-up of he NTC resisor. See also: E opion. Inrush Curren Peak Value The inrush curren peak value (iniial swich-on cycle) can be deermined by following calculaion: U i rms 2 I inr p = (R s ex + R i + R NTC ) U i rms R s ex I inr p R i R NTC Fig. 2 Equivalen circui diagram for inpu impedance C i /23

5 Rugged Environmen AC-DC Converers > Wa KP Series Inpu Inrush Curren Characerisic Saic Inpu curren Characerisic I inr [A] 5 l i [A rms ] Û i = 36 V Û i = 26 V.5 Power Facor [ms] Fig. 3 Theoreical inpu inrush curren versus ime a Û i = 87 V 2 (26 V) and 255 V 2 (36 V), R ex = Power Facor, Harmonics Power facor correcion is achieved by conrolling he inpu curren waveform synchronously wih he inpu volage waveform. The power facor conrol is acive under all operaing condiions. 57 U i = 255 V AC U i = 87 V AC I o /I o nom Fig. Power facor versus oupu power a U i 255 V AC and 87 V AC. 75 I i [ma/w] Fig. 5 Inpu curren versus inpu volage a I o nom U i [V AC] Harmonic Currens The harmonic disorion is well below he limis specified in IEC/EN 6-3-2, class D. 55 Harm Fig. 6 Harmonic currens a he inpu, IEC/EN 6-3-2, class D. U i = U i nom, I o = I o nom. 5/23

6 KP Series AC-DC Converers > Wa Rugged Environmen Elecrical Oupu Daa General Condiions T A = 25 C, unless T C is specified. Pin 8 (i) conneced o pin (S /Vo ), U o adjused o U o nom (opion P), R inpu no conneced. Table a: Oupu daa double oupu modules Oupu LKP LKP 57-6 (Oupus conneced in Series) 8 V (2 2 V) 5.36 V ( V) Characerisics Condiions min yp max min yp max Uni U o Oupu volage 2 U i nom, I o nom V U o max Maximum oupu 56.5 volage for baery charging U o P Overvolage proecion I o nom Oupu curren U i min...u i max A T C min...t C max I ol Oupu curren limi U i min...u i max u 7 o Oupu Low frequency U i nom, I o nom 5 5 mv pp volage IEC/EN 62 Swiching freq. 3 3 noise 3 BW = 2 MHz Toal 8 8 DU o U Saic line regulaion U i min...u i nom ±2 ±2 mv U i nom...u i max I o nom DU o I Saic load regulaion U i nom, I o = (...) I o nom u 5 o d Dynamic Volage U i nom ±2 ±2 load deviaion I o nom /2 I o nom 5 regulaion IEC/EN 62 d Recovery.3.3 ms ime a Uo Temperaure coefficien T C min...t C max mv/k of oupu volage 6...I o nom If he oupu volages are increased above U o nom hrough R-inpu conrol, opion P seing, remoe sensing or opion T, he oupu currens should be reduced accordingly so ha P o nom is no exceeded. Series connecion for U o nom = 8 V or 5.35 V, see: R-Funcion for differen oupu configuraions. Facory adjused wih open R-inpu. Shores possible wiring for series connecion a he connecor. See: Typical Oupu Volage Regulaion of Single or Double Oupu Modules wih Oupus and 2 Conneced in Series. See: Typical dynamic load regulaion of U o and U o2. Negaive emperaure coefficien (... 3 mv/cell and K) available on reques. Measured according o IEC/EN 62 sub clause 3. wih a probe acc. o annex A of he same sandards. (See: Technical Informaion: Measuring and Tesing.) 6/23

7 Rugged Environmen AC-DC Converers > Wa KP Series Table b: Oupu daa double oupu modules Oupu LKP LKP 57-6 (Oupus independenly loaded) 2 V/2 V V/25.68 V Characerisics Condiions Oupu Oupu 2 Oupu Oupu 2 min yp max min yp max min yp max min yp max Uni U o Oupu volage 2 U i nom, I o nom V U o max Maximum oupu volage for baery charging U o P Overvolage proecion I o nom Oupu curren 3 U i min...u i max A T C min...t C max I ol Oupu curren limi U i min...u i max u 8 o Oupu Low frequency U i nom, I o nom mv pp volage IEC/EN 62 Swiching freq. noise BW = 2 MHz Toal 5 5 DU o U Saic line regulaion U i min...u i nom ± ± ± ± mv U i nom...u i max I o nom DU o I Saic load regulaion U i nom, I o = 5 5 (...) I 5 o nom u 6 o d Dynamic Volage U i nom ±5 ±5 load deviaion I o nom /2 I o nom 6 d regulaion Recovery IEC/EN ms ime a Uo Temperaure coefficien T C min...t C max mv/k of oupu volage 7...I o nom Depending upon he desired oupu configuraion he wiring should be made as shown in: R-Funcion for differen oupu configuraions. 2 Same condiions for boh oupus. Facory adjusmen wih open R-inpu. 3 If he oupu volages are increased above U o nom via R-inpu conrol, opion P seing, remoe sensing or opion T, he oupu currens should be reduced accordingly so ha P o nom is no exceeded. See: Typical Oupu Volage Regulaion of Single or Double Oupu Modules wih Oupus and 2 Conneced in Series. 5 Condiion for specified oupu. Oher oupu loaded wih consan curren I o = I o nom. See fig.: Oupu volage regulaion of double oupu unis. 6 See: Typical dynamic load regulaion of U o and U o2. 7 Negaive emperaure coefficien (... 3 mv/cell and K) available on reques. 8 Measured according o IEC/EN 62 sub clause 3. wih a probe acc. o annex A of he same sandards. (see: Technical Informaion: Measuring and Tesing) 7/23

