Technical Specification 400 W Single Vout Series Industrial Grade AC/DC Power Supply With PFC 85-264 Vrms 12/24/36/48 V 400 W 500 W Up to 91 % Input Voltage Semi-Regulated Output Output Continuous Output Transient Full Load Efficiency 400 W Open Frame Configurations • 400 W Encased or Open Frame • 800 W Encased Flat or Stacked • 1200 W Encased Flat or Stacked 400 W Encased 1200 W Encased Stacked 800 W Encased Flat 400 W Single Vout Series Features • • • • • • • • High efficiency (91% for 48 VOUT Model at 400 W) Universal input voltage range Semi-regulated output for bus stability Parallel operation supported Integral fan cooling with speed control Active PFC; EN61000-3-2 compliant Low leakage; EN60601-1 compliant Low noise; EN55011 / EN55022 Class B compliant Product # AQ0400IUxx Series Phone 1-888-567-9596 • Over–current, over–voltage, and over–temp protection • DC Power Good / AC Power Good signals • Remote enable input • Fan status output / Fan enable input • Small size: 3" x 5" x 1.45" (open frame) • RoHS 6/6 compliant • 5 V (250 mW) standby output www.synqor.com Doc.# 005-005052 Rev. A 09/08/08 Page 1 AC Input: 85-264 VRMS DC Output: 12/24/36/48V Semi-reg. Power: 400 W Series Grade: Industrial Technical Specification ACuQor 400W Series ELECTRICAL CHARACTERISTICS All specifications typical with TA = 25 °C, unless otherwise specified. MAIN OUTPUT SPECIFICATIONS GENERAL SPECIFICATIONS Output power (continuous) 85-132/170-264 Vrms (5 s transient) 85-132/170-264 Vrms 132-170 Vrms Nominal DC output 12 Vout voltage (at 250W) 24 Vout (Semi-regulated) 36 Vout 48 Vout Efficiency (see figs. 3 - 10) 12 48 12 48 Vout, Vout, Vout, Vout, Hold-up time (to -20%) Vout / 36 / 48 Vout Vout Vout Vout Vout 12 24 Maximum load capacitance 12 24 36 48 Output ripple voltage 115 115 230 230 Vrms, Vrms, Vrms, Vrms, 400 400 400 400 400 W 500 W See Figure 10 12.4 V 25 V 37.5 V 50 V 88% 90% 89% 91% W W W W 16 ms @ 400 W 20 ms @ 400 W 16,000 µF 8,000 µF 4,000 µF 2,000 µF Switching frequency (20 MHz BW) Twice line frequency (at 300W) 0.5% p-p 5.0% p-p Turn-on delay 2 s max. Transient response Iout steps from 50-75% At 0.2 A/µs Overvoltage protection Cyclic restart Short circuit protection Cyclic operation Total regulation Over line, load and temperature Auxillary Output typ. typ. typ. typ. 3% typ / 6% max. dev. 100 ms recovery 110-120% 115% rated Iout ±6.0% 5 V @ 50 mA Always on (See Note 1) Thermal protection Automatic recovery +125 ºC (PCB Temp) REMOTE_ENABLE Input Low Voltage Input High Voltage 0.45 V (max) 4.15 V (min) Fundamental ripple freq. Audible noise Input Output Fan speed varies with temp. Weight (EA \ EC) (SC \ RC) (UC \ TC) MTBF MIL-217 Demonstrated ISOLATION SPECIFICATIONS Isolation voltage Insulation resistance 500 kHz 250 kHz 39 dBA @ 1 m max. 343 g (12.1 oz) \ 446 g (15.7 oz) 846 g (29.8 oz) \ 879 g (31 oz) 1224 g (43.2 oz) \ 1298 g (45.8 oz) 343.6 kHours TBD kHours Input to output Input to ground Output to ground 3000 Vrms 1500 Vrms 500 Vrms Output to ground 10 MΩ min. Leakage currents See Note 2 ENVIRONMENTAL CHARACTERISTICS Thermal performance Relative humidity Altitude Operating ambient (see Figure 9) Non-operating ambient Non-condensing Random vibration Operating Non-operating 5-500 Hz Shock Half-sine, 10 ms, 3 axes 0 ºC to +70 ºC -40 ºC to +85 ºC 5-95% RH 10,000 ft max. 30,000 ft max. 0.03 g2/Hz 20 g peak EMC CHARACTERISTICS Conducted emissions Line frequency harmonics EN55011 and EN55022, FCC part15 EN61000-3-2 Level B Voltage fluctuations EN61000-3-3 Clause 5b Class A ESD air EN61000-4-2 Level 3 INPUT SPECIFICATIONS ESD contact EN61000-4-2 Level 3 AC input voltage Radiated immunity EN61000-4-3 Level 3 Fast transients EN61000-4-4 Level 3 Line surge immunity EN61000-4-5 Level 3 Conducted immunity EN61000-4-6 Level 3 Power freq. mag. field EN61000-4-8 Voltage dip immunity EN61000-4-11 Universal range Input frequency Input current 85-264 Vrms 47-63 Hz 115 Vrms @ 400 W 230 Vrms @ 400 W Power factor Input surge current 264 Vrms (cold start) Internal input fuses Both AC lines 4 Arms 2 Arms >0.98 40 A max. 3 A/m Perf Criteria A, A, B <5% UT 10 ms, 70% UT 500 ms, 40% UT 100 ms 6.3 A SAFETY AGENCY CERTIFICATIONS (pending) All certification marks appear on individual unit labels. UL60950 IEC/EN 60950 CE Marked cUL CSA Standards NOTES: 1. Derate 1 mA per °C above 50 °C ambient temperature. 