CompactPCI CPA, CPD Series Data Sheet Watt AC-DC and DC-DC Converters

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1 " 6 U 3.94" 3 U 4.4.6" 8 HP " Features 4.6.6" 8 HP " Description The CPA and CPD Series are highly reliable power supplies for CompactPCI 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 power interface specification for CompactPCI systems. The s use the patented EDGE TM technology and provide important advantages such as flexible output power, extremely high efficiency, excellent reliability, full input-tooutput isolation, negligible inrush current, hot-swap capability, soft start, and overtemperature protection. 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 9 to 264 VAC or 36 to 75 VDC. The outputs are protected against continuous overload, open, and short-. Full n redundant operating mode is made possible by integrated FETs or diodes. When several s are connected in parallel, a single- RoHS lead-free-solder and lead-solder-exempted products available Compliant to PICMG CompactPCI specifications Wide range DC or AC input with PFC Extremely high efficiency and high power density Low inrush current 4 high current outputs with flexible load distribution Integrated FETs / diodes for true redundancy Inhibit and enable inputs Remote sense lines Single-wire current share function for 3 outputs Hot-swap capability 47 pin connector, type Positronic Overtemperature, overvoltage, overcurrent, and overpower protection Safety-approved to the latest edition of UL/CSA 695- and IEC/EN Table of Contents Page Page Description... Model Selection... 2 Functional Description... 3 Electrical Input Data... 5 Electrical Output Data... 7 Auxiliary Functions... Electromagnetic Compatibility (EMC)... 3 Immunity to Environmental Conditions... 5 Mechanical Data... 6 Safety and Installation Instructions... 7 Options... 9 Copyright 27, Bel Power Solutions Inc. All rights reserved. Page of 9

2 wire connection between s ensures proper current sharing. The s are designed with two or three separate forward s with fixed switching frequency and synchronous rectifiers at their output. LEDs on the front panel and various warning signals display the status of the. The aluminum case acts as a heat sink and as an RFI shield. It is designed for vertical insertion into 9" 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 are available to meet different requirements. Model Selection Table : Standard models Model Output Operating input Rated power Efficiency 2 Case Options 4 range η No. V o nom I o nom I o max V i min V i max P o nom min typ [V] [A] [A] f i min f i max [W] [%] [%] CPD2-453G Vo (48)...75 VDC U x 8HP non-g Vo Vo Vo CPD25-453G Vo U x 8HP L, A, C Vo non-g Vo Vo4 2 2 CPD5-453G Vo U x 8HP C Vo Vo Vo CPA2-453G Vo (23) U x 8HP non-g Vo VAC Vo Hz 3 Vo CPA25-453G Vo U x 8HP L, A, C Vo non-g Vo Vo4 2 2 CPA5-453 Vo U x 8HP L, A, F, C, Vo non-g Vo Vo CPA Vo U x 8HP non-g Vo Vo Vo The sum of the power of all outputs may not exceed the total power for the specified required forced-air cooling. 2 Efficiency at T A = 25 C, V i nom, I o nom. 3 Rated input voltage range is 24 VAC, rated input frequency range is 5 6 Hz. 4 RoHS is standard, marked with G at the end of the part number. Non G versions only on request. Note: The sequence of options in the model designation must follow the order above. G is always placed at the end. NFND: Not for new designs Preferred for new designs Page 2 of 9

3 Product Marking Label with specific type designation, applicable safety approvals and recognition marks, CE mark, warnings, patents, company logo, input voltage range, 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. Functional Description The inputs of all s 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 breakers and fuses from tripping at switch-on. All CPA models have an additional bridge rectifier and a boost to provide active power factor correction (PFC) according to EN The CPx2/25 models (see fig.a) are equipped with two independent high efficient 2-switch forward s, switching 8 out of phase to minimize the ripple current at the input. On the secondary side, two high-current synchronous rectifiers supply Vo (5 V) and Vo2 (3.3 V) with up to 4 A. The secondary-led Vo3 (2 V) post regulator is supplied by an additional winding of the 3.3 V main transformer. The linear regulator for Vo4 ( 2 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. The models CPD5 (fig. b) and CPA5/55 (fig. c) exhibit a third forward for both outputs Vo3 and Vo4. The outputs Vo an Vo2 provide up to 5 and 6 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 starts to reduce the output power by decreasing the output voltages. In contrast to the outputs Vo (5 V), Vo2 (3.3 V), and Vo3 (2 V) with active current sharing, output Vo4 ( 2 V) has a droop characteristic for passive current sharing. If for some reason the voltage of any output exceeds the nominal value significantly, the 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. Melcher'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 utilising a transitional resonant switching technique and proprietary ACN DCIN 46 ACL DCIN Fuse Input filter Only CPA models have a bridge rectifier and a boost Bridge rectifier Inrush current limiter Boost 35 khz C b Primary Primary Forward 35 khz Forward 35 khz 3f FET FET V o V o2 RTN (22) INH# 39 EN# 27 Inhibit logic FET V o3 Fig. a Block diagram of CPA/CPD2 and CPA/CPD25 models. For the pin allocation, see Mechanical Data. Linear regulator C y diode V o4 Page 3 of 9