8 KP Series AC-DC Converers > Wa Rugged Environmen Thermal Consideraions If a converer is locaed in free, quasi-saionary air (convecion cooling) a he indicaed maximum ambien emperaure T A max (see: able Temperaure specificaions) and is operaed a is nominal inpu volage and oupu power, he emperaure measured a he Measuring poin of case emperaure T C (see: Mechanical Daa) will approach he indicaed value T C max afer he warm-up phase. However, he relaionship beween T A and T C depends heavily on he condiions of operaion and inegraion ino a sysem. The hermal condiions are influenced by inpu volage, oupu curren, airflow and emperaure of surrounding componens and surfaces. T A max is herefore, conrary o T C max, an indicaive value only. Cauion: The insaller mus ensure ha under all operaing condiions T C remains wihin he limis saed in he able: Temperaure specificaions. Noes: Sufficien forced cooling or an addiional hea sink allows T A o be higher han 6 C (e.g. 7 C) if T C max is no exceeded. I o /I o nom convecion cooling forced cooling T C max.3.2. T A min T A [ C] Fig. 7 Oupu curren deraing versus emperaure for -5, -6 and -7 unis. Thermal Proecion A emperaure sensor generaes an inernal inhibi signal which disables he oupus if he case emperaure exceeds T C max. The oupus are auomaically re-enabled if he emperaure drops below his limi. Oupu Proecion Each oupu is proeced agains overvolage which could occur due o a failure of he conrol circui by means of a volage suppressor diode which, under wors case condiions, may become a shor circui. The suppressor diodes are no designed o wihsand exernally applied overvolages. Overload a any of he wo oupus will cause a shu-down of boh oupus. A red LED indicaes he overload condiion. 53 Parallel or Series Connecion of Unis Unis wih equal nominal oupu volage can be conneced in parallel wihou any precauions using opion T. Wih opion T (curren sharing), all unis share he curren approximaely equally. Main and second oupus can be conneced in series wih any oher (similar) oupu. Noe: Parallel connecion of double oupu unis should always include boh, main and second oupu o mainain good regulaion of boh oupus. No more han 3 unis should be conneced in parallel. Series connecion of second oupus wihou involving heir main oupus should be avoided as regulaion may be poor. The maximum oupu curren is limied by he oupu wih he lowes curren limiaion if several oupus are conneced in series. Efficiency versus Load Efficiency U i = 87 V AC U i = 23 V AC I o /I o nom Fig. 8 Efficiency versus load a U i 23 V AC and 87 V AC Swiching Frequency versus Load Frequency [khz] load [I o /I o nom ] Fig. 9 Swiching frequency versus load. (The boos converer a he inpu sage has a fixed frequency of khz) 8/23

9 Rugged Environmen AC-DC Converers > Wa KP Series Oupu Volage Regulaion Oupu is under normal condiions regulaed o U o nom, independen of he oupu currens. U o2 is dependen upon he load disribuion. If boh oupus are loaded wih more han % of I o nom, he deviaion of U o2 remains wihin ±5% of he value of U o. The following figure shows he regulaion wih varying load disribuion. If I o = I o2 or he wo oupus are conneced in series, he deviaion of U o2 remains wihin ±% of he value of U o provided ha a oal load of more han % of I o nom is applied. If boh oupus of a single LKP 5 module are conneced in parallel he paralleled oupu is fully regulaed. No precauions are necessary in using he R-inpu and he es sockes. Dynamic Load Regulaion I o /I o nom I o2 /I o2 nom U o U od d U o2 U o2d U r U od d 55 U r [V] U o I o = % I o = 5% I o = %.5 < µs < µs Fig. 2 Typical dynamic load regulaion of U o and U o Oupu Volage Regulaion Conneced in Series U o U o nom I o2 /I o2 nom Fig. LK 566: DU o2 (yp.) versus I o2 wih differen I o.5 I o 558 Hold-up Time versus Oupu Power ime [ms] I o /I o nom Fig. 3 Hold-up ime h versus oupu power I ol Fig. U o versus I o.5. I o I o nom 9/23

