(R) 200 - 550 Watt CompactPCI (R) CPA, CPD Series Data Sheet AC-DC and DC-DC Converters 100 3.94" 3U 162.5 6.4" 40.6 1.6" 8 HP 233.3 7.8" 6U Features 40.4 1.6" 8 HP * RoHS lead-free-solder and lead-solder-exempted products are available 162.5 6.4" * Compliant with PICMG(R) CompactPCI(R) specifications * Wide range DC or AC input with PFC Description * Extremely high efficiency and high power density The CPA and CPD Series are highly reliable power supplies for CompactPCI(R) systems, which are increasingly used in communications, industrial, military, aerospace, and other applications. These power supplies offer high power density in plug-in modules that meet the requirements of the PICMG(R) power interface specification for CompactPCI(R) systems. * Low inrush current The converters use the patented EDGETM technology and provide important advantages such as flexible output power, extremely high efficiency, excellent reliability, full input-to-output isolation, negligible inrush current, hot-swap capability, soft start, and overtemperature protection. * Single-wire current share function for 3 outputs The input is protected by a transient suppressor (varistor) against surges and transients occurring on the source lines and cover an operating input voltage range from either 90 to 264 VAC or 36 to 75 VDC. * 4 high current outputs with flexible load distribution * Integrated ORing FETs / diodes for true redundancy * Inhibit and enable inputs * Remote sense lines * Hot-swap capability * 47-pin connector, type Positronic * Overtemperature, overvoltage, overcurrent, and overpower protection Safety according to IEC/EN 60950-1 2nd Ed. and UL/CSA 60950-1 2nd Ed. The outputs are protected against continuous overload, open-circuit, and short-circuit. Full n+1 redundant operating mode is made possible by integrated ORing FETs or ORing Table of Contents Page Description ....................................................................... 1 Model Selection ............................................................... 2 Functional Description ..................................................... 3 Electrical Input Data ......................................................... 5 Electrical Output Data ...................................................... 7 Auxiliary Functions ......................................................... 10 BCD20005-G Rev. AF, 18-Aug-10 Page Electromagnetic Compatibility (EMC) ............................ 13 Immunity to Environmental Conditions .......................... 15 Mechanical Data ............................................................ 16 Safety and Installation Instructions ................................ 17 Options ........................................................................... 19 Page 1 of 19 www.power-one.com 200 - 550 Watt (R) CompactPCI (R) diodes. When several converters are connected in parallel, a single-wire connection between converters ensures current sharing. The converters are designed as two or three separate forward converters with fixed switching frequency and synchronous rectifiers at their output. LEDs on the front panel and various warning signals display CPA, CPD Series Data Sheet AC-DC and DC-DC Converters the status of the converter. The aluminum case acts as a heat sink and as an RFI shield. It is designed for vertical insertion into 19" rack systems, but it can also be mounted in any other position, as long as the necessary airflow is ensured. The connector is a 47-pin type from Positronic or similar. Several options requirements. are available to meet different Model Selection Table 1: Standard models Model 3 Output No. Operating input range Rated power 1 Efficiency 2 Case Options Vo nom [V] Io nom [A] Io max [A] Vi min - Vi max fi min - fi max Po nom 1 [W] min [%] typ [%] 36 - 75 VDC 200 80 82.2 3U x 8HP G7 CPD200-4530 Vo1 Vo2 Vo3 Vo4 5.0 3.3 12 -12 20 20 2.5 0.5 40 40 5.5 2 CPD250-4530 Vo1 Vo2 Vo3 Vo4 5.0 3.3 12 -12 25 20 4 1 40 40 5.5 2 250 80 82.2 3U x 8HP L 5, C 6, G 7 CPD500-4530G Vo1 Vo2 Vo3 Vo4 5.0 3.3 12 -12 40 50 8 3 50 60 12 4 500 83 84.5 6U x 8HP C6 CPA200-4530 Vo1 Vo2 Vo3 Vo4 5.0 3.3 12 -12 20 20 2.5 0.5 40 40 5.5 2 200 81.5 83 3U x 8HP G7 CPA250-4530 Vo1 Vo2 Vo3 Vo4 5.0 3.3 12 -12 25 20 4 1 40 40 5.5 2 250 81.5 82.6 3U x 8HP L 5, C 6, G 7 CPA500-4530 Vo1 Vo2 Vo3 Vo4 5.0 3.3 12 -12 40 50 8 3 50 60 12 4 500 83 84.3 6U x 8HP F 8, L 5, C 6 G7 CPA550-4530 Vo1 Vo2 Vo3 Vo4 5.0 3.3 12 -12 50 50 8 3 50 60 12 4 550 83 84.5 6U x 8HP G7 1 2 3 4 5 6 7 8 90 - 264 VAC 47 - 63 Hz 4 The sum of the power of all outputs may not exceed the total power for the specified required forced-air cooling. Efficiency at TA = 25 C, Vi nom, I o nom. Models ending with G are RoHS-compliant for all 6 substances. Rated input voltage range is 100 - 240 VAC, rated input frequency range is 50 - 60 Hz. Option L: Permanent shutdown in the case of overcurrent; see Options Option C: PCBs covered with a protective lacquer; see Options Option G: RoHS-compliant for all 6 substances. G is always placed at the end of the part number. Option F: 2nd fuse in the neutral line; see Options Models highlighted in yellow are not for new designs. BCD20005-G Rev. AF, 18-Aug-10 Page 2 of 19 www.power-one.com 200 - 550 Watt (R) CompactPCI (R) Product Marking Label with specific type designation, applicable safety approvals and recognition marks, CE mark, warnings, Power-One patents, company logo, input voltage range, Functional Description The inputs of all converters are protected against surges and transients occurring on the source lines. A highly efficient input filter and an active inrush current limiter ensure a very low inrush current of short duration. This prevents circuit breakers and fuses from tripping at switchon. All CPA models have an additional bridge rectifier and a boost