2. Leakage currents: AC Leakage Current from Input to Earth Normal Open Neutral Condition Fault AC Line Connection 240 V L-N, 1 phase ACuQor Typical at 110% nominal input 208 V L-L, 120 V L-N, 1 of 3 phases voltage 60 Hz 240 V L-N-L, 120 V L-N, split phase Product # AQ0400IUxx Series Phone 1-888-567-9596 www.synqor.com Doc.# 005-005052 Rev. A 400 µA 800 µA 200 µA 400 µA 200 µA 400 µA 09/08/08 Page 2 AC Input: 85-264 VRMS DC Output: 12/24/36/48V Semi-reg. Power: 400 W Series Grade: Industrial Technical Specification EFFICIENCY, DERATING, AND VOUT DROOP CURVES 100 14.0 95 13.5 13.0 Output Voltage (V) Efficiency (%) 90 85 80 75 12.5 12.0 11.5 11.0 115 Vrms 70 10.5 230 Vrms 65 10.0 0 100 200 300 400 500 0 4 8 12 Figure 1: 12 VOUT efficiency curves. 20 24 28 32 36 12 14 16 18 Figure 2: 12 VOUT droop characteristic. 100 28 95 27 26 Output Voltage (V) 90 Efficiency (%) 16 Output Load (A) Output Power (W) 85 80 75 25 24 23 22 115 Vrms 70 21 230 Vrms 65 20 0 100 200 300 400 500 0 2 4 6 Figure 3: 24 VOUT efficiency curves. 10 Figure 4: 24 VOUT droop characteristic. 42 100 95 40 Output Voltage (V) 90 Efficiency (%) 8 Output Load (A) Output Power (W) 85 80 75 115 Vrms 38 36 34 32 70 230 Vrms 65 30 0 100 200 300 400 500 0 Figure 5: 36 VOUT efficiency curves. Product # AQ0400IUxx Series Phone 1-888-567-9596 2 4 6 8 10 12 Output Load (A) Output Power (W) Figure 6: 36 VOUT droop characteristic. www.synqor.com Doc.# 005-005052 Rev. A 09/08/08 Page 3 AC Input: 85-264 VRMS DC Output: 12/24/36/48V Semi-reg. Power: 400 W Series Grade: Industrial Technical Specification EFFICIENCY, DERATING, AND VOUT DROOP CURVES 100 54 95 52 Output Voltage (V) Efficiency (%) 90 85 80 75 115 Vrms 50 48 46 44 70 230 Vrms 65 42 0 100 200 300 400 500 0 1 2 3 Output Power (W) 4 5 6 7 8 9 Output Load (A) Figure 8: 48 VOUT droop characteristic. Figure 7: 48 VOUT efficiency curves. 600 500 500 400 Power (W) Power (W) 400 300 200 300 200 24 / 36 / 48 V with Fan Enabled 12 V with Fan Enabled Transient 100 100 24 / 36 / 48 V with Fan Disabled Continuous 12 V with Fan Disabled 0 0 85 0 10 20 30 40 50 60 70 Product # AQ0400IUxx Series Phone 1-888-567-9596 170 264 Input AC Voltage (VRMS) Ambient Temperature (ºC) Figure 9: Continuous power derating curve in natural convection. 132 80 Figure 10: Rated output power vs Input AC Voltage. www.synqor.com Doc.# 005-005052 Rev. A 09/08/08 Page 4 AC Input: 85-264 VRMS DC Output: 12/24/36/48V Semi-reg. Power: 400 W Series Grade: Industrial Technical Specification MECHANICAL DRAWINGS (1 Module Open Frame Version — E Package Type) Front Back Top Bottom Right MECHANICAL DRAWINGS (1 Module Encased Version — E Package Type) Top Right Bottom Front Back NOTES (applies to all mechanicals) 1) Recommended screw tightening torque of 6 in.lbs 2) Undimensioned components are shown for visual reference only 3) All dimensions in inches [mm] Tolerances: x.xx in ± 0.02 x.xxx in ± 0.010 Product # AQ0400IUxx Series Phone 1-888-567-9596 www.synqor.com Doc.# 005-005052 Rev. A 09/08/08 Page 5 AC Input: 85-264 VRMS DC Output: 12/24/36/48V Semi-reg. Power: 400 W Series Grade: Industrial Technical Specification MECHANICAL DRAWINGS (2 Modules Flat Version — R Package Type) Product # AQ0400IUxx Series Phone 1-888-567-9596 www.synqor.com Doc.# 005-005052 Rev. A 09/08/08 Page 6 AC Input: 85-264 VRMS DC Output: 12/24/36/48V Semi-reg. Power: 400 W Series Grade: Industrial Technical Specification MECHANICAL DRAWINGS (2 Modules Stacked Version — S Package Type) Product # AQ0400IUxx Series Phone 1-888-567-9596 www.synqor.com Doc.