10 KP Series AC-DC Converers > Wa Rugged Environmen Auxiliary Funcions i Inhibi for Remoe On and Off Noe: Wih open i inpu: Oupu is disabled (U o = off). The oupus of he module may be enabled or disabled by means of a logic signal (TTL, CMOS, ec.) applied beween he inhibi inpu i and he negaive pin of oupu (Vo ). In sysems wih several unis, his feaure can be used, for example, o conrol he acivaion sequence of he converers. If he inhibi funcion is no required, connec he inhibi pin 8 o pin o enable he oupus (acive low logic, fail safe). For oupu response refer o: Hold-up Time and Oupu Response. Vi+ Vi Fig. Definiion of U inh and I inh. I inh [ma] U inh =.8 V U o = on Table 5: Inhibi characerisics Vo+ Characerisic Condiions min yp max Uni U inh Inhibi U o = on U i min U i max 5.8 V volage Uo = off 2. 5 i Vo I inh U inh = 2. V U inh U o = off Fig. 5 Typical inhibi curren I inh versus inhibi volage U inh U inh [V] Baery Charging/Temperaure Sensor The LKP 57-6R, LKP 57-5R, LKP 572-7R are inended for lead acid baery charger applicaions. For an opimum baery charging and life expecancy of he baery an exernal emperaure sensor may be conneced o he R-inpu. The sensor is mouned as close as possible o he baery pole and adjuss he oupu volage of he LKP uni according o he emperaure of he baery (which is relaed o he load of he baery and he ambien emperaure). Depending on he cell volage and he emperaure coefficien of he baery, differen sensor ypes are available. For more informaion please ask Melcher. Cell volage [V] U o /U o nom. r f Inhibi Fig. 6 Oupu response as a funcion of inhibi conrol U o nom U z = 2.23 V, 3.5 mv/k U z = 2.27 V, 3.5 mv/k U o max 2. [ C] Fig. 7 Dependance of oupu volage vs. emperaure for defined emperaure coefficien. I inh Inhibi curren U inh = µa r Rise ime 3 ms f Fall ime depending on I o /23

11 Rugged Environmen AC-DC Converers > Wa KP Series Programmable Oupu Volage (R-Funcion) As a sandard feaure, he modules offer an adjusable oupu volage, idenified by leer R in he ype designaion. The conrol inpu R (pin 6) acceps eiher a conrol volage U ex or a resisor R ex o adjus he desired oupu volage. When no conneced, he conrol inpu auomaically ses he oupu volage o U o nom. a) Adjusmen by means of an exernal conrol volage U ex beween pin 6 (R) and pin : The conrol volage range is V DC and allows an oupu volage adjusmen in he range of approximaely...% U o nom. U o U ex = 2.5 V (approximae formula) U o nom b) Adjusmen by means of an exernal resisor: Depending upon he value of he required oupu volage he resisor shall be conneced eiher: Beween pin 6 and pin (U o < U o nom ) o achieve an oupu volage adjusmen range of approximaely...% U o nom or: Beween pin 6 and pin 2 (U o > U o nom ) o achieve an oupu volage adjusmen range of approximaely...% U o nom. Table 6a: R ex for U o < U o nom ; approximae values (U i nom, I o nom, series E 96 resisors); R' ex = U o nom = 2 V U o [V] R ex [kω] Remarks: The R-Funcion excludes opion P (oupu volage adjusmen by poeniomeer). If he oupu volages are increased above U o nom via R- inpu conrol, opion P seing, remoe sensing or opion T, he oupu curren(s) should be reduced accordingly so ha P o nom is no exceeded. The R-inpu (as well as opion P) is relaed o he main oupu. Wih double oupu unis he second oupu follows he value of he conrolled main oupu. Resisor values as indicaed for he single oupu unis should be used. For correc oupu volage adjusmen of double oupu unis he exernal wiring of he oupus should be according o: R-funcion for differen oupu configuraions depending upon he desired oupu configuraion. In case of parallel connecion he oupu volages should be individually se wihin a olerance of...2%. Warning: U ex shall never exceed 2.75 V DC. The value of R' ex shall never be less han he lowes value as indicaed in able R' ex (for U > U nom ) o avoid damage o he uni! Table 6b: R ex for U o > U o nom ; approximae values (U i nom, I o nom, series E 96 resisors); R ex = U o nom = 2 V U o [V] R' ex [kω] Firs column: single oupu unis or double oupu unis wih separaed oupus, second column: oupus in series connecion /23

