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TRC ELECTRONICS, INC.

Providing exceptional customer service since 1982

TRC ELECTRONICS, INC.

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www.

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.com

Designers Manual

Advanced Energy CoolX600 Series

Flyback

converter

Resonant

LLC

Interleaved

PFC

Rectifier and

inrush current

limiting

EMI filter

Dual fused

input

Rectifier

Synchronous

buck

Auxiliary

Out

Vout

Synchronous

buck

Synchronous

rectifier

Synchronous

rectifier

Communications

board

Synchronous

buck

Buck

controller

Bias

AC fail

OTP

UVP

OTP

OCP

OVP

UVP

Synch

controller

Enable/

disable

trim

AC fail

OTP alarm

Power good

PMBus

LLC

controller

PFC

controller

OCP

OVP

UVP

FFiigguurree 22‑‑22..

Operational block diagram

The chassis is an open-frame chassis containing circuitry for an offline, single-phase,

AC front end; an EMI filter; and a customer interface and associated housekeeping

circuits. Input AC mains voltage (L, N, and GND) is applied to either a screw

terminal input block or an IEC type input connector (optional), and then through an

EMI filter designed to meet EN55022 Class B. Some applications might require an

external ferrite on cabling to meet Class B radiated EMI. Contact AE Global Services

for recommendations.
For medical applications, the EMI filter also ensures that the power supply meets the

low earth leakage current requirements of EN60601-1 3rd Edition. All modules

provide medical isolation of 4000 VAC (2 x MOPP) from input to output and

extended isolation of 1850 VAC from output to earth.

☞

Important

1 x MOPP requirement is 1500 VAC.

A 24 W auxiliary, always-on, isolated bias supply of 12 VDC or 5 VDC (optional) is

provided for peripheral use. This bias supply also has medical isolation of 4000 VAC

(2 x MOPP). A suite of monitoring and controls are provided. Refer to

“Communication Controls”

on page 5

‑

1 for more details.

Modules provide isolated DC outputs. These can be set to the required voltage

setpoints by the user or factory as required. Each module has its own discrete

controls. Refer to

“Communication Controls”

on page 5

‑

1 for more details.

To see the galvanic isolation barriers for a configured CoolX unit, refer to

Table 1

‑

Advanced Energy

CoolX

600 Modular Power Supply

57010208-00B

Product Overview

2‑4

Содержание Advanced Energy CoolX 600 Series

Страница 1: ...o ol lX X 6 60 00 0 M Mo od du ul la ar r P Po ow we er r S Su up pp pl ly y Designers Manual S Se ep pt te em mb be er r 2 20 01 19 9 5 57 70 01 10 02 20 08 8 0 00 0B B TRC ELECTRONICS INC 1 888 612...

Страница 2: ...ctives and Standards 1 7 Environmental Compliance 1 7 C Ch ha ap pt te er r 2 2 P Pr ro od du uc ct t O Ov ve er rv vi ie ew w General Description 2 1 CoolPac Options 2 1 CoolPac Operation 2 2 Auxilia...

Страница 3: ...7 PMBus Communications 5 7 C Ch ha ap pt te er r 6 6 I In ns st ta al ll la at ti io on n S Se et tu up p a an nd d O Op pe er ra at ti io on n Preparing to Install the Unit 6 1 Installation Consider...

Страница 4: ...Measurement of Ripple and Noise 6 24 Maintenance 6 25 To Remove CoolMod Modules 6 25 Reliability 6 25 Calculating MTBF 6 27 MTBF and Temperature 6 27 Shelf Life of Power Supplies 6 27 C Ch ha ap pt t...

Страница 5: ...k module protective limits specifications 3 11 Table 3 17 Bulk module hiccup characteristics specifications 3 11 Table 3 18 Bulk module transient response specifications 3 12 Table 3 19 Bulk module st...

Страница 6: ...s for bulk modules 5 9 Table 5 7 Applicable PMBus commands for dual modules 5 10 Table 5 8 Applicable PMBus commands for chassis 5 11 Table 6 1 Options for connecting AC mains input to the CoolX unit...

