NEVO 600 series User Manual
Contents
1. Remote sensing For seriesed modules remote sensing is achieved by connecting the upper most positive sense terminal S and the lower most negative sense terminal S from the series of modules to their respective load regulation points All inner sense terminals in the series must be daisy chained S to S from the first module in the series to the last module in the series An example of two seriesed modules is shown below Output Twisted sense cables Module 2 ME SE EP EE BP AA Me de Output Module 1 Seriesed remote voltage current control Remote voltage and or current control is possible with any number of seriesed outputs using the advanced V_control and I_control functions as 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 attain control over the full voltage range In practice individual control of each module is rarely required and a more straightforward method is to control all outputs simultaneously with a single control voltage With NEVO output modules this is effortlessly achieved with the use of an external tracking circuit details of which can be provided upon request Using the external tracking circuits allows all modules in a series to be controlled by a single control voltage that can be referenced to the COM J5 5 pin on any2. 50 ms tz 25 ms t4 15 ms ts 5 ms minimum ts 100 ms When the AC mains voltage is removed the internal hold up capacitors will supply power to the load for typically 20 ms t ts at maximum power The ACOK signal will go low at least 5ms before the output voltages 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 Hold up For short line distubances lt 20ms the output voltages will not be affected However the ACOK signal may still go low to warn that there is an impending loss of output power The ACOK signal will return to the high state once the unit has recovered from the disturbance Outputs that are adjusted above the hold up voltage as detailed in their respective datasheets may experience a dip in voltage but never below the hold up voltage specified I dle power The idle power of the NEVO PSU is extremely low when compared to similar power supplies With the output modules enabled the unit typically only requires 28 W with no output load To reduce the idle power further the outputs can be disabled using the global inhibit GINH pin With the outputs disabled the unit typically requires less than 21 W Over temperature Protection OTP The input module is protected from excessive temperatures by means of various internal sensors If temperature thre
3. Hence Vctrl should never fall below 0 66V otherwise OVP may latch the entire unit off Alternatively by manually adjusting the output voltage to less than 1 3 of the OVP voltage ensures that OVP can never be tripped by remote voltage control Also remote adjustment of the output voltage using the Vcontrol pin does not affect the preset power good threshold Hence remotely adjusting the output voltage below 0 9 Vset will cause the power good signal to go low Remote current programming External voltage control The output current limit of the module can be reduced using an external voltage source connected between the COM and Icontrol pins on the signals connector as shown below In practice this also means that the output can be used as a modulated or constant current source Signals Output current control 14 7 oe lcontrol 0 8 4 0 6 4 Output current normalised to Irated 0 4 0 2 g 0 5 1 1 5 2 Control voltage In the diagram above Vi_out is an internal voltage source that is proportional to the internal inductor current and approximates the equation Vi out 0 6 Iout Iratea 1 25 where Irated is the maximum rated current for the module In this configuration the output current limit will approximate the following equation limit Vctrl 0 6 I atea 1 25 where Irateq is the maximum rated current for the module It is not possible to increase the maximum current limit of the module and
4. ImaxA ImaxB ImaxC Amps Connecting the Icontrol pins together forces all the outputs to deliver the same current ensuring that the system reliability is maximised and the work load is distributed evenly across all paralleled modules In this mode the lowest adjusted output module will determine the actual output voltage and all higher adjusted outputs will reduce their voltage There may be a small amount of circulating current between the modules approximately 6 of the maximum rated current for each module The current output signal Icontrol can still be used to measure the output current but it must be scaled by N where N is the number of paralleled modules WARNING Care must be taken to avoid differential voltages between the negative power output terminals of the paralleled modules as this can cause errors at the control pins To avoid this it is recommended that a low impedance connection be made between the negative power terminals close to the PSU output and cables then connected from this common point to the load Paralleling across multiple chassis Paralleling across multiple chassis is not possible without external protection such as external diodes or controlled MOSFETs to prevent circulating currents between each chassis Failure to provide such protection may result in damage to the units Consult Vox Power for details on how best to implement such applications Where units are paralleled across multiple chassis the