12 KP Series AC-DC Converers > Wa Rugged Environmen R-Funcion for differen oupu configuraions Vo+ Vo U o 8 V Vo+ Vo U o 2 V R 6 R ex R' ex R 6 R ex R' ex Fig. 8a LKP 5 wih H5 connecor. R-inpu for oupu volage conrol. Wiring for oupu volage 8 V wih main and second oupu conneced in series. Fig. 8b LKP 5 wih H5 connecor. R-inpu for oupu volage conrol. Wiring for oupu volage 2 V wih main and second oupu conneced in parallel. V V 62 + Vo+ Vo R U o2 2 V U o +2 V R ex R' ex + Vo+ Vo R R ex U o R' ex U o2 +2 V V + Fig. 8c LKP 5 wih H5 connecor. R-inpu for oupu volage conrol. Wiring of main and second oupu for wo symmerical oupu volages U o and U o2 : ±2 V. Fig. 8d LKP 5 wih H5 connecor. R-inpu for oupu volage conrol. Wiring of main and second oupu for wo oupu volages U o and U o2 : +2 V and +8 V U o2 2 V 8 A ceramic mulilayer capacior conneced across he load reduces ripple and spikes. 2 Shores possible wiring for series connecion a he female connecor Vo+ Vo R 2 6 R ex R' ex 2 V U o Fig. 8e LKP 5 wih H5 connecor. R-inpu for oupu volage conrol. Wiring of main and second oupu for wo oupu volages U o and U o2 : 2 V/2 V, he oupus are galvanically isolaed. + Remarks: Double oupu unis fied wih H5 connecors have he oupu pins of he second oupu, pins /6 and 8/, inernally paralleled. I is recommended ha pins /6 and 8/ be direcly paralleled a he female connecor as well o reduce he volage drop across he connecor. Please noe: U o2 varies depending upon is own load and he load on oupu. 2/23

13 Rugged Environmen AC-DC Converers > Wa KP Series Display Saus of LEDs OK i I o L U o > U o adj 62 U i Fig. 9 LEDs "OK", "i" and "I o L "saus versus inpu volage Condiions: I o I o nom, T C T C max, U inh.8 V U i uv = undervolage lock-ou, U i ov = overvolage lock-ou U i uv U i min U i max U i ov U i abs OK I o L i U o > U o adj I o U o < U o adj I o nom I ol T C LEDs "OK" and "I o L "saus versus oupu curren Condiions: U i min...u i max, T C T C max, U inh.8 V LED "i"versus case emperaure Condiions: U i min...u i max, I o I o nom, U inh.8 V T C max T PTC hreshold U inh hreshold i -5 V LED off +.8 V +2. V LED Saus undefined U i inh +5 V LED on LED "i"versus U inh Condiions: U i min...u i max, I o I o nom, T C T C max Tes Sockes (Main oupu only ) Tes sockes for measuring he oupu volage U o are locaed a he fron of he module. The posiive es socke is proeced by a series resisor (see: Funcional Descripion, block diagrams). The volage measured a he es sockes is approximaely 3 mv lower han he value measured a he oupu erminals. In case of double oupu unis exernally conneced in series for U o = 5 V or 8 V he moniored oupu volage is 25,5 V or 2 V respecively. 3/23

14 KP Series AC-DC Converers > Wa Rugged Environmen Elecromagneic Compaibiliy (EMC) A meal oxide VDR ogeher wih an inpu fuse and an inpu filer form an effecive proecion agains high inpu ransien volages which ypically occur in mos insallaions. The KP series has been successfully esed o he following specificaions: Elecromagneic Immuniy Table 7: Immuniy ype ess Phenomenon Sandard Level Coupling Value Waveform Source Tes In Permode 2 applied imped. procedure oper. form. 3 Volage surge IEC 657- i/c, +i/ i 8 V p µs Ω pos. and neg. yes 5 V p 5 µs volage surge per coupling mode 3 V p 5 µs V p µs 7 V p ns Supply relaed RIA 2 B +i/ i.5 U ba.//. s.2 Ω posiive yes surge surge Direc ransien C +i/c, i/c 96 V p / µs 5 Ω 5 pos. and 5 neg. yes D 8 V p 5/5 µs impulses E 36 V p.5/5 µs Ω F 8 V p./ µs G 8 V p.5/. µs Indirec coupled H +o/c, o/c 8 V p 5/5 µs ransien J 36 V p.5/5 µs K 8 V p./ µs L 8 V p.5/. µs Elecrosaic IEC/EN conac discharge 8 V p /5 ns 33 Ω posiive and yes A discharge 6--2 negaive air discharge 5 V p (o case) discharges Elecromagneic IEC/EN 3 anenna V/m AM 8% n.a. 26 MHz yes field 6--3 khz Elecromagneic ENV 52 5% duy cycle, 9 ±5 MHz yes field, 2 Hz repeiion pulse modulaed frequency Elecrical fas IEC/EN capaciive, o/c 2 V p burss of 5/5 ns 5 Ω min posiive yes A ransien/burs /5 khz over min negaive i/c, +i/ i V p 5 ms; burs ransiens per direc period: 3 ms coupling mode Surge IEC/EN 3 i/c 2 V p.2/5 µs 2 Ω 5 pos. and 5 neg. yes B i/ i 2 Ω surges per Conduced IEC/EN 3 i, o, signal wires V rms AM 8% 5 Ω MHz yes disurbances 6--6 ( dbµv) khz Volage dips, IEC/EN % +i/ i //2 s n.a. B shor inerrup V ions and vola- (able of he % 23 ge variaions sandard) 23 V B Relaed and previous sandards are referenced in: Technical Informaion: Sandards. 2 i = inpu, o = oupu, c = case. 3 A = Normal operaion, no deviaion from specificaions, B = Normal operaion, emporary deviaion from specs possible. Tes in progress, please consul facory. Noe: Previous sandards are referenced in: Technical Informaion: Sandards. /23

