LRS Series Data Sheet AC-DC Subrack Systems MK007

Transcription

1 Features Compliant to AREMA, EN 5055, and EN 50-4 RoHS-compliant for all 6 substances 9-inch DIN-rack system, convection cooling Different output configurations Extremly rugged, reliable design for harsh environment Class I equipment Extremely high isolation of all output circuits Excellent surge and transient protection Wide input voltage range 85 to 64 VAC, 50 to 60 Hz Power factor >0.93, harmonics IEC/EN Output voltage adjust Active output current sharing Output voltage monitor with relay contacts Inrush current limitation PCBs with conformal coating except PCBs of the rack Hot swappable Safety-approved to the latest edition of IEC/EN and UL/CSA Description MK007 is a power supply system designed for railway and subway application. The applicable railway standards, mainly EN 5055, EN 50-4, and the respective AREMA standards are observed. The power supply system is designed to accommodate special LK converters, such as LK554-9ERD8TG or LK566-9ERD8TG. A main feature is the enhanced voltage isolation (3000 VAC) between outputs, alarm signals, and the metallic chassis respectively the ground. The system consists of one or two racks. Each rack can accommodate up to 4 converters, which allows redundant configuration in terms of input and output energy. The power supply rack system supports also battery charging with temperature sensors controling the LK converters. A floating relay contact is available to monitor the function of each converter. Table of Contents Page Page Description... Model Selection... Functional Description... 3 Electrical Input Data... 4 Electrical Output Data... 6 Electromagnetic Compatibility (EMC)... 8 Immunity to Environmental Conditions... 9 Mechanical Data... 0 Safety and Installation Instructions... Battery Charging /Temperature Sensor... 3 Copyright 07, Bel Power Solutions Inc. All rights reserved. Page of 3

2 Model Selection The system consists of converters and racks. Table : Converters. Other output configurations or special customer adaptations are available on request. Output Output Operating input range Type designation Efficiency Options V o nom I o nom V o nom I o nom V i min V i max f i min f i max η min η typ [VDC] [A] [VDC] [A] [VAC] [Hz] [%] [%] LK554-9ERD8TG LK566-9ERD8TG 8 84 Min. efficiency at V i = 30 V, I o nom and T A = 5 C Second output semi-regulated 3 Operating frequencies >60 Hz are possible with some restrictions; see web data sheet of the LK PFC Series (BCD000-G). Table : DIN-racks MK007. Other configurations or special customer adaptations are available on request. Type designation Output current Redun- Population Configuration of the of the system V o nom I o nom dancy converters in the DIN-rack 3 MK007-00G MK007-00G (Rack with backplane, but without converters) suits for LK554 suits for LK566 Pos Pos Pos 3 Pos 4 Subrack Systems LRS G 5 V 0 A no LK554 LRS G LRS G 8 V 5 A no LK554 4 LRS G LRS0-5-90G 5 V 0 A yes LK554 LRS0-5-95G LRS G 8 V 5 A yes LK554 4 LRS G LRS0-5-90G 5 V 0 A yes 4 LK554 LRS-4-90G 4 V A yes 4 LK566 LRS0-8-90G 8 V 0 A yes 4 LK554 4 LRS0-8-95G LRS G 50 V 6 A yes 4 LK566 LRS G 5 V 30 A no 3 LK554 LRS G LRS G 8 V 5 A no 3 LK554 4 LRS G LRS G 5 V 40 A no 4 LK554 LRS G LRS G 8 V 0 A no 4 LK554 4 LRS G LRS G 50 V A no 4 LK566. Pos Pos 3 Pos 4 Pos Pos 4 Pos 4 For a redundant system, identical racks must be provided. With customer-specific logos 3 Positions without converter are covered with blank panels 4 Converters LK554 with both output in series connection, trimmed to 4 V Page of 3