5. one or both of the deratings may apply Where both apply the derating factors given above can be multiplied together to obtain the total derating factor Example What are the NEVO600 input and output module deratings at 60 C at 120V line Input power rating Prated line derating factor Temp derating factor Output power rating Prated Temp derating factor Line derating factor 1 0 0055 180 Vin 1 0 0055 180 120 0 67 Temperature derating factor 1 Temp 50 0 025 1 60 50 0 025 0 75 Input power rating 600 0 67 0 75 301 5W Output 2 power rating 150 0 75 112 5W Efficiency The efficiency of the overall unit is dependent on several parameters such as input voltage load level and on the combination of output modules The plots below show typical efficiencies of a NEVO600 over the full load and line voltage range and fitted with four of each type of output module equally loaded An estimate of the efficiency for any particular system may be obtained from these graphs using the procedure outlined in the example below Example 1 2 3 4 Efficiency Efficiency Typical Line Efficiency o OP1 400W OP2 400W e OP3 400W OP1 500Wout OP2 600Wout OP3 600Wout 140 160 180 RMS input Voltage Typical Load Efficiency OP2 220V OP1 220V OP3 220V 350 Watts Out Estimate the efficiency of an NEVO600 1123 at 160Vrms input and 100W load on each ou
6. and securing all the screws STEP 5 Reconnect the power cable and apply power to ensure all the output modules are working by checking that the LED light on each output module comes on Always check the output voltage of each module to ensure it is adjusted to your requirements Remove power and attach all other cables The unit is now ready for use Safety The NEVO unit has been designed to comply with the Low Voltage Directive 73 23 EEC LVD and is CE marked to show its compliance When correctly installed according to the installation manual in a limited access environment the NEVO600S complies with the requirements of UL60950 1 EN60950 1 IEC60950 1 CSA22 2 no 60950 1 and the NEVO600M complies with the requirements of UL60601 1 3 ED EN60601 1 EN61010 1 IEC60601 1 IEC61010 1 CSA22 2 no 601 1 The power supply should not be operated close to combustible materials or atmosphere Care should be taken to ensure liquid or metal shavings do not enter the power supply as this can cause a fire hazard The power supply does not contain any user serviceable parts and should be returned to Vox Power for repair Approval limitations NORTH AMERICA When this product is used with 180VAC 253VAC mains where no neutral is present connect the two live wires to L Live and N Neutral on the input connector WARNING Seriesed modules with combined voltages exceeding 60 volts are not considered SELV Paralleled and or seriesed modul
7. control voltages Ver exceeding 1 53 V will have no effect on the current limit When using an output module as a modulated current source the output voltage should be manually adjusted to the maximum that will be required by the application and this will be the upper voltage limit Once the load is connected the output current can then be modulated by applying a control voltage as described above Note that the power good threshold level is fixed and defined by the manually preset voltage Hence while the output module is limiting or modulating the output current the PG signal may go low Output current measurement The output current of the module can be measured using the Icontroi Signal If this pin is unloaded its output voltage will follow the equation Vi out 0 6 lout Crateq 1 25 where Irated is the maximum rated current for the module signals signals lcontro COM Note that the Icontrol output voltage is representative of the internal inductor current not the actual load current However this will only have an influence during dynamic events It is recommended to add an external amplifier as shown above left when using the Icontroi 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 reguired to measure the output current and adjust the output current limit simultaneously this can be achieved by using a clamp circu
