1.2 KW, N+1 REDUNDANT, POWER-FACTOR CORRECTED, 12V FRONT END

Transcription

1 PS2379 CHARACTERIZATION 1.2 KW, N+1 REDUNDANT, POWER-FACTOR CORRECTED, 12V FRONT END October 26, 2005 Rev 1

2 Table of Contents 0. Introduction Line Current Harmonics Line Conducted EMI Leakage Current Cold Start Inrush Current Turn-On Time Output Voltage Rise/ Fall Characteristics Hold-Up Time Status Signals Line/ Load Regulation Differential Mode Output Ripple and Noise Common Mode Output Ripple and Noise Output Dynamic Performance Over Load Protection Current Sharing During Parallel Operation Overvoltage / Over Temperature Protection Power Factor and Efficiency

3 Table of Contents (Continued) 17. Temperature Measurements Performance Summary Bay

4 0. INTRODUCTION PS2379 Power Supply Features Input Power: Inrush Current: Output Power: Control Signals: Reporting Signals: Front Panel LEDs: 90 Vac Vac Line to neutral, Hz 17A Max service, with Active Power Factor Correction Limited by Active Inrush Current Protection to less than 50A 240Vac. 1.2 kw Max ( A) with Third Wire current sharing capability. 0.1A Remote on DC Good, AC Good AC OK, DC OK Operating Ambient: 0 to 50 C Cooling: Input / Output / Signal Connector: Construction: Nominal Size: Weight: Two 12V, 24 CFM fans. Air flow from front to back. Positronics PCIM30 series Fully enclosed steel chassis L X 1.69 H X 3.37 W (330.2mm X 42.9mm X 85.5mm) Approx. 5.4 lbs 4

5 0. INTRODUCTION PS2379 Power Supply Features (Continued) Protections: Input Power: AC Input undervoltage protection - Non latching Over-voltage protection on 400 Vdc bus - Non latching Primary power limiting for PFC Boost and Down Converter - Non Latching Secondary over-temperature protection - Non latching (with hysterisis). Output over-voltage protection - Latching Output current limiting and short circuit protection - Latching with delay 136kHz, power factor corrected boost converter 120kHz Flyback converter Output Power: 1.2kW, 100A) 120kHz, Zero Voltage Switching, Phase Shifted, Full Bridge 5

6 0. INTRODUCTION Power Supply Mechanical Outline 6

7 0. INTRODUCTION Isometric View of Power Supply 7

8 0. INTRODUCTION Isometric View of Power Supply 8

9 0. INTRODUCTION Positronic Connector PIN Assignment Pin Number Function Pin Number Function Pin Number Function 1 Common RTN V 21 N.U. 2 Common RTN V 22 N.U. 3 Common RTN 13 Enable 23 N.U. 4 Common RTN 14 DC_OK 24 5V Aux V 15 Current Share 25 N.U. 6 Common RTN 16 N.U. 26 N.U V 17 N.U. 27 N.U. 8 Common RTN 18 N.U. 28 Chassis 9 +12V 19 AC_OK 29 AC Neutral V 20 RTN Sense 30 AC line Rear View 9

10 0. INTRODUCTION Top-Level Power Supply Functional Block Diagram VAC 20A FUSE EMI FILTER PFC / BOOST CONVERTER HVDC 400V DOWN CONVERTER OR ING DIODE +12V 10

11 0. INTRODUCTION PFC Boost Rectifier Functional Block Diagram (see functional map on page 13) RELAY CONTROL 7 PRIMARY FLYBACK BIAS SUPPLY 6 SECONDARY SECONDARY BIAS SINGLE PHASE VAC EMI FILTER 1 BRIDGE RECTIFIER 2 ACTIVE INRUSH PROT 3 BOOST PFC CONVERTER W/ HIGH FREQ FILTERING 4 ENERGY STORAGE CAPS 5 HVDC 400V AVERAGE CURRENT- MODE PFC CONTROL 7 VOLTAGE FEEDBACK UNDER VOLTAGE PROT 7 OVER VOLTAGE PROT 7 11

12 0. INTRODUCTION Power Factor Correcting Boost Converter I s I 1 I 2 L1 CR1 HV BUS V s C1 Q1 + C2 I s I 1 I 2 12

