VoxPower VCCM600M Series User Manual Download Page 27

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DOC-MN-007-03 VCCM600 User Manual

Vox Power Limited | Unit 2, Red Cow Interchange Estate, Ballymount, Dublin 22, D22 Y8H2, Ireland | T +353 1 4591161 | www.vox-power.com

Connector details

PINOUTS

Circuit

Details

J1 – Mains Input

Live

Neutral

Earth

J2 – Standby control

Standby control negative

Standby control positive

J3 – Global Signals

Slot 4 - Power Good

Slot 4 - Inhibit

Slot 3 - Power Good

Slot 3 - Inhibit

Slot 2 - Power Good

Slot 2 - Inhibit

Slot 1 - Power Good

Slot 1 - Inhibit

Temperature sense (T

SNS

)

AC OK

+5V (Bias Supply 1A)

COM

J4 -Output Signals

- Sense

+ Sense

COM

I Control

V Control

+5V (Bias Supply 10mA)

MATING CONNECTORS

Ref.

Details

Manufacturer

Housing

Terminal

J1 - Mains Input

3 Pin, Barrier, 6-32 Steel Screws, 0.8 Nm or 7 Lb-In Torque

(1)

J2 - Standby control

2 Pin, 1.25mm, with Friction Lock, 28-30AWG

MOLEX

0510210200

0500588000

J3 - Global Signals

12 Pin, 2mm, with Friction Lock, 24-30 AWG, WIRE TO BOARD

MOLEX

0511101260

0503948051

12 Pin, 2mm, with Friction Lock, 24-30 AWG, IDT CABLE TO BOARD

MOLEX

0875681273

J5 - Output Signals

6 PIN, 1.25mm, with Friction Lock, 28-30AWG

MOLEX

0510210600

0500588000

Output Power

Positive/Negative, M4 terminal, 0.55Nm, use appropriately rated crimp terminal

Notes

1. Cable 14-18AWG, 300V, 16A, 105°C, use appropriately rated crimp terminal.
2. Direct equivalents may be used for any connector parts.
3. All cables must be rated 105°C min, equivalent to UL1015

Summary of Contents for VCCM600M Series

Page 1: ...in connection with life support systems human implantations nuclear facilities or systems aircraft spacecraft military or naval missile ground support or control equipment used for the purpose of guidance navigation or direction of any aircraft spacecraft or military or naval missile or any other application where product failure could lead to loss of life or catastrophic property damage The user ...

Page 2: ...t installation information 4 Theory of Operation 5 Input Module Operation 6 Input Module Protections 7 Efficiency Performance 8 Power Ratings 9 System Cooling 10 Signalling 13 Output Module Operation A B C D 15 Advanced Output Module Features 18 Series Connected Outputs 22 Parallel Connected Outputs 23 Mechanical Dimensions and Mounting 26 Connector details 27 Safety 28 EMC Compliance 29 Reliabili...

Page 3: ... Nominal voltage Rated current Rated Power Adjustment range Load regulation Line regulation OVP OP 0 Unused slots OP A 5V 25A 125W 1 5V 7 5V 50mV 0 1 Vnom 9V OP B 12V 15A 150W 4 5V 15V 100mV 0 1 Vnom 18V OP C 24V 7 5A 150W 9V 30V 150mV 0 1 Vnom 36V OP D 48V 3 5A 150W 18V 58V 300mV 0 1 Vnom 66V PART NUMBERING SYSTEM VCCM Input Module VCCM600 S A B C D 0 0 0 Factory use Product Type USE 0 for unused...

Page 4: ...uthorised personnel and to ensure continued protection against risk of fire fuses must be replaced with the same type and rating of fuse For DC operation an appropriately rated DC fuse must be included in the end application SERVICING The power supply contains no user serviceable parts Repairs must be carried out by authorised personnel only Contact Vox Power for further information APPROVAL LIMIT...

Page 5: ...ntrolled by a resistive element upon initial connection to the AC line Once the internal capacitances have been charged the resistive element is bypassed to reduce losses Active Power Factor Correction PFC is used to ensure an accurate input current waveform with extremely low harmonic content exceeding the requirements of EN61000 This stage also provides active input current limiting which preven...

Page 6: ...es fall below the power good threshold level This allows the application to prepare for the impending loss of power The 5V bias supply will remain on for typically 100ms after the output modules have turned off Output modules that are adjusted above nominal voltage will have reduced ACOK warning time Standby control The unit may be completely shut down by shorting 10Ω the terminals of J2 The unit ...

