DATASHEET Rev. D PSRL0402 SERIES 90~264VAC Input Voltage Range 250W Convection Cooling, 400W with Forced Air Single Outputs, Active PFC AC/DC Switching Power Supplies FEATURES • Single Outputs • Providing Peak Power 700W within 500µs Duty Duration • RoHS Compliant • Active Power Factor Corrected to EN61000-3-2 Class D • High Quality & Reliable Component Usage • Current Monitoring and Remote Voltage Adjustment (Margin) • Variable Fan Speed & Low Acoustical Noise • U-Chassis and Enclosed with Built-in Fan Mechanical Options • 90~264VAC Input Voltage Range • Short Circuit, Input Circuit, Over Power, Input Voltage, Over • Optional N+1 Forced Active Current Sharing • MTBF: 100,000 Hours (MIL-HDBK-217F) Voltage, and Over Temperature Protection • UL60950-1, EN60950-1, IEC60950-1 Safety Approvals DESCRIPTION The PSRL0402 series of AC/DC switching power supplies offers up to 400 Watts of output power. This series consists of single output models with active PFC and a 90~264VAC input voltage range. These supplies also have short circuit, input voltage, over voltage, over power, and over temperature protection. Models are available in Uchassis (Type U) and enclosed with built-in fan (Type E) designs. This series has UL60950-1, EN60950-1, and IEC60950-1 safety approvals. Optional N+1 forced active current sharing (suffix “I”) is also available. For dual output models see the PSRL0402D series and for medical version see the PSRL0402M and PSRL0402DM series. 02/05/2013 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 1 of 7 Rev. D PSRL0402 Series 250~400 Watts Single Outputs, Active PFC AC/DC Switching Power Supplies SPECIFICATIONS: PSRL0402 SERIES All specifications are based on 25oC, Nominal Input Voltage, and Maximum Output Current unless otherwise noted. We reserve the right to change specifications based on technological advances. INPUT SPECIFICATIONS Input Voltage Input Frequency Input Current Inrush Current Power Factor Correction OUTPUT SPECIFICATIONS Output Voltage Output Power (See Note 2) Output Adjustability Total Regulation Output Current Minimum Load Ripple & Noise Transient Response Overshoot Hold-Up Time Turn-on Delay PROTECTION Input Circuit Protection (primary) Over Power Protection Input Voltage Protection Over Voltage Protection Short Circuit Protection Over Temperature Protection GENERAL SPECIFICATIONS Switching Frequency Efficiency Input Line to Chassis HI-POT test Primary to Secondary Primary to Core Burn-in Leakage Current Grounding Test ENVIRONMENTAL SPECIFICATIONS Operating Temperature Storage Temperature Operating Humidity (non-condensing) Storage Humidity (non-condensing) Vibration U Type Models Cooling E Type Models MTBF FUNCTIONS Remote Sense Remote ON/OFF Power Supply ON LED Display Power Good Current Sharing Current Monitor Margin (option) AC Fail (option) Fan Drive PHYSICAL SPECIFICATIONS U Type Models Weight E Type Models U Type Models Dimensions (L x W x H) E Type Models SAFETY & EMC Safety Approvals EMI Conduction & Radiation Harmonic Current EMS Immunity 02/05/2013 90 ~ 264VAC full range 47 to 63Hz 6.35A at 90VAC full load 35A max at 230VAC with full load and cold start 0.98 at 230VAC and full load See Table See Table Output adjustable ±5% minimum ±1% See Table 1% minimum load is required to maintain the ripple and regulation ±1% Returns to within 1% in less than 2.5ms for a 50% load change and the peak transient does not exceed 5% Turn-on/off not exceed 5% over nominal voltage 20ms min. at 80% of full load 1 second maximum at 120VAC Two T8A/250V fuses inserted 110~140% of I-max and automatic recovery Power shutdown under 80 ±5VAC and recovered over 86VAC Latching down will occur when output voltage exceeds 130%. Recycle AC input to reset Trip without damage and automatic recovery Protected in the event of excessive operating ambient 85°C and automatic recovery 30KHz fixed frequency 70%~80% depending on model 1500VAC (2mA DC cut off current) for 3 seconds 4000VAC for 3 seconds 1500VAC for 3 seconds 45±5°C for one hour at 230VAC with full load. < 1.5mA Apply 40A from ground pin to the earthed connection point. Max allowable resistance is 0.1Ω 0°C to +70°C ambient, de-rating at 2.5% per degree from +50°C to +70°C. -20°C to +85°C 5% to 90% RH 5% to 95% RH Frequency 5 to 50Hz, acceleration ±7.35 m/(s x s) on X, Y, and Z axis. Convection Fan 100,000 hours at 30°C according to MIL-HDBK-217F Designated as RS+ and RS- on the CN3 (Not available for current sharing models) Designated as RSW on the CN3, requires a low signal to inhibit output. Green LED designated as LED 1 on the PCB Bi-color green LED in front panel (E Type only). Any protection occurred or RSW applied low signal will emit orange Designated as PG on the CN3 will go high 100-500ms after regulation and goes low 1ms before loss of regulation Designated as CSH on the CN3, optional single wired forced current sharing function and parallel up to 4 units within 10% accuracy at full load Designated as CMN on the CN3 for current sense for a 0.5V to 3VDC to represent 0% to 100% output current Designated as MAG on the CN3 providing 50% of output voltage remote adjustment by applying 0.4 ~ 5V signal on MAG Designated as ACF on the CN3 to monitor the input voltage. When the input goes under 80 ±5VAC the signal will go low (0), and when the input reaches 86VAC the signal will go high (+5V). 12VDC/400mA is available to drive an external fan. 2.87 lbs (1.3kg) 3.53 lbs (1.6kg) 8 x 5 x 1.6 inches (203.2 x 127 x 40.64 mm) 9 x 5 x 1.6 inches (228.6 x 127 x 40.64 mm) UL60950-1, EN60950-1, IEC60950-1 EN55022 Class B EN61000-3-2, EN61000-3-3 EN55024, IEC61000-4-2,3, 4, 5, 6, 8, 11 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 2 of 7 PSRL0402 Series 250~400 Watts Single Outputs, Active PFC AC/DC Switching Power Supplies Rev. D MODEL SELECTION TABLES U-CHASSIS MODELS (TYPE “U”) Model Number (1) PSRL0402U-03(I) PSRL0402U-05(I) PSRL0402U-12(I) PSRL0402U-18(I) PSRL0402U-24(I) PSRL0402U-36(I) PSRL0402U-48(I) Input Voltage Range Output Voltage (4) Preset Voltage (4) 90 ~ 264 VAC 2 ~ 3.3 VDC 5 ~ 6 VDC 12 ~ 15 VDC 16 ~ 21 VDC 22 ~ 30 VDC 31 ~ 41 VDC 42 ~ 58 VDC 3.3 VDC 5 VDC 12 VDC 18 VDC 24 VDC 36 VDC 48 VDC Output Power (2) Output Current Convection 45 A 45 A 20.83 A 13.89 A 10.42 A 6.94 A 5.21 A With Forced Air 60 A 60 A 33.33 A 22.22 A 16.67 A 11.11 A 8.33 A Convection 148.5W 225W 250W 250W 250W 250W 250W With Forced Air 198W 300W 400W 400W 400W 400W 400W ENCLOSED