converter to provide active power factor correction (PFC) according to EN 61000-3-2. The CPx200/250 models (see fig.1a) are equipped with two independent high efficient 2-switch forward converters, switching 180 out of phase to minimize the ripple current at the input. On the secondary side, two high-current synchronous rectifiers supply Vo1 (5 V) and Vo2 (3.3 V) with up to 40 A. The secondary-controlled Vo3 (+12 V) post regulator is supplied by an additional winding of the 3.3 V main transformer. The linear regulator for Vo4 (-12 V) is supplied from the output choke of the Vo3 output. The output filters reduce ripple and noise to a minimum without compromising the dynamic response. CPA, CPD Series Data Sheet AC-DC and DC-DC Converters nominal output voltages and output currents, degree of protection, batch no., serial no., and data code including production site, modification status, and date of production. Identification of LEDs on the front panel. The models CPD500 (fig. 1b) and CPA500/550 (fig. 1c) exhibit a third forward converter for both outputs Vo3 and Vo4. The outputs Vo1 an Vo2 provide up to 50 and 60 A. All outputs are fully regulated and protected from the bus by decoupling FETs or diodes. A current monitor calculates the output power. As soon as the output power exceeds the maximum threshold level, the converter starts to reduce the output power by decreasing the output voltages. In contrast to the outputs Vo1 (5 V), Vo2 (3.3 V), and Vo3 (+12 V) with active current sharing, output Vo4 (-12 V) has a droop characteristic for passive current sharing. If for some reason the voltage of any output exceeds the nominal value significantly, the converter is permanently shut down. If option L is fitted, this occurs as well, if the max. output current is exceeded for a predefined time. To reset, the input voltage must be removed for a short time. Power-One's Efficient Dual Geometric Edge Technology (EDGE TM ) facilitates high current density, increases reliability by reducing component stresses, and decreases the amount of heat dissipated. The backbone of this patented technology is an interleaved, multi-channel forward converter utilising a transitional resonant switching Cy Secondary control circuit Primary control circuit + Forward converter 135 kHz + ORing FET Vo2 ORing FET Vo3 ORing diode Vo4 + + Cy + Cy Only CPA models have a bridge rectifier and a boost converter Fig. 1a Block diagram of CPA/CPD200 and CPA/CPD250 models. For the pin allocation, see Mechanical Data. Linear regulator + BCD20005-G Rev. AF, 18-Aug-10 Vo1 Cy + 1 ORing FET Secondary control circuit Bridge rectifier1 Inrush current limiter + Forward converter 135 kHz Secondary control circuit 45 Input filter Fuse ACL -DCIN 47 Cy Primary control circuit ACN +DCIN 46 Vi Boost converter 135 kHz1 03110e - + Cy Page 3 of 19 www.power-one.com 200 - 550 Watt (R) CompactPCI (R) technique and proprietary leading and trailing-edge pulsewidth modulation. It has a proven track record in highavailability power solutions. The switching frequency is typically 135 kHz. Some models (CPx200/250 version V117, CPA500/550 version V110) CPA, CPD Series Data Sheet AC-DC and DC-DC Converters exhibit a crystal oscillator with 131 kHz. All models have a separate auxiliary supply for the primary circuits, the CPD500 as well for the secondary circuits. The secondary bias voltage of the other models is generated by the forward converters. +DCIN 46 Secondary control circuit Secondary control circuit Secondary control circuit + ORing FET Vo3 ORing diode Vo4 ORing FET Vo1 ORing FET Vo2 ORing FET Vo3 ORing diode Vo4 + + Cy VSBias Forward converter 135 kHz Primary control circuit Vo2 Secondary control circuit Auxiliary converter ORing FET Secondary control circuit VPBias Vo1 Secondary control circuit 45 ORing FET Cy Forward converter 135 kHz Primary control circuit Cy + Secondary control circuit VDR + Forward converter 135 kHz Secondary control circuit Fuse -DCIN 47 Input filter Cy Dual interleaved boost converter 110 kHz Inrush current limiter with reverse polarity protecton Vi Primary control circuit JM041 + + Cy Fig. 1b Block diagram of CPD500 models. For the pin allocation, see Mechanical Data. + + Cy JM014a 45 Bridge rectifier Fuse ACL 47 Input filter Cy Inrush current limiter Cy VPBias Primary control circuit Auxiliary converter + Primary control circuit Vi Primary control circuit 2nd fuse (option F) Boost converter 135 kHz ACN 46 Forward converter 135 kHz + Cy Forward converter 135 kHz + Cy Forward converter 135 kHz + VSBias + + Cy + Fig. 1c Block diagram of CPA500/550 models. For the pin allocation, see Mechanical Data. BCD20005-G Rev. AF, 18-Aug-10 + + Cy Page 4 of 19 www.power-one.com (R) 200 - 550 Watt CompactPCI (R) CPA, CPD Series Data Sheet AC-DC and DC-DC Converters Electrical Input Data General Conditions: TA = 25 C, unless TC is specified. Table 2a: Input data of CPD models Input CPD200/250 Characteristics Conditions min Io = 0 - Io max 36 Vi Operating input voltage Vi nom Nom. input voltage TC min - TC max Vi abs Input voltage limits without damage typ Ii Typical input current Vi nom, Io nom I i max Max. input current Vi min, Io nom 7.0/8.7 2 I inr p Peak inrush current Vi max, Io nom Pi0 No-load input power Vi min, Io = 0 Vi nom, Io = 0 Vi max, Io = 0 Input power, when inhibited Vi min - Vi max Ci Input capacitance fswitch Switching frequency Vi nom, Io nom th Hold-up time Vi min 0 V, Io nom 4 Vi nom, Io nom 4 Brown-out time t su Start-up time min 75 36 80 0 typ max VDC 48 80 12.5 7.6/9.5 2 17 A 17.5 25 28.6 28 27.5 30 3.2 W 31 9.4 1360 135 Vi nom, Io nom Unit 75 12 14 18 27 Pi inh t bo max 48 0 5.1/6.3 2 4 CPD500 15 F 135 kHz 5 ms 5 150 200 1500 Table 2b: Input data of CPA models Input CPA200/250 Characteristics Conditions min Vi Rated input voltage range