Страница 7: ...CoolX IEC version unit dimensions side view 6 4 Figure 6 7 CoolX IEC version unit dimensions AC input view 6 4 Figure 6 8 CoolX IEC version unit dimensions top view 6 4 Figure 6 9 Three screw termina...

Страница 8: ...Energy CoolX600 Series Figure 6 27 CoolMod wiring diagram for remote current setting using external resistance 6 21 Figure 6 28 Rtrim versus Iout 6 22 Figure 6 29 Foldback current limit circuit 6 22 F...

Страница 9: ...o or r s se er ri io ou us s i in nj ju ur ry y D DA AN NG GE ER R i is s l li im mi it te ed d t to o t th he e m mo os st t e ex xt tr re em me e s si it tu ua at ti io on ns s WARNING W WA AR RN N...

Страница 10: ...ng modules Use properly sized wires to avoid overheating and excessive voltage drop Take appropriate precautions when touching the CoolX unit after it has been operating for a period of time Due to th...

Страница 11: ...CE Marking Self declaration assessed by AE Corporate Compliance EMC measurements Verified by AE Corporate Compliance SEMI guidelines Verified by AE Corporate Compliance Safety Approvals CoolX units a...

Страница 12: ...D The relevant European standard for the CX06S model is EN 60950 1 2nd Edition information technology and 62368 1 Edition 2 The relevant European standard for the CS06M model is EN60601 1 3rd Edition...

Страница 13: ...characteristics of CoolX unit under load conditions P Pa ar ra am me et te er r C Co on nd di it ti io on ns s D De es sc cr ri ip pt ti io on ns s C Cr ri it te er ri ia a Radiated emissions EN55011...

Страница 14: ...rmal operation D During the test loss of function that is not recoverable occurs A AD DD DI IT TI IO ON NA AL L E EM MI I C CH HA AR RA AC CT TE ER RI IZ ZA AT TI IO ON N CoolX units are compliant wit...

Страница 15: ...er to the EU Declaration of Conformity for this unit The Declaration of Conformity might also include a supplementary section covering compliance to non EU regulatory requirements and or industry stan...

Страница 16: ...CS INC 1 888 612 9514 www trcelectronics com Designers Manual Advanced Energy CoolX600 Series ECHA that are contained in this product at concentrations greater than 0 1 by weight Advanced Energy CoolX...

Страница 17: ...to increase output voltage subject to staying within isolation ratings and giving due consideration to any SELV requirements You can connect CoolPac chassis in parallel for higher power and N 1 redund...

Страница 18: ...lated bias supply voltage Option B 5 V auxiliary voltage The chassis includes a 5 V 4 7 A isolated bias supply voltage Option C Conformal coating The CoolPac chassis has a conformal coating for harsh...

Страница 19: ...ring displays For system housekeeping In control circuits As an additional output voltage Important The negative of the auxiliary Vo is connected to the common of the system signal connector J1 AUXILI...

Страница 20: ...al and then through an EMI filter designed to meet EN55022 Class B Some applications might require an external ferrite on cabling to meet Class B radiated EMI Contact AE Global Services for recommenda...

Страница 21: ...screws Four mounting holes on base Two mounting holes on each side The CoolX unit can be mounted on its base or on its side It can also be mounted on the Excelsys DIN rail accessory Connectors AC DC...

Страница 22: ...I IO ON NS S The nominal values of the following specifications apply when the unit operates at 25 C 77 F with nominal output voltage T Ta ab bl le e 3 3 2 2 Electrical specifications D De es sc cr ri...

Страница 23: ...A 4 7 A Output capacitive load maximum 1 000 F Output overcurrent protection 110 to 140 hiccup condition Short circuit protection Yes autorecovery Leakage Currents at mains voltage 264 VAC 60 Hz Type...

Страница 24: ...15 105 130 180 CmC 24 15 28 105 125 105 135 8 33 105 130 200 CmD 48 28 58 105 125 103 115 4 17 105 150 200 Each type of CoolMod module has unique specifications The following figures and tables detail...