3 Part number Description LRS Sxxx G Series (product family)... LRS Output current... 05, 06, 0,, 5, 0, 30, 40 Output voltage... 5, 8, 48 Operating ambient temperature range T A = 40 to +7 C Options: Bel Power logo on front panel... 0 Custom logo on front panel... 5 Features: Redundancy (no, yes)... 0, Customer specific model... Sxxx RoHS-compliant for all 6 substances... G Applicable for non safety critical deviations. xxx are 3 digits assigned for each customer-specific model Functional Description The input voltage is supplied to up to 8 converters type LK554/LK566. The outputs of converters in each half of rack are connected together through OR-ing diodes. These converters share their output current evenly due their current share feature. The converters LK554 has two outputs with 5 V and the LK566 have two outputs with 4 V, which can be connected in parallel or in series. The connection of the outputs is done in the factory by the output voltage selector on the backplane. The output voltage can be adjusted by an external resistor located in the backplane (one resistor per converter) in the range of 80 to 0% of the output voltage. For the use as battery charger, an external thermal sensor can be connected to regulate the trickle charge voltage dependant on the battery temperature. The output voltage is monitored in each converter. When the output voltage is in range, a relay with an isolated contact is activated. All relay contacts are connected to the alarm signal connectors. The redundancy of the whole system is depending on the numbers of the converters; see table. DIN-racks with three or four converters must be duplicated for fully redundancy. JM34 N~ L~ PE Fuse Input filter C Y C Y Bridge retifier Boost converter (approx. 00 khz) C i 3 + Forward converter (approx. 80 khz) C Y Control circuit Output filter Output filter Vo R i D T Vo Vo+ Vo Fig. Block diagram of a converter Transient suppressor (VDR) Inrush current limiter (with opt. E) 3 Bulk capacitor + Page 3 of 3

4 PE A:N~ A:L~ VoA+ VoA PE B:N~ B:L~ VoB+ VoB JM4b Input filter Output filter SECTION A Input filter Output filter SECTION B D D D3 D4 Rdec Rinc Rdec Rinc Rdec3 Rinc3 Rdec4 Rinc4 Converter Converter Converter 3 Converter 4 Relay Relay T Share Relay 3 Relay 4 Links for Vo = 5 V Link for Vo = 8 V CC AL OK CC AL OK CC3 AL3 OK3 CC4 AL4 OK4 Signaling: CC = change contact; OK = operating contact (Vo okay); AL = rest contact (alarm) Fig. Block diagram of the DIN-rack. The converters in the different positions are fitted depending on the configuration; see table. The green connections are valid for the parallel configuration with 5 V output, the red connections for serial configuration with 8 V or 50 V output. For details of contacts and wires, see Mechanical Data. Electrical Input Data General Conditions: T A = 5 C, unless T C is specified. Pin 8 connected to pin 4, R input not connected. Table 3: Electrical input data per converter Input LK554-9ERD8TG LK566-9ERD8TG Unit Characteristics Conditions min typ max min typ max V i Rated input voltage range I o = 0 I o nom VAC V i op Operating input voltage range T C min to T C max V i nom Nominal input voltage Hz 5 / 30 5 / 30 I i Input current per converter V i = 30 V, I o nom A P i0 No-load input power per converter V i min V i max, I o = W C b Input capacitance per converter µf V i abs Input voltage limits VAC without damage VDC 3 Rated input frequency: Hz, operating input frequency: H z. Higher frequencies are possible with some restrictions; see web data sheet of the LK PFC Series (BCD000) Outputs loaded with I o nom 3 For s. Page 4 of 3

5 Input Fuse and Protection of the Converters A VDR together with the input fuse and a symmetrical input filter form an effective protection against high input transient voltages. Input fuse: slow-blow, SP T, 4 A, 50 V, 5 0 mm Input Under-/Overvoltage Lockout If the input voltage remains below approx. 65 VAC or exceeds V i abs, an internally generated inhibit signal disables the outputs. Do not check the overvoltage lockout function! If V i is below V i min, but above the undervoltage lockout level, the output voltage may be below the value specified in the tables Electrical Output Data. Power Factor and Harmonics Power factor correction is achieved by controlling the input current waveform synchronously with the input voltage waveform. The power factor control is active under all operating conditions. Harmonic distortions are below the limits specified in IEC/ EN , class D. Hold-up time ms V i = 85 V V i = 30 V I o /I o nom Fig. 5 Hold-up time versus output power LK450-hu-a Inrush Current Limitation The converters exhibit an electronic circuit to limit the inrush current at switch-on. Note: Subsequent switch-on cycles at start-up are limited to max. 0 cycles during the first 0 seconds (cold converter) and then to max. cycle every 8 s V i = 85 VAC V i = 30 VAC LK450-pf Input Filter Rectifier Control FET PFC - correct. + 00b Converter I o /I o nom R s R I C b Fig. 3 Power factor versus output current Fig. 6 Inrush current limtation, schematic diagram Efficiency Table 4: Inrush current characteristics per converter V i = 30 V V i = 85 V LK450-eta Characteristics Inrush current Unit V i = 30 VAC typ max I inr p Peak inrush current 5.3 A t inr Inrush current duration ms I o /I o nom Fig. 4 Efficiency versus output current Page 5 of 3