WITH BUILT-IN FAN MODELS (TYPE “E”) Model Number (1) PSRL0402E-03(I) PSRL0402E-05(I) PSRL0402E-12(I) PSRL0402E-18(I) PSRL0402E-24(I) PSRL0402E-36(I) PSRL0402E-48(I) Input Voltage Range 90 ~ 264 VAC Output Voltage (4) 2 ~ 3.3 VDC 5 ~ 6 VDC 12 ~ 15 VDC 16 ~ 21 VDC 22 ~ 30 VDC 31 ~ 41 VDC 42 ~ 58 VDC Preset Voltage (4) 3.3 VDC 5 VDC 12 VDC 18 VDC 24 VDC 36 VDC 48 VDC Output Current 60 A 60 A 33.33 A 22.22 A 16.67 A 11.11 A 8.33 A Output Power (2) 198W 300W 400W 400W 400W 400W 400W NOTES 1. The “I” suffix denotes forced current sharing option (OR-ring diode). See page 6 for installation guide. Optional top cover (Type “C”) is also available for U-Chassis Models. Please call factory for more details. 2. PSRL0402U Models (U-Chassis): 400W max. with 23CFM forced airflow or 250W max with convection cooling. PSRL0402E Models (Enclosed with built-in fan): 400W max with built-in fan airflow. 3. Provides peak power to 700W within 500µs for all models; for longer duty duration must contact manufacturer. 4. All output ranges are covered in agency certifications and the preset voltage will be set as standard models if nothing different is requested. If desired preset output does not appear, please contact factory. 5. 1% minimum load is required to maintain the ripple and regulation specifications. 6. Output is fully isolated. 7. For dual output models see the PSRL0402D series. DERATING CURVE Output Power (%) 120 100 80 60 40 20 0 0 10 20 30 40 50 60 70 80 Ambient Temperature (°C) 02/05/2013 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 3 of 7 PSRL0402 Series 250~400 Watts Single Outputs, Active PFC AC/DC Switching Power Supplies Rev. D MECHANICAL DRAWING U-Chassis Models (Type “U”): 8(L) x 5(W) x 1.6(H) inches; Weight: 2.87 lbs CN3 2 X 0.80 [20.32] FAN Unit: inches [mm] 1.25 [31.75] 2 X 1.25 [31.75] C C B B 0.50 [12.7] RS+ RSRSW PG ACF RTN CSH CMN MAG 0.50 [12.7] 7.00 [177.8] 1.60 [40.64] CN3 pin 1 VO- VO- B N C B C B 8.00 [203.2] TERMINAL BLOCK M3.5 SCREW 3PINS 9.5mm CENTER VO+ L CN2 CN1 VO+ MOLEX PART NO. 09-91-0700 (7 PINS, 5 USED) PIN NO. 3,6 NC 5.00 [127] OPTIONAL CONNECTOR MOLEX PART NO. 09-91-1600 (16 PINS) FAN 4.00 [101.6] B C 3.25 [82.55] B C TERMINAL BLOCK M3.5 SCREW 3PINS 9.5mm CENTER 7.01 [177.80] 0.50 [12.70] MOUNTING HOLE: B: 6-32 UNC (Zn-plated) 8 PLACES C: M4X0.7 UNC 8 PLACES B B C C 1.60 [40.64] 2 X 1.25 [31.75] 2 X 0.80 [20.32] I/O CONNECTOR PIN ASSIGNMENTS: Input Connector (CN1): PSRL0402U (U-Chassis Type): Mating Molex Part No. 09-91-0700 (7pin, 5 used) or Howder Terminal block Part No. HD-121-3P PSRL0402E (Enclosed with Built-in Fan Type): IEC320 or equivalent Snap-in mounting type or DINKLE Terminal block Part No. DT-35-A02W-03 (3 pin) Output Connector (CN2): Mating Molex 16 pins (09-91-1600) or Howder (HD-121-6P) M3.5, 8 pins terminal block, 9.5 mm center OUTPUT PIN ASSIGNMENT Molex Logic Signal Connectors (CN3): Mating JST XHP-9 or equivalent (CHYAO SHIUNN JS-2001-09) Mating Pins: JST SXH-002T-P0.6 for AWG 30 to 26 Mounting Inserts: Howder VO+ Pins 1-8 Pins 1-3 VO- Pins 9-16 Pins 4-6 6-32, M4 4 places individually with maximum penetration 0.15” on bottom side and 0.25” on both sides 02/05/2013 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 