CCM250 Series • 250 W Convection Cooled • 300 W Peak Rating 500 ms • Very High Efficiency up to 95% • Class B Conducted & Radiated Emissions • 1U Form Factor • 5 V Standby Rail • 80 V - 275 VAC Input Operation • IT, Industrial & Medical Safety Approvals • Remote On/Off & Power Fail Signal as Standard The CCM250 range of single output AC-DC 250 W nominal, 300 peak power supplies feature industry leading efficiency of 95% and absolute minimum efficiency of 90% with 90 VAC input and full load. This leap in efficiency has been achieved with full resonant ZCS topology and careful consideration to every aspect of power loss resulting in a convection cooled power supply packaged in a 6” (153mm) x 4” (102mm) x 1.5” (38mm) chassis which can be easily installed into the end application due to a 70% reduction in the dissipated heat, associated with other power supplies in this power range. The six standard models cover the voltage range from 12V - 48V , have dual input fusing and are compliant with IEC60601-1 Medical and IEC60950-1 IT safety approvals. The CCM250 series also boasts low earth leakage current of typically 90μA at 115V and 160μA at 230V, class B conducted and radiated emissions 5V standby rail, power fail signal and remote on / off. xppower.com Models and Ratings - Convection-cooled Output Power P nom P peak Output Voltage V1 (1) Output Current V1 I nom I peak (1) Standby Supply Model Number 250 W 300 W 12.0 VDC 20.8 A 25 A 5.0 V/0.5 A CCM250PS12 250 W 300 W 15.0 VDC 16.7 A 20 A 5.0 V/0.5 A CCM250PS15 250 W 300 W 24.0 VDC 10.4 A 12.5 A 5.0 V/0.5 A CCM250PS24 250 W 300 W 28.0 VDC 8.9 A 10.7 A 5.0 V/0.5 A CCM250PS28 250 W 300 W 36.0 VDC 6.9 A 8.3 A 5.0 V/0.5 A CCM250PS36 250 W 300 W 48.0 VDC 5.2 A 6.25 A 5.0 V/0.5 A CCM250PS48 Notes: 1. Peak duration is 500 ms max, average power must not exceed 250 W. Input Characteristics Characteristic Minimum Typical Maximum Units Notes & Conditions Derate output power <90 VAC. See fig 1. Power fail signal cannot be used <90 VAC. Input Voltage - Operating 80 115/230 275 VAC Input Frequency 47 50/60 >0.9 63 Hz Power Factor EN61000-3-2 class A compliant Input Current - No Load 0.13/0.17 A 115/230 VAC Input Current - Full Load 2.4/1.2 A 115/230 VAC 30 A 230 VAC, 25 ºC 250 µA 115/230 VAC/50 Hz (Typ.), 264 VAC/60 Hz (Max.) Inrush Current Earth Leakage Current Input Protection 90/160 T5.0A/250 V internal fuse in both line and neutral Output Characteristics Characteristic Output Voltage - V1 Minimum Typical 12 Minimum Load Units Notes & Conditions 48 VDC See Models and Ratings table ±0.5 (V1) , ±5 (V2) Initial Set Accuracy Output Voltage Adjustment Maximum ±3 0 Start Up Delay % 50% load, 115/230 VAC % V1 only via potentiometer. See mech. details (page 11). A 0.5 s 40 ms 90 VAC full load (see fig.3) ±0.2 % After 20 min warm up Line Regulation ±0.5 % 90-264 VAC Load Regulation ±1 (V1) , ±5 (V2) % 0-100% load. % Recovery within 1% in less than 500 µs for a 50-75% and 75-50% load step Hold Up Time 20 Drift Transient Response - V1 4 Over/Undershoot - V1 Ripple & Noise 5 % 1 (V1), 2 (V2) % pk-pk