13 0. INTRODUCTION Functional Map

14 0. INTRODUCTION Isolating Down Converter Functional Block Diagram (see functional map on page 13) 400V DC BUS PRIMARY SECONDARY PRIMARY BIAS / HOLD OFF PEAK CURRENT MODE CONTROLLER 8 PRIMARY GND PRIMARY CURRENT SENSE XFMER 9 ACTIVE SWITCH ELEMENTS (ZVS FULL BRIDGE) 11 GATE DRIVE XFMER 10 ZVS CHOKE 12 CURRENT SENSE REGULATION OPTO-COUPLER 13 PROTECTION OPTO-COUPLER ISOLATION POWER XFMER 14 CURRENT REGULATOR 16 RECTIFIER & FILTER (CURRENT DOUBLER) Ω RTN SENSE OR ING DIODE 12V RETURN I INFO VEA OUT SECONDARY BIAS +12V SHUT DOWN CIRCUITRY 16 RTN SENSE 14

15 0. INTRODUCTION ZVS, Phase Shifted Full Bridge Converter + HVDC BUS T1:A L2 L3 OR ING DIODE +12V Q1 T2 T3 L1 Q3 T2 + - C2 CR3 CR4 - Q2 Q4 3.9Ω 12V RTN GATE DRIVE XFMR GATE DRIVE XFMR RTN SENSE CR5 C D B A RAMP IC3 CURRENT MODE PWM F/B REGULATION OPTO COUPLER SECONDARY BIAS E/A + - IIN C4 VEA OUT R2 CR6 T3 T1:B R1 C3 RTN SENSE PRIMARY GND 15

16 0. INTRODUCTION Output Logic Functional Block Diagram INPUT BOARD PRIMARY BIAS 400 VDC BUS OUTPUT SECTION V OUT I INFO OR ING DIODE + 12V REGULATION OPTO- COUPLER VEA OUT OUTPUT VOLTAGE SENSE & COMPENSATION THIRD WIRE SHARING I SHARE PROTECTION OPTO- COUPLER SHUT DOWN / TURN ON SECONDARY SHUTDOWN LOGIC SECONDARY BIASING TEMP V OUT OVER VOLTAGE CURRENT LIMIT OVER TEMP REMOTE ON/OFF REMOTE ON/OFF 16

17 1. LINE CURRENT HARMONICS Measurement Procedure AC SUPPLY 3 Ø ELECTRONIC AC SOURCE PACIFIC S 140-TMX POWER SUPPLY HP6050A ACTIVE LOAD AND RESISTIVE LOAD 17

18 1. LINE CURRENT HARMONICS Conditions: Line Voltage: 230 Vac Line to Neutral Load: 1.2 kw Harmonic Current Results Odd Harmonics as a % of Limit Hn AMPS % of Limit Limit Result N/A NaN PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS % of Limit Harm onic # 18

19 2. LINE CONDUCTED EMI Measurement Procedure LINE IMPEDANCE STABILIZATION NETWORK (LISN) 2379 POWER SUPPLY + - RESISTIVE LOAD 50Ω COAX AC MAINS SPECTRUM ANALYZER 19

20 2. LINE CONDUCTED EMI CISPRA 150 khz khz sweep Conditions Input: 115Vac Load: 100A 10 khz BW, peak detection Results: 215kHz Margin: -8 dbm CISPR A Spec: -28 dbm Qp (max) CISPRA 500 khz - 30 MHz sweep Conditions: Line: 115Vac Load: 100A 10 khz BW, peak detection Results: - 650kHz Margin: -13 dbm CISPR A Spec: -34 dbm Qp (max) 20

21 3. LEAKAGE CURRENT Single Unit Measurement Procedure AC LINE PS2379 UNIT UNDER TEST RESISTIVE LOAD ISOLATION XFMR L S 1 N A ED&D MODEL LT-952HC AC LEAKAGE CURRENT TESTER FLOATING CHASSIS GND RESULT: 264 Vac (in bay) SPEC: 264Vac 21

22 4. COLD START INRUSH CURRENT Inrush Current Conditions: Line: 240Vac Load: 100A line current (20A / div) Tektronix TDS 420A oscilloscope and Tektronix A6303 current probe used for measurement. Results: 25 C line voltage (250V/div) Spec: 25 C 22