4 leading and trailing-edge pulse-width modulation. It has a proven track record in high-availability power solutions. The switching frequency is typically 35 khz. Recent models (CPD2/25 version V9 or later, CPA2/25 version V7 or later, CPA5/55 version V or later, not CPD5) exhibit a crystal oscillator with 3 khz. All models have a separate auxiliary supply for the primary s, the CPD5 as well for the secondary s. The secondary bias voltage of the other models is generated by the forward s. Only the forward s are led by the inhibit and enable inputs; see Auxiliary Functions. DCIN 46 V i DCIN Fuse RTN (22) INH# 39 EN# 27 Input filter VDR V PBias Inhibit logic Inrush current limiter with reverse polarity protecton Auxiliary Dual interleaved boost 5 khz Fig. b Block diagram of CPD5 models. For the pin allocation, see Mechanical Data. C b Primary Primary Primary Forward 35 khz Forward 35 khz Forward 35 khz V SBias JM4a FET FET FET diode V o V o2 V o3 V o4 ACN 46 2 nd fuse (option F) JM4b V i ACL Fuse RTN (22) INH# 39 EN# 27 Input filter Bridge rectifier Inhibit logic Inrush current limiter V PBias Boost 35 khz Auxiliary C b Primary Primary Primary Forward 35 khz Forward 35 khz Forward 35 khz V SBias FET FET FET V o V o2 V o3 Fig. c Block diagram of CPA5/55 models. For the pin allocation, see Mechanical Data. Page 4 of 9 diode V o4

5 Electrical Input Data General Conditions: T A = 25 C, unless T C is specified. Table 2a: Input data of CPD models Input CPD2/25 CPD5 Unit Characteristics Conditions min typ max min typ max V i Operating input voltage I o = I o max VDC V i nom Nom. input voltage T C min T C max V i abs Input voltage limits 6 s, no damage 8 8 I i Typical input current V i nom, I o nom 5./ A I i max Max. input current V i min, I o nom 7./ / I inr p Peak inrush current V i max, I o nom 2 25 P i No-load input power V i min, I o = W V i nom, I o = 8 28 V i max, I o = P i inh Input power, when inhibited V i min V i max C i Input capacitance 36 5 µf f switch Switching frequency V i nom, I o nom khz t h Hold-up time V i min V, I o nom 4 5 ms t bo Brown-out time 4 V i nom, I o nom 4 5 t su Start-up time V i nom, I o nom Table 2b: Input data of CPA models Input CPA2/25 CPA5/55 Unit Characteristics Conditions min typ max min typ max V i Rated input voltage range I o = I o max VAC V i op Operating input voltage T C min T C max V i nom Nom. input voltage 5 6 Hz V i abs Input voltage limits 6 s, no damage I i Typical input current V i nom, I o nom./ /3. 3 A I i max Max. input current V i min, I o nom 2.9/ / /7.8 3 I inr p Peak inrush current V i max, I o nom 5 2 P i No-load input power V i min V i max W I o = P i inh Input power, when inhibited V i min V i max C i Input capacitance 4 µf f switch Switching frequency V i nom, I o nom khz t h Hold-up time V i min V, I o nom 2 2 ms t bo Brown-out time 4 V i nom, I o nom t su Start-up time V i nom, I o nom 5 5 Power factor V i nom, I o nom W/VA Rated input frequency: 5 6 Hz, operating input frequency range: Hz 2 First value for CPD/CPA2, 2 nd value for CPD/CPA25 3 First value for CPA5, 2 nd value for CPA55 4 Short interruption of V i without affecting the outputs (EN 6-4-) Page 5 of 9