Io = 0 - Io max 100 Vi op Operating input voltage TC min - TC max 90 Vi nom Nom. input voltage 50 - 60 Hz 1 Vi abs Input voltage limits without damage typ CPA500/550 max min 240 100 264 90 230 05 280 Ii Typical input current Vi nom, Io nom Ii max Max. input current Vi min, Io nom 2.9/3.6 2 3.2 /4.0 2 23 30 Iinr p Peak inrush current Vi max, Io nom No-load input power Vi min - Vi max Io = 0 Pi inh Input power, when inhibited Vi min - Vi max Ci Input capacitance fswitch Switching frequency Vi nom, Io nom th Hold-up time Vi min 0 V, Io nom 4 t bo Brown-out time Start-up time Vi nom, Io nom Power factor Vi nom, Io nom 1 2 3 4 5 VAC 1 264 0 280 2.8/3.1 3 A 7.1/7.8 3 20 26 3.2 32 W 3.2 1 t su 240 15 135 20 max 230 1.1/1.4 2 Pi0 typ Unit 4 F 135 kHz 20 ms Vi nom, Io nom 150 0.95 150 0.95 W/VA Rated input frequency: 50 - 60 Hz, operating input frequency range: 47 - 63 Hz First value for CPD/CPA200, 2nd value for CPD/CPA250 First value for CPA500, 2nd value for CPA550 Short interruption of Vi without affecting the outputs CPA200/250 with version V117 or higher, as they are equipped with an input voltage trigger BCD20005-G Rev. AF, 18-Aug-10 Page 5 of 19 www.power-one.com 200 - 550 Watt (R) CompactPCI (R) CPA, CPD Series Data Sheet AC-DC and DC-DC Converters Input Fuse and Reverse Polarity Protection Efficiency A metal oxide varistor (voltage dependent resistor VDR) together with the input filter form an effective protection against high input voltage transients, which typically occur in most installations. The efficiency is specified in table 1. Its dependence upon the input voltage Vi is shown in fig. 2a (CPA models) and fig. 2b (CPD500 models). The efficiency of CPD200/250 models depends only marginally upon Vi. An incorporated fuse protects the converter against further damage in the case of a failure. [%] 90 Note: The fuse is not customer-accessible. Model Fuse rating CDP200/250 250 V, 12.5 A T Schurter SPT 5x20, 0001.2515 CPA200/250 250 V, 5 A T Schurter SPT 5x20, 0001.2511 CPD500 80 V, 25 A F Littlefuse FKS, 166.7000.525 CPA500/550 250 V, 10 A T Schurter MXT250, 0034.6925 JM018a 86 Table 3: Fuse specification CPA500/550 Reference To avoid unwanted power losses, the CPD200/250 models are not protected against reverse polarity at the input by a serial diode, but only with an antiparallel diode. In the case of reversed input voltage, the input fuse will blow; however no further damage will occur. 82 CPA200/250 78 0 50 100 150 200 250 VAC Fig. 2a CPA Series: Efficiency versus input voltage [%] 86 The CPA Series converters are designed for AC input and have a rectifier bridge on the input. 85 JM042 The CPD500 models are protected against reverse polarity by a special circuitry, which generates no losses. The converter will simply not start-up, but no damage will occur. CPD500 Input Current Limitation All converters incorporate an active inrush current limiter in the input circuitry, which reduces the peak inrush current value by a factor of 10 - 15 to protect connectors and switching devices from damage. Note: The inrush current limitation is achieved using an electronic circuitry. For effective limitation the converter should not be switched on and off more frequently than every 8 seconds. 84 83 40 50 60 70 V Fig. 2b CPD500 Series: Efficiency versus input voltage Input Undervoltage Shutdown CPD200/250 models start at approx. Vi = 22 V, when the input voltage is applied; at decreasing Vi, they switch off at approx. 21 V. Note: The input current I i may exceed I i max, if Vi Vi min. CPD500 models start at Vi = 35 V and switch off at Vi = 33 V. CPA models exhibit an undervoltage trigger controlling start-up and shutdown. The threshold is between 80 and 90 VAC. See also Power Fail Signal. Note: CPA200/250 with version V116 should not be operated at Vi Vi min, as these models have no undervoltage shutdown and will therefore operate with a high input current at full load. BCD20005-G Rev. AF, 18-Aug-10 Page 6 of 19 www.power-one.com (R) 200 - 550 Watt CompactPCI (R) CPA, CPD Series Data Sheet AC-DC and DC-DC Converters Electrical Output Data General Conditions for table 4: - TA = 25 C, unless Tc is specified. - CPD/CPA200: 250 LFM (1.25 m/s), CPD/CPA250: 400 LFM (2 m/s) - Sense lines connected directly at the connector Table 4a: Output data of CPD/CPA200 and CPD/CPA250 Output Vo1 (5.0 V) Characteristics Output voltage Vo IoL Output current limit Io min Minimum load vo Output voltage noise 4 Switch. frequ. Total Unit Conditions min typ max min typ max Vi nom, 50% Io nom 4.95 5.0 5.05 3.25 3.3 3.35 Io nom Nominal output current Io max Max. output current Vo2 (3.3 V) Vi min - Vi max TC min - TC max 20/25 1 20 40 40 A 50 no min. load required Vi nom, Io nom BW = 20 MHz 4 C ext = 22 F + 100 nF 50 no min. load required 25 20 mVpp 60 60 VoV Static line regulation Vi min - Vi max, Io nom 10 10 VoL Vi nom, 50 - 100% Io max 10 10 Static load regulation VoS Overshoot at switch on/off 0 Dynamic Voltage Vo1: Io1 = 10 A, dIo1 /dt = 2 A/s load deviation Vo2: Io2 = 10 A, dIo2 /dt = 2 A/s regulation Recovery time vo d td Vo Temperature coefficient of output voltage mV 0 120 TC min - TC max 0 - Io nom, Vi min - Vi max VDC 120 100 100 s 0.3 0.2 mV/K Table 4b: Output data of CPD/CPA200 and CPD/CPA250 Output Vo3 (+12 V) Characteristics Conditions Vo Vi nom, 50% Io nom Output voltage min 11.76 IoL Output current limit Io min Minimum load vo Output voltage noise 4 Switch. frequ. max min 12.0 12.24 -11.30 2.5/4 1 Io nom Nominal output current Io max Max. output current Vo4 (-12 V) typ Vi min - Vi max TC min - TC max 2 VoV Static line regulation Vi min - Vi max, Io nom 10 Vi nom, Io = 1 - 2 A 30 Vo 1 2 3 4 0 Dynamic Voltage Vo3: Io3 = 2 A, dIo3/dt = 2 A/s load deviation Vo4: Io4 = 0.5 A, dIo4/dt = 2 A/s regulation Recovery time Temperature coefficient