HK-Family AC-DC Converters >100 W Benign Environment TOKO 300 W AC-DC Converters HK-Family Single output • Universal input: (85...264 V AC) • Power factor corrected • Special functions, as current sharing, power fail signal, remote control and sense lines • Noise standards: EN 55011/55022 class B Safety according to EN 60950 Table of Contents Page Type Survey ............................................................ 11 - 92 Description .............................................................. 11 - 92 Safety and Installation Instructions ......................... 11 - 93 Electromagnetic compatibility EMC......................... 11 - 93 Electrical Input and Output Data ............................. 11 - 94 Operating Instructions ............................................. 11 - 95 Immunity to Environmental Conditons .................... 11 - 97 Input and Output Terminals ..................................... 11 - 97 Mechanical Data ..................................................... 11 - 98 Type Key and Product Marking ............................... 11 - 98 Type Survey Table 1: Type survey Output configuration Input voltage Rated power Power factor Type designation U I range P correction o nom o nom o tot [V DC] [A] U ...U T = 50°C i min i max A 5 60.0 HK 300-05 12 25.0 HK 300-12 15 20.0 85...264 V AC 300 W 0.95 (230 V AC) HK 300-15 24 12.5 47...63 Hz HK 300-24 36 9 HK 300-36 48 6.3 HK 300-48 Description This design of the HK 300 allows for the use of smaller in- Key applications ductive components and filtering circuitry. The power MOS- The smaller-than-usual size of the HK 300 series makes FET technology also reduces size and increases power them well suited to newer, smaller footprint personal com- density. For a new generation product or as a running de- puters as well as telecommunications equipment, instru- sign change, a manufacturer can replace a conventional mentation and control systems. power supply with a HK 300. 11 - 92 MELCHER Edition 2/96 - © Melcher AG The Power Partners. 11.3 Benign Environment AC-DC Converters >100 W HK-Family +V L Inrush Rectifier Input current and Rectifier filter limiter filter N –V Power FG Current Control circuit switcher detector Current detector Remote sense Current share Power fail Fig. 1 Remote on/off Block diagram HK 300 Safety and Installation Instructions Safety If the AC-DC converter is installed acoording to the relevant safety regulations, its output is considered to be an SELV If the output circuit of an AC-DC converter is operator-ac- circuit up to a nominal output voltage of 36 V, provided the cessible according to the IEC 950 related safety standards, output is connected to ground according to the relevant it shall be an SELV circuit (Safety Extra Low Voltage circuit, safety standard, a suitable input line fuse is installed and an i.e. a circuit, separated from mains by at least basic insula- adequate voltage limiting device is connected across the tion, that is so designed and protected that under normal output. and single fault conditions, the voltage between any two conductors and between any conductor and earth does not Installation instruction exceed 60 V DC). Installation of the power supply must strictly follow the na- In the following section an interpretation is provided of the tional safety regulations. To observe the safety require- IEC 950 safety standard with respect to the safety status of ments according to EN 60950/IEC 950, the module shall be the output circuit. However, it is the sole responsibility of the connected via the female connector or terminal block. installer or user to assure the compliance with the relevant Other installation methods may not meet the safety require- and applicable safety standards: ments. At least one external fuse, installed in the wiring to the input is essential! Electromagnetic compatibility EMC Immunity A metal oxide VDR together with an input fuse and an input but especially in battery driven mobile applications. The HK filter form an effective protection against high input tran- family has been successfully tested to the following specifi- sient voltages which typically occur in most installations, cations: Table 2: Immunity type tests Phenomenon Standard Class Coupling Value Waveform Source Test In Per- 3 Level mode applied Imped. procedure oper. form. 1 Electrostatic IEC 801-2 3 air discharge 6 kV 1/50 ns 330 Ω 10 positive and yes p discharge (1991-04) to frame 10 negative discharges 1 Electric field IEC 801-3 3 antenna in 10 V/m sine wave mod- 26...1000 MHz yes (1984) 1m distance ulated w. 1 kHz 1 Fast transient/ IEC 801-4 3 i/c, +i/–i 2000 V 5/50 ns 50 Ω 1 min positive yes p burst (1988) 1 min negative bursts per coupling