The TCP3500 series is a universal 3-phase AC-DC converter with adjustable DC output and universal 3-phase AC input. Conduction cooling (No Fans) makes this power supply series suitable for a wide variety of Industrial Applications that can utilize conduction or liquid cooling, negating the use of fans. Emphasis is given on reliability and long life. Parallel operation is possible up to 16 units (50.4 kW). Passive or active current share system can be selected. The PSU includes DSP which enables monitoring of electrical parameters (including input voltage of all 3 phases) and controlling the PSU from system controller. An RS485 bus is used for command, monitoring and diagnostic information that can be supplied to a system controller. * World-Wide 3-phase Input Voltage Range (nom. 115 - 277 V / 200 - 480 V) * Power Factor > 0.94 * High Power Density 16 W/in3 * 94% Typical Efficiency * Parallel Operation up to 16 Units (50.4 kW) * Cold-Plate Cooling System * 0 to 50C of Cold-Plate Surface, 0 to 70C of Ambient Air Temperature * Possibility to Install 4 Units in 2U 19" Rack * Advanced Performance for Fast Dynamic and Pulsed Load up to 100 kHz (Optional) * RS485 Interfaces * Wide Adjustable Output Voltage Range * Fast Output Voltage Set Response (5 ms) * Active Current Sharing TCP3500 Series 2 INPUT VOLTAGE RANGE MODEL TCP3500-1024G TCP3500-H048G TCP3500-1048G TCP4000-H0902 1 2 180 - 528 Vrms, 50/60 Hz 180 - 528 Vrms, 50/60 Hz 180 - 528 Vrms, 50/60 Hz 180 - 528 Vrms, 50/60 Hz NOMINAL OUTPUT VOLTAGE 28 V 48 V 48 V 90 V OUTPUT VOLTAGE RANGE Adjustable 10 - 32 VDC Adjustable 10 - 50 VDC Adjustable 10 - 50 VDC Adjustable 30 - 100 VDC MAX OUTPUT CURRENT MAX OUTPUT POWER AVAILABILITY 125 ADC 3500 W Engineering samples available 73 ADC or pulse1 3500 W Mass production 73 ADC 3500 W Mass production 45 ADC or 39 A pulse1 3500 / 4000 W Mass production PSU model with pulse load operation capability 0 - 100 kHz, 0 - 100% Duty, 0 A/Iout_max. Output Power 4000W at Input Voltage range 340 - 528 Vrms (L-L) PARAMETER DESCRIPTION / CONDITION MIN NOM MAX UNIT 3-phase (L-N / L-L), 3 wires + PE 115 - 277 / 200 - 480 V Permitted variation (L-N / L-L) 104 - 305 / 180 - 528 V Input Voltage Permitted variation 47 Input Current per Line at 3 x 180 V (line to line) Input Current THDi Typical Power Factor Load above 40% Fuse 3 x 20 A, Fast acting PARAMETER DESCRIPTION / CONDITION Output Voltage Adjustable or fixed (see Model Selection table) 63 Hz 14 Arms 30 % 94 MIN Output Power Rating Output Current Fixed or Adjustable (60 - 100%) Efficiency Input Voltage 400 Vrms (L-L) and load above 40% Voltage Setting Accuracy Line Regulation Hz 50/60 Input Frequency Io = 0.5 * Io_nom NOM MAX UNIT 3500 W 94 % 0.5 % 0.5 % Load Regulation 0.3 % Thermal Drift 0.02 %/C load variation 10-100% and back: Transient Response 5 Recovery time: load variation 50-100% and back: Output Start Up Rise Time Vout_nom (BW 20 MHz) ms 0.4 ms 1.5 % 3 Recovery time: Ripple % 2 % 2 s 250 ms tech.support@psbel.com TCP3500 Series 3 PARAMETER DESCRIPTION / CONDITION Over Temperature Protection Cooling Plate surface (PSU bottom side) Input Under Voltage Protection 3-phase (L-N / L-L) Input Over Voltage Protection 3-phase (L-N / L-L) Reversed Sense Output Protection Latch type Output Under Voltage Protection Output Over Voltage Protection Output Over Current Short Circuit Protection MAX UNIT 55 C 305 / 528 Latch type - Fixed SW, based on Minimal Output Voltage Latch type - Fixed HW, based on Nominal Output Voltage Resettable - Floating SW, based on Output Voltage Set Point (configurable) PSU starts operating as a current source, based