Page 7: ... average power remains within ratings Note that input module de ratings apply to both rated power and peak power Input Module Protections Over current protection OCP The input module is protected from excessive input current by means of an over current protection circuit which limits the input current to approximately 7Arms If the OCP threshold is exceeded the unit may shut down and attempt to aut...

Page 8: ...79 0 80 0 81 0 82 0 83 0 84 0 85 0 86 0 87 0 88 0 89 0 90 0 91 0 50 100 150 200 250 300 350 400 450 500 550 600 Efficiency Output Power Watts Typical Load Efficiency at 120VRMS input voltage OPA OPB OPC OPD 0 73 0 74 0 75 0 76 0 77 0 78 0 79 0 80 0 81 0 82 0 83 0 84 0 85 0 86 0 87 0 88 0 89 0 90 0 91 0 50 100 150 200 250 300 350 400 450 500 550 600 Efficiency Output Power Watts Typical Load Effici...

Page 9: ...oltages ambient temperatures and baseplate temperatures 1 2 3 4 5 6 7 VIN VRMS 120 85 85 120 120 100 120 Normalised VIN Rating A 1 0 708 0 708 1 1 0 833 1 TAMBIENT C 70 50 70 50 60 60 50 Normalised TAMBIENT Rating B 0 5 1 0 5 1 0 75 0 75 1 TBASE C 85 85 85 95 105 95 105 Normalised TBASE Rating C 1 1 1 0 75 0 5 0 75 0 5 Normalised Total input rating A B D 0 5 0 708 0 354 1 0 75 0 624 1 Normalised T...

Page 10: ... 2 used for mounting orientations A B C and D 0 50 100 150 200 250 300 350 400 450 500 550 40 30 20 10 0 10 20 30 40 50 60 70 80 Pout Ambient Temperature OPA 120Vin 4x5Vout A B CD EF 0 50 100 150 200 250 300 350 400 450 500 550 40 30 20 10 0 10 20 30 40 50 60 70 80 Pout Ambient Temperature OPA 220Vin 4x5Vout A B CD EF 0 50 100 150 200 250 300 350 400 450 500 550 600 650 40 30 20 10 0 10 20 30 40 5...

Page 11: ...50 200 250 300 350 400 450 500 550 40 30 20 10 0 10 20 30 40 50 60 70 80 Pout Ambient Temperature OPA 220Vin 4x5Vout 2MS 1 1 5MS 1 1MS 1 0 5MS 1 0 50 100 150 200 250 300 350 400 450 500 550 600 650 40 30 20 10 0 10 20 30 40 50 60 70 80 Pout Ambient Temperature OPB C D 120Vin 4x10 20 40Vout 2MS 1 1 5MS 1 1MS 1 0 5MS 1 0 50 100 150 200 250 300 350 400 450 500 550 600 650 40 30 20 10 0 10 20 30 40 50...

Page 12: ...ots 2 and 3 The bottom side should be flush for heatsink mounting if necessary Glue should be used to hold the thermocouple in place 2 Setup the application in worst case conditions considering Input line voltage Output power ambient temperature airflow and cooling restrictions 3 Power the system and monitor the baseplate temperature until it reaches steady state 4 Ensure that under worst case con...

Page 13: ... Signals to Chassis 500 VDC Signals to Output 500 VDC Bias Supply 5V Power The VCCM600 series has one isolated bias supply located on the transformer module J3 beside slot 4 The output side bias supply generates 5V and is rated up to 1A The supply is available whenever the AC mains voltage is connected and the input module is operating correctly A shutdown through the standby control on J2 or any ...

Page 14: ...manual potentiometer Output Inhibits INH1 INH4 Input The signals circuit provides an inhibit input to disable each output module individually Each inhibit input is internally connected through an opto isolator to the respective output modules The basic internal electrical circuit and timing diagrams are shown below Internal circuit Timing Typically tOFF 100 μs and tON 8 ms Internal Temperature sen...

Page 15: ...the power profile table above However certain precautions must be taken to ensure correct operation Please see the Advanced output module features section for more details Over Voltage Protection OVP In the event of an output module fault the modules are protected against excessive output voltages This is implemented as a fixed voltage threshold VOVP in the table above If the output voltage exceed...