8. little effect at the load The optimum solution is to locate a low impedance electrolytic capacitor at the load which will eliminate the inductive cable drop and also reduce the typical voltage deviation at the module S V Output Twisted power cables Length lt 0 5m Module Measurement atA amp B With EL CAP Measurement at B No EL CAP Measurement atA No EL CAP Volts Volts ms ms ms Advanced output module features Remote voltage programming External voltage control The output voltage of the module can be adjusted using an external voltage source connected between the COM and Vcontrol pins on the signals connector J5 as shown below In this configuration the output voltage will follow the equation below Vo Vset 1 8 Vctrl 0 6 where Vset is the manual preset voltage of the module Output voltage control signals Vecontrol a Vout Normalised to Vset hd lt tl rt i UI i Oo D 5 1 1 5 2 0 Vcontrol The output voltage can be controlled from 0 to 300 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 is considered a safety hazzard and will latch the entire unit off To determine the level of control voltage that will trigger OVP insert Vovp into the equation above Example Vovp 9 5V Vset 5V gt Vctrl 1 8 Vovp 0 6 Vset 0 66V
9. outputs in each chassis will not be synchronised and the peak to peak output ripple may contain beat frequencies in the audio spectrum Ve ImaxC ImaxB Amps ImaxA Parallel remote sensing Remote sensing can be used as normal with paralleled modules The sense lines S and S from each of the output modules should be connected together S to S and S to S as shown below This should be done close to the power supply output and a single pair of cables brought from these sense lines to the load Keeping cable lengths to a minimum and using twisted pairs where necessary will help reduce noise pickup in the sense lines Output Module Output Module Output Module A B C S V V S Ictri S V V S Ictrl S V V S Ictri N 1 configurations When using N 1 redundant configurations a suitably rated diode or controlled MOSFET must be used on each output 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 Output Module Typically this configuration can damage the internal sense resistors used within a power supply However the NEVO outputs have integrated protection to prevent this type of damage and are completely N 1 compatible without any additional external protection circuitry Not
10. x 8 Screw type Tightening Penetration depth CHASSIS x 5 Screw type Tightening Penetration depth Screw type Tightening Penetration depth M3x5 C Sink Posi Stainless Steel Tighten to 0 75 Nm Defined by screw M3x5 C Sink Posi Stainless Steel Tighten to 0 75 Nm Defined by screw M3x24 C Sink Posi Stainless Steel Tighten to 0 75 Nm Defined by screw i ma VOEL j i N Ns ati ii ale j ID L S MHI 38 aii o H O 38 O a MH3 19 De AS 61 6 O i MH MHS S SLOTD o E 18 3 N store fo 4 ra LY l Airlfow 18 A SLOT B DIE Ee E 18 i ae 4 sLOTA o Connectors PINOUTS J1 J2 Power Good Inhibit 38 0 N Neatral Power Good E Earth Inhibit L Live Power Good Inhibit Power Good Inhibit Global Inhibit AC OK 5V 200mA Bias Sup
11. 1206 capacitor Use twisted pair lt 300mm i E SCOP LALALALA AC Coupling i Pd Ferrite to reduce 20M Hz bandwidth Magnetic pickup Terminate with common mode noise Minimise loop area 1O00nF ceramic 1206 not normally required 10uF tantalumlow EL Over Temperature Protection OTP Each output module is protected against excessive temperatures In the event of the internal temperatures exceeding safe levels the entire unit may be latched off To resume operation of the unit disconnect the AC input voltage for 2 minutes ensure external ambient temperatures are within specifications and then reconnect the AC input voltage Note that no warning is given on the AC_OK signal for faults of this type Transient response The NEVO output modules have been especially designed to have high reliability and to achieve this all electrolytic capacitors have been eliminated from the design Due to this high dynamic load transients can cause relatively high voltage deviations at the output and although the outputs have a very high loop bandwidth with typical recovery times of less than 100us the voltage deviations may still be excessive for some applications An example application is detailed in the diagram below and shows typical responses at the terminals of the output module and at the load Notice that the voltage deviation due to cable inductance exceeds the module response and hence a capacitor located at the module terminals will have