on Maximal Output Current Latch type - Fixed SW, based on Maximal Measured Output Current Fast Acting Fuse for min. 120% of Rated Output Current Input under and over voltage Output under and over voltage Output overload Over temperature PARAMETER DESCRIPTION / CONDITION Safety Standards NOM 104 / 180 Alarms Insulation (Factory tested) MIN V V 50 85 % 115 125 % +4 +6 V 104 112 % 114 122 % SPECIFICATION Input to output: Input to chassis: Output to chassis: Signals to chassis: UL/CSA60950-1 2nd, EN60950-1 2nd and IEC60950-1 2nd UL/CSA62368-1, IEC 62368-1 2122 VDC 2122 VDC 500 VDC 500 VDC Emission Requirements Radiated Emission EN55011 Class A Conducted Emissions EN55011 Class A Immunity Requirements Electrostatic Discharge (ESD) EN IEC 61204-3 Radiated Electromagnetic Field EN IEC 61204-3 8 kV contact, 15 kV air Criterion A Criterion A Electrical Fast Transients (EFT)/Burst EN IEC 61204-3 Criterion A Surge Immunity EN IEC 61204-3 Criterion A RF Conducted Immunity EN IEC 61204-3 Criterion A Useful Life Assessment >5 years life at ambient temperature of +70C and case temperature 55C >10 years of predicted electrolytic capacitor life at 55C of case temperature and 100% load. Europe, Middle East +353 61 225 977 North America +1 408 785 5200 (c) 2019 Bel Power Solutions & Protection BCD.00509_AA Asia-Pacific +86 755 298 85888 TCP3500 Series 4 PARAMETER DESCRIPTION / CONDITION Humidity Operating range according IEC 60068-2-78 Operating Temperature Cold-plate cooling: of base plate (Tc - ref. point) of ambient air temperature MIN Storage Temperature NOM MAX UNIT 10 90 RH 0 0 +55 +70 C -40 +85 C 7.1 GUI (GRAPHIC USER INTERFACE) AND RS485 COMMUNICATION PROTOCOL Bel Power Solutions provides a Windows(R) XP/Vista/Win7 compatible Graphical User Interface SW for TCP/TXP3500/4000 PSU's program, control and monitor via Serial Communication Interface - RS485. The SW GUI can be downloaded from: belfuse.com/power-solutions. For detailed information please see Communication Manual (BCA.00140) or contact Bel Power Solutions sales representative. 7.2 LED SIGNALING LED NAME COLOR STATUS OPERATING CONDITIONS AC-OK Green ON AC Input Voltage is within operation range DC-OK Green ON Output is Enabled and Operational Orange ON Blinking Over Temperature conditions inside the unit or FAIL appeared (e.g. Overload) FW upgrade via RS485-1 OT/FAIL PARAMETER DESCRIPTION / CONDITION Input Connector 4-pin, Pitch 7.62 mm (Weidmuller 1081850000, see Figure 1) Output Connector Bus bars, screw size M4, see Fig.1 Signal Input Connector 15-pin D-SUB Male (Wurth Elektronik, 61801529221, see Figure 1) Signal Output Connector 15-pin D-SUB Female (Wurth Elektronik, 61801529321, see Figure 1) Figure 1a. Rear View of TCP3500-1048G - Detail of Signal Connectors Pin Position tech.support@psbel.com TCP3500 Series 5 Figure 1b. Rear View of TCP3500-1024G (left) and TCP4000-H090 (right) - Connectors Position 8.1 INPUT POWER CONNECTOR: PINOUT SIGNAL NAME PIN # TYPE RECOMMENDED WIRES Earth / Chassis Min. 2.5 mm2 AC Line 1 L1 Input Power AC Fused Min. 2.5 mm2 AC Line 2 L2 Input Power AC Fused Min. 2.5 mm2 Input Power AC Fused 2 Earth AC Line 3 L3 Min. 2.5 mm V MAX I MAX 528 Vrms (L-L) 16 Arms (per line) Connector type: Weidmuller 1081850000 Mating part: Weidmuller 1173520000 8.2 POWER OUTPUTS CONNECTOR: +/- BUSBARS LOW LEVEL HIGH LEVEL V MAX I MAX SIGNAL NAME PIN # TYPE SIGNAL REFERENCE Vout+ + Output Power DC Vout- see Model Selection table Vout- - Output Power DC - see Model Selection table Connector type: Busbar see Figure 1 Mating part: Ring terminal for M4 screw, with appropriate cross section for wire. Europe, Middle