6 Input Fuse and Reverse Polarity Protection 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. An incorporated fuse protects the against further damage in the case of a failure. Note: The fuse is not customer-accessible. Efficiency The efficiency is specified in table. Its dependence upon the input voltage V i is shown in fig. 2a (CPA models) and fig. 2b (CPD5 models). The efficiency of CPD2/25 models depends only marginally upon V i. η [%] 9 Table 3: Fuse specification Model Fuse rating Reference CDP2/25 25 V, 2.5 A T Schurter SPT 5x2,.255 CPA2/25 25 V, 5 A T Schurter SPT 5x2,.25 CPD5 8 V, 25 A F Littlefuse FKS, CPA5/55 25 V, A T Schurter MXT25, CPA5/55 JM8a CPA2/25 To avoid unwanted power losses, the CPD2/25 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. The CPD5 models are protected against reverse polarity by a special ry, which generates no losses. The will simply not start-up, but no damage will occur. The CPA Series s are designed for AC input and have a rectifier bridge on the input VAC Fig. 2a CPA Series: Efficiency versus input voltage η [%] 86 JM42 Input Current Limitation All s incorporate an active inrush current limiter in the input ry, which reduces the peak inrush current value by a factor of 5 to protect connectors and switching devices from damage CPD5 Note: The inrush current limitation is achieved using electronic ry. For effective limitation the should not be switched on and off more frequently than every 8 seconds. Input Undervoltage Shutdown CPD2/25 models start at approx. V i = 22 V, when the input voltage is applied; at decreasing V i, they switch off at approx. 2 V. Note: The input current I i may exceed I i max, if V i V i min. CPD5 models start at V i = 35 V and switch off at V i = 33 V. CPA models exhibit an undervoltage trigger ling startup and shutdown. The threshold is between 8 and 9 VAC. See also Power Fail Signal. Note: CPA2/25 with version V6 should not be operated at V i V i min, as these models have no undervoltage shutdown and will therefore operate with a high input current at full load V Fig. 2b CPD5 Series: Efficiency versus input voltage Page 6 of 9

7 Electrical Output Data General Conditions for table 4: T A = 25 C, unless T c is specified. CPD/CPA2: 25 LFM (.25 m/s), CPD/CPA25: 4 LFM (2 m/s) Sense lines connected directly at the connector Table 4a: Output data of CPD/CPA2 and CPD/CPA25 Output Vo (5. V) Vo2 (3.3 V) Unit Characteristics Conditions min typ max min typ max V o Output voltage V i nom, 5% I o nom V I o nom Nominal output current 2/25 2 A I o max Max. output current V i min V i max 4 4 I ol Output current limit T C min T C max 5 5 I o min Minimum load no min. load required no min. load required v o Output Switch. frequ. V i nom, I o nom 2 2 mv pp voltage BW = 2 MHz 4 noise 4 Total C ext = 22 µf nf V ov Static line regulation V i min V i max, I o nom ± ± mv V ol Static load regulation V i nom, 5 % I o max ± ± V os Overshoot at switch on/off v o d Dynamic Voltage Vo: I o = A, di o /dt = 2 A/µs ± 2 ± 2 load deviation Vo2: I o2 = A, di o2 /dt = 2 A/µs t d regulation Recovery time µs αv o Temperature coefficient T C min T C max ±.3 ±.2 mv/k of output voltage I o nom, V i min V i max Table 4b: Output data of CPD/CPA2 and CPD/CPA25 Output Vo3 (2 V) Vo4 ( 2 V) Unit Characteristics Conditions min typ max min typ max V o Output voltage V i nom, 5% I o nom V I o nom Nominal output current 2.5/4.5/ A I o max Max. output current V i min V i max I ol Output current limit T C min T C max I o min Minimum load I o3 > 75% I 2 o4 no min. load required v o Output Switch. frequ. V i nom, I o nom mv pp voltage BW = 2 MHz 4 noise 4 Total C ext = 22 µf nf 2 2 V ov Static line regulation V i min V i max, I o nom ± ± mv V ol Static load regulation V i nom, I o = 2 A ± V os Overshoot at switch on/off v o d Dynamic Voltage Vo3: I o3 = 2 A, di o3 /dt = 2 A/µs ± 2 ± 2 load deviation Vo4: I o4 =.5 A, di o4 /dt = 2 A/µs t d regulation Recovery time 5 5 µs αv o Temperature coefficient T C min T C max ±.3 ±.5 mv/k of output voltage I o nom, V i min V i max First value for CPD2/CPA2, second value for CPD25/CPA25 2 Minimum load is only required to maintain regulation of output Vo4 3 Droop characteristic for passive current sharing 4 Measured with a probe according to IEC/EN 624, annex A Page 7 of 9