12. 601 1 EN60601 1 EN61010 1 IEC60601 1 IEC61010 1 CSA22 2 no 601 1 where the incoming wiring earth is intended for connection as the main protective earthing conductor and where the terminals for such a connection is not supplied on a component or subassembly such as a terminal block the user shall add an appropriate label displaying a protective earth symbol in accordance with 60417 2 IEC 5019 directly adjacent to the terminal The label should be durable and legible and should withstand the 15s rub test as per UL60950 1 section 1 7 15 Mounting The unit can be mounted using the bottom or side mounting points Each mounting point accepts an M4 screw where the maximum penetration inclusive of 1 75 mm chassis thickness should never exceed 4 00 mm The maximum torque for the M4 screws is 1 50 Nm Other e To prolong the life of the unit use in a dust free environment If units are damaged during transit contact your sales agent or Vox Power and DO NOT apply power to the unit Always use adequately sized cables and ensure good crimp connections Use cable supports to minimise stress on connectors Avoid excessive shock or vibration General installation parameters e Equipment class I e Installation category IT e Pollution degree 2 e Material group IIIb Indoor use only e Flammability rating 94V 2 IP rating IP10 e RoHS compliance 2002 95 EC Theory of operation The diagram below outlines the topology and major internal comp
13. ITY FITNESS FOR PURPOSE MECHANTABILITY OR CONDITION OF THE PRODUCTS AND WHETHER EXPRESS OR IMPLIED BY STATURE OR COMMON LAW OR OTHERWISE ARE EXCLUDED Document DOC6100 rev 01
14. NEVO 600 series User Manual The NEVO series user manual has been prepared by the Vox Power design team to assist qualified engineers in correctly implementing the product and to achieve the best reliability and performance At time of print the information contained in this document is believed to be correct and accurate However specifications are subject to change without prior notice and Vox power will not be liable for any damage caused as a result of the information within this document For continued product improvement please report any errors contained in the document to Vox Power Ltd NEVO series overview The NEVO600 switch mode power supply series offers truly unrivalled power density providing 600 W at 25 W in in a 5 x 3 x 1U package It is the ultimate power solution for system designers as they address the pressing demands for more power within less space Providing multiple isolated outputs the series carry full UL60601 34 Ed NEVO 600M only and UL60950 safety approvals The basic system consists of an input module together with up to four fully isolated output modules all supplied with advanced remote voltage and current programming functionality as standard The input module delivers up to 600 W of output power and has 4 slots each capable of separately delivering up to 150 W A 5 V 200 mA medically isolated bias supply together with an AC OK signal and a global inhibit signal that can disable all outputs simult
15. V 15 45 9 Om Vmax V 7 5 15 30 Vivo Vovp V 9 5 17 32 S z TRarep A 25 15 7 5 5 D A Tocp A 27 5 16 5 8 25 4 g luiccup z 8 Vurccup V 1 2 4 TN aii a 7 Turccup A 22 132 6 6 EE Praten W 125 150 150 REG VHICUP Ppeak W 187 5 225 225 T T T gt d Pi 4 Current Output voltage adjustment Each output can be adjusted within the range as described in the table above or in the datasheet Voltage adjustment can be achieved by two methods 1 Manual potentiometer adjustment Using the manual adjust potentiometer the preset output voltage Vser of each output module is adjustable over the entire range Of Vin to Vmax as specified in the power profile table above A clockwise rotation of the potentiometer results in an increase of the output voltage while an anti clockwise rotation results in a decrease of the output voltage 2 Remote voltage programming Using remote voltage programming the output voltage may be adjusted beyond the Vum and Vmax range specified in 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 Vo in the table above and if the output voltage exceeds this threshold the entir
16. aneously comes as standard on all models Output modules are currently available in single output types with models covering voltage ranges from 1 5 V to 60 V and currents up to 25 A All outputs are parallelable and seriesable resulting in a voltage range of up to 240 V and a maximum current of up to 100 A from a single chassis By selecting the correct output modules a custom power solution can be configured in a few minutes This instantly available custom solution offers industry leading power density total system efficiencies of up to 89 and suits all types of applications including industrial medical aerospace military and telecoms Contents NEVO SENES OVERVIEW EEUE SE EE ke Ge N Ge se vue EG N DE AE 1 Part numbers and ordering information seke ee EE RR RE RE ER RR RR EE RR Re RR RR Re ee Re GE ee 3 Installation Notes EES EE GES GE Ge DE de OS GE OE ER De AG EG Pe 4 THEG of opera ss ES ES GE GE GE E ee 5 TAPUE module operation EE EG Ge GE EG Ge GE EG Ge Ge GE De AA 6 SIQMANNMG EE EE OR ER A AT 9 Output Module Obed HO EG OE EG GR EG RE Ge EG ER GO Gee De 11 Adv nced output moddle FES EU Fes EE o i e eiiiai aiiai 14 Sale gehn Br a EE EE OEO EOE O E E A Ge E EG Ee 17 Paralele d Out HIE arene Aaaa aaia aa E 18 Mechanical dimensions and mouNtING ee eke EE EE ER RR ER EE RR Re RE RR Re eee RR Re ee ee Ge ee 22 COMME CEORS SR Br RS OG GE ee Ge GE GE Ge ANA ANE NANE DOD ee Ge 23 GoniieUuririd yor power SUDO IY EE IE SR aa be ER G