# 005-005052 Rev. A 09/08/08 Page 7 AC Input: 85-264 VRMS DC Output: 12/24/36/48V Semi-reg. Power: 400 W Series Grade: Industrial Technical Specification MECHANICAL DRAWINGS (3 Modules Flat Version — T Package Type) Product # AQ0400IUxx Series Phone 1-888-567-9596 www.synqor.com Doc.# 005-005052 Rev. A 09/08/08 Page 8 AC Input: 85-264 VRMS DC Output: 12/24/36/48V Semi-reg. Power: 400 W Series Grade: Industrial Technical Specification MECHANICAL DRAWINGS (3 Modules Stacked Version — U Package Type) Product # AQ0400IUxx Series Phone 1-888-567-9596 www.synqor.com Doc.# 005-005052 Rev. A 09/08/08 Page 9 AC Input: 85-264 VRMS DC Output: 12/24/36/48V Semi-reg. Power: 400 W Series Grade: Industrial Technical Specification CONNECTOR DETAILS OUTPUT CONNECTOR PINOUT (top side) Pin 1 FAN_GOOD Open collector with internal 5V pullup. See Figure A. Pulsed low on fan failure, 100ms, 50% duty. Short to VOUT(-) to disable fan. Pin 2 AC_POWER_GOOD Open collector with internal 5V pullup. See Figure B. Pulled low on AC power dropout. Pin 3 DC_POWER_GOOD Open collector with internal 5V pullup. See Figure B. Pulled low during startup ramp and within 5 ºC of temperature shutdown threshold. Pin 4 5V_STANDBY 5 V @ 50 mA available whenever AC power is applied. Pin 5 VOUT(+) Positive Output Voltage. Pin 6 VOUT(+) Positive Output Voltage. Pin 7 VOUT(+) Positive Output Voltage. Pin 8 VOUT(+) Positive Output Voltage. Pin 9 Reserved Reserved for future use. Pin 10 Reserved Reserved for future use. Pin 11 REMOTE_ENABLE Logic input. See Figure C. Pull high to enable main output. Pin 12 VOUT(–) Negative Output Voltage. Pin 13 VOUT(–) Negative Output Voltage. Pin 14 VOUT(–) Negative Output Voltage. Pin 15 VOUT(–) Negative Output Voltage. Pin 16 VOUT(–) Negative Output Voltage. Figure A: Fan status output / Fan enable input interface circuitry. 5V_STANDBY 1N4148 5k 10 Ohms AC_POWER_GOOD or DC_POWER_GOOD 2N3904 From AC/DC Monitor Circuitry 0.1 µF VOUT(-) Figure B: Power good interface circuitry. 12 V OUTPUT CONNECTOR PINOUT (bottom side) Pin 1 VOUT(+) Positive Output Voltage. Pin 2 VOUT(+) Positive Output Voltage. Pin 3 VOUT(+) Positive Output Voltage. Pin 4 VOUT(+) Positive Output Voltage. Pin 5 VOUT(–) Negative Output Voltage. Pin 6 VOUT(–) Negative Output Voltage. Pin 7 VOUT(–) Negative Output Voltage. Pin 8 VOUT(–) Negative Output Voltage 5V_STANDBY 5V_STANDBY 10 Ohms 5k To Enable Circuitry REMOTE_ENABLE 0.1 µF 10k VOUT(-) Figure C: Remote enable interface circuitry. MATING CONNECTORS INDIVIDUAL INPUT CONNECTOR PINOUT Pin 1 Ground Pin 3 AC Neutral Pin 5 AC Line Product # AQ0400IUxx Series Connector Type Contact OUTPUT (16 pins) Molex 430251600 Molex 430300008* 12V_OUTPUT (8 pins) Molex 436450800 Molex 430300008* INPUT JST VHR-5N JST SVH-41T-P1.1 * Each contact rated for a maximum of 5.5 A. Phone 1-888-567-9596 www.synqor.com Doc.# 005-005052 Rev. A 09/08/08 Page 10 AC Input: 85-264 VRMS DC Output: 12/24/36/48V Semi-reg. Power: 400 W Series Grade: Industrial Technical Specification PARALLEL OPERATION - MULTIPLE UNITS Chassis configurations for Parallel Units ACuQor units are available either open-frame or pre-mounted at the factory. Up to 3 units can be mounted into a chassis, in either side-by-side or stacked configurations. For a complete list of options, see the “Part Numbering System” table on the last page, under “Package Type”, along with the Mechanical Drawings pages. Only side-by-side configurations can be populated with 500W units, since each includes a thermal pad underneath. Interconnection of Parallel Units ACuQor units mounted in 2 and 3 unit chassis are not connected together. This allows the physical routing and connectivity of the external wiring to be customized to each application. The following table summarizes the recommended wiring to operate multiple units in parallel: Specifications