15 Rugged Environmen AC-DC Converers > Wa KP Series [dbµv] A B [dbµv/m] A B MHz [MHz] Fig. 2 Typical disurbance volage (quasi-peak) a he inpu according o CISPR /22 and EN 55/22, measured a U i nom and I o nom. Fig. 2 Typical radiaed elecromagneic field srengh (quasi-peak) according o CISPR /22 and EN 55/22, normalized o a disance of m, measured a U i nom and I o nom. Immuniy o Environmenal Condiions Table 8: Mechanical sress Tes mehod Sandard Tes condiions Saus Ca Damp hea IEC/DIN IEC Temperaure: ±2 C Uni no seady sae MIL-STD-8D secion 57.2 Relaive humidiy: 93 +2/-3 % operaing Duraion: 56 days Ea Shock IEC/EN/DIN EN Acceleraion ampliude: g n = 98 m/s 2 Uni (half-sinusoidal) MIL-STD-8D secion 56.3 Bump duraion: 6 ms operaing Number of bumps: 8 (3 each direcion) Eb Bump IEC/EN/DIN EN Acceleraion ampliude: g n = 392 m/s 2 Uni (half-sinusoidal) MIL-STD-8D secion 56.3 Bump duraion: 6 ms operaing Number of bumps: 6 ( each direcion) Fc Vibraion IEC/EN/DIN EN Acceleraion ampliude:.35 mm (...6 Hz) Uni (sinusoidal) MIL-STD-8D secion g n = 9 m/s 2 (6...2 Hz) operaing Frequency ( Oc/min):...2 Hz Tes duraion: 7.5 h (2.5 h each axis) Fda Random vibraion IEC Acceleraion specral densiy:.5 g 2 n /Hz Uni wide band DIN 6 par 23 Frequency band: Hz operaing Reproducibiliy Acceleraion magniude:.9 g n rms high Tes duraion: 3 h ( h each axis) Kb Sal mis, cyclic IEC/EN/DIN IEC Concenraion: 5% (3 C) Uni no (sodium chloride Duraion: 2 h per cycle operaing NaCl soluion) Sorage: C, 93% rel. humidiy Sorage duraion: 22 h per cycle Number of cycles: 3 Table 9: Temperaure specificaions, values given are for an air pressure of hpa (8...2 mbar) Temperaure Characerisics Condiions min max min max min max Uni T A Ambien emperaure U i min...u i max C Case emperaure I o =...I o nom T C T S Sorage emperaure No operaional 5/23

16 KP Series AC-DC Converers > Wa Rugged Environmen Mechanical Daa Dimensions in mm. Tolerances ±.3 mm unless oherwise indicaed TE 9 TE Measuring poin of case emperaure T C 6.5 (3U) Graviaional axis Tes jacks (+/ ) Opion P (U o ) Opion D (U o ) Opion D (U i ) LED i (red) LED OK (green) LED I ol (red) = Ø 3.5 = Ø (DIN 9) 2 8 Fron plae Main face d 68.5 ±.5 Back plae European Projecion Fig. 22 Case K2 wih heasink, case aluminium, black finish and self cooling, weigh: approx..55 kg Noe: d 5 mm, recommended minimum disance o nex par o ensure proper air circulaion a full oupu power. free air locaions: he module should be mouned wih fins in verical posiion o achieve a maximum air flow hrough he hea sink TE TE M (3U) Measuring poin of case emperaure T C ± (DIN 9) Fig. 23 Case K2 wih opion B (cooling plae), case aluminium, black finish and self cooling, weigh: Approx..5 kg /23