17. e aa ee DA Gee 24 SIE si GE SE EE ES EE GE GO GE eee ae ee Ge ne ee 25 EMC ornpliari e tortie iiei Ge Ge N RE N N OR RR EG N ie 27 Part numbers and ordering information INPUT MODULES Model Details O OUTPUT MODULES Model Nominalvoltage Rated current Rated Power Adjustment range Loadregulation Line regulation OVP ET Wees Ee TA MET FI EE ET 4 5V 15V 100mV 0 1 Vnom A sa asem asmates Re aa ae aa sw ase gom omtnem e ps woa a wa vw ow O o w e woa a wo rewvsvehh sov onom wv COo vexo a ww vw PART NUMBERING SYSTEM E Leakage Current Current Use 0 for unused slots S ease Current Blanking plates will be M Medical inserted at factory Slot A Output Slot D Output Slot B Output Slot C Output When initially ordering non nominal voltage settings add Voltage after each output where a special voltage setting is required E g If 3 30Vdc is required in slot B and all other slots require nominal voltages then use The factory will then issue a 3 digit code for your specific configuration that can be used for all future orders of the same configuration When ordering an input unit with no outputs inserted simply order NEVO 600M or NEVO 600S Installation Notes This power supply is intended for use within equipment or enclosures which restricts access to authorised personnel only The instructions in this manual a
18. e chassis will be latched off To resume operation of the unit disconnect the AC input voltage for 2 minutes remove the faulty output module and reconnect the AC input voltage Note that no warning is given on the AC_OK signal for faults of this type Over Current amp Short Circuit Protection OCP amp SCP For increased safety and reliability all output modules in the NEVO series have over current and short circuit protection The over current threshold is typically set at 110 of the rated current and has a constant current straight line characteristic that reduces the output voltage as the load resistance decreases If the output voltages falls below the hiccup voltage threshold Vurccup the module enters short circuit protection mode In this mode the output module uses a hiccup scheme to reduce system losses and potential damage When in this mode the output will be enabled for approximately 3 of the time disabled for 97 and will attempt to restart at approximately 125 ms intervals The module remains in this state until the short circuit condition is removed at which point the module returns to normal operation Reverse Current Protection RCP The standard output modules use synchronous rectification in the output stages to achieve high efficiency and as a result the outputs can both source and sink current The sink current is internally limited to approximately 6 of the maximum rated current However in applications where the o
19. e that only the positive sense terminal is protected and diodes should be used in the positive connection only Paralleled remote voltage current adjust The simplest way to achieve remote voltage current programming with paralleled outputs is to operate the modules in share parallel mode Follow the procedure outlined earlier to configure the outputs in share parallel mode and once configured in this mode all the Vcontrol and COM pins can be connected together Remote voltage current programming can then be performed exactly as with a stand alone module It is not recommended to use remote voltage current programming in normal parallel mode Output Module LOAD Output Module 2 lout Vtrim COM WARNING Care must be taken to avoid differential voltages between the negative power output terminals of the paralleled modules as this can cause errors at the control pins To avoid this it is recommended that a low impedance connection be made between the negative power terminals close to the PSU output and cables then connected from this common point to the load Mechanical dimensions and mounting Screw type Tightening Penetration depth 5 AQ TE a N ane a A L p jj Nea E Earth L Live SCREWS M4 Tighten to 1 5 Nm 4 00mm max including chassis OUTPUT MODULES