6 Electrical Output Data Table 5: Output data of the converters Model LK554 LK566 Unit Output + in series Output + in series Characteristics Conditions min typ max min typ max V o Output voltage V i nom, I o nom V I o nom Output current nom. V i min V i max A T C min T C max I ol Output current limit V i min V i max V o u Static line regulation V i min V i max ±30 ±40 mv with respect to V i nom I o nom V o I Static load regulation V i nom (0. ) I o nom α vo Temperature coefficient T C min T C max ±0.0 ±0.0 %/K of output voltage I o nom Thermal Protection of the Converters A temperature sensor generates an internal inhibit signal, which disables the outputs when the case temperature exceeds the value T C max. The outputs automatically recover, when the temperature drops below this limit. Continuous operation under simultaneous extreme worst-case conditions of the following three parameters should be avoided: Minimum input voltage, maximum output power, and maximum temperature. Output Protection of the Converters Each output is protected by a suppressor diode against overvoltage, which could occur due to a failure of the control circuit. In such a case, the suppressor diode becomes a short circuit and V o = 0. A short circuit at any of the two outputs will cause a shutdown of the other output. A red LED indicates any overload condition. Output Voltage Regulation of the Converters The following figures apply to double-output models with parallel-connected outputs. V o V o nom I o I ol 0500a Output Voltage Monitor of the Converters An output undervoltage monitoring circuit (D8) is integrated to each converter. A logic "high" signal (NPN output) is generated at the D output (pin 0), when the monitored voltage Vo drops below the preselected threshold level V t. This signal is referenced to S / Vo. The D output recovers, when the monitored voltages exceed V t + V h. The threshold level is adjusted in the factory to a fixed value suitable for the application. This output activates a relay located on the backplane MK007 with a floating contact, which is closed when the output voltage of the respective converter is present. Output Voltage Adjust of the Converters The control input R (pin 6) allows for adjusting the output voltage by means of an external resistor. When pin 6 is not connected, the output voltage is set to V o nom. If the converters are inserted in the rack, use Rinc or Rdec according to fig. 3. Note: Only converter can be adjusted at once. Pull out all other converters, to adjust the first one, then repeat this procedure with all other converters. Depending on the value of the required output voltage, the resistor must be connected: either between pin 6 and pin 4 (V o < V o nom ) to achieve an output voltage adjustment range of approximately 0 00% of V o nom. If the converter is in the rack, use Rdec (fig. 3). or between pin 6 and pin (V o > V o nom ) to achieve an output voltage adjustment range of 00 0% of V o nom. If the converter is in the rack, use Rinc (fig. 3). The second output of double-output models follows the value of the controlled main output Fig. 7 Typical output characteristic V o versus I o. I o I o nom Current Sharing between Converters This feature ensures that the output currents are approximately shared between all parallel-connected converters, hence Page 6 of 3

7 increasing system reliability. To use this facility, simply interconnect the T pins of all converters and make sure that the references for the T signal (Vo, pin 4) are also connected together. Display Status of LEDs V o > 0.95 to 0.98 V o adj 0600a OK i I o L V i LEDs "OK", "i " and "I o L " status versus input voltage Conditions: I o I o nom, T C T C max, V inh 0.8 V V i uv = undervoltage lock-out, V i ov = overvoltage lock-out V i uv V i min V i max V i ov V i abs OK I o L i V o > 0.95 to 0.98 V o adj I o V o < 0.95 to 0.98 V o adj I o nom I ol T C LEDs "OK" and "I o L " status versus output current Conditions: V i min V i max, T C T C max, V inh 0.8 V LED "i " versus case temperature Conditions: V i min V i max, I o I o nom, V inh 0.8 V T C max T PTC threshold V inh threshold i -50 V LED off +0.8 V +.4 V LED Status undefined V i inh +50 V LED on LED "i " versus V inh Conditions: V i min V i max, I o I o nom, T C T C max Fig.8 LED indicators Page 7 of 3