Overvoltage Protection 115 140 % Overload Protection 125 165 % I nom 0.05 %/˚C Short Circuit Protection 2 20 MHz bandwidth (see fig.4 & 5) Vnom DC. Output 1 only, recycle input to reset Output 1 only, auto reset (see fig.6) Continuous, trip & restart (hiccup mode) all outputs Temperature Coefficient Overtemperature Protection 230 VAC full load (see fig.2) 110 °C Auto recovery - temperature of main transformer xppower.com Input Voltage Derating 300 Peak Power Availability Figure. 1 Output Power (W) 250 200 150 100 50 80 85 90 Input Voltage (VAC) 264 275 Start Up Delay From AC Turn On AC Figure. 2 V1 & V2 start up example from AC turn on (490 ms) V1 V2 Hold Up Time From Loss of AC Figure 3 V1 hold up example at 250 W load with 90 VAC input (43 ms) 3 xppower.com Output Ripple & Noise Figure 4 V1 CCM250PS12 (full load) 86 mV pk-pk ripple. 20 MHz BW Figure 5 V1 CCM250PS24 (full load) 84 mV pk-pk ripple. 20 MHz BW Output Overload Characteristic 14 12 Figure 6 Typical V1 Overload Characteristic (CCM250PS12 shown) Output Volts (V) 10 Output enters Trip & Restart Mode 8 6 4 2 0 0 2 4 6 18 20 Output Current (A) 4 22 24 26 xppower.com General Specifications Xxxxxxxxxx Characteristic Minimum Typical Maximum Units 93 95 % Efficiency Isolation: Input to Output Input to Ground Output to Ground 4000 VAC 1500 VAC 500 Notes & Conditions Full load (see fig.7 & 8) VAC Switching Frequency 30-500 / 25.6 / 51.2 kHz Power Density Mean Time Between Failure Weight PFC / Boost / Main Converter. W/in3 6.9 365 kHrs 1.7 (780) lb (g) MIL-HDBK-217F, Notice 2 +25 °C GB 100% 100% 90% 90% 80% 80% Efficiency Efficiency Efficiency Versus Load 70% 70% 60% 60% 50% 50% 40% 40% 10 20 30 40 50 60 70 80 90 100 10 20 Load (%) 30 40 50 60 70 80 90 100 Load (%) 230Vac input 230VAC input Figure 7 CCM250PS12 Figure 8 CCM250PS24 Power Loss Waste heat creates a big headache for system designers. The industry leading efficiency achieved by the CCM250 is 5-10% above existing topologies used in this power area. This can result in a 70% reduction in generated heat as shown below and enables the overall system to run much cooler and more reliably. Example 2 Example 1 Efficiency Generated Heat % Losses Conventional Products 85 % 44.1 W 100 % CCM250 95 % 13.1 W 30 % Efficiency Generated Heat % Losses Conventional Products 90 % 27.8 W 100 % CCM250 95 % 13.1 W 47 % 5 xppower.com Characteristic Notes & Conditions Signals Power Fail Uncomitted opto isolated transistor, normally off when AC is good (see fig.9 - 11) Provides ≥ 5 ms (typically 20-30ms) warning of loss of output from AC failure Remote On/Off (Inhibit/Enable) Uncommited isolated optocoupler diode, powered diode inhibits the supply (see fig.12-17) Standby Supply V2 Isolated 5 V/0.5 A supply, always present when AC supplied. Signals Power Fail POWER SUPPLY Pin 2, 4 & 6 CON 1 5 V Standby 8V Max 3 mA 2K2 Pin 7 CON 1 Power Fail Collector Figure 9 Transistor On (<0.8 V): Input & Output Not OK Transistor Off (>4.5 V): Input & Output OK Power Fail Emitter Pin 8 CON 1 5 V Standby Rtn Pin 1, 3 & 5 CON 1 Signal Connector Power