East +353 61 225 977 North America +1 408 785 5200 (c) 2019 Bel Power Solutions & Protection BCD.00509_AA Asia-Pacific +86 755 298 85888 TCP3500 Series 6 8.3 SIGNAL INPUT CONNECTOR: PINOUT SIGNAL NAME PIN # TYPE SIGNAL REFERENCE RS485-1A 1 RS485 Half Duplex, Differential pair 1 RS485-1B RS485-2A 2 RS485 Half Duplex, Differential pair 2 RS485-2B ADDR-INIT IN 3 The unit's address change required SRTN - Active Current Share SRTN 0.2 VDC 5.0 VDC Optional - analog signal for Output Voltage adjustment - Not connected - - - 4 OUT OK 5 INHIBIT 6 ENABLE 7 SRTN1 8 RS485-1B 9 RS485 Half Duplex, Differential pair 1 RS485-1B RS485-2B 10 RS485 Half Duplex, Differential pair 2 RS485-2B Not Connected 11 OT/FAIL 12 SRTN PS-PRESENT 13 Over Temperature /PSU Fail, open collector, external pull-up needed to max. 7 VDC Power Supply Seated - signal internally connected through 10 Ohm resistor to SRTN Margin 14 15 +/-60 mA @ 60 , 0 pF2 +/-60 mA @ 60 , 50 pF2 <0.4 VDC >2.5 VDC <0.4 VDC Pull up <0.4 VDC Pull up <0.4 VDC >2.5 VDC <0.4 VDC >2.5 VDC +/-60 mA @ 60 , 50 pF2 +/-60 mA @ 60 ,50 pF2 <0.4 VDC Pull up SRTN IN OK ACSH V MAX I MAX -7 to 12 VDC 8 mA -7 to 12 VDC 8 mA 3.6 VDC 0.2 mA 7 VDC 20 mA 7 VDC 20 mA 3.6 VDC 0.2 mA 3.6 VDC 0.2 mA -7 to 12 VDC 8 mA -7 to 12 VDC 8 mA 7 VDC 20 mA 1 VDC 100 mA 7 VDC 0.7 mA AC Power Fail Warning - open collector, external pull-up needed to max. 7 V Output Voltage Fault - open collector, external pull-up needed to max. 7 V Output Inhibit - Open circuit or "High" to SRTN shuts OFF Vout Power Supply Enable pin - for unit enable short this pin to SRTN Signal Return 3 LOW LEVEL HIGH LEVEL SRTN SRTN SRTN SRTN - - Connector type: Wurth Elektronik, 61801529221 Mating part: Wurth Elektronik, 61801529321 1 2 3 SRTN and Vout- are connected together inside the power supply (not valid for TCP4000-H090). The power supplies with maximal output voltage >60V have all signals on 15-pin DSUB connector galvanically isolated from main output (including SENSE +/- and ACSH). 120 resistors connection required between RS485-xA and RS485-xB on both sides externally. The pin 14 on TCP4000-H090 is not internally connected to ACSH signal (see capture 8.6). tech.support@psbel.com TCP3500 Series 7 8.4 SIGNAL OUTPUT CONNECTOR: PINOUT SIGNAL NAME PIN # TYPE SIGNAL REFERENCE LOW LEVEL HIGH LEVEL V MAX I MAX RS485-1A 1 RS485 Half Duplex, Differential pair 1 RS485-1B +/-60 mA @ 60 , 50 pF2 +/-60 mA @ 60 , 50 pF2 <0.4 VDC Pull up <0.4 VDC Pull up <0.4 VDC Pull up <0.4 VDC >2.5 VDC <0.4 VDC >2.5 VDC +/-60 mA @ 60 , 50 pF2 +/-60 mA @ 60 , 50 pF2 <0.4 VDC Pull up -7 to 12 VDC 8 mA -7 to 12 VDC 8 mA 7 VDC 20 mA 7 VDC 20 mA 7 VDC 20 mA 3.6 VDC 0.2 mA 3.6 VDC 0.2 mA -7 to 12 VDC 8 mA -7 to 12 VDC 8 mA 7 VDC 20 mA RS485-2A 2 RS485 Half Duplex, Differential pair 2 RS485-2B ADDR-INIT OUT 3 The unit's address change accepted SRTN SRTN <0.4 VDC >2.5 VDC 3.6 VDC 0.2 mA IN OK 4 OUT OK 5 INHIBIT 6 ENABLE 7 SRTN1 8 AC Power Fail Warning - open collector, external pull-up needed to max. 7 V Output Voltage Fault - open collector, external pull-up needed to max. 7 V Output Inhibit - Open circuit or "High" to SRTN shuts OFF Vout Power Supply Enable pin - for unit enable short this pin to SRTN Signal Return RS485-1B 9 RS485 Half Duplex, Differential pair 1 RS485-1B RS485-2B 10 RS485 Half Duplex, Differential pair 2 RS485-2B Not Connected 11 OT/FAIL 12 PS-PRESENT OUT 13 Over Temperature /PSU Fail, open collector, external pull-up needed to max.7 VDC Power Supply Seated - last unit in string will pull down this signal (external short to SRTN) and informs Master Controller that all units in string