mode 21 Transient IEC 801-5 3 i/c 2000 V 1.2/50 μs 12 Ω 5 pos. and 5 neg. yes p (Draft 1993-01) impulses per coupling mode 1 2 3 Normal operation, no deviation from specifications No load i = input, o = output, c = case Emission Internal input filtering keeps the conducted noise of the level B according to EN 55011 and EN 55022 standards units within the frequency range of 10 kHz to 20 MHz below (CISPR 11/22 respectively). Refer also to table "Input Data". Edition 2/96 - © Melcher AG MELCHER 11 - 93 The Power Partners. Control circuit Comparator 11.3 HK-Family AC-DC Converters >100 W Benign Environment Electrical Input and Output Data General condition: T = 25°C unless otherwise specified A Table 3: Input Data Characteristics HK 300-.. Unit U Input voltage range 85...264 V AC i f Line frequency 47...63 Hz i I Input current (max.) 100/200 V AC 8/4 A i I Inrush current (max.) 100/200 V AC 15/30 inr I Leakage current (max.) 100/200 V AC 0.5/0.75 mA i leak PF Power factor correction min. 0.95 U Input RFI level EN 55011/22 B i RFI General condition: T = 25°C unless otherwise specified A Table 4: Output data Characteristics HK 300-05 HK300-12 HK300-15 HK300-24 HK300-36 HK300-48 Unit U Output voltage 5 12 15 24 36 48 V o nom Adjustable output range ±10 % I Output current 60 25 20 12.5 9 6.3 A o U Overvoltage protection 6.0...6.9 13.5...15.5 17...20.0 27...31 40.5...46.5 53...59 V oL 1 I Overcurrent protection 105 % o L u Ripple-noise max. 120 150 150 200 200 400 mVp o ΔU Line regulation ±3% o U ΔU Load regulation 0...100% ±3 o I ΔU Drift (t = 0.5...8 hours) typ. ±3 o t αU Change in temp. 0...50°C typ. ±3 o Remote sensing standard Remote on/off standard Current sharing standard Output indicator LED on front panel Power fail standard 2 t Rise time max. 500 ms o r 2 t Hold up time min. 20 o h 2 η Efficiency typ. 74 76 78 80 80 81 % Cooling forced air (fan built in) 1 Operate at 105% of rated current, CC method, automatic recovery 2 At rated input and output 11 - 94 MELCHER Edition 2/96 - © Melcher AG The Power Partners. 11.3 Benign Environment AC-DC Converters >100 W HK-Family P [%] Operating Instructions o 120 Derating of Output Power The derating characteristic of the output power is shown in 100 fig. 2. 80 Output Voltage Adjustment The output voltage adjustment range (V at the front ADJ 60 panel) is ±10% of U . The actual output power should o nom not exceed the specified maximum output power. 40 Overcurrent Protection 20 When the output current exceeds 105 % of the rated current the overcurrent protection circuit operates (see fig. 3). The 0 T [°C] A output will recover automatically as soon as the overload 0 10 20 30 40 50 60 70 condition is removed (constant current method). Fig. 2 Output power vs. ambient temperature Overvoltage Protection 3% 100 If there is an overvoltage condition at the output, the inter- nal latch circuit will operate and the output will be cut off. In this instance, turn off the input. At least 90 seconds should be allowed as recovery time. Output Current, (%) 100 105 Fig. 3 Output voltage vs. output current Sense Lines HK 300 CS PF Note: Sense lines must always be connected! V+ RC+ This feature enables compensation of voltage drop across the connector contacts and the load lines including the di- RC– S+ ode in true redundant wired-OR system configurations. L Applying generously dimensioned cross-section load leads S– N avoids troublesome voltage drop. To minimize noise pick- V– up, sense lines should be twisted and 330...470 μF capaci- tors connected between the voltage output and sense in- load HK 300 put. For unsymmetrical loads it is recommended to connect CS PF the sense lines directly at the terminals. V+ RC+ To ensure correct operation, both sense lines must be con- nected to their respective power output potential. RC– S+ L S– N V– Fig. 4 Sense lines connection for redundant (n+1) or parallel op- eration using wired-OR diodes Inrush Current Fan Monitor A thyristor is built-in to protect against excessive inrush cur- If the cooling fan is defective or mechanically blocked, the rent. Appropriate selection of the AC input switch is recom- power supply is automatically turned-off. After fixing the mended. Repeating switching cycles within short period problem the unit will return to normal operation. In case the should be avoided. fan monitor fails, the power supply is protected by over- temperature shut-down. Insulation and Dielectric Strength Test Preshipment tests have been applied at the factory and fur- ther tests are not necessary. Edition 2/96 - © Melcher AG MELCHER 11 - 95 The Power Partners. Output Voltage (%) 11.3 HK-Family AC-DC Converters >100 W Benign Environment Inhibit (i Input) The outputs of the module