Page 16: ...d maximum current for each module Full peak power is only possible when the output voltage is adjusted to VMAX and the maximum current is drawn from the module Note that both average and peak power ratings are subject to the same temperature derating as the input module derate by 2 5 per C above 50 C but are not subject to any line derating Start up Shut Down All outputs are designed to have a reg...

Page 17: ... for 20 seconds then reconnect If all temperatures are within specifications the unit will restart Note that no warning is given on the AC_OK signal for faults of this type Transient Response The VCCM output modules have been especially designed to have high reliability To achieve this all electrolytic capacitors have been eliminated from the design As a result of this high dynamic load transients...

Page 18: ... VSET 5 VCONTROL 3 8 where VSET is the manual preset voltage of the module Equivalent internal circuit Control function The output voltage can be controlled from 0 to 131 5 of the preset voltage using this control method However care must be taken to ensure the output voltage does not exceeed the OVP level as this will trigger OVP protection Remote adjustment of the output voltage using the VCONTR...

Page 19: ...onfiguration the output current limit will approximate the following equation ILIMIT IRATED VCTRL 4 where IRATED is the maximum rated current for the module It is not possible to increase the maximum current limit of the module and control voltages exceeding 4 6V will have no effect on the current limit When using an output module as a modulated current source the output voltage should be manually...

Page 20: ...ly have an influence during dynamic events It is recommended to add an external buffer amplifier as shown below when using the ICONTROL signal to measure the output current as loading the ICONTROL signal even with microamps can cause the current limit to be reduced If it is required to measure the output current and adjust the output current limit simultaneously this can be achieved by using a cla...

Page 21: ... reduced to benign levels During system design care must be taken to ensure power cables have a sufficiently low voltage drop at maximum load current to ensure this protection does not activate unintentionally In systems where remote sensing is not used the output voltage at the power terminals will be slightly higher than that at the sense terminals This voltage difference is termed open sense of...

Page 22: ...ed Remote Voltage Current Control Remote voltage and or current control is possible with series connected modules using the advanced VCONTROL and ICONTROL functions described earlier However individual control of each module can be complex as the various control terminals are referenced to the positive output of the preceding module and require the use of multiple isolated control voltages to atta...

Page 23: ... the total number of paralleled modules The diagram above shows the VI curve for such a system Output modules that are not delivering current will typically sink a small amount of current from the other outputs but this will not exceed 6 of each module s maximum rated current Typically system reliability is reduced in this mode as the higher adjusted modules will do most of the work with the lower...

Page 24: ...tput to prevent a device failure from causing a system failure However the diode introduces voltage drops between the supply and the load that significantly degrade the load regulation To counteract this the remote sense lines can be used to regulate the voltage at the load as shown below Typically this configuration can damage the internal sense resistors used within a power supply However the VC...

Page 25: ... programming in normal parallel mode Paralleling Across Multiple Products Paralleling across multiple product is not possible without external protection such as external diodes or controlled MOSFETs to prevent circulating currents between each product Failure to provide such protection may result in damage to the power supplies Consult Vox Power for details on how best to implement such applicati...

Page 26: ...cation Details Penetration Tightening Baseplate Mount M1 M6 Hole diameter 5 00mm 4mm Baseplate thickness 0 55 NM Output Module Mount O1 O8 M3 CSK M3 CSK screw 8mm max length 0 35NM Input module Mount F1 F5 Do not remove or adjust Do not remove or adjust Do not remove or adjust Transformer module Mount F6 F7 M3 CSK M3 CSK screw 6mm max length 0 35NM Output Module Terminal M4 SEM M4 SEM screw 8mm ma...

Page 27: ...ol 5 V Control 6 5V Bias Supply 10mA MATING CONNECTORS Ref Details Manufacturer Housing Terminal J1 Mains Input 3 Pin Barrier 6 32 Steel Screws 0 8 Nm or 7 Lb In Torque 1 J2 Standby control 2 Pin 1 25mm with Friction Lock 28 30AWG MOLEX 0510210200 0500588000 J3 Global Signals 12 Pin 2mm with Friction Lock 24 30 AWG WIRE TO BOARD MOLEX 0511101260 0503948051 12 Pin 2mm with Friction Lock 24 30 AWG I...