8 Electromagnetic Compatibility (EMC) The converters and populated subrack systems successfully been tested to the following specifications: Immunity Table 7: Electromagnetic immunity (type tests) Phenomenon Standard Level Coupling Value Waveform Source Test In Perf. mode applied imped. procedure oper. crit. Electrostatic IEC / EN 4 contact discharge 8000 V p /50 ns 330 W 0 positive and yes A discharge pf 0 negative air discharge 5000 V p (to case) discharges Electromagnetic IEC / EN 3 antenna 0 V/m AM 80%, khz n.a. 80 MHz GHz yes A field / Radiated susceptibiliy 0 V/m.4. GHz 5 V/m..5 GHz Electrical fast IEC / EN 3 capacitive, o/c ±000 V p bursts of 5/50 ns 50 Ω 60 s positive yes A transients/burst /5 khz over 60 s negative ±i/c, +i/ i 5 ms; burst transients per direct period: 300 ms coupling mode Surges IEC / EN 3 ±i/c ±000 V p./50 µs Ω 5 pos. and 5 neg. yes A surges per +i/ i Ω coupling mode Conducted IEC / EN 3 i, o, signal wires 0 VAC AM 80% 50 Ω MHz yes A disturbances (40 dbµv) khz sine wafe i = input, o = output, c = case A = Normal operation, no deviation from specifications, B = Temporary loss of function or deviation from specs. Emissions For conducted emissions, the converters comply with class A according to EN 550 and FCC Part 5. For radiated emissions, the converters comply with class A according to EN 550 and FCC Part 5 (30 MHz 0 GHz). dbµv/m MK007: Quasi peak, radiated LRS GG, V i =30 VAC, V o =5 V I o = 40 A EN 550 A The populated subrack systems have been tested for conducted and radiated emissions; see fig. 9 and fig JM37 dbµv MK007: Peak, conducted QP + AV LRS G, V i =30 VAC, V o =5 V I o = 40 A EN 550 A (qp) EN 550 A (av) JM MHz 40 0 Fig.0 Radiated emissions quasi peak, antenna distance 0 m (populated subrack system LRS G at V in = 30 VAC, V o = 5 V, I o = 40 A) MHz Fig. 9 Conducted emissions peak and average at the input (populated subrack system LRS G at V in = 30 VAC, V o = 5 V, I o = 40 A) Page 8 of 3

9 Immunity to Environmental Conditions The populated subrack system has been tested as per table 8. Table 8: Mechanical and climatic stress for a populated rack Test method Standard Test conditions Status Cab Damp heat IEC/EN :00 Temperature: 40 ± C System incl. steady state MIL-STD-80D section 507. Relative humidity: 93 +/-3 % converters Duration: 56 days not operating Kb Salt mist, cyclic IEC/EN :996 Concentration: 5% (30 C) for h per cycle System incl. (sodium chloride Storage: 40 C, 93% rel. humidity for converters NaCl solution) Duration: 3 cycles of h not operating Fc Vibration AREMA Part..5. Acceleration amplitude:.54 mm (5 0 Hz) System and (sinusoidal) class B (wayside outdoors) g n = 9.6 m/s (0 00 Hz) converters Frequency (0.9 Oct/min): 5 00 Hz operating Test duration: h (4 h in each axis) Ea Shock AREMA Part..5. Acceleration amplitude: 0 g n = 98 m/s System and (half-sinusoidal) class B (wayside outdoors) Bump duration: ms converters Number of bumps: 8 (3 in each direction) operating The converters have been tested separately to more severe limits and with more tests. For details, see K Series Data Sheet on our web site (BCD000-G). Temperatures Table 9: Temperature specifications Temperature -9 Unit Characteristics Conditions min typ max T A Ambient temperature Converter operating C T C Case temperature T S Storage temperature Non operational For converters and the systems For converters. Overtemperature lockout at T C >95 C Page 9 of 3

10 Mechanical Data Dimensions in mm. The converters are designed to be inserted into a 9" rack, 60 mm long, according to IEC European Projection Front plate Front plate TE 9 TE JM-A09 Test jacks mm (Vo+/Vo ) Measuring point of case temperature T C (3U) LED OK (green) LED i (red) LED I ol (red) Gravitational axis (5) 8.4 (3) 50 Main face ( ) 68.5 Back plate Fig. Converter with mounted front plate and handle. Aluminum case K0 with heat sink, black finish (EP powder coated). Total weight approx..8 kg. Note: Weight of a blanc panel is 0.5 kg. Page 0 of 3

11 Fig. 9" DIN-rail rack MK007-00G, dimensions in mm. Weight approx..8 kg (empty) SECTION A SECTION B PE A:N~ A:L~ W-87 W-84 W-8 AWG #8 # # VoA VoA+ W-84 W-8 AWG #8 #8 PE B:N~ B:L~ W-87 W-84 W-8 AWG #8 # # VoB VoB+ W-84 W-8 AWG #8 #8 JM5d Input A Input B Output A Output B Rinc Rdec (V o adjust) OK CC AL all W-03 AWG #6 OK CC AL all W-03 AWG #6 jumpers for V o = 5 or 8 V OK3 CC3 AL3 all W-03 AWG #6 jumper for current sharing between sect. A and B OK4 CC4 AL4 all W-03 AWG #6 Fig. 3: Rear view and connections. "W-" stands for "WAGO 745-". Recommended cable cross sections; see table 0 for min / max cross sections. Rinc Rdec (V o adjust) Page of 3