are seated and connected ACSH 143 Active Current Share SRTN 0.2 VDC 5.0 VDC 7 VDC 0.7 mA Margin 15 Optional - analog signal for Output Voltage adjustment - Not Connected SRTN - - SIGNAL REFERENCE LOW LEVEL HIGH LEVEL V MAX I MAX Vout+ - - Vout- - - SRTN SRTN SRTN SRTN - SRTN Connector type: Wurth Elektronik, 61801529321 Mating part: Wurth Elektronik, 61801529221 8.5 SIGNAL OUTPUT CONNECTOR: PINOUT SIGNAL NAME PIN # SENSE+ 1 SENSE- 2 TYPE Sense line for Vout+ - voltage drop compensation for positive pole Sense line for Vout- - voltage drop compensation for negative pole Connector type: Phoenix Contact, MC 1.5/ 2-G-3.81 Mating part: Phoenix Contact, MC 1.5/ 2-ST-3.81 8.6 SIGNAL OUTPUT CONNECTOR TCP4000-H090: PINOUT SIGNAL NAME PIN # TYPE SIGNAL REFERENCE LOW LEVEL HIGH LEVEL V MAX I MAX ACSH 1 Active Current Share SRTN - - SRTN 2 - - - SENSE+ 3 Vout+ - - SENSE- 4 Signal Return Sense line for Vout+ - voltage drop compensation for positive pole Sense line for Vout- - voltage drop compensation for negative pole Vout- - - Connector type: Phoenix Contact, MC 1.5/ 4-G-3.81 Mating part: Phoenix Contact, MC 1.5/ 4-ST-3.81 Europe, Middle East +353 61 225 977 North America +1 408 785 5200 (c) 2019 Bel Power Solutions & Protection BCD.00509_AA Asia-Pacific +86 755 298 85888 TCP3500 Series 8 PARAMETER DESCRIPTION / CONDITION MIN NOM Dimensions (W x D x H) See Figure 2 400 x 103 x 85 15.7 x 4 x 3.3 Weight Single PSU 6.5 Cooling Insulation Enclosure Liquid cooled cold-plate, power dissipation ~300 W/PSU Recommended water flow rate: 2 - 4 liters/min. (depends on the cooling plate design) Input to Output: Input to Chassis: 3.0 1.5 MAX UNIT mm in kg kVAC IP20 Main heatsink surface - bottom side (good thermal connection to the cold plate is required, T 5C) Tc - reference point Figure 2. Mechanical Dimensions tech.support@psbel.com TCP3500 Series ITEM 9 ORDERING PART NUMBER SOURCE Windows XP/Vista/7 compatible GUI to program, control and monitor TCP3500 PSU (and other Serial Communication units) N/A belfuse.com/power-solutions M4 x 80mm, Hex socket XFM.00183.0 BOSSARD: 3186737 ZES.00962 Weidmuller: 1173520000 1-111890-G PHOENIXCONTACT: 1803578 4-pin Straight Cable Receptacle, pitch 3.81 mm (SENSE+/- and ACSH) 1-114261-G PHOENIXCONTACT: 1803594 USB 2.0 compatible adapter to dual RS485 with jumpers for signals: ENABLE, INHIBIT and ADDR-INIT_IN VKA.00489.0 Bel Power Solutions PCB (ZGN.00383) with 15-pin DSUB connector and 6 jumpers: two for setting-up of 120 resistors for RS485-1 and -2, and signals ADDR-INIT_OUT, ENABLE, INHIBIT, PS PRESENT OUT VKA.00488.0 Bel Power Solutions PCB (ZGN.00382) with two 15-pin DSUB connectors. This PCB makes practical and space saving solution for parallel signals connection. VKA.00487.0 Bel Power Solutions DESCRIPTION SW GUI Bel Power Solutions Graphical User Interface Mounting Screws AC Input connector 4-pin Straight Cable Receptacle (Female) Signal Connector 2-pin Straight Cable Receptacle, pitch 3.81 mm (SENSE+/-) 2 Adapter USB to RS485 Signal End Board Signal Connection Board 2 For TCP4000-H090 only NUCLEAR AND MEDICAL APPLICATIONS - Products are not designed or intended for use as critical components in life support systems, equipment used in hazardous environments, or nuclear control systems. TECHNICAL REVISIONS - The appearance of products, including safety agency certifications pictured on labels, may change depending on the date manufactured. Specifications are subject to change without notice. Europe, Middle East +353 61 225 977 North America +1 408 785 5200 (c) 2019 Bel Power Solutions & Protection BCD.00509_AA Asia-Pacific +86 755 298 85888