8 General conditions for table 5: T A = 25 C, unless T c is specified. CPD5, CPA5: 3 LFM (.5 m/s), CPA55: 4 LFM (2 m/s) Sense lines connected directly at the connector Table 5 a: Output data of CPD5 and CPA5/55 Output Vo (5. V) Vo2 (3.3 V) Unit Characteristics Conditions min typ max min typ max V o Output voltage V i nom, 5% I o nom V I o nom Nominal output current 4/5 5/5 A I o max Max. output current V i min V i max 5 6 I ol Output current limit T C min T C max I o min Minimum load no min. load required no min. load required v o Output Switch. frequ. V i nom, I o nom mv pp voltage BW = 2 MHz 2 noise 2 Total C ext = 22 µf nf 5 5 V ov Static line regulation V i min V i max, I o nom ± ± mv V ol Static load regulation V i nom, 5 % I o max ± ± V os Overshoot at switch on/off v o d Dynamic Voltage Vo: I o = 2 A, di o /dt = 2 A/µs ±5 ±5 load deviation Vo2: I o2 = 4 A, di o2 /dt = 2 A/µs t d regulation Recovery time 3 3 µs αv o Temperature coefficient T C min T C max ±.3 ±.2 mv/k of output voltage I o nom, V i min V i max Table 5 b: Output data of CPD5 and CPA5/55 Output Vo3 (2 V) Vo4 ( 2 V) Unit Characteristics Conditions min typ max min typ max V o Output voltage V i nom, 5% I o nom V I o nom Nominal output current 8 3 A I o max Max. output current V i min V i max 2 4 I ol Output current limit T C min T C max I o min Minimum load no min. load required no min. load required v o Output Switch. frequ. V i nom, I o nom mv pp voltage BW = 2 MHz 2 noise 2 Total C ext = 22 µf nf 2 2 V ov Static line regulation V i min V i max, I o nom ± ± mv V ol Static load regulation V i nom, I o = 2 4 A ± V os Overshoot at switch on/off v o d Dynamic Voltage Vo3: I o3 = 4 A, di o3 /dt = 2 A/µs ±2 ±5 load deviation Vo4: I o4 = A, di o4 /dt = 2 A/µs t d regulation Recovery time 3 3 µs αv o Temperature coefficient T C min T C max ±.3 ±.5 mv/k of output voltage I o nom, V i min V i max First value for CPA5, second value for CPA55 2 Measured with a probe according to IEC/EN 624, annex A 3 Droop characteristic for passive current sharing Page 8 of 9

9 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 P o (t h total t h ) C i ext = η (V 2 ti V i min2 ) whereas: C i ext = external input capacitance [mf] P o = output power [W] η = efficiency [%] t h total = total hold-up time [ms] t h = hold-up time [ms] V i min = minimum input voltage [V] V ti = threshold level [V] Note: After V i was removed, the outputs maintain their voltage for the time t h. Even if V i comes back during t h, but after t h, the output voltage might be affected. Redundant Operation and Hot Swap Due to the integrated FETs/diodes, the s 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 / plugout 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 s. Output Characteristic and Protection All outputs are fully protected against continuous open- (no load) and continuous short- conditions. All outputs of CPx2/25 models have a constant current limitation with a rectangular characteristic; see figure 3. In addition, the total power from outputs Vo, Vo2, and Vo3 is limited to P o max, resulting in a free choice of load distribution between these outputs. Output Vo4 is disabled in the case of overtemperature generated by overcurrent. In CPA5/55 and CPD5 models, the total power of all four outputs is limited to P o max. In all models, all outputs are monitored for an overvoltage V o /V o nom..95 I o nom I o max I o L 586b condition. If an overvoltage of 2 3% is detected, the is permanently disabled. To reset, the input voltage must be removed for 2 seconds. Note: The models CPA5/55 with version number before V need approx. 6 s to recover. Thermal Considerations and Protection If a 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 T A max (see Temperatures), the temperature at the measurement point of the case temperature T C (see Mechanical Data) will approach after an initial warm-up phase the indicated maximum value of T C max (5 C). However, the relationship between T A and T C 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. T A max is therefore, contrary to T C max, an indicative value only. Caution: The installer must ensure that under all operating conditions T C remains within the limits shown in the diagrams fig. 4. P o /P o nom..6.5 JMa Convection cooling in upright position 25 LFM =.25 m/s T A min C Fig. 4a Output power versus temperature T A at V i nom (CPD/ CPA2) P o /P o nom. 59c Convection cooling in upright position 2 LFM = m/s 4 LFM = 2 m/s.5.5 Fig. 3 Typical output characteristic V o versus I o I o T A min C Fig. 4b Output power versus temperature T A at V i nom (CPD/CPA25) Page 9 of 9