Fail V1 Power Fail V2 V1 Figure 10 Power Fail signal example at AC switch off 6 Figure 11 V1 warning time example at Power Fail signal 230 VAC 250 W load (35 ms) xppower.com Signals Remote On/Off (Inhibit/Enable) POWER SUPPLY POWER SUPPLY 5 V Standby 2, 4 & 6 CON 1 5 mA 5 V Standby Pin 2, 4 & 6 CON 1 8 V Max Inhibit Hi Pin 10 CON 1 Inhibit Lo Pin 9 CON 1 8 V Max Inhibit Hi Pin 10 CON 1 5 mA 1K Signal Connector 1K Logic GND Pin 1, 3 & 5 CON 1 Logic GND Pin 1, 3 & 5 CON 1 Figure 12 Inhibit (Hi) Inhibit Lo Pin 9 CH 1 Figure 13 Inhibit (Lo) Signal Connector Inhibit Figure 14 Example of outputs switching off when Inhibit (Lo) configuration used & switch closed V1 V2 Inhibit Figure 15 Example of outputs switching on when Inhibit (Lo) configuration used & switch open V1 V2 7 xppower.com Signals Xxxxxxxxxx Remote On/Off (Inhibit/Enable) 1K Figure 16 Enable (Hi) POWER SUPPLY 5 V Standby Pin 2, 4 & 6 CON 1 1K Inhibit Hi Pin 10 CON 1 5 mA Inhibit Lo Pin 9 CON 1 Logic GND Pins 1, 3 & 5 CON 1 Signal Connector 1K POWER SUPPLY Figure 17 Enable (Lo) 5 V Standby Pin 2, 4 & 6, CON 1 1K Inhibit Hi Pin 10 CON 1 5 mA Inhibit Lo Pin 9 CON 1 Logic GND Pins 1, 3 & 5, CON 1 Signal Connector Notes 1. At AC switch on the output (VI) may momentarily rise when the unit is disabled using the 5 V standby in conjunction with the Remote On/Off function. Environmental Characteristic Minimum Operating Temperature -20 (-40) Warm up Temperature Storage Temperature Typical Maximum Units +70 ºC 20 -40 Operating Altitude 8 Derate linearly from +50 ºC at 2.5%/ºC to 50% at 70 ºC. See fig.18 & Thermal Considerations, p.11. (-40 ºC consult sales) Minutes +85 ºC Convection cooled. See fig.18 & Thermal Considerations, p.12. Cooling Humidity Notes & Conditions 5 95 %RH 3000 m Non-condensing Shock 3 x 30 g/11 ms shocks in both +ve & -ve directions along the 3 orthogonal axis, total 18 shocks. Vibration Single axis 10-500 Hz at 2 g x 10 sweeps xppower.com Derating Curve 300 Figure 18 Output Power (W) Peak Power Availability 250 200 150 100 50 0 -20 -10 0 10 Ambient Temperature (°C) 50 40 60 70 Electromagnetic Compatibility - Immunity Phenomenon Standard Test Level Criteria EN61204-3 High severity level as below Harmonic Current EN61000-3-2 Class A Radiated EN61000-4-3 3 EFT EN61000-4-4 3 A Surges EN61000-4-5 Installation class 3 A EN61000-4-6 3 A MIL-STD 461 CS114 Curve 3, 10 KHz-200 MHz Low Voltage PSU EMC Conducted EN61000-4-11 Dips and Interruptions EN60601-1-2 (EN61000-4-11) Notes & Conditions A Dip: 30% 10 ms A Dip: 60% 100 ms B Dip: 100% 5000 ms B Dip: 30% 500 ms A Dip: 60% 100 ms A Dip: 100% 10 ms A Int.: >95% 5000 ms B Requires load derating to approx 80% with 115 VAC input. Electromagnetic Compatibility - Emissions Phenomenon Conducted Radiated Voltage Fluctuations Standard Test Level EN55022 Class B MIL-STD 461D-F, CE102 10 KHz-10 MHz EN55022 Class B RTCA D0160D 21.4 Cat. M Criteria Notes & Conditions See fig. 19 EN61000-3-3 9 xppower.com Typical EMC Plot Figure 19 Typical conducted noise plot Safety Agency Approvals Safety Agency Safety Standard CB Report