23 5. TURN-ON TIME Turn On Time Conditions: Line: 90Vac Load: 100A 12V output AC line Tektronix TDS 420A oscilloscope and Tektronix P5200 differential probe used for measurement Results: Start-up time: 1.9s Spec: 2.5s 23

24 6. OUTPUT VOLTAGE RISE Voltage Rise Conditions: Input Voltage: 90Vac Load: 100A +12V Output Tektronix TDS 420A oscilloscope used for measurement Results: Rise Time: <6ms Spec: <30ms Voltage Rise +12V Output Conditions: Input Voltage: 264Vac Load: 0A Tektronix TDS 420A oscilloscope used for measurement Results: Rise Time: <4ms Spec: <30ms 24

25 7. HOLD-UP TIME Hold Up Time Conditions: Line: 90Vac Load: 100A Tektronix TDS 420A oscilloscope and Tektronix P5200 differential probe used for measurement +12V Output AC line Results: Measured Hold up time: 16ms Spec: 16ms typical 25

26 8. STATUS SIGNALS DC GOOD 12V Conditions: Line Voltage: 220Vac Load: 3A Results: DC GOOD goes 11.4V DC GOOD Spec: DC GOOD should go high if output is lower than 11.4V AC GOOD Conditions: Line Voltage: 220Vac Load: 3A Boost voltage AC OK Results: AC GOOD goes high when boost drops to 338Vdc Spec: AC GOOD High indicates PFC converter is not working 26

27 9. LINE/LOAD REGULATION Line Regulation Load: 100A 60Hz 100A Vo 264 Vac Vac V = 39mV % = 0.3 % HP 3468A multimeter used for measurements. Spec = 1% Load Regulation AC Line voltage: 90 Vac Load V OUT 0A A V = 58mV % = 0.5% Spec = 1% HP 3468A multimeter used for measurements. 27

28 10. DIFFERENTIAL MODE OUTPUT RIPPLE & NOISE Measurement Procedure LINE VOLTAGE POWER SUPPLY OUTPUT + - * LOAD X10 PROBE TEKTRONIX TDS420A OSCILLOSCOPE LINE VOLTAGE * 0.1 µf and 1 µf Capacitors 28

29 10. DIFFERENTIAL MODE OUTPUT RIPPLE & NOISE Output Ripple Conditions: Line: 220Vac Load: 1.2kW 100A) 12V output (AC coupled) Scope set to 20 MHz B.W. and High Res. Mode. Results: Meas: 14.2mV Spec: 200mV p-p Output Noise Conditions: Line: 220Vac Load: 100A (active loads) 12V output (AC coupled) A 1µF tantalum and 0.1µF ceramic cap were connected at measurement point and scope set to 100Mhz B.W. and peak detect mode Results: Meas: 96mV p-p Spec: 200mV p-p 29

30 11. COMMON MODE OUTPUT RIPPLE & NOISE Measurement Procedure POWER SUPPLY + LOAD - BYPASS CAPACITOR C238 GROUND X10 PROBE TEKTRONIX TDS420A OSCILLOSCOPE LINE VOLTAGE 30

31 11. COMMON MODE OUTPUT RIPPLE & NOISE Common Mode Ripple Conditions: Input: 264 Vac Load: 100A Scope set to 20 MHz B.W., Hi-Res. Mode and AC coupled Voltage Across C238 Results: Meas: 18mV p-p Spec: 200mV p-p Common Mode Noise Conditions: Input: 264 Vac Load: 100A Scope set to 20 MHz B.W. Peak Detect Mode and AC coupled Results: Meas: 45mV p-p Voltage Across C238 Spec: 200mv p-p 31

32 12. OUTPUT DYNAMIC PERFORMANCE Control Loop Measurement Setup 10 OHM ZFDBK (ALTERNATE) ZIN REF - ERROR AMP OHM SWITCHING CONVERTER OUTPUT + + T CH2 CH1 GEN HP4194, IMPEDANCE/ GAIN PHASE ANALYZER 32