Страница 25: ...imum 180 kHz 180 kHz 180 kHz 180 kHz Nominal Typical 240 kHz 240 kHz 240 kHz 240 kHz Maximum 450 kHz 450 kHz 450 kHz 450 kHz T Ta ab bl le e 3 3 6 6 Standard module regulation specifications P Pa ar r...

Страница 26: ...nal Typical 130 W 220 5 W 232 W 230 W Maximum 137 W 234 W 260 W 260 W Overvoltage protection shutdown autorecovery Minimum 6 8 V 17 V 32 V 60 V Nominal Typical 8 V 19 8 V 35 V 62 2 V Maximum 9 V 21 V...

Страница 27: ...V 7 2 V 14 3 V Nominal Typical 1 4 V 4 2 V 8 1 V 16 2 V Minimum 2 0 V 4 9 V 9 6 V 19 8 V Recovery time Recovery time Positive voltage deviation Negative voltage deviation F Fi ig gu ur re e 3 3 3 3 M...

Страница 28: ...Vout AC In F Fi ig gu ur re e 3 3 4 4 Module startup shutdown timing T Ta ab bl le e 3 3 1 10 0 Standard module startup shutdown timing specifications P Pa ar ra am me et te er r V Va al lu ue e T Ty...

Страница 29: ...0 35 ms 0 35 ms 0 35 ms 0 35 ms Maximum 3 ms 3 ms 3 ms 3 ms Bulk Module Specifications Bulk modules include CmE and CmF modules The following tables provide specifications for bulk modules T Ta ab bl...

Страница 30: ...ading Maximum 10 mF 2 5 mF For an illustration of the module ripple and noise see Figure 3 1 on page 3 5 T Ta ab bl le e 3 3 1 14 4 Bulk module ripple and noise specifications P Pa ar ra am me et te e...

Страница 31: ...er 5 hiccup cycles Maximum 5 A 2 5 A Power limit hiccup autorecovery Minimum 615 W 615 W Nominal Typical 695 W 670 W Maximum 755 W 755 W Overvoltage protection shutdown autorecovery Minimum 29 V 45 5...

Страница 32: ...000 s 1000 s In Figure 3 4 on page 3 8 t1 is the turn on delay and t2 is the hold up Table 3 19 contains t1 and t2 values for each type of bulk module T Ta ab bl le e 3 3 1 19 9 Bulk module startup sh...

Страница 33: ...dj ju us st t V Vs se et t V V O OV VP P T Tr ra ac ck ki in ng g o of f V Vs se et t O OV VP P L La at tc ch hi in ng g o of f V Vm ma ax x M Ma ax xi im mu um m C Cu ur rr re en nt t I Im ma ax x A...

Страница 34: ...se specifications P Pa ar ra am me et te er r V Va al lu ue e T Ty yp pe e C Cm mG G V V1 1 a an nd d V V2 2 C Cm mH H V V1 1 C Cm mH H V V2 2 Output ripple and noise 20 MHz bandwidth Nominal Typical...

Страница 35: ...dule transient response see Figure 3 3 on page 3 7 T Ta ab bl le e 3 3 2 26 6 Dual module transient response specifications 25 to 75 load change P Pa ar ra am me et te er r V Va al lu ue e T Ty yp pe...

Страница 36: ...Specifications Wide trim modules include CmM CmN CmP and CmQ modules The following tables provide specifications for wide trim modules T Ta ab bl le e 3 3 2 29 9 General wide trim module outputs M Mo...

Страница 37: ...mF 4 7 mF 1 Full dynamic specifications might not be met at full load when you trim a CmM module above 13 V in a CoolX unit 2 Maximum output current is derated by 5 when a module is used in parallel 3...

Страница 38: ...T Ta ab bl le e 3 3 3 33 3 Wide trim module protective limits specifications P Pa ar ra am me et te er r V Va al lu ue e T Ty yp pe e C Cm mN N C Cm mM M C Cm mP P C Cm mQ Q Current limit constant cu...