17 Rugged Environmen AC-DC Converers > Wa KP Series Safey and Insallaion Insrucions Connecor Pin Allocaion The connecor pin allocaion able defines he elecrical poenials and he physical pin posiions on he H5 connecor. Pin no. 2, he proecive earh pin presen on all LKP AC-DC converers is leading, ensuring ha i makes conac wih he female connecor firs. Table : H5 connecor pin allocaion Pin Connecor ype H5 No. LKP 5 Oupu 2 6 Oupu 2 8 Oupu 2 Oupu 2 2 Vo+ Oupu Vo Oupu 6 R Conrol of U o 8 i Inhibi 2 D Save daa 22 T Curren sharing 2 2 Proecive earh 26 N Neural 28 N Neural 3 P Phase 32 P Phase Feaure R excludes opion P and vice versa 2 Leading pin (pregrounding) 32 Fixures for connecor reension clips V (see Accessory Producs) Fig. 2 View of module's male connecors Proecion Degree Condiion: Female connecor fied o he uni. IP 3: All unis excep hose wih opion P, and excep hose wih opion D wih poeniomeer. IP 2: All unis fied wih opion P, or wih opion D wih poeniomeer. 8 Insallaion Insrucions The KP series AC-DC converers are componens, inended exclusively for inclusion wihin oher equipmen by an indusrial assembly operaion or by professional insallers. Insallaion mus sricly follow he naional safey regulaions in compliance wih he enclosure, mouning, creepage, clearance, casualy, markings and segregaion requiremens of he end-use applicaion. Connecion o he sysem shall be made via he female connecor H5 (see: Accessories). Oher insallaion mehods may no mee he safey requiremens. The AC-DC converers are provided wih pin no. 2 ( ), which is reliably conneced wih heir case. For safey reasons i is essenial o connec his pin wih he proecive earh of he supply sysem. An inpu fuse is buil-in in he connecion from pins no. 3 and 32 (P~) of he uni. Since his fuse is designed o proec he uni in case of an overcurren and does no necessarily cover all cusomer needs, an exernal fuse suiable for he applicaion and in compliance wih he local requiremens migh be necessary in he wiring o one or boh inpu poenials, pins nos. 26 and 28 and/or nos. 3 and 32. Imporan: Whenever he inhibi funcion is no in use, pin no. 8 (i) should be conneced o pin no. (Vo ) o enable he oupu(s). Do no open he modules, or guaranee will be invalidaed. Due o high curren values, all LKP unis provide wo inernally parallel conneced conacs for cerain pahs (pins /6, 8/, 26/28 and 3/32, respecively). I is recommended o connec load and supply o boh female connecor pins of each pah in order o keep he volage drop across he connecor pins o an absolue minimum and o no oversress he connecor conacs if currens are higher han approx. 8 A. The connecor conacs are raed 8 A over he whole emperaure range. Make sure here is sufficien air flow available for convecion cooling. This should be verified by measuring he case emperaure when he uni is insalled and operaed in he end-use applicaion. The maximum specified case emperaure T C max shall no be exceeded. See also: Thermal Consideraions. If he end-produc is o be UL cerified, he emperaure of he main isolaion ransformer should be evaluaed as par of he end-produc invesigaion. Check for hazardous volages before alering any connecions. The oupu provides a hazardous energy level according o IEC/EN 695. Ensure ha a uni failure (e.g. by an inernal shor-circui) does no resul in a hazardous condiion. See also: Safey of operaor accessible oupu circui. Cleaning Agens In order o avoid possible damage, any peneraion of cleaning fluids is o be prevened, since he power supplies are no hermeically sealed. 7/23

18 KP Series AC-DC Converers > Wa Rugged Environmen Sandards and Approvals All AC-DC converers correspond o class I equipmen. They are UL recognized according o UL 95, UL recognized for Canada o CAN/CSA C22.2 No and LGA approved o IEC/EN 695 sandards. The unis have been evaluaed for: Building in Basic insulaion beween inpu and case, based on 25 V AC and V DC Double or reinforced insulaion beween inpu and oupu, based on 25 V AC and V DC Operaional insulaion beween oupu and case. Operaional insulaion beween oupu and oupu The use in a polluion degree 2 environmen Connecing he inpu o a primary or secondary circui which is subjec o a maximum ransien raing of 25 V (overvolage caegory III based on a V primary circui, overvolage caegory II based on a 23 V primary circui). The AC-DC converers are subjec o manufacuring surveillance in accordance wih he above menioned UL, CSA, EN and ISO 9 sandards. Isolaion The elecric srengh es is performed as facory es in accordance wih IEC/EN 695 and UL 95 and should no be repeaed in he field. Melcher will no honour any guaranee claims resuling from elecric srengh field ess. Table : Isolaion Characerisic Inpu o Inpu o Oupu o Oupu o Uni case oupu case oupu Imporan: Tesing by applying AC volages will resul in high and dangerous leakage currens flowing hrough he Y-capaciors (see fig.: Block diagram). Elecric Required according o.5 3. kv rms srengh IEC/EN 695 es volage 2..2 kv DC Acual facory es s AC es volage equivalen kv rms o acual facory es Insulaion resisance a 5 V DC >3 >3 >3 > 2 MΩ For creepage disances and clearances refer o Technical Informaion: Safey. In accordance wih IEC/EN 695 only subassemblies are esed in facory wih his volage. 2 Tesed a V DC. Leakage Currens in AC-DC operaion Leakage currens flow due o inernal leakage capaciance and RFI suppression Y-capaciors. The curren values are proporional o he mains volage and nearly proporional o he mains frequency and are specified a an inpu volage of 25 V (5 Hz) where phase, neural and proecive earh are correcly conneced as required for class I equipmen. MI 5 Ω 5 Ω kω 22 nf 6 Under es condiions he leakage curren flows hrough a measuring insrumen (MI) as described in fig.: Measuring insrumen for earh leakage curren ess, which akes ino accoun impedance and sensiiviy of a person ouching unearhed accessible pars. The curren value is calculaed by dividing he measured volage by 5 Ω. If inpus of K- unis are conneced in parallel, heir individual leakage currens are added. P N P N 62 Vo+ Vo 22 nf V Fig. 25 Measuring insrumen (MI) for earh leaking curren ess according o IEC/EN 695. Fig. 26 Tes se-up MI for earh leakage curren Table 2: Leakage currens Characerisic Class I Uni LKP 5 Maximum earh Permissible according o IEC/EN ma leakage curren Specified value a 25 V, 5 Hz.82 8/23