of Parallel Units As a rule, units wired in parallel behave the same as single units. Any specification will remain unchanged that is expressed in units of voltage, time, frequency, or efficiency. Specifications expressed in terms of power, current, or capacitance, should be scaled by the number of units wired in parallel. ACuQor units are individually calibrated at the factory, so that the output voltage vs. output current characteristic is always consistent (see Vout droop characteristic figures). As such, multiple units will share output current accurately. Full current is guaranteed from a bank of multiple units wired in parallel. Output Connector Signal Suggested Connection Behavior with Multiple Units REMOTE_ENABLE Wire in parallel Inputs activated simultaneously FAN_GOOD “ Wired-OR outputs – can be pulled low by any unit during an abnormal condition. AC_POWER_GOOD “ “ DC_POWER_GOOD “ “ VOUT(+), VOUT(-) “ Built-in droop characteristic ensures graceful current sharing. 12V_STANDBY* “ “ 5V_STANDBY Do not wire in parallel Fully regulated characteristic does not support current sharing. If placed in parallel, only the output with the highest set-point will drive current. *Note: Triple output models only. Product # AQ0400IUxx Series Phone 1-888-567-9596 www.synqor.com Doc.# 005-005052 Rev. A 09/08/08 Page 11 AC Input: 85-264 VRMS DC Output: 12/24/36/48V Semi-reg. Power: 400 W Series Grade: Industrial Technical Specification INSTALLATION INSTRUCTIONS General: ACuQor AC/DC power supplies are intended for use as components in industrial equipment. ACuQor units must be properly installed within end use equipment before they can be safely applied as described in this document. The suitability of the ACuQor/equipment combination must be verified through end product investigation. Mounting: Refer to the Mechanical Drawings section. ACuQor units are provided with threaded stainless-steel stand-offs or inserts for mounting. This mounting hardware is internally connected to the input connector protective-earth terminal for functional-earth EMC control. Any orientation (vertical, horizontal, etc.) may be used. Adequate air space should be provided over the fan intake (top) and exhaust (sides) to allow for exchange of cooling air. ACuQor is designed for a pollution degree 2 environment. The suitability of the enclosed ACuQor mechanical assemblies must be verified through end product investigation. Encased models: A minimum of 5 mm electrical clearance should be allowed from the connector ends of encased models. Input: Refer to the Connector Details section for input connector wiring. ACuQor products require a single phase AC power source of 100-240V 50/60Hz nominal. Refer to nameplate label for input current ratings. A protective-earth connection is also required. Minimum wire size of 18 AWG (0.8mm2) is recommended. Both sides of the AC line are internally fused (see table for specific models). These fuses are not user replaceable. MODEL AQ0300 AQ0400 AQ0500 Input Fuses (in Both AC Lines) Littelfuse 6.3A 250V 21606.3XEP Littelfuse 6.3A 250V 21606.3XEP Littelfuse 10.0A 250V 216010XEP Product # AQ0400IUxx Series Phone 1-888-567-9596 Output: Refer to the Connector Details section for output connector wiring and signal I/O functionality. Refer to nameplate label for output current ratings. Main DC output (Vout+, Vout-) pins should use 20 AWG (0.5mm2) wire size. Individual main output pins should not be loaded to more than 5.5 A. For currents greater than 5.5 A, multiple main output pins/wires must be used in parallel. All signal I/O pins are referenced to Vout-. EMC: ACuQor products have been tested to the EMC specifications listed in the Electrical Characteristics section. However, end use equipment must be tested to verify EMC compliance. Hipot Testing: ACuQor products are rated for Hipot testing levels of 1500 Vac input to protective-earth, 500 Vac output to protective-earth, and 3000 Vac input to output. When performing the 3000 Vac input to output test, the test voltage must be balanced evenly 1500 Vac input and output to protective-earth. Two oppositely phased test voltage sources or a single test voltage source with external balancing impedances (capacitors) may be used to prevent overstressing input or output to protective-earth insulation per IEC/ENC 60950-1. Fuses Total 2 2 2 www.synqor.com Doc.