10 P o /P o nom..6.5 JM2b Convection cooling in upright position CPA55 CPA/CPD5 3 LFM =.5 m/s (CPA/CPD5) 4 LFM = 2 m/s (CPA55) drops back below this limit; see Temperature Warning and Shutdown. Output Filter The output ripple voltage can be reduced by an external filter to less then 5 mv pp. Recommended values: C, C2: Low ESR capacitor, e.g., OS-CON 47 µf L, L2: Choke 4.7 µh with appropriate rated current, e.g., Coiltronics HC2LP µh /33 A or 2.2 µh /24 A. T A min C Fig. 4c Output power versus T A at V i nom (CPA5/55, CPD5) Note: Forced-air cooling (or an additional heat sink on customerspecific models) can improve the reliability or allow for higher T A, as shown in the diagrams fig. 4, but T C max shall never be exceeded. A temperature sensor fitted on the main PCB provides approx. 2 C below T C max a warning signal (DEG#), at which the logic begins to reduce the output power. The output power returns to the normal value, when the temperature Input 46 JMb VoSENSE Vo Vo2SENSE Vo2 RTN Ω Ω L 2 L C 2 Fig. 5 Output filter reducing the output ripple of Vo and Vo2. An alternative solution is shown in green. C 5 V 3.3 V Gnd Auxiliary Functions Inhibit and Enable The inhibit input INH# enables (logic high) or disables (logic low, pull down) all outputs, when a logic signal (TTL, CMOS) is applied. In systems consisting of several s this feature may be used to the activation sequence of the s or to enable the source to start-up, before full load Fig. 6 Inhibit and enable inputs 653d INH# 39 EN# 27 RTN (22) V INH# Table 6: Inhibit data Characteristics Conditions min typ max Unit V inh Inhibit V o = off V i min V i max 2.8 V voltage V o = on I o = I o max t r Rise time 2 ms t f Fall time depending on I o is applied. When INH# is low, the cannot be activated by the EN# pin Note: If this function is not used, the inhibit pin 39 can be left open- (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. EN# (pin 27) is CMOS-compatible. However, we recommend to connect it directly with a return pin (e.g. pin 22) to enable the. Pin 27 is shorter than the others, ensuring start-up only, after all other pins were connected to the system. This provides true hot-swap capability. Note: When a CPA or CPD5 is disabled by INH# and/ or EN#, the PFC booster remains active, keeping the boost capacitor C b (fig. ) charged. As a result, there is no inrush current at restart. Note: When a CPD 5/55 is disabled, on outputs 3 and 4 may appear a little voltage under no-load condition. This can be avoided by a small preload. V o /V o nom. t Inhibit t r Fig. 7 Typical output response as function of inhibit voltage. t f 655a t Page of 9

11 Temperature Warning and Shutdown A temperature warning ry monitors the case temperature T C. Its output signal V DEG# changes from high to low impedance, when the T C exceeds the upper threshold level, and changes back to high impedance, when T C 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 4 ma, and V DEG# should not exceed 4 V. If T C exceeds 5 C, the will be disabled. It resumes operation automatically, once T C falls below 5 C. The threshold levels for V i correspond to approx. 34 V for CPD models and 8 9 VAC for CPA models. Note: CPD2/25 (and CPA2/25 up to version V6) provide only the signal FAL#, but the is not inhibited. Note: V i min of CPA models is considered as insufficient, when V i remains for typ. 3 ms below 2 V i min. Connector pin 42 (signal V FAL# ) 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 ma. V FAL# should not exceed 4 V, as the JFET is not protected against overvoltage. JM 56a 46 Vo 46 Vo R p Input 38 I DEG# DEG# R p Input 42 I FAL# FAL# V FAL# V DEG# RTN RTN Fig. 8 Degrade signal: NPN output V DEG# 4 V, I DEG# 2 ma V DEG# [V] signal DEG# 589c thermal shutdown C Fig. 9 Degrade signal V DEG# versus case temperature T C Power Fail Signal P o /P o max The power fail ry monitors the input voltage V i and all output voltages. The signal V FAL# changes from high to low impedance (<.5 V), when one of the monitored voltages falls below the threshold. V FAL# changes back to high impedance, when all monitored voltages exceed their threshold level. The threshold level for V o corresponds to approx. 9% of V o nom Fig. Power Fail: JFET output, I FAL# ma Sense Lines This feature is available only for the outputs Vo, 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 (VoSENSE, Vo2SENSE, and Vo3SENSE) should be connected to the respective power outputs. The common sense return S (SRTN) should be connected to RTN (pin 5 2). 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. Table 7: Sense line data Output Total voltage difference between sense lines [V] and their respective outputs V 5 V 2 V Page of 9