19 Rugged Environmen AC-DC Converers > Wa KP Series Safey of operaor accessible oupu circui If he oupu circui of an AC-DC converer is operaor accessible, i shall be an SELV circui according o he IEC/EN 695 relaed safey sandards. The following able shows a possible insallaion configuraion, compliance wih which causes he oupu circui of an KP series AC-DC converer o be an SELV circui according o IEC/EN 695 up o a configured oupu volage (sum of nominal volages if in series or +/ configuraion) of 36 V. However, i is he sole responsibiliy of he insaller o assure he compliance wih he relevan and applicable safey regulaions. More informaion is given in: Technical Informaion: Safey. Table 3: Safey concep leading o an SELV oupu circui Condiions AC-DC converer Insallaion Resul Nominal volage Grade of insulaion Measures o achieve he resuling Safey saus of he AC-DC beween inpu and oupu safey saus of he oupu circui converer oupu circui provided by he AC-DC converer Mains Double or reinforced Earhed case and insallaion SELV circui 25 V AC according o he applicable sandards The earh connecion has o be provided by he insaller according o he relevan safey sandards, e.g. IEC/EN 695. Mains Earh connecion ~ ~ Fuse Fuse AC-DC converer 2 + SELV Fig. 27 Schemaic safey concep. Use fuses and earh connecion as per :Insallaion Insrucions and able: Safey concep leading o an SELV oupu circui. 9/23

20 KP Series AC-DC Converers > Wa Rugged Environmen Descripion of Opions Table : Survey of opions Opion Funcion of Opion Characerisics E Elecronic inrush curren limiaion circuiry Acive inrush curren limiaion P, 2 Poeniomeer for fine adjusmen of oupu volage Adjusmen range +/ 6% of U o nom excludes R inpu D Inpu and/or oupu undervolage monioring circuiry Safe daa signal oupu (Versions D...DD) T Curren sharing Inerconnec T-pins if paralleling oupus (3 unis max.) B Cooling plae Replaces sandard hea sink, allowing direc chassis-mouning Opion R excludes opion P and vice versa. 2 Opion P no available for LKP 57-6R Opion T Curren Sharing This opion ensures ha he oupu currens are approximaely shared beween all paralleled modules and increases sysem reliabiliy. To use his faciliy, simply inerconnec he T pins of all modules. The load leads should have equal lengh and cross secion o ensure equal volage drops. No more han 3 unis should be conneced in parallel. If oupu volage adjusmen is requesed we srongly recommend o use he R-inpu insead of opion P, as wih opion P he required seing accuracy is difficul o achieve. The oupu volages mus be individually se prior o paralleling o wihin a olerance of...2% or he R pins should be conneced ogeher. Module Module max. 5 unis in parallel connecion T Vo+ Vo Vo+ Vo Power bus + Fig. 28 Paralleling of double oupu unis using opion T wih Power Bus T 37 Load Opion P Poeniomeer The poeniomeer provides an oupu volage adjusmen range of +/ 6% of U o nom and is accessible hrough a hole in he fron cover. This feaure enables compensaion for volage drops across he connecor and wiring. Opion P is no recommended if unis are conneced in parallel. Opion P excludes he R-funcion. Wih double oupu unis boh oupus are affeced by he poeniomeer seing (doubling he volage seing if he oupus are in series). If he oupu volages are increased above U o nom via R-inpu conrol, opion P seing, remoe sensing or opion T, he oupu curren(s) should be reduced accordingly so ha P o nom is no exceeded. E Inrush Curren Limiaion The converers may be supplemened by an elecronic circui (opion E, replacing he sandard buil-in NTC) o achieve an enhanced inrush curren limiing funcion. Table 5: Inrush curren characerisics wih opion E Characerisics LKP Uni U i = 23 V AC yp max I inr p Peak inrush curren 2.7 A inr Inrush curren duraion 35 5 ms Inpu Filer Precauion: Subsequen swich-on cycles a sar-up are limied o max. cycles during he firs 2 seconds (cold uni) and a coninuing on/off (T C =95 C) max. cycle every 8 sec I i [A] Recifier Fig. 29 Opion E block diagram R S inr Conrol FET Capacior C i fully charged Normal operaion (FET fully conducing) [ms] Fig. 3 Inrush curren wih opion E, U i = 23 V AC, P o = P o nom R I PFC - Conrol C i Converer 2/23