NEMKO certificate #NO50564 IEC60950-1 Ed 2 Category Information Technology CSA CSA certificate #2124603 CSA C22.2 No, 60950-1-07 Information Technology TUV TUV certificate #B09 04 45240 011 EN60950-1 Information Technology CE LVD Safety Agency Safety Standard CB Report NEMKO certificate #NO50564 IEC60601-1 Category Medical CSA CSA certificate #2124603 CSA C22.2 No, 601.1-M90 Medical TUV TUV certificate #B08 03 45240 009 EN60601-1 Medical Safety Agency Safety Standard Category CB Certificate NEMKO certificate #NO50564 IEC61010-1:2001 Ed 2 Measurement, Control & Laboratory Equipment Protection Class Safety Standard Notes & Conditions Class I IEC60950-1:2005 Ed 2 10 xppower.com Xxxxxxxxxx Details Mechanical 3.94 (100.0) Input Connector CON 4 Pin 1 Line Pin 2 Neutral Pin 3 Earth 2.95 (74.9) 0.94 (23.9) 0.53 (13.3) CON 4 mates with Molex housing 09-50-1051 and Molex series 5194 crimp terminals. M3 MOUNTING HOLES (IN 4 POSITIONS). MAX. PENETRATION BY SCREW TO BE 2.5mm FROM BOTTOM FACE OF CHASSIS. +5Ve P/F Emitter +Ve ROF 6.00 (152.4) L2 1 2 -5Ve Output Connector CON 3 +V1 V 1 RTN P/F Collector -Ve ROF SIGNALS CONNECTIONS Signals Connector CON 1 + - OUTPUT VOLT AGE AD JUSTMENT. 4.00 (101.6) C12 OUTPUT TERMINALS ALLO W CONNECTION FROM EITHER TOP OR SIDE OUTPUT TERMINALS M4 SCREWS IN 2 POSITIONS. TORQUE TO 90 cNm Max. 1 5 V Standby Return 2 5 V Standby 3 5 V Standby Return 4 5 V Standby 5 5 V Standby Return 6 5 V Standby 7 Power Fail (Collector) C21 M3 MOUNTING HOLES (IN 2 POSITIONS, EACH SIDE). MAX. PENETRATION BY SCREW TO BE 3.5mm FROM OUTSIDE FACE OF CHASSIS. 0.75 (19.1) 1.54 (39.1) INPUT TERMINAL BLOCK 1.73 (44.0) 4.00 (101.6) 8 Power Fail (Emitter) 9 Remote On / Off (Cathode) 10 Remote On / Off (Anode) CON 1 mates with JST housing PHDR-10VS with contact SPHD-001T-P0.5 Notes 1. All dimensions in inches (mm). Tolerance .xx = ±0.02 (0.50); .xxx = ±0.01 (0.25) Weight 1.7 lb (780 g) approx 11 xppower.com Thermal Considerations In order to ensure safe operation of the PSU in the end-use equipment, the temperature of the components listed in the table below must not be exceeded. Temperature should be monitored using K type thermocouples placed on the hottest part of the component (out of any direct air flow). See Mechanical Details for component locations. Temperature Measurements (Ambient ≤ 50 ºC) Component Max Temperature ºC L2 120 ºC C12 105 ºC C21 105 ºC Service Life The estimated service life of the CCM250 Series is determined by the cooling arrangements and load conditions experienced in the end application. Due to the uncertain nature of the end application this estimated service life is based on the actual measured temperature of a key capacitor within the product when installed in the end application. The graph below expresses the estimated lifetime for a given component temperature and assumes continuous operation at this temperature. Estimated Service Life vs Component Temperature Figure 20 185000 165000 Lifetime (Hrs) 145000 125000 105000 85000 65000 45000 25000 5000 105 95 85 75 65 55 C64 Temperature (°C) 12 10-Sep-13