Страница 39: ...0 ms 1100 ms Short circuit hiccup level Minimum 0 6 V 0 6 V 0 6 V 1 1 V Minimum 0 9 V 0 9 V 0 9 V 2 0 V For an illustration of the module transient response see Figure 3 3 on page 3 7 T Ta ab bl le e...

Страница 40: ...e timing specifications P Pa ar ra am me et te er r V Va al lu ue e T Ty yp pe e A Al ll l M Mo od du ul le es s Enable delay t1 enable to Vout Nominal Typical 8 5 ms Maximum 10 ms Rise time from 10 t...

Страница 41: ...Climatic specifications D De es sc cr ri ip pt ti io on n S Sp pe ec ci if fi ic ca at ti io on n External Ambient Temperature Operating 20 C to 40 C 4 F to 104 F Operates to specification below 20 C...

Страница 42: ...ed for your power requirements Refer to Electrical Specifications on page 3 2 for CoolPac specifications Once you have determined the appropriate configuration for your application use CoolX Configura...

Страница 43: ...um mb be er r D Di ig gi it t F Fe ea at tu ur re e O Op pt ti io on ns s a an nd d D De es sc cr ri ip pt ti io on ns s 1 Reserved C 2 Reserved X 3 Reserved 0 4 Reserved 6 5 CoolPac type S Standard I...

Страница 44: ...ge 13 Frame type Not used or Standard open framed L Covered 14 Reserved Not included in configuration order Specifying Modules in the Part Number Digits 6 9 in a CoolX part number specify the modules...

Страница 45: ...specifies which part number digit corresponds to which chassis slot The examples in Selecting and Ordering a Configured CoolX Unit further demonstrate how to specify modules in a CoolX unit part numb...

Страница 46: ...150 A leakage current Solution CoolX part number CX06M ABC0 P4B specifies the following product CX06M 600 W IEC60601 1 approved Slot 1 CmA 5 V 10 A module Slot 2 CmB 12 V 15 A module Slot 3 CmC 24 V...

Страница 47: ...me en nt t 1 Common 2 SCL PMBus CLK 3 Control 4 SDA PMBus DATA 5 PG Global 6 NU not used or no connection 7 OTP 8 AC Fail CoolPac Open Collector Driving Common Logic Levels Each CoolPac logic output...

Страница 48: ...Lo og gi ic c V Vo ol lt ta ag ge e V Vo ol lt t L Lo og gi ic c R R1 1 k k R R2 2 k k V Vh hi ig gh h V V V Vl lo ow w V V I Is si in nk k M Ma ax x m mA A 12 V 12 12 Open 12 0 4 12 12 V 5 10 7 4 9 0...

Страница 49: ...ble Inhibit Control You can enable or inhibit all module outputs simultaneously by using the control pin input on the J1005 system signal connector between pin 3 control and pin 1 common Under normal...

Страница 50: ...for driving logic level circuits with open collector signal outputs M MO OD DU UL LE E S SI IG GN NA AL LS S Each module has the following discrete controls Module Enable Inhibit CoolMod Power Good S...

Страница 51: ...in 3 control and pin 1 common of the J1005 system signal connector Advanced Energy recommends a Harwin M22 1900005 2 mm jumper socket for the J1011 connector F Fi ig gu ur re e 5 5 4 4 PMBus address h...

Страница 52: ...GND 3k F Fi ig gu ur re e 5 5 5 5 Dual module enable inhibit wiring diagram Applying a signal voltage to the inhibit pins disables the channel The specifications for this signal are detailed in the f...

Страница 53: ...al module POWER GOOD wiring diagram The POWER GOOD signal is the unbiased open collector of an optocoupler that is available on the module signal connector J1 via the collector on the positive PG pin...

Страница 54: ...ement of the selected paged module Accuracy 4 Module Resolution mA CmA 40 CmB 29 CmC 16 CmD 8 CmM TBD CmN TBD CmP TBD CmQ TBD READ_TEMPERATURE_1 0x8D Returns the temperature measurement of the selecte...

Страница 55: ...s the current limit of the selected paged module to the commanded value When read this command returns the last ILIMIT_TRIM value sent to the selected paged module This command is not compatible with...