may be enabled or disabled by means of a relay contact or opto-coupler between the in- puts RC+ and RC–. If the inhibit function is not used, RC+ and RC– are not connected. L V+ V– ON Relay or Opto-coupler RC+ OFF Relay contact ON N RC– or opto-coupler V out OFF Fig. 5 Fig. 6 Definition of inhibit signal Remote control (inhibit) connection Output Power Fail Signal The power fail signal toggles to high (H = 5 V) 50...500 ms U o nom after the output voltage has reached 95% of U . The o nom 0.95U o nom sink current at 5 V is 1 mA. If the output voltage drops be- low 95% of U , the power fail signal drops to low (L = o nom 0 V) after less than 4 ms. t 0 PF H (5 V) L (0 V) t 50 - 500 ms < 4 ms Fig. 7 Output response as a function of input voltage (on/off switching) or inhibit control Current Sharing HK 300 CS PF For higher power and n+1 systems, a current sharing facil- V+ ity allows several units to operate in parallel-connection RC+ with the assurance that a single fault will not lead to a sys- RC– tem failure. Interconnection of the current sharing terminals S+ L CS causes the units to share the load current, resulting in S– N lower stress and further improved reliability. Parallel-con- nected modules with interconnected CS terminals share V– their output currents within a tolerance of approx. ±20% of I . When operating with dynamic loads, the current onom HK 300 CS sharing will be less accurate. PF V+ The current sharing and sense lines are wired as follows: RC+ Besides connecting the load with the terminals V+ and V–, RC– another twisted wire pair is connected with S+ and S– re- S+ L spectively of each unit to be operated in parallel. A second S– wire should be connected between the negative side of the N load and S–. This wire is twisted together with the current V– sharing wire to avoid noise pick-up. – + Load Fig. 8 Parallel connection of several modules, sense lines con- nected at connector side 11 - 96 MELCHER Edition 2/96 - © Melcher AG The Power Partners. 11.3 Benign Environment AC-DC Converters >100 W HK-Family Immunity to Environmental Conditons Table 5: Temperature specifications Characteristic min max Unit T Operating ambient temperature range without derating 0 50 °C A T Operating ambient temperature range with derating (see fig. 2) 0 60 A T Storage temperature range –20 75 S Table 6: Humidity Test Parameters Ca Humidity Relative humidity: 30...85% (no condensing) Unit operating/storage 2 Ea Shock Acceleration: 20 g (196 m/s ) Bump duration: 11 ms, ±5 ms Number of bumps: 18 (3 each direction) Unit not operating Fc Vibration Frequency: 5...55 Hz Maximum vibration amplitude: 10 mm (5...10 Hz) 2 Acceleration: 2 g (19.6 m/s , 10…55 Hz) Duration: 3 h (1 h each axis) Unit not operating Table 7: Isolation Test Input to output Input to frame Output to frame 1 Dielectric strength test 3000 V AC, 1 minute 3000 V AC, 1 minute – leakage current <10 mA. 1 Insulation resistance >100 MΩ at 500 V DC – >100 MΩ at 500 V DC 1 At normal temperature and humidity Table 8: Safety approvals 1 Safety Approvals UL 1950 CSA 234 TÜV HK 300 x x x 1 EN 60950 Table 9: MTBF Ratings at specified HK 300 Fan (Life time) Unit Ambient temperature 40 °C25°C MTBF 122'000 30'000 h Input and Output Terminals –S Remote Sensing Remote Control RC+ –V Output Remote Control RC– –V Output Power Fail PF –V Output Currant Sharing CS +V Output Earth +V Output AC Input N +V Output AC Input L +S Remote Sensing Output Indicator Output Voltage Adjustment Fig. 9 Terminal designation of HK 300 types Edition 2/96 - © Melcher AG MELCHER 11 - 97 The Power Partners. 11.3 HK-Family AC-DC Converters >100 W Benign Environment Mechanical Data Dimensions in mm. Tolerances ±1 mm unless otherwise indicated. European Projection – 4 - M4 0.5 15 190– – 4 - M4 0.5 25 180–67 16.5 14 220 100 – 4 - M4 0.5 15 190– Fig. 10 HK 300, weight 2600 g Type Key and Product Marking Type Key HK 300 - 12 Family ........................................................................... HK Blank .................................................................................. Nominal output power [W]............................................ 300 Dash ................................................................................ Nominal output voltage [V] ....................................... 5…48 Example: HK 300-12 = AC-DC converter providing 12 V/25 A, 300 W in a case with terminal strips. Product Marking Label: Type designation, applicable safety approvals and recognition marks, specific type designation, input voltage range, nominal output voltage and current and pin allocation. 11 - 98 MELCHER Edition 2/96 - © Melcher AG The Power Partners. 11.3 100 100 10 0.5 0.5 25 100 50 25 0.5 50 120 10 50 15 10 15 96