of output voltage A 3.5 mVpp VoS Overshoot at switch on/off td VDC no min. load required VoL vo d -12.48 2 120 Static load regulation -12.0 7 Vi nom, Io nom BW = 20 MHz 4 Cext = 22 F + 100 nF Total max 0.5/1 1 5.5 I o3 > 75% Io 4 Unit typ TC min - TC max 0 - Io nom, Vi min - Vi max 120 10 mV - 380 3 0 200 200 500 500 s 0.3 0.5 mV/K First value for CPD200/CPA200, second value for CPD250/CPA250 Minimum load is only required to maintain regulation of output Vo4 Droop characteristic for passive current sharing Measured with a probe according to IEC/EN 61204, annex A BCD20005-G Rev. AF, 18-Aug-10 Page 7 of 19 www.power-one.com (R) 200 - 550 Watt CompactPCI (R) CPA, CPD Series Data Sheet AC-DC and DC-DC Converters General conditions for table 5: - TA = 25 C, unless Tc is specified. - CPD500, CPA500: 300 LFM (1.5 m/s), CPA550: 400 LFM (2 m/s) - Sense lines connected directly at the connector Table 5 a: Output data of CPD500 and CPA500/550 Output Vo1 (5.0 V) Characteristics Conditions min Vo Vi nom, 50% Io nom 4.95 Output voltage Io nom Nominal output current Io max Max. output current IoL Output current limit Io min Minimum load vo Output voltage noise 4 Switch. frequ. Total Vi min - Vi max TC min - TC max Vo2 (3.3 V) typ max min 5.0 5.05 3.25 typ max 3.3 3.35 40/50 1 50/50 1 50 60 52.2 62 74 no min. load required mVpp 50 50 VoV Static line regulation Vi min - Vi max, Io nom 10 10 VoL Vi nom, 50 - 100% Io max 10 10 Static load regulation VoS Overshoot at switch on/off 0 Dynamic Voltage Vo1: Io1 = 20 A, dI o1/dt = 2 A/s load deviation Vo2: Io2 = 40 A, dIo2 /dt = 2 A/s regulation Recovery time vo d td Vo Temperature coefficient of output voltage VDC A 63 no min. load required Vi nom, Io nom BW = 20 M Hz 4 C ext = 22 F + 100 nF Unit 0 150 TC min - TC max 0 - Io nom, Vi min - Vi max mV 150 300 300 s 0.3 0.2 mV/K Table 5 b: Output data of CPD500 and CPA500/550 Output Vo3 (+12 V) Characteristics Conditions Output voltage Vo Vi nom, 50% Io nom IoL Output current limit Io min Minimum load vo Output voltage noise 4 Switch. frequ. max min typ max 11.76 12.0 12.24 -11.52 -12.0 -12.48 8 Vi min - Vi max TC min - TC max 3 12 4 4.3 I o3 > 75% Io 4 2 no min. load required 120 VoV Static line regulation Vi min - Vi max, Io nom 10 VoL Vi nom, I o = 2 - 4 A 50 Static load regulation mVpp VoS Overshoot at switch on/off vo d td Vo 1 2 3 4 0 Dynamic Voltage Vo3: Io3 = 4 A, dIo3 /dt = 2 A/s load deviation Vo4: Io4 = 1 A, dIo4 /dt = 2 A/s regulation Recovery time Temperature coefficient of output voltage VDC A 13.5 Vi nom, Io nom BW = 20 MHz 4 Cext = 22 F + 100 nF Total Unit typ Io nom Nominal output current Io max Max. output current Vo4 (-12 V) min TC min - TC max 0 - Io nom, Vi min - Vi max 120 10 mV - 220 3 0 200 150 300 300 s 0.3 0.5 mV/K First value for CPA500, second value for CPA550 Minimum load is only required to maintain regulation of output Vo4. No min. load for CPD500. Droop characteristic for passive current sharing Measured with a probe according to IEC/EN 61204, annex A BCD20005-G Rev. AF, 18-Aug-10 Page 8 of 19 www.power-one.com (R) 200 - 550 Watt CompactPCI (R) Hold-up Time of CPD Models For extended hold-up time of CPD models, use external output capacitors or decoupling diodes and input capacitors of adequate size. Formula for additional external input capacitor: 2 * Po * (t h total - t h) * 100 C i ext = --------------------- * (Vti 2 - Vi min2) whereas: C i ext Po h t h total th Vi min Vti = = = = = = = CPA, CPD Series Data Sheet AC-DC and DC-DC Converters In all models, all outputs are monitored for an overvoltage condition. If an overvoltage of 120 - 130% is dedected, the converter is permanently disabled. To reset, the input voltage must be removed for 10 - 20 seconds. Note: The models CPA500/550 with version V110 need approx. 60 s to recover. Thermal Considerations and Protection external input capacitance [mF] output power [W] efficiency [%] total hold-up time [ms] hold-up time [ms] minimum input voltage [V] threshold level [V] Note: After Vi was removed, the outputs maintain their voltage for the time t h. Even if Vi comes back during t h, but after t h, the output voltage might be affected. Redundant Operation and Hot Swap Due to the integrated ORing FETs/diodes, the converters are designed to be operated in redundant systems. Hot swap is also possible, but the output voltages of each bus may deviate dynamically by 5% during the plug-in / plug-out operation. Note: We recommend connecting some capacitors parallel to the bus to limit voltage deviations during hot swapping and during switch-on / switch-off of the input voltage of one of the parallel-connected converters. Output Characteristic and Protection If a converter is mounted in the upright position with airflow as specified in the general conditions of the tables 4 and 5, allowing unrestricted forced-air cooling, and is operated at its nominal input voltage and power at maximum ambient temperature TA max (see Temperatures), the temperature at the measurement point of the case temperature TC (see Mechanical Data) will approach after an initial warm-up phase the indicated maximum value of TC max (105 C) . However, the relationship between TA and TC depends heavily on the operating conditions and the system integration. The thermal conditions are significantly influenced by the input voltage, the output current, the airflow, and the temperature of the adjacent elements and surfaces. TA max is therefore, contrary to TC max , an indicative value only. Po /Po nom 250 LFM = 1.25 m/s JM011 1.0 Convection cooling in upright position 0.6 0.5 All outputs are fully protected against continuous opencircuit (no load) and continuous short-circuit conditions. All outputs of CPx200/250 models have a constant current limitation with a rectangular characteristic; see figure 3. In addition, the total power from outputs Vo1, Vo2, and Vo3 is limited to Po max, resulting in a free choice of load distribution between these outputs. Output Vo4 is disabled in the case of overtemperature generated by overcurrent. 