4 of 7 PSRL0402 Series 250~400 Watts Single Outputs, Active PFC AC/DC Switching Power Supplies Rev. D MECHANICAL DRAWING Enclosed with Built-in Fan Models (Type “E”): 9(L) x 5(W) x 1.6(H) inches; Weight: 3.53 lbs 0.80 [20.32] C B B B B C C CN3 RS+ RSRSW PG ACF RTN CSH CMN MAG FAN C 1.25 [31.75] Unit: inches [mm] CN3 1.60 [40.64] 1.60 [40.64] TERMINAL BLOCK M3 SCREW 3PINS 8.25mm CENTER 1.50 [38.1] C B B 7.00 [177.8] 0.87 [22.225] VO- VOVO+ TERMINAL BLOCK M3.5 SCREW 3PINS 9.5mm CENTER B B C C 1.50 [38.1] VO+ N 1.60 [40.64] C 0.50 [12.7] L CN2 1.25 [31.75] CN1 3.25 [82.55] 4.00 [101.6] 5.00 [127] 5.00 [127] OPTIONAL CONNECTOR MOLEX PART NO. 09-91-1600 (16 PINS) 0.80 [20.32] MOUNTING HOLE: B: 6-32 UNC (Zn-plated) 8 PLACES C: M4X0.7 UNC 8 PLACES 7.00 [177.8] I/O CONNECTOR PIN ASSIGNMENTS: Input Connector (CN1): PSRL0402U (U-Chassis Type): Mating Molex Part No. 09-91-0700 (7pin, 5 used) or Howder Terminal block Part No. HD-121-3P PSRL0402E (Enclosed with Built-in Fan Type): IEC320 or equivalent Snap-in mounting type or DINKLE Terminal block Part No. DT-35-A02W-03 (3 pin) Output Connector (CN2): Mating Molex 16 pins (09-91-1600) or Howder (HD-121-6P) M3.5, 8 pins terminal block, 9.5 mm center OUTPUT PIN ASSIGNMENT Molex Logic Signal Connectors (CN3): Mating JST XHP-9 or equivalent (CHYAO SHIUNN JS-2001-09) Mating Pins: JST SXH-002T-P0.6 for AWG 30 to 26 Mounting Inserts: Howder VO+ Pins 1-8 Pins 1-3 VO- Pins 9-16 Pins 4-6 6-32, M4 4 places individually with maximum penetration 0.15” on bottom side and 0.25” on both sides 02/05/2013 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 5 of 7 PSRL0402 Series 250~400 Watts Single Outputs, Active PFC AC/DC Switching Power Supplies Rev. D CURRENT SHARING INSTALLATION GUIDE (“I” SUFFIX) MATING: JST XHP-9 or EQU. (CHYAO SHIUNN JS-2001-09) RS+ RSRSW PG ACF RTN CSH CMN MAG RS+ RSRSW PG ACF RTN CSH CMN MAG VO- FOR POWER SHARE CONNECTION VO+ L N G VO- RS+ RSRSW PG ACF RTN CSH CMN MAG VO+ L N G VO- RS+ RSRSW PG ACF RTN CSH CMN MAG 02/05/2013 VO+ L N G Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 6 of 7 Rev. D PSRL0402 Series 250~400 Watts Single Outputs, Active PFC AC/DC Switching Power Supplies COMPANY INFORMATION Wall Industries, Inc. has created custom and modified units for over 50 years. Our in-house research and development engineers will provide a solution that exceeds your performance requirements on-time and on budget. Our ISO9001-2008 certification is just one example of our commitment to producing a high quality, well-documented product for our customers. Our past projects demonstrate our commitment to you, our customer. Wall Industries, Inc. has a reputation for working closely with its customers to ensure each solution meets or exceeds form, fit and function requirements. We will continue to provide ongoing support for your project above and beyond the design and production phases. Give us a call today to discuss your future projects. Contact Wall Industries for further information: Phone: Toll Free: Fax: E-mail: Web: Address: 02/05/2013 (603)778-2300 (888)597-9255 (603)778-9797 [email protected] www.wallindustries.com 5 Watson Brook Rd. Exeter, NH 03833 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 7 of 7