12 Active Current Sharing for Vo, Vo2, Vo3 The current share facility, consisting of a single-wire link, should be used, where several s are operated in parallel connection, for example, high reliability n redundant systems or systems providing higher output power. Note: Maximum six s can be connected in parallel. Using this feature reduces the stress of the individual s and improves the reliablity of the system. Interconnection of the current sharing terminals causes the s to share the output current evenly. In n redundant systems a failure of a single will not lead to a system failure, since the outputs are already decoupled by FETs and diodes internally. 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 s are connected in parallel. An increase in output current decreases the output voltage according to fig.. V o 4% 2% V o4 set 2% 4% CPx5/55 CPx2/25..5 I o /I o nom Fig. Output voltage V o4 versus output current I o4. LEDs A green LED "Input OK" and a red LED "Fault" are incorporated in the front panel. 588c 656a Input OK Fault V i LEDs "Input OK" and "Fault" status versus input voltage. Conditions: P o P o max, T C T C max, V inh = open V i min V i max Fault I ol I O LED "Fault" status versus output current. Conditions: V i min V i max, T C T C max, V inh = open Fault T C LED "Fault" status versus case temperature. Conditions: P o P o max, V i min V i max, V inh = open T C max V inh threshold Fault -2 V V i inh.8 V 2.4 V 5 V LED off LED Status undefined LED on If 2 V bus voltage is present, LED is on. LED "Fault" status versus V inh. Conditions: P o P o max, V i min V i max, T C T C max Fig. 2 Display status of LEDs Page 2 of 9

13 Electromagnetic Compatibility (EMC) A metal oxide VDR together with the input fuse and a filter form an effective protection against high input voltage transients, which typically occur in most installations. The s have been successfully tested to the following specifications: Electromagnetic Immunity Table 8: Immunity type tests Phenomenon Standard Level Coupling Value Waveform Source Test In Permode applied imped. procedure oper. form. 2 Electrostatic IEC/EN 4 contact discharge 8 V p /5 ns 33 Ω positive and yes A discharge negative air discharge 5 V p (to case) discharges Electromagnetic IEC/EN 3 antenna V/m AM 8% n.a. 8 MHz yes A field khz V/m 5% duty cycle 9 ±5 MHz 2 Hz repetition frequency Electrical fast IEC/EN 2 capacitive, o/c V p bursts of 5/5 ns 5 Ω 6 s positive yes A transients/burst /5 khz over 6 s negative 3 direct, i/c, i/ i 2 V p 5 ms; burst transients per period: 3 ms coupling mode Surges IEC/EN 3 i/c 2 V p.2/5 µs 2 Ω 5 pos. and 5 neg. yes B surges per i/ i V p 2 Ω coupling mode Conducted IEC/EN 3 i, o, signal wires VAC AM 8% 5 Ω.5 8 MHz yes A disturbances (4 dbµv) khz i = input, o = output, c = case connected to PE 2 A = normal operation, no deviation from specifications, B = normal operation, temporary loss of funciton or deviation from specs possible. Power Factor The CPA models exhibit a booster providing a correction of the power factor (PFC). The power factor is better when the input voltage is low. Table 9: Electromagnetic emissions for CPA models. Phenomenon Standards Conditions Results Harmonics EN A2: 29 V i = 23 V, V o nom, I o nom Class A Voltage fluctuation and flicker EN 6-3-3: 28 V i = 23 V, V o nom, I o nom Class A Page 3 of 9

14 Electromagnetic Emissions dbµv/m 5 Power-One EMC Test Lab. Dubnica, CPA25-453G, V6, B U942, 2-5-_ Testdistance m,, U i =23 VAC / 5 Hz, Po = Ponom, no filter, 25 C EN 55 A dbµv CPD25-453G, V9: Vi = 48 VDC, Po = 25 W, SN: B , EN 55: 29A:2, Group Class A. EMC Product Service. 8-Mar-26 4 JM3 8 6 EN 55 A qp EN 55 A av JM dbµv/m MHz Fig. 3a CPD25: Typical disturbance voltage (peak) at line input according to EN 55/5522, measured at V i nom and P o nom. CPD25-453G, V9: Vin=48 VDC, Vo=5V/24.3A; Vo2= 3.3V/8.9A; Vo3=2V/4A Vo4=-2V/A Testdistance m, Group Class A. EMC Product Service. 8-Mar MHz Fig. 4b CPA25-453: Typical disturbance voltage at line input according to EN 55/22, measured at V i nom and P o nom. To improve related emission results, use a ferrite core on the Iinput wires, of type Kitagawa GRFC- or equivalent. Fig. 4c shows that EN 55/5522, class A is kept. This is a condition for the CCC approval. 5 EN 55 A JM23 dbµv/m EMC Product Service Divina, CPA25-453G, B976 U942, Testdistance m,, U i =23 VAC / 5 Hz, Po = Ponom, filter KITAGAWA RFC- 5 EN EN A 4 4 JM2 3 2 <25 db (µv/m) <3 db (µv/m) 3 <25 dbµv/m MHz Fig. 3b CPD25 : Radiated emissions according to EN 55/22, measured at V i nom and P o nom MHz Fig. 4c CPA with a core across the input lines. Radiated emissions EN 55/22, measured at V i nom and P o nom. dbµv Power-One EMC Labatory, Vi = 23 VAC, Pout = Ponom CPA25-453G, B8563 U25 V5,3..22 dbµv CPA5-453S2 V7 W622, Vi=23VAC, Ponom, Peak, Phase, Uster, 2-Sep EN 55 A qp EN 55 A av JM 8 6 EN 5522 A EN 5522 B CPA5-conp MHz MHz Fig. 4a CPA25-453: Typical disturbance voltage at line input according to EN 55/22, measured at V i nom and P o nom. Fig. 5 CPA5-453: Typical disturbance voltage (peak) at line input accord. to EN 55/22, measured at V i nom and P o nom Note: Conducted and radiated emissions of CPD5 comply with EN 55/5522 class A (not shown). Page 4 of 9