Страница 56: ...aged module VOUT_COMMAND 0x21 Sets the output voltage of the selected paged module to the commanded value When read this command returns the last VOUT_COMMAND value sent to the selected module ILIMIT_...

Страница 57: ...an nd d D De es sc cr ri ip pt ti io on n PAGE 0x00 Selects which module the subsequent commands will affect When read this command returns the currently selected paged module number OPERATION 0x01 E...

Страница 58: ...penetration depth is 2 mm 0 08 DIN rail mounting is also possible using the Excelsys DIN rail mounting bracket Avoid excessive bending of output power cables after they are connected to the modules Fo...

Страница 59: ...CoolX600 Series 39 mm 1 5 114 mm 4 5 24 mm 0 9 F Fi ig gu ur re e 6 6 1 1 CoolX unit dimensions DC outputs view 162 mm 6 4 6 mm 0 2 39 mm 1 5 10 mm 0 4 3 mm 0 1 216 mm 8 5 F Fi ig gu ur re e 6 6 2 2 C...

Страница 60: ...ions bottom view I IE EC C U UN NI IT T D DI IM ME EN NS SI IO ON NA AL L D DR RA AW WI IN NG GS S The CoolX mechanical outlines for the IEC version of the unit follow You can download full 3D and STE...

Страница 61: ...th sides 162 mm 6 4 6 mm 0 2 39 mm 1 5 10 mm 0 4 3 mm 0 1 216 mm 8 5 F Fi ig gu ur re e 6 6 6 6 CoolX IEC version unit dimensions side view 27 mm 1 1 26 mm 1 114 mm 4 5 41 mm 1 6 F Fi ig gu ur re e 6...

Страница 62: ...9 9 Three screw terminal block Earth Live Neutral F Fi ig gu ur re e 6 6 1 10 0 Optional IEC320 inlet terminal T Ta ab bl le e 6 6 1 1 Options for connecting AC mains input to the CoolX unit I In np...

Страница 63: ...OL LM MO OD D O OU UT TP PU UT T P PO OW WE ER R A AN ND D S SE EN NS SE E C CO ON NN NE EC CT TO OR RS S Each standard and wide trim module DC output has power terminals J1 and J2 and a sense connect...

Страница 64: ...CO ON NN NE EC CT TO OR RS S Dual modules have a signal connector J1 and a dual power terminal J2 J J1 1 Inhibit V1 J J1 1 PG V1 J J1 1 Inhibit V2 J J1 1 PG V2 J J1 1 Inhibit V1 J J1 1 PG V1 J J1 1 In...

Страница 65: ...ON Refer to Global Signals on page 5 1 for J1005 system signal connector information T Ta ab bl le e 6 6 4 4 J1005 system signal connector types C Co on nn ne ec ct to or r C Co on nn ne ec ct to or r...

Страница 66: ...g Molex 51110 0650 or locking and polarizing Molex 51110 0650 Crimp terminal Molex p n 50394 I IN NS ST TA AL LL LI IN NG G T TH HE E U UN NI IT T To Install CoolMod Modules 1 Plug one module into the...

Страница 67: ...load Special series connection links can be fitted to modules to reduce wiring complexity These links can be specified and fitted by the installer or added at the factory Important You can connect dua...

Страница 68: ...6 6 7 7 Standard and wide trim module parallel voltage tolerances M Mo od du ul le e P Pa ar ra al ll le el l V Vo ol lt ta ag ge e T To ol le er ra an nc ce e m mV V CmA 10 CmB 10 CmC 10 CmD 20 CmM...

Страница 69: ...To Parallel Connect Bulk Module Outputs 1 Enable current sharing by adding an LK1 jumper on the J1017 connector of a module The J1017 connector is located on the communication board of the chassis J10...

Страница 70: ...by using a single control voltage Mounting the CoolPac There are three ways to mount the CoolPac Base plate mounting Use the four mounting holes on the base of the power supply Refer to the mechanica...