33 12. OUTPUT DYNAMIC PERFORMANCE Control Loop Bode Plot Conditions: Line: 220Vac, 60Hz Load: 100A Results: Crossover Freq: 4K Hz Phase Margin: 73 deg Gain Margin: -15dB Spec: 30 degree phase margin Step Load Transient Response 12V (AC coupling) Conditions: Line: 220Vac, 60Hz Base Current: 50A Load Current step: 50A Current Slew rate: 1A/µs Transient Frequency: 30Hz Results: Overshoot: 0.4 V Settling time: <3ms Spec: 600mv, settling within 4ms of a 50% load step 33

34 12. OUTPUT DYNAMIC PERFORMANCE Control Loop Bode Plot Conditions: Line: 220Vac, 60Hz Load: 0.5A (active load) Results: Crossover Freq: 2.4kHz Phase Margin: 68 degrees Gain Margin: -22dB Spec: 30 degree phase margin Step Load Transient Response Conditions: Line: 220Vac Base Current: 1A Load Current step: 50A Current Slew rate: 1A/µs Transient Frequency: 30Hz Results: Overshoot: 0.4V Settling time: < 3ms Spec: 600mv, settling within 5ms of a 50% load step 34

35 13. OVERLOAD PROTECTION Conditions: Input Voltage: 220 Vac Results: Current Limit: 113 A (113 %) Output Voltage (V) Unit latches Output Load (A) Spec: 106% - 120% 35

36 14. CURRENT SHARING, THIRD WIRE Current Sharing / Reference Adjusting Technique - A(S) + VOLTAGE AMPLIFIER CONVERTER POWER STAGE LOCAL CURRENT ORING DIODE LOAD CURRENT MONITOR + Vref + CR 1 R ADJ - A(S) + Vc Rshare SHARING LINK ADJUSTING AMPLIFIER 36

37 14. CURRENT SHARING BETWEEN POWER SUPPLIES Conditions: Input Voltage: 220 Vac, 60hz Load: 0 to > 2.4kW (resistive and active loads) Current Sharing Between Two modules Module Load Current (A) Total Load Current (A) Module A Module B 40A error = 0.9% *@ 100A error = 1.2% *@ 200A error = 2% *Spec: Accuracy should be within 4% from 20% load to 100% load 37

38 15. OVERVOLTAGE PROTECTION Overvoltage Protection Condition Output Over Voltage Limit Point Over Voltage Limit Spec Type Load Static +12V V to 14.6V Latching 1A Dynamic +12 V V Latching 1A * For static OVP a pot was put in parallel with the feedback resistor and dialed down slowly. Dynamic OVP Conditions: Line: 220Vac Load: 1A The feedback opto-coupler was shorted while the unit was running. Results: Unit 16.6V due to OVP Spec: Unit should latch (see table above) 38

39 15. OVER VOLTAGE / OVER TEMPERATURE PROTECTION Dynamic Boost OVP Boost voltage Conditions: AC line: 220Vac Load: 10A Results: Trips at 432Vdc Spec: None OTP Verification Conditions: Short put across temperature switch while unit was running to simulate an Over Temperature condition. Results: Unit turns off while short is present, then recovers when short is removed. 12V output Spec: Shut down due to high temperature, then recovers when unit cools down 39

40 16. POWER FACTOR AND EFFICIENCY Measurement Procedure V s VOLTECH PM1000 DIGITAL AC POWER ANALYZER 2379 POWER SUPPLY Vo R s R 1 LINE VOLTAGE I rms V rms P in PF P in P = o Vo V s R s PF = I V rms rms Eff = P o P in 40

41 16. POWER FACTOR AND EFFICIENCY Conditions: Line Voltage: Per 60Hz Output voltage measured at Positronics connector. Results: Input Voltage (Vac) Input Current (A) Input Power (W) Output Power (W) Power Factor % Efficiency % Efficiency Spec: > 264Vac > 90Vac Power Factor Spec: 90 Vac and Full load 41