15 Immunity to Environmental Conditions Table : Mechanical and climatic stress (tests of CPD5 are in process) Test method Standard Test conditions Status Cab Damp heat IEC/EN Temperature: 4 ±2 C Converter steady state Relative humidity: 93 2/-3 % not Duration: 56 days operating Ea Shock IEC/EN Acceleration amplitude: 2 g n Converter (half-sinusoidal) Bump duration: ms operating Number of bumps: 8 (3 in each direction) Eb Bump IEC/EN Acceleration amplitude: 5 g n Converter (half-sinusoidal) Bump duration: 6 ms operating Number of bumps: 6 ( in each direction) Fda Random vibration IEC/EN Acceleration spectral density:.5 g 2 n /Hz Converter wide band, CPD2/25, CPA2/25 Frequency band: 2 5 Hz operating reproducibility Acceleration magnitude: 4.9 g n rms high Test duration: 3 h ( h in each axis) IEC/EN Acceleration spectral density:. g 2 n /Hz Converter CPD5, CPA5/55 Frequency band: 2 5 Hz operating Acceleration magnitude: 2.2 g n rms Test duration:.5 h (.5 h in each axis) Temperatures Table : Temperature specifications, valid for an air pressure of 8 2 hpa (8 2 mbar) Characteristics Conditions Relative humidity 2 CPD5 Other models Unit min max min max min max T A Ambient temperature Converter operating 5% 95% C T C Case temperature 5% 95% T S Storage temperature Not operating % 95% See Thermal Considerations 2 Non condensing humidity 3 For CPA2/25 version V7 (or later), CPD25 version V9 (or later), CPA5/55 version V (or later), else 25 C. Increased output ripple at very low temperature. Reliability Table 2: MTBF Ratings at specified Model Ground Ground fixed Ground Unit case temperature benign mobile 4 C 4 C 7 C 5 C MTBF acc. to CPD h MIL-HDBK-27F, notice 2 CPA CPA Bellcore CIR SR-332- CPD5 Page 5 of 9

16 Mechanical Data Dimensions in mm (inches) pin d Fig. 6 CPA2/25 and CPD2/25. Overall size: 62.5 x 28.7 x 4.6 mm. Weight:.8 kg Measuring point of the case temperature T C AIRFLOW 95 (3.74") (3.937") 28.7 (5.67") pin 4.6 (.6") 2.5 (.98") (6.43") (6.674") 2.88 (.57") 6.6 (.26") Size: 3U x 8HP European Projection JM5a pin 47 Fig. 7 View of the connector AIRFLOW Measuring point of the case temperature T C (8.99") pin ( 9.87") 26.9 (.3") Fig. 8 CPD5 and CPA5/55. Overall size: x 62.5 x 4.6 mm. Weight:.65 kg 4.34 (.588") 2.5 (.98") (6.43") 2.88 (.57") 6.6 (.26") Size: 6U x 8HP (6.674") Page 6 of 9