Страница 71: ...uts can be sequenced using the enable function in order to allow controlled start up if required The following table contains the maximum startup delays for all modules T Ta ab bl le e 6 6 8 8 Startup...

Страница 72: ...its maximum power as per the module specification tables The following optional additions to the CoolX unit can affect the optimum temperature range for normal operation EXTERNAL SYSTEM COOLING FANS I...

Страница 73: ...he onboard potentiometer Refer to Onboard Potentiometer Use the Vtrim pin of the output signal connector J1001 to J1004 Refer to Remote Voltage Adjustment Using External Voltage and Remote Voltage Adj...

Страница 74: ...g external voltage The Vtrim voltage required for your desired output voltage can be calculated using the following formula and table Vtrim Vout F K T Ta ab bl le e 6 6 9 9 K and F values for calculat...

Страница 75: ...6 2 22 2 CoolMod wiring diagram for remote voltage setting using external resistance You can calculate the Rtrim resistance required for your desired output voltage by using Table 6 9 and the followin...

Страница 76: ...it The default current limit characteristic is straight line current limit Simple external application circuits can be used to achieve programmable foldback current and user programmable reduced curre...

Страница 77: ...trim return Pin 1 or Pin 3 5 V F Fi ig gu ur re e 6 6 2 25 5 CoolMod wiring diagram for remote current setting using external voltage The Itrim voltage required for your desired current limit can be c...

Страница 78: ...esistor Rtrim across the output signal connector pins pin 5 Vtrim and pin 1 common Important Current limit adjustment is not available on dual modules 10k 100 nF Comms Board uController 5 6 Module 47k...

Страница 79: ...Limit Programming Foldback current limit requires the common pin of the output connector to be tied to the V output connector of the module the common pin is also Vo of the auxiliary voltage Foldback...

Страница 80: ...ted by the fixed OVP at high output voltages The fixed OVP level is fixed relative to Vmax and activates between 125 and 160 of the maximum output voltage This OVP is latching and can only be reset by...

Страница 81: ...ute the sensing leads to prevent pickup which might appear as ripple on the output Never disconnect the output power rail with the sensing still connected to the load In certain applications where the...

Страница 82: ...tional details about how to measure and reduce output ripple and noise M MA AI IN NT TE EN NA AN NC CE E To Remove CoolMod Modules Important CoolX units do not have user serviceable components the uni...

Страница 83: ...e the first signs of wear appear and failures become more frequent The lifetime of a unit is generally defined as the time when the failure rate increases to five times the statistical rate of the fla...

Страница 84: ...e following values are preliminary Module 0 52 failures per million hours Chassis 1 08 failures per million hours Example CX06S chassis FPMH 1 08 CmA CmB CmC CmD module FPMH 0 52 each Total FPMH 1 08...

Страница 85: ...tor which results in additional heating of the component and has a direct impact on reliability According to published research the commencement of this chemical reaction can occur after a two year pe...

Страница 86: ...identify the causes of high frequency noise Is the noise conducted or radiated If changing the position of the power supply or screening improves performance the noise is likely radiated Refer to EMC...

Страница 87: ...Excelsys to get the correct shipping address T Ta ab bl le e 7 7 1 1 Contact information O Of ff fi ic ce e C Co on nt ta ac ct t Excelsys Technologies Ltd Address 27 Eastgate Drive Eastgate Business...

Страница 88: ...startup and shutdown 6 14 CoolPac global signals 5 1 mounting 6 13 open collector 5 1 options 2 1 CoolPac chassis global enable inhibit control 5 3 Global Power Good signal 5 3 operation 2 2 current...

Страница 89: ...t time 6 13 measurement of ripple and noise 6 24 normal 6 14 parallel connection of bulk CoolMod outputs 6 12 parallel connection of CoolMod outputs 6 10 series connection of module outputs 6 9 theory...

Страница 90: ...standards 1 7 straight line current limit 6 19 symbols in user manual 1 1 on unit 1 2 T T theory of operation 2 3 U U unit compliance 1 3 icons and symbols used 1 2 preparing to install 6 1 unit desc...

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