12 Safety and Installation Instructions Please read the Installation Instruction BCM Table 0: Cross sections Position WAGO reference min/recom/max cross sect. Input, Output , AWG AWG 6 AWG PE AWG 8 AWG 6 AWG Alarme signals AWG 6 AWG AWG Connector Pin Allocation of the Converters The connector pin allocation table defines the electrical potentials and the physical pin positions on the H Fixtures for retention clips S000b Fig. 4 View of converter's male connector, type H5 Table : Pin allocation of the converter Pin LK554, LK566 4, 6 Vo+ Pos. output 8, 0 Vo Neg. output Vo+ Pos. output 4 Vo Neg. output 6 R Control of V o 8 i Inhibit 0 D Save data T Current share _ 4 Protective earth PE 6, 8 N Neutral line 30, 3 L Phase line Leading pin (pre-connecting) connector. The protective earth is connected by a leading pin (no. 4), ensuring that it makes contact with the female connector first. Standards and Approvals The converters correspond to Class I equipment and are safety-approved to the latest edition of EN/IEC and UL/ CSA For more details see the special data sheets of LK544 and LK566 and the LK PFC Series on our web site. All products are subject to manufacturing surveillance in accordance with the above mentioned standards and ISO 900:008. Leakage Currents per Converter Leakage currents flow due to internal leakage capacitances and Y-caps. The current values are proportional to the voltage and frequency of the supply. They are specified in the table. Table : Leakage currents per converter Characteristic Class I Unit Maximum Permissible according to IEC/EN ma earth leakage Typ. value at 5 V, 60 Hz; per converter 0.4 Typ. value at 30 V, 50 Hz; per converter 0.7 Protective Lacquer All boards of the converters are coated with a protective lacquer. The DIN-rack including the back plane is designed with higher creepage distances and clearances, but is not protected by lacquer. Isolation and Safety Test The electric strength test of the converters is performed in the factory as routine test in accordance with EN 5054 and IEC/ EN The DIN-racks are tested without converters, but with all relays and signaling circuits. Table 3 is valid for the DIN-racks populated with converters. Table 3: Isolation (including converters which are separately tested) Characteristic Input to case Output(s) to case Output to Alarm signals Unit and output(s) and input output to everything Electric Factory test to 6 s kvdc strength AC test voltage equivalent kvac test to factory test Insulation resistance at 500 VDC >300 >00 -- MΩ Creepage distances converters mm DIN-racks According to EN 506 and IEC/EN 60950, subassemblies (of converters and rack) connecting input to output, e.g. transformers, opto couplers, relays, etc.) are pre-tested with 5.6 kvdc or 4 kvac. Tested with 50 VDC 3 Input to outputs: 6.4 mm Page of 3

13 Battery Charging /Temperature Sensor All converters with an R-input are suitable for battery charger applications For optimal battery charging and life expectancy of the battery, an external temperature sensor can be connected with the Cell voltage [V] V o safe 0639b C V C =.7 V, 3 mv/k V C =.3 V, 3 mv/k V C =.7 V, 3.5 mv/k V C =.3 V, 3.5 mv/k Fig. 5 Trickle charge voltage versus temperature for defined temperature coefficient. R-input. The sensor is mounted as close as possible to the battery and adjusts the output voltage according to the battery temperature. Depending upon cell voltage and the temperature coefficient of the battery, different sensor types are available (other models on request): Table 3: Sensors for converters LK554 and LK566 Battery Sensor Cell Cell temp. Cable voltage type voltage coefficient length nom. [V] [V] [mv/k] [m] S-KSMH S-KSMH S-KSMH S-KSMH S-KSMH S-KSMH S-KSMH S-KSMH S-KSMH Input Power supply Vo+ Vo R 03099d Load European Projection L L = m (standard length) other cable lengths on request 56 (.") 095a 6 (.0") adhesive tape 9.8 (0.4") + ϑ Temperature sensor + Battery Fig. 6 Mechanical data of a temperature sensor Fig. 7 Connection of a temperature sensor NUCLEAR AND MEDICAL APPLICATIONS - These 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. Copyright 07, Bel Power Solutions Inc. All rights reserved. belfuse.com/power-solutions Page 3 of 3