0 30 TA min 40 50 70 90 C Fig. 4a Output power versus temperature TA at Vi nom (CPD/ CPA200) In CPA500/550 and CPD500 models, the total power of all four outputs is limited to Po max. Po /Po nom 200 LFM = 1 m/s Vo/Vo nom 1.0 0.95 05190b 1.0 Io nom Io max Io L 05186b Convection cooling in upright position 400 LFM = 2 m/s 0.5 0.5 0 0 Fig. 3 Typical output characteristic Vo versus I o BCD20005-G Rev. AF, 18-Aug-10 Io TA min 20 30 40 50 70 90 C Fig. 4b Output power versus temperature TA at Vi nom (CPD/CPA250) Page 9 of 19 www.power-one.com 200 - 550 Watt (R) Po /Po nom CompactPCI (R) which the control logic begins to reduce the output power. The output power returns to the normal value, when the temperature drops back below this limit; see Temperature Warning and Shutdown. 300 LFM = 1.5 m/s (CPA/CPD500) 400 LFM = 2 m/s (CPA550) JM012a 1.0 Convection cooling in upright position Output Filter The output ripple voltage can be reduced by an external filter to less then 5 mVpp. Recommended values: CPA/CPD500 0.6 0.5 CPA, CPD Series Data Sheet AC-DC and DC-DC Converters * C1, C2: Low ESR capacitor, e.g., OS-CON 100 - 470 F CPA550 * L1, L2: Choke 1 - 4.7 H with appropriate rated current, e.g., Coiltronics(R) HC2LP 1 H /33 A or 2.2 H /24 A. 0 30 TA min 40 50 70 JM010 90 C 30 Fig. 4c Output power versus TA at Vi nom (CPA500/550, CPD500) 46 33 Input Caution: The installer must ensure that under all operating conditions TC remains within the limits shown in the diagrams fig. 4. 1-4 13 -18 Vo1SENSE L1 Vo1 5V Vo2SENSE Vo2 L2 3.3 V C2 Note: Forced-air cooling (or an additional heat sink on customer-specific models) can improve the reliability or allow for higher TA, as shown in the diagrams fig. 4, but TC max shall never be exceeded. 47 5 -12 + + C1 RTN Gnd A temperature sensor fitted on the main PCB provides approx. 20 C below TC max a warning signal (DEG#), at Fig. 5 Output filter reducing the output ripple of Vo1 and Vo2 Auxiliary Functions CMOS) is applied. In systems consisting of several converters this feature may be used to control the activation sequence of the converters by means of logic signals, or to enable the source to start-up, before full load is applied. Inhibit and Enable The inhibit input INH# enables (logic high) or disables (logic low, pull down) all outputs, if a logic signal (TTL, Note: If this function is not used, the inhibit pin 39 can be left open-circuit (not connected). If pin 39 is connected to a return pin (e.g., pin 22), the internal logic will disable all outputs. The inhibit input is protected by a decoupling diode. 06153d 46 INH# 39 EN# 27 RTN 47 Vo /Vo nom 1 VINH# 0.1 0 (22) 0 Table 6: Inhibit data Vinh Inhibit voltage tr Rise time tf Fall time Conditions Vo = off Vi min - Vi max I = 0 - Io max Vo = on o BCD20005-G Rev. AF, 18-Aug-10 t tr tf Inhibit 1 Fig. 6 Inhibit and enable inputs Characteristics 06155a min typ max Unit -2 0.8 2.4 50 120 depending on I o t Fig. 7 Typical output response as a function of inhibit voltage. V ms Pin 27 (EN#) must be connected to a return pin (e.g., pin 22) to enable the converter. Pin 27 is shorter than the others ensuring start-up only, when all other pins are already connected to the system providing true hot-swap capability. Page 10 of 19 www.power-one.com 200 - 550 Watt (R) CompactPCI (R) Temperature Warning and Shutdown A temperature warning circuitry monitors the case temperature TC. Its output signal V DEG# changes from high to low impedance, when the TC exceeds the upper threshold level, and changes back to high impedance, when TC falls below the lower threshold level, which is 85 C 5 C. Pin 38 (degrade signal DEG#) is internally connected via the collector-emitter path of an NPN transistor to the signal return pin 22. The current I DEG# through pin 38 should not exceed 40 mA, and VDEG# should not exceed 40 V. If TC exceeds 105 C, the converter will be disabled. It resumes operation automatically, once TC falls below 105 C. CPA, CPD Series Data Sheet AC-DC and DC-DC Converters The threshold levels for Vi correspond to approx. 34 V for CPD models and 80 - 90 VAC for CPA models. Note: CPD200/250 (and CPA200/250 up to version V116) provide only the signal FAL#, but the converter is not inhibited. Note: Vi min of CPA models is considered as insufficient, when - Vi remains for typ. 30 ms below 2 * Vi min. Connector pin 42 (signal VFAL#) is internally connected via the drain-source path of a JFET (self-conducting type) to the signal return pin 22. The current I FAL# should not exceed 10 mA. VFAL# should not exceed 40 V, as the JFET is not protected against overvoltage. 11006c Vo+ 46 11056a Vo+ Rp Input Rp 38 IDEG# IFAL# 42 Input 46 FAL# VFAL# DEG# VDEG# 47 22 RTN 22 47 RTN Fig. 8 Degrade signal: NPN output VDEG# 40 V, I DEG# 20 mA Fig.10 Power Fail: JFET output, IFAL# 10 mA Sense Lines VDEG# [V] Po /Po max 10 1 05189c thermal shutdown 8 6 0.8 0.6 signal DEG# 4 0.4 2 0.2 0 0 60 70 80 90 100 110 C This feature is available only for the outputs Vo1, Vo2, Vo3, and allows the compensation of voltage drops across the connector contacts and if necessary, across the load lines. To ensure correct operation, all sense lines S+ (Vo1SENSE, Vo2SENSE, and Vo3SENSE) should be connected to the respective power outputs. The common sense return S- (SRTN) should be connected to RTN (pin 5 - 12). Note: Open sense lines are admissible, but the output voltage regulation will be poor. The voltage difference between any sense line at its respective power output pin (as measured on the connector) should not exceed the following values. Note: If the sense lines S+ and S- compensate for a considerable voltage drop, the output loads shall be reduced in order to respect the maximum output power. Fig. 9 Degrade signal VDEG# versus case temperature TC Power Fail Signal Table 7: Sense line data The power fail circuitry monitors the input voltage Vi and all output voltages. The signal VFAL# changes from high to low impedance (<0.5 V), when one of the monitored voltages falls below the threshold. VFAL# changes back to high impedance, when all monitored voltages exceed their threshold level. Output [V] 3.3 Total voltage difference between sense lines and their respective outputs 0.8 V 5 1V 12 1V The threshold level for Vo corresponds to approx. 