# 005-005052 Rev. A 09/08/08 Page 12 AC Input: 85-264 VRMS DC Output: 12/24/36/48V Semi-reg. Power: 400 W Series Grade: Industrial Technical Specification PART NUMBERING SYSTEM The part numbering system for SynQor’s ACuQor AC/DC power supplies follows the format shown in the table below. Not all combinations make valid part numbers, please contact SynQor for availability. Family AQ ACuQor series of ac-dc semi-regulated output power supplies Output Power 0300: 300 W 0400: 400 W 0500: 500 W 0600: 600 W (2 x 300 W) 0800: 800 W (2 x 400 W) 0900: 900 W (3 x 300 W) 1000: 1000 W (2 x 500 W) 1200: 1200 W (3 x 400 W) 1500: 1500 W (3 x 500 W) Grade I: industrial Range U: universal (85-264 VRMS) Output Voltage Package Type (xx=Standard; xT=Triple) (Correlates to Output Power) 12: 12 V 1T: 12 V / 5 & 12 V STBY 24: 24 V 2T: 24 V / 5 & 12 V STBY 36: 36 V 3T: 36 V / 5 & 12 V STBY 48: 48 V 4T: 48 V / 5 & 12 V STBY E: 1 unit (3" x 5") R: 2 units; flat S: 2 units; stacked T: 3 units; flat U: 3 units; stacked Thermal Design A: open frame C: encased Q: encased only Options Industrial Grade: IND: Industrial Example: AQ0400IU24EAIND ACCESSORIES SynQor offers a series of assemblies that can be ordered according to the table below. Mechanical drawings for these accessories are available for download in pdf format from the SynQor website. Part Number Description AQ-CBL-INPUT1C Input mating cable with pre-stripped wire ends (36" long). AQ-CBL-OUT1C Output mating cable with pre-stripped wire ends (18" long). AQ-CBL-OUT1CD Same as AQ-CBL-OUT1C with an additional 8-pin connector. AQ-CBL-OUT2C AQ-CBL-OUT2CD AQ-INSUL1M AQ-EVAL-PRL3 Output mating cable with connectors on both ends (18" long). Same as AQ-CBL-OUT2C with an additional 8-pin connector. Single module bottom-side Mylar insulator for open frame mounting. Evaluation board for up to three paralleled modules. APPLICATION NOTES A variety of application notes and technical white papers can be downloaded in pdf format from the SynQor website. PATENTS SynQor holds the following patents, one or more of which might apply to this product: 5,999,417 6,222,742 6,545,890 6,594,159 6,731,520 6,894,468 6,927,987 7,050,309 7,072,190 7,119,524 7,269,034 7,272,021 Contact SynQor for further information: Phone: Toll Free: Fax: E-mail: Web: Address: 978-849-0600 888-567-9596 978-849-0602 [email protected] www.synqor.com 155 Swanson Road Boxborough, MA 01719, USA Product # AQ0400IUxx Series Phone 1-888-567-9596 6,577,109 6,896,526 7,085,146 7,272,023 Warranty: SynQor offers a two (2) year limited warranty. Complete warranty information is listed on our website or is available upon request from SynQor. Limitation on use: SynQor’s products are not authorized for use and should not be used, without the specific prior written approval of an authorized officer of SynQor making specific reference hereto, in any life support system, nuclear facility or application, aircraft control application or any other application in which failure of the product could reasonably result in harm to life, property or the environment. Information furnished by SynQor is believed to be accurate and reliable. However, no responsibility is assumed by SynQor for its use, nor for any infringements of patents or other rights of third parties which may result from its use. No license is granted by implication or otherwise under any patent or patent rights of SynQor. www.synqor.com Doc.# 005-005052 Rev. A 09/08/08 Page 13