42 17. TEMPERATURE MEASUREMENTS Conditions: Input voltage: 90 Vac, Load: 1200W resistive load Results taken after two hours of continuous running. For component locations see temperature map on page 46. Loc. Thermocoupled Components 50 Deg C Tj Max *Temp Limit Temp Margin 1 L1 (common mode choke) L2 (differential mode choke) BR1 Body (input bridge) Heat sink above BR n/a - 5 L3 Core (PFC choke) L3 Coil (PFC choke) Q4 Body (PFC FET) Heat sink between Q3 & Q4 (PFC FETs) n/a - 9 Heat sink between Q12 & Q4 (PFC FETs) n/a - 10 R37 (PFC current sense resistor) T400 Core (fly back transformer) Q210 Body (down conv. FET) Q210 Heat sink (down conv. heat sink) n/a - 14 L4 Body (ZVS choke) T203 Core (main transformer) CR210 body (ZVS clamp diode) BR3 body (output rectifier) BR4 body (output rectifier) Heat sink above BR2 (output rectifier) n/a - 20 Heat sink above BR3 (output rectifier) n/a - 21 L201 Core / body (otuput choke) L202 Core / body (output choke) Q53 Body (oring diode FET) Heat sink above Q n/a - * Temperature limited by 110 switch located at the tip of the output rectifier heat sink 42

43 17. TEMPERATURE MEASUREMENTS Conditions: Input voltage: 90 Vac, Load: 1200W resistive load Results taken after two hours of continuous running. For component locations see temperature map on page 46 Loc. Thermocoupled Components 45 Deg C Tj Max *Temp Limit Temp Margin 1 L1 (common mode choke) L2 (differential mode choke) BR1 Body (input bridge) Heat sink above BR n/a - 5 L3 Core (PFC choke) L3 Coil (PFC choke) Q4 Body (PFC FET) Heat sink between Q3 & Q4 (PFC FETs) n/a - 9 Heat sink between Q12 & Q4 (PFC FETs) n/a - 10 R37 (PFC current sense resistor) T400 Core (fly back transformer) Q210 Body (down conv. FET) Q210 Heat sink (down conv. heat sink) n/a - 14 L4 Body (ZVS choke) T203 Core (main transformer) CR210 body (ZVS clamp diode) BR3 body (output rectifier) BR4 body (output rectifier) Heat sink above BR2 (output rectifier) n/a - 20 Heat sink above BR3 (output rectifier) n/a - 21 L201 Core / body (otuput choke) L202 Core / body (output choke) Q53 Body (oring diode FET) Heat sink above Q n/a - * Temperature limited by 110 switch located at the tip of the output rectifier heat sink 43

44 17. TEMPERATURE MEASUREMENTS Conditions: Input voltage: 90 Vac, Load: 1200W resistive load Results taken after two hours of continuous running. For component locations see temperature map on page 46 Loc. Thermocoupled Components 35 Deg C Tj Max *Temp Limit Temp Margin 1 L1 (common mode choke) L2 (differential mode choke) BR1 Body (input bridge) Heat sink above BR n/a - 5 L3 Core (PFC choke) L3 Coil (PFC choke) Q4 Body (PFC FET) Heat sink between Q3 & Q4 (PFC FETs) n/a - 9 Heat sink between Q12 & Q4 (PFC FETs) n/a - 10 R37 (PFC current sense resistor) T400 Core (fly back transformer) Q210 Body (down conv. FET) Q210 Heat sink (down conv. heat sink) n/a - 14 L4 Body (ZVS choke) T203 Core (main transformer) CR210 body (ZVS clamp diode) BR3 body (output rectifier) BR4 body (output rectifier) Heat sink above BR2 (output rectifier) n/a - 20 Heat sink above BR3 (output rectifier) n/a - 21 L201 Core / body (otuput choke) L202 Core / body (output choke) Q53 Body (oring diode FET) Heat sink above Q n/a - * Temperature limited by 110 switch located at the tip of the output rectifier heat sink 44