17 Safety and Installation Instructions Connector Pin Allocation 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 s 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 enduse application. Connection to the system shall be made via the mating female connector (see fig. 6). Other installation methods may not meet the safety requirements. Check for hazardous voltage, before altering any connections. Connector: Positronic PCIH47M4A or similar Mating female connector: Positronic PCIH47F3A or similar Fig. 9 Pinout of the front connector Table 3: Pin allocation of the front connector 46 87a The s 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 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 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 CPA5 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 s, or the warranty will be invalidated! Important: If the inhibit function is not used, pin 39 (i) should be left open- to enable the outputs. Enable Pin 27 (EN#) should be connected to pin 22 (RTN) to enable the outputs. Make sure that there is sufficient airflow available for convection cooling. This should be verified by measuring the case temperature, when the is installed and operated in the end-use application. The maximum specified case temperature T C max should not be exceeded. Pin Length 2 Signal Description Pin Length 2 Signal Description name name 4 B Vo Output 32 C n.c. Do not connect 5 2 B RTN Return (Vo and Vo2) 33 C Vo2SENSE Vo2 remote sense 3 8 B Vo2 Output 2 34 C SRTN Sense return 9 B RTN Return (Vo3) 35 C VoSHARE Vo current share 2 B Vo3 Output 3 36 C Vo3SENSE Vo3 remote sense 2 C Vo4 Output 4 37 C n.c. Do not connect 22 C RTN Return 38 C DEG# Degrade signal 23 C Reserved Reserved 39 C INH# Inhibit 24 C RTN Return (Vo4) 4 C n.c. Do not connect 25 C n.c. Do not connect 4 C Vo2SHARE Vo2 current share 26 C Reserved Reserved 42 C FAL# Fail signal 27 D EN# Enable 43 C n.c. Do not connect 28 C n.c. Do not connect 44 C Vo3SHARE Vo3 current share 29 C n.c. Do not connect 45 A 3 CGND Chassis ground 3 C VoSENSE Vo remote sense 46 A DCIN 4 ACN 5 Pos. DC input 4 Neutral line 5 3 C n.c. Do not connect 47 A DCIN 4 ACL 5 Neg. DC input 4 Line input (phase) 5 Pin numbers shown are for the female backplane connector 2 A = very long pins, B = long pins, C = short pins, D = very short pins. 3 Pin 45 of the female connector is leading, ensuring that chassis ground makes contact first. 4 CPD models (DC input) 5 CPA models (AC input) Page 7 of 9

18 Table 4: Isolation CPD models CPA models Unit Characteristic Input to Output to Input to Output to (case output) case (case output) case Electric Actual factory test s VDC strength AC test voltage equivalent test to factory test VAC Insulation resistance at 5 VDC >3 >3 >3 >3 MΩ According to IEC/EN 695, subassemblies connecting input to output are pre-tested with 3 kvdc. 2 According to IEC/EN 695, subassemblies connecting input to output are pre-tested with 4.3 kvdc or 3 kvac. Make sure that a failure (e.g. by an internal short) does not result in a hazardous condition. Standards and Approvals The s are safety-approved to the latetest edition of UL/CSA 695- and IEC/EN The s 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. A suitable fire enclosure shall be provided at end use. 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 upon 25 VAC. CPA-models up to 6 Hz. The s are subject to manufacturing surveillance in accordance with the above mentioned standards. decreases by approx. 2%, and the leakage currents are proportional higher. Protection Degree and Cleaning Liquids The s correspond to protection degree IP 2, provided that the female connector is fitted. The power supplies are not hermetically sealed. In order to avoid possible damage, any penetration of cleaning and other fluids shall be avoided. Safety of Operator-Accessible Output Circuits If the output of a is operator- accessible, it shall be an SELV according to the IEC/EN 695 related safety standards. However, it is the sole responsibility of the installer to ensure the compliance with the relevant and applicable local safety regulations Isolation The electric strength test is performed in the factory as routine test in accordance with EN 554 and IEC/EN 695; see table 3. Only the test between input and [caseoutputs], marked with footnotes and 2, may be repeated by the customer. Notes: The DC test voltage shall be slowly increased (within several seconds) and maintained for max. 2 seconds. Trigger level 25 µa. The factory is executing these 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. The Company will not honor warranty claims resulting from incorrectly executed electric strength tests. Operation at >6 Hz and Leakage Currents Operation up to 44 Hz is possible, but the X and Y caps are not safety-approved to this frequency. The efficiency Page 8 of 9

19 Options L: Output Current Latch 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..5 s. A: Face Plate without Logo No logo is not printed to the front plate. F: Built-in Second Fuse Available for CPA5 models only. A 2 nd fuse in the neutral input line provides safe phase to phase connection at low mains voltages (e.g., USA 2/28 V /6 Hz systems). 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. C: Protective Lacquer All boards are covered by a protective lacquer. G: RoHS RoHS-compliant for all six substances (standard for CPD5). This feature is standard. Products soldered with leaded tin (non G) are only available on request. 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 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 27, Bel Power Solutions Inc. All rights reserved. Page 9 of 9