90% of Vo nom. BCD20005-G Rev. AF, 18-Aug-10 Page 11 of 19 www.power-one.com (R) 200 - 550 Watt CompactPCI (R) CPA, CPD Series Data Sheet AC-DC and DC-DC Converters connected in parallel. An increase in output current decreases the output voltage according to fig. 11. Active Current Sharing for Vo1, Vo2, Vo3 The current share facility, consisting of a single-wire link, should be used, where several converters are operated in parallel connection, for example, high reliability n+1 redundant systems or systems providing higher output power. Vo -4% 05188c CPx200/250 +2% Note: Maximum six converters should be connected in parallel. Vo4 set Using this feature reduces the stress of the individual converters and improves the reliablity of the system. Interconnection of the current sharing terminals causes the converters to share the output current evenly. In n+1 redundant systems a failure of a single converter will not lead to a system failure, since the outputs are already decoupled by FETs and diodes internally. -2% CPx500/550 -4% 0.01 0.5 1 Io /Io nom Fig. 11 Output voltage Vo 4 versus output current Io 4. Passive Current Sharing for Vo4 The output voltage changes slightly with the output current (droop characteristic) ensuring automatic current sharing without further precautions, when several converters are LEDs A green LED "Input OK" and a red LED "Fault" are incorporated in the front panel. 06156a Input OK Fault Vi max Vi min Vi LEDs "Input OK" and "Fault" status versus input voltage. Conditions: Po - Po max , TC - TC max , Vinh = open IO LED "Fault" status versus output current. Conditions: Vi min - Vi max, TC - TC max , Vinh = open TC LED "Fault" status versus case temperature. Conditions: Po - Po max , Vi min - Vi max , Vinh = open Fault IoL Fault TC max Vinh threshold LED "Fault" status versus Vinh. Fault Vi inh Conditions: Po - Po max , Vi min - Vi max , TC - TC max -2 V +0.8 V +2.4 V +50 V LED Status undefined LED off LED on If +12 V bus voltage is present, LED is on. Fig. 12 Display status of LEDs BCD20005-G Rev. AF, 18-Aug-10 Page 12 of 19 www.power-one.com 200 - 550 Watt (R) CompactPCI (R) Electromagnetic Compatibility (EMC) A metal oxide VDR together with the input fuse and a filter form an effective protection against high input voltage CPA, CPD Series Data Sheet AC-DC and DC-DC Converters transients, which typically occur in most installations. The converters have been successfully tested to the following specifications: Electromagnetic Immunity Table 8: Immunity type tests Phenomenon Standard Level Coupling mode 1 Value applied Waveform Source imped. Test procedure Electrostatic discharge (to case) IEC/EN 61000-4-2 4 contact discharge 8000 Vp 1/50 ns 330 yes A air discharge 15000 Vp 10 positive and 10 negative discharges Electromagnetic IEC/EN field 61000-4-3 3 antenna 10 V/m AM 80% 1 kHz n.a. 80 - 1000 MHz yes A 10 V/m 50% duty cycle 200 Hz repetition frequency capacitive, o/c 1000 Vp 50 A 2000 Vp 60 s positive 60 s negative transients per coupling mode yes direct, i/c, +i/- i bursts of 5/50 ns 2.5/5 kHz over 15 ms; burst period: 300 ms 1.2/50 s 12 yes B 2 5 pos. and 5 neg. surges per coupling mode 150 0.15 - 80 MHz yes A Electrical fast transients/burst IEC/EN 61000-4-4 3 Surges IEC/EN 61000-4-5 3 i/c 2000 Vp 2 +i/- i 1000 Vp IEC/EN 61000-4-6 3 i, o, signal wires 10 VAC (140 dBV) Conducted disturbances 1 2 AM 80% 1 kHz In Peroper. form. 2 900 5 MHz i = input, o = output, c = case connected to PE A = normal operation, no deviation from specifications, B = normal operation, temporary loss of funciton or deviation from specs possible. BCD20005-G Rev. AF, 18-Aug-10 Page 13 of 19 www.power-one.com 200 - 550 Watt (R) CompactPCI (R) dBV Electromagnetic Emission dBV 80 EN 55022 A EN 55022 B 60 40 CPD200, B738613, 50807-TU, Peak L, Conducted 0.15 - 30 MHz, Divina, 7-Mar-07 80 EN 55022 B CPD200-con+p_a EN 55022 A 60 CPA500-4530S211 V107 W0622, Vi=230VAC, Ponom, Peak, Phase, Uster, 20-Sep-07 CPA500-con+p Radiated and conducted emissions comply with EN 55011/ 55022, class A. In addition, CPD500 and CPA500/550 meet conducted emissions class B. CPA, CPD Series Data Sheet AC-DC and DC-DC Converters 20 0.2 40 0.5 1 2 5 10 20 MHz 20 0.2 0.5 1 2 5 10 Fig. 13c Typical disturbance voltage (peak) at the line input according to EN 55022, measured at Vi nom and Io nom (CPA500-4530). 