45 17. TEMPERATURE MEASUREMENTS Conditions: Input voltage: 90 Vac, Load: 1200W resistive load Results taken after two hours of continuous running. For component locations see temperature map on page 46 Loc. Thermocoupled Components 25 Deg C Tj Max *Temp Limit Temp Margin 1 L1 (common mode choke) L2 (differential mode choke) BR1 Body (input bridge) Heat sink above BR n/a - 5 L3 Core (PFC choke) L3 Coil (PFC choke) Q4 Body (PFC FET) Heat sink between Q3 & Q4 (PFC FETs) n/a - 9 Heat sink between Q12 & Q4 (PFC FETs) n/a - 10 R37 (PFC current sense resistor) T400 Core (fly back transformer) Q210 Body (down conv. FET) Q210 Heat sink (down conv. heat sink) n/a - 14 L4 Body (ZVS choke) T203 Core (main transformer) CR210 body (ZVS clamp diode) BR3 body (output rectifier) BR4 body (output rectifier) Heat sink above BR2 (output rectifier) n/a - 20 Heat sink above BR3 (output rectifier) n/a - 21 L201 Core / body (otuput choke) L202 Core / body (output choke) Q53 Body (oring diode FET) Heat sink above Q n/a - * Temperature limited by 110 switch located at the tip of the output rectifier heat sink 45

46 17. TEMPERATURE MEASUREMENTS Temperature Map Air Flow

47 PS2379 Total Power 1200 Watts Input Voltages Outputs VAC 100A SPECIAL FEATURES Power factor > VAC input with under voltage lockout UL, CSA, TUV, BABT (pending) Efficiency >86% Redundant system with Oring diodes and Third Wire current sharing 16W/ cu in. fits 2U applications Self cooling (internal fan) Remote sensing on RTN line ENVIRONMENTAL Ambient Operating Temperature: 0 to +50 C, full rating. Humidity: Up to 95% non-condensing Temperature coefficient: ±0.01% / C Storage Temperature: -20 to +85 C Cooling: Two 24 CFM fans. Air flow front to back. ELECTRICAL SPECIFICATIONS Input Input VAC; 47-63Hz; Power Factor >0.97 Inrush Current (264 Vac) 50 Amps peak Isolation..4242VDC (Input to Output) Susceptibility specifications: EN AC Input line harmonic limits Complies with EN55022 & FCC Class A with minimum 6 db margin Efficiency > 87% typical at full load Output DC Output.Maximum continuous output power 1200 Watts with internal cooling. See Voltage/Current Rating Chart. Load Regulation..0.5% (total) Ripple and Noise < 200mV typical Transient Response 4% Maximum deviation; Current Sharing; Third Wire. MECHANICAL 13.0 L x 1.7 H x 3.4 W (330.2mm x 42.9mm x 85.5mm) Status signals and indicators DC Good AC Good Visual LED indicators identify power supply status. The indicators are: AC Good DC Good 47

48 Output Over voltage protection (Latching) Over current protection (Latching) Over temperature protection. (non-latching) Short Circuit Protection..Will withstand a continuous short without damage. Minimum Load Rqmt 0% of full load main output. No Load Operation..No damage to supply when operating at no load. Hold-Up Time 16 msec typical OVP 14V typical Voltage/Current Rating Chart Voltage 12V 12V Current 100A 0A Topologies PFC, boost converter (136kHz) Phase shifted, ZVS full bridge (120kHz) 48

49 2379 Bay 49

50 2379 BAY Features Input Power: Output Power: Control Signals: 90Vac - 264Vac Line to neutral, 47-63Hz, 6000kW Max 500A) with Third Wire current sharing capability. Enable (on/off) Reporting Signals: DC Good 1, DC Good 2, DC Good 3, DC Good 4, DC Good 5, AC Good 1, AC Good 2, AC Good 3, AC Good 4, AC Good 5 Front Panel LEDs: AC OK and DC OK on each power supply Operating Ambient: 0 to 50 C Cooling: Power supplies provide their own cooling Output Connection: Two bus bars, one for 12V RTN and one for +12V Construction: Nominal Size: Weight: Steel chassis L X 1.75 H X 19 W (426.7mm X 282.6mm X 44.5mm) Approx. 10 lbs. 50

51 18. BAY Mechanical Outline PS1 PS2 PS3 PS4 PS5 51

52 18. BAY Isometric View 52

53 18. BAY Isometric View with Power Supply 53

54 18. BAY 25 PIN D-SUB Connector PIN Outs Function Pin DC_OK 1 1 DC_OK 2 2 AC_OK 2 3 DC_OK 3 4 AC_OK 3 5 DC_OK 4 6 AC_OK 4 7 DC_OK 5 8 5V AUX. 9 - Sense 10 AC_OK 5 11 ENABLE 13 AC_OK 1 14 N.U. 12,