21 Rugged Environmen AC-DC Converers > Wa KP Series Opion D Undervolage Monior The inpu and/or oupu undervolage monioring circui operaes independenly of he buil-in inpu undervolage lockou circui. A logic "low" (JFET oupu) or "high" signal (NPN oupu) is generaed a pin 2 as soon as one of he moniored volages drops below he preseleced hreshold level U. The reurn for his signal is Vo. The D oupu recovers when he moniored volage(s) exceed(s) U + U h. The hreshold level U i is adjused in he facory. The hreshold level U o is eiher adjused by a poeniomeer, accessible hrough a hole in he fron cover, or facory adjused o a fixed value specified by he cusomer. Opion D exiss in various versions D...DD as shown in he following able. Table 6: Undervolage monioring funcions Oupu ype Monioring Minimum adjusmen range Typical hyseresis U ho [% of U ] JFET NPN U i U o of hreshold level U for U min...u max U i U o U ho D D5 no yes V D2 D6 yes no 355 V DC - - D3 D7 yes yes 355 V DC ( U o ) 2 "" D D8 no yes - ( U o ) 2 "" D D9 no yes V yes yes 355 V DC V DD yes yes 355 V DC V Threshold level adjusable by poeniomeer 2 Fixed value. Tracking if U o adjused via R-inpu, opion P or sense lines. 3 The hreshold level permanenly adjused according o cusomer specificaion ±2% a 25 C. Any value wihin he specified range is basically possible bu causes a special ype designaion in addiion o he sandard opion designaions (D/D9)! Opion D moniors he boos regulaor oupu volage. The rigger level is adjused in he facory o 355 V DC. JFET oupu (D D): Connecor pin D is inernally conneced via he drainsource pah of a JFET (self-conducing ype) o he negaive poenial of oupu. U D. V (logic low) corresponds o a moniored volage level (U i and/or U o ) <U. The curren I D hrough he JFET should no exceed 2.5 ma. The JFET is proeced by a.5 W Zener diode of 8.2 V agains exernal overvolages. Inpu 6 Vo+ I D D U D R p U i, U o saus U i or U o < U U i and U o > U + U h D oupu, U D low, L, U D. V a I D = 2.5 ma high, H, I D 25 µa a U D = 5.25 V NPN oupu (D5...DD): Connecor pin D is inernally conneced via he collecoremier pah of a NPN ransisor o he negaive poenial of oupu. U D <. V (logic low) corresponds o a moniored volage level (U i and/or U o ) > U + U h. The curren I D hrough he open collecor should no exceed 2 ma. The NPN oupu is no proeced agains exernal overvolages. U D should no exceed V. Fig. 3 Opion D...D: JFET oupu, I D 2.5 ma Inpu 7 Vo Vo+ D I D U D R p U i, U o saus U i or U o < U U i and U o > U + U h D oupu, U D high, H, I D 25 µa a U D = V low, L, U D. V a I D = 2 ma Vo Fig. 32 Opion D5...DD: NPN oupu, U o V, I D 2 ma Table 7: D-oupu logic signals Version of D U i < U resp. U o < U U i > U + U h resp. U o > U Configuraion D, D2, D3, D, D low high JFET D5, D6, D7, D8, D9, DD high low NPN 2/23

22 KP Series AC-DC Converers > Wa Rugged Environmen D-signal wih respec o inpu and oupu volage versus ime: Inpu volage monioring NPN U D U D high U D low I D I D high I D low JFET U D U D high U D low h low min low min low min high min U o U o nom.95 h U ci [V DC] Inpu volage failure Swich-on cycle Inpu volage sag Swich-on cycle and subsequen Oupu volage monioring inpu volage failure NPN U D U D high 2 U D low I D I D high I D low JFET U D U D high U D low low min U o U o nom U o +U ho U o Oupu volage failure Fig. 33 Relaionship beween U ci, U o, U D, U o /U o nom versus ime Hold-up ime see secion: Elecrical Inpu Daa. 2 Wih oupu volage monioring, hold-up ime h =. 3 The signal will remain high if he D oupu is conneced o an exernal source. low min =...7 ms, ypically 3 ms. 22/23

23 Rugged Environmen AC-DC Converers > Wa KP Series B Cooling Plae (see: Mechanical Daa) Where a cooling surface is available, we recommend he use of a cooling plae (opion B) insead of he sandard heasink. The mouning sysem should ensure sufficien cooling capaciy o guaranee ha he maximum case emperaure T C max is no exceeded. The cooling capaciy is calculaed by: (% η) P Loss = (U o I o ) η Efficiency h see: Type survey. Accessories A variey of elecrical and mechanical accessories are available including: Fron panels for 9" rack mouning, Schroff and Inermas sysems. Maing H5 connecors wih screw, solder, fas-on or press-fi erminals. Connecor reenion faciliies. Code key sysem for connecor coding. Chassis mouning plaes for mouning he 9" cassee o a chassis/wall where only fronal access is given. Universal mouning bracke for DIN-rail or chassis mouning. For more deailed informaion please refer o: Accessory Producs. Fron panels H5 female connecor, Code key sysem Mouning plae, Connecor reenion clips Universal mouning bracke for DIN-rail mouning. 23/23