20 MHz Fig. 13a Typical disturbance voltage (peak) at the negative input according to EN 55022, measured at Vi nom and Io nom (CPD200-4530). [dBmV/m] 50 EN 55022 A 40 30 CPA250 B30510100 /00239, Peak N, Conducted 0.15 - 30 MHz, Divina, 10-Jan-07 EN 55022 A EN 55022 B 60 CPA250-con+p_a 80 07122b dBV EN 55022 B 20 10 40 0.2 0.5 1 2 5 10 20 MHz Fig. 13b Typical disturbance voltage (peak) at the line input according to EN 55022, measured at Vi nom and Io nom (CPA250-4530). BCD20005-G Rev. AF, 18-Aug-10 300 250 230 200 150 100 50 30 [MHz] 20 Fig. 14 Typical radiated electromagnetic field strength (quasi peak) according to EN 55022, normalised to a distance of 10 m, measured at Vi nom and Io nom. Page 14 of 19 www.power-one.com 200 - 550 Watt (R) CompactPCI (R) CPA, CPD Series Data Sheet AC-DC and DC-DC Converters Immunity to Environmental Conditions Table 9: Mechanical and climatic stress (tests of CPD500 are in process) Test method Standard Test conditions Cab Damp heat steady state IEC/EN 60068-2-78 Temperature: Relative humidity: Duration: 40 2 C 93 +2/-3 % 56 days Converter not operating Ea Shock (half-sinusoidal) IEC/EN 60068-2-27 Acceleration amplitude: Bump duration: Number of bumps: 20 gn 11 ms 18 (3 in each direction) Converter operating Eb Bump (half-sinusoidal) IEC/EN 60068-2-29 Acceleration amplitude: Bump duration: Number of bumps: 15 gn 6 ms 6000 (1000 in each direction) Converter operating Fda Random vibration wide band, reproducibility high IEC/EN 60068-2-35 CPD200/250, CPA200/250 Acceleration spectral density: Frequency band: Acceleration magnitude: Test duration: 0.05 g n2/Hz 20 - 500 Hz 4.9 gn rms 3 h (1 h in each axis) Converter operating IEC/EN 60068-2-35 CPD500, CPA500/550 Acceleration spectral density: Frequency band: Acceleration magnitude: Test duration: 0.01 g n2/Hz 20 - 500 Hz 2.2 gn rms 1.5 h (0.5 h in each axis) Converter operating Converter in proper packing CPD200/2501 only 0.75 m 3 directions Not operating Drop test 1 Status Version V106 or higher Temperatures Table 10: Temperature specifications, valid for an air pressure of 800 - 1200 hPa (800 - 1200 mbar) Relative humidity 3 [%] Characteristics Conditions min TA Ambient temperature Operational 1 TC Case temperature 2 TS 1 2 3 4 Storage temperature Non operational typ Temperature [C] max min 5 95 -25 4 typ max 50 5 95 -25 4 105 2 10 95 -40 85 See Thermal Considerations Overtemperature shutdown at TC 105 C Non condensing humidity CPx200/250 version V117 (or higher) and CPA500/550 version V110 (or higher) can be operated at - 40 C with increased output ripplel. Reliability Table 11: MTBF Ratings at specified case temperature MTBF acc. to MIL-HDBK-217F, notice 2 Model Ground benign 40 C Ground fixed Unit 70 C Ground mobile 50 C 40 C CPD250 288 000 59 000 33 000 27 000 h CPA250 279 000 57 000 31 000 33 000 195 000 35 000 17 000 16 000 CPD500 CPA500 BCD20005-G Rev. AF, 18-Aug-10 Page 15 of 19 www.power-one.com (R) 200 - 550 Watt CompactPCI (R) CPA, CPD Series Data Sheet AC-DC and DC-DC Converters Mechanical Data 09135d pin 47 Dimensions in mm (inches) 100 (3.937") 95 (3.74") AIRFLOW 128.7 (5.067") Measuring point of the case temperature TC Fig. 15 CPA200/250 and CPD200/250. Overall size: 162.5 x 128.7 x 40.6 mm. Weight: 0.8 kg pin 1 12.88 (0.507") 162.63 (6.403") 169.52 (6.674") European Projection JM015a pin 47 AIRFLOW Measuring point of the case temperature TC 228.35 (8.99") pin 1 261.9 (10.311") Fig. 16 View of the connector Size: 3U x 8HP 233.35 ( 9.187") 2.5 (0.098") 6.6 (0.260") 40.6 (1.60") Fig. 17 CPD500 and CPA500/550. Overall size: 223.4 x 162.5 x 40.6 mm. Weight: 1.65 kg 162.63 (6.403") 6.6 (0.260") 2.5 (0.098") 12.88 (0.507") 40.34 (1.588") Size: 6U x 8HP 169.52 (6.674") BCD20005-G Rev. AF, 18-Aug-10 Page 16 of 19 www.power-one.com 200 - 550 Watt (R) CompactPCI (R) CPA, CPD Series Data Sheet AC-DC and DC-DC Converters Safety and Installation Instructions may not meet the safety requirements. Check for hazardous voltage, before altering any connections. Connector Pin Allocation The converters are provided with a leading pin no. 45, which is reliably connected to the case. For safety reasons it is essential to connect this pin to the protective earth of the supply system. The connector pin allocation table defines the electrical potentials and the physical pin positions on the Positronic connector. Pin no. 45 (protective earth) is a leading pin, ensuring that it makes contact with the female connector first. Installation Instructions These converters are components, intended exclusively for installation within other equipment by an industrial assembly process or by a professionally, competent person. Installation must strictly follow the national safety regulations in respect of the enclosure, mounting, creepage distances, clearance, casualty markings, and segregation requirements of the end-use application. Connection to the system shall be made via the mating female connector (see fig. 16). Other installation methods Connector: Positronic PCIH47M400A1 or similar Mating female connector: Positronic PCIH47F300A1 or similar 10087a 1 3 5 7 9 11 13 15 17 19 21 24 27 30 33 36 39 42 46 22 25 28 31 34 37 40 43 23 26 29 32 35 38 41 44 45 2 4 6 8 10 12 14 16 18 20 47 The input -DCIN or ACL (pin no. 47) is internally fused; see Input Fuse and Protection. This fuse is designed to break an overcurrent in case of a malfunction of the converter and is not customer-accessible. External fuses in the wiring to one or both input lines (pin 47 and/or pin 46) may be necessary to ensure compliance with local requirements. A built-in second fuse in the neutral line (pin 47) is available as option F for CPA500 models. A second fuse in the wiring to the neutral line or option F may be needed if: * Local requirements demand an individual fuse in each source line * Neutral and earth impedance is high or undefined * Phase and neutral of the mains are not defined or cannot be assigned to the corresponding terminals. Caution: Installation must strictly follow the national safety regulations. Models with option F: Caution! Double-pole/neutral fusing. Do not open the converters, or the warranty will be invalidated! Important: If the inhibit function is not used, pin 39 (i) should be left open-circuit to enable the outputs. Enable Pin 27 (EN#) should be connected to pin 22 (RTN) to enable the outputs. Fig. 18 Pinout of the front connector Table 12: Pin allocation of the front connector Pin1 Length 2 1-4 5 - 12 13 - 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 Description B Signal name Vo1 B B B B C C C C C C D C C C C RTN Vo2 RTN Vo3 Vo4 RTN Reserved RTN n.c. Reserved EN# n.c. n.c. Vo1SENSE n.c. Return (Vo1 and Vo2) Output 2 Return (Vo3) Output 3 Output 4 Return Reserved Return (Vo4) Do not connect Reserved Enable Do not connect Do not connect Vo1 remote sense Do not connect Output 1 Pin1 Length 2 Signal name 32 C n.c. 