Page 28: ...500 VAC Global signals J3 to Output Chassis 500 VDC Output to Output Chassis Standard modules 500 VDC Earth Leakage Current INDUSTRIAL Normal condition 264Vac 63Hz 25 C 1500 uA MEDICAL Normal condition 264Vac 63Hz 25 C 200 uA Touch Leakage Current Standard modules NC SFC 20 200 uA Patient Leakage Current Standard modules 264Vac 63Hz 25 C NC SFC uA Not applicable INSTALLATION SPECIFICATIONS Paramet...

Page 29: ...ts IEC61000 4 4 Test Level 3 2kV Power 1kV I O 5kHz ed3 100kHz ed4 Conducted susceptibility Bulk cable injection impulse excitation MIL STD 461F CS115 Surges IEC61000 4 5 Test Level 3 1kV L N 2kV L E Conducted susceptibility damped sinusoidal transients cables and power leads 10kHz 100MHz MIL STD 461F CS116 Shipboard Electric Power Voltage Spike Test MIL STD 1399 SECTION 300A Type 1 115V 60Hz sing...

Page 30: ...utput cables should be fixed as close as possible to the ground plate or metal enclosure Input and output cables should be separated as much as possible from each other or a shield screen used to isolate RF currents Output power and sense cables should be twisted pairs and routed parallel to each other Do not twist sense and power cables together All cables lengths and loop areas should be minimis...

Page 31: ...lly assembled system Assembly Failure Rate FPMH MTBF Hrs IP 0 962972 1038452 XFMR 0 371919 2688754 OPA 0 415368 2407499 OPB 0 397808 2513774 OPC 0 398170 2511487 OPD 0 405630 2465300 VCCM600M AAAA 2 996363 333737 934 To calculate the MTBF of any VCCM system Add the FPMH figures for each system component to give the total FPMH Get the MTBF by dividing 1 000 000 by the total FPMH The variation in FP...

Page 32: ...fect the warranty of the power supply Output power modules may be added replaced or moved by strictly following the sequence of operations described below Before configuring your VCCM product remove the VCCM600 input module and any output modules which are going to be used in the configuration from their packaging and inspect for damage DO NOT use parts if any part of the product exhibits any kind...

Page 33: ... both clean and free from any debris Insert output modules as required into any one of the four available slots in the VCCM600 transformer module Ensure the output module and transformer connectors are properly aligned and push together There will be a solid click once a proper connection is established Each VCCM600 product can be configured to have up to four isolated outputs by inserting the des...

Page 34: ...n the configured unit upside down and identify the slot of the module you need to remove Remove the two screws using an appropriate No1 Posi drive screwdriver STEP 2 Turn the configured unit right side up and unplug the module by pulling it away from the transformer module To minimise stress on the connectors do not wriggle the module to remove Take care not to damage the thermal interface materia...

Page 35: ...crease the voltage Once the desired voltage has been achieved remove the trimming tool and disconnect the voltmeter Repeat this step for each output module in need of adjustment Connecting Output Modules in series VCCM output modules of the same type can be series connected to achieve higher output voltages Below is an illustration of how to series connect two output modules in slot 1 and slot 2 u...

Page 36: ...t modules in parallel The example below shows a parallel connection from slot 1 to slot 2 Attaching a heatsink or cooling plate For improved performance the baseplate of the VCCM600 unit can be attached to a heatsink or cooling plate Vox Power has a range of heatsinks available to allow the VCCM600 to be mounted horizontally or vertically Each heatsink comes pre assembled with a high performance t...

Page 37: ... code Output Parallel Links 2 way LINK VP2 3 way LINK VP3 4 way LINK VP4 Current share cables 2 way CAB CS2 3 way CAB CS3 4 way CAB CS4 Output Series Link LINK VS Output Quick Connect terminal 6 3x0 8mm TAB x2 ACC QCT Output Cable Set 1x Signals cable 200mm 2x Power terminals CAB VSOPL Input Cable Set 1x Signals cable 200mm 1x Standby cable 200mm 3x Power terminals CAB VC6 2 WAY PARALLEL LINK 4 WA...

Page 38: ...2 D22 Y8H2 Ireland T 353 1 4591161 www vox power com Heatsink1 Provided with 6x M4 x 10mm Posi Drive screws for baseplate mounting and thermal interface ACC TF ACC HS1 Heatsink2 Provided with 6x M4 x 10mm Posi Drive screws for baseplate mounting and thermal interface ACC TF ACC HS2 Thermal interface 170mmx80mm ACC TF ...

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