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 C C C C C C C C C C C C A3 A A Vo2SENSE SRTN Vo1SHARE Vo3SENSE n.c. DEG# INH# n.c. Vo2SHARE FAL# n.c. Vo3SHARE CGND +DCIN4 ACN5 -DCIN4 ACL5 Description Do not connect Vo2 remote sense Sense return Vo1 current share Vo3 remote sense Do not connect Degrade signal Inhibit Do not connect Vo2 current share Fail signal Do not connect Vo3 current share Chassis ground Pos. DC input 4 Neutral line 5 Neg. DC input 4 Line input (phase)5 Pin numbers shown are for the female backplane connector A = very long pins, B = long pins, C = short pins, D = very short pins. Pin 45 of the female connector is leading, ensuring that chassis ground makes contact first. CPD models (DC input) CPA models (AC input) BCD20005-G Rev. AF, 18-Aug-10 Page 17 of 19 www.power-one.com (R) 200 - 550 Watt CompactPCI (R) CPA, CPD Series Data Sheet AC-DC and DC-DC Converters Table 13: Isolation CPD models Input to Output to (case + output) case Characteristic Electric strength test 2 Unit Actual factory test 1 s 1500 1 700 2200 2 700 VDC AC test voltage equivalent to factory test 1000 500 1500 500 VAC >300 >300 >300 >300 M Insulation resistance at 500 VDC 1 CPA models Input to Output to (case + output) case According to IEC/EN 60950, subassemblies connecting input to output are pre-tested with 3 kVDC. According to IEC/EN 60950, subassemblies connecting input to output are pre-tested with 4.3 kVDC or 3 kVAC. Make sure that there is sufficient airflow available for convection cooling. This should be verified by measuring the case temperature, when the converter is installed and operated in the end-use application. The maximum specified case temperature TC max should not be exceeded. Make sure that a converter failure (e.g., by an internal shortcircuit) does not result in a hazardous condition. Standards and Approvals All converters are safety-approved to IEC/EN 60950-1 2nd Ed. and UL/CSA 60950-1 2nd Ed. The converters correspond to Class I equipment. The following considerations have been made during design concerning safety: * * * * Build-in component Functional insulation between output(s) and case Use in a pollution degree 2 environment. CPD-models: Basic insulation between input and case/ output, based upon 75 VDC. The input is identified as TNV-2. * CPA-models: Basic insulation between input and case, and double or reinforced insulation between input and output, based on 250 VAC. Note: The DC test voltage shall be slowley increased (within several seconds) and maintained for max. 2 seconds. Trigger level 25 A. Power-One is executing these factory tests with a reasonable margin, to guarantee its repetition. Test with AC is not possible due to the incorporated Y caps. However, the standards allow testing with a corresponding DC voltage. Power-One will not honor any warranty claims, if the customer provides other or incorrect electric strength tests. Safety of Operator-Accessible Output Circuits If the output circuit of a converter is operator- accessible, it shall be an SELV circuit according to the IEC/EN 60950 related safety standards. However, it is the sole responsibility of the installer to ensure the compliance with the relevant and applicable local safety regulations The converters are subject to manufacturing surveillance in accordance with the above mentioned UL standards. Cleaning Agents The power supplies are not hermetically sealed. In order to avoid possible damage, any penetration of cleaning and other fluids shall be avoided. Protection Degree The converters correspond to protection degree IP 20, provided that the female connector is fitted. Isolation The electric strength test is performed as factory test in accordance with EN 50116 and EN/IEC 60950; see table13. Only the test between input and [case+outputs], marked with footnotes 1 and 2, may be repeated by the customer. BCD20005-G Rev. AF, 18-Aug-10 Page 18 of 19 www.power-one.com (R) 200 - 550 Watt CompactPCI (R) CPA, CPD Series Data Sheet AC-DC and DC-DC Converters Options F: Built-in Second Fuse L: Output Current Latch Available for CPA500 models only. A 2nd fuse in the neutral input line provides safe phase to phase connection at low mains voltages (e.g., USA 120/208 V / 60 Hz systems). All CPA/CPD models exhibit a latching shutdown, which is activated if only one output voltage is too high; see Output Characteristic and Protection. If option L is fitted, this latch is as well activated, if the current limit of one output is exceeded for approx. 0.5 s. C: Protective Lacquer All boards are covered by a protective lacquer. The built-in second fuse enables safe connection to the mains, where phase and neutral line are not defined, as e.g., in the case of plug and socket connection to the mains via German Schuko-plugs; see also Safety and Installation Instructions. G: RoHS RoHS-compliant for all six substances (standard for CPD500). NUCLEAR AND MEDICAL APPLICATIONS - Power-One products are not designed, intended for use in, or authorized for use as critical components in life support systems, equipment used in hazardous environments, or nuclear control systems without the express written consent of the respective divisional president of Power-One, Inc. TECHNICAL REVISIONS - The appearance of products, including safety agency certifications pictured on labels, may change depending on the date manufactured. Specifications are subject to change without notice. BCD20005-G Rev. AF, 18-Aug-10 Page 19 of 19 www.power-one.com