20. emote adjustments of the output voltage using the ACOK 10 Vcontrol and Icontrol pins do not change the PG signal threshold The PG threshold is always approximately 90 of the voltage set with the manual potentiometer COM 12 Outputs Output I nhibits I NH1 I NH4 GI NH I nput The signals circuit provides four inhibit inputs to disable each output module individually and a fifth global inhibit input GINH to inhibit all modules simultaneously 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 Typically tor 100 us and ton 8 ms To inhibit each output module individually GINH should be connected to COM and 5V applied to the appropriate input INH1 2 3 4 To start with all outputs inhibited and then enable them individually GINH should be connected to 5V then pull down the appropriate input INH1 2 3 4 If GINH is left unconnected then INH1 2 3 4 will all behave as global inhibit inputs i e 5V on any INH input will disable all outputs _ GINH 8 INH1 2 INH2 4 INH3 6 INH4 8 Inhibit COM 12 Output module operation Power profile The power profile diagram below is a voltage current plot that together with the associated table provides details of the main features of the currently available output modules VovP Parameter VAK PERK Vnom V 5 12 24 Ven
21. erence is termed open sense offset and occurs due to internal bias currents in the sensing circuit Factory set units are set with the sense cables connected unless otherwise specified Local Bias supply A local non isolated 5 V bias supply is provided on each output module 5 V on J5 6 referenced to COM on J5 5 This supply is intended to power interface circuits for monitoring and controlling the output modules such as amplifying the current output signal as described earlier The output can supply up to 10mA maximum and exceeding this can damage the unit Also as COM is connected to an internal voltage that is NOT equivalent to S or V particular attention must be given to grounding issues when interfacing COM to any control circuit in the application Connecting COM to S or V may result in damage to the unit Seriesed outputs NEVO output modules of the same type can be seriesed in any number to achieve higher output voltages even across multiple chassis The following instructions must be followed for output modules configured in this manner WARNING Energy and voltage hazards may arise when individual modules are seriesed See the Safety section for more details solation to ground Care must be taken not to exceed the output module isolation to chassis ground when seriesing outputs Each output is rated for 250 volts maximum between each output terminal and chassis ground Exceeding this voltage may damage the unit
22. es with combined energy ratings greater than 240 VA may cause energy hazards The equipments manufacturer must provide additional and adequate protection to service and technical personnel Always remove the power before handling the unit During operation the external surface of the unit can become hot Leave to stand for 10 minutes to allow the unit to cool down before handling the unit Dangerous voltages are present within the power supply Covers may only be removed by qualified personnel when the power supply has been disconnected from the mains supply voltage for more than 3 minutes Covers must be replaced and all screws secured properly before reconnecting to the mains voltage Parameter Details Isolation voltage Input to Output 4000 Vac Input to Chassis 1500 Vac Output to Chassis 250 Vdc Output to Output 250 Vdc Isolation clearance Primary to Secondary Reinforced 7 mm Primary to Chassis Basic 2 5 mm Isolation creepage Primary to Secondary Reinforced 12 mm Primary to Chassis Basic 4 mm Leakage current Medical 265 Vac 63 Hz 25 C 300 A Standard 265 Vac 63Hz 25 C 1500 5 Agency Approvals cURus Demko CB Certificate Standards IEC EN60950 1 UL60950 1 CSAC22 2No 60950 1 03 IEC EN60601 1 3 ED UL60601 1 3 ED CE Mark LVD 73 23 EEC Agency File Numbers UL E316486 EMC compliance TO Support compliance of the final system design with the EMC directive 89 336 EEC the NEVO PSU has been designed and tested to
23. gulated monotonic start up with a rise time of approximately 3 ms as shown in the diagram right The power good signal stays low until the voltage exceeds the power good threshold 290 Where multiple output modules are used the default start up scheme is ratio metric with all outputs starting at the same time as shown in the diagram right External control circuits may be used to implement ad tracking or seguenced start up if necessary SS ms 48 The outputs are not designed to start into a pre biased load and may discharge any externally capacitance before beginning to ramp the output voltage up in the normal way At shutdown the outputs enter a high impedance state Where no external load is present it may take some time for the voltage to decay When driving inductive loads care must be taken to limit the voltage at the 12V output terminals so as to prevent damage to the unit Synchronisation All output modules in the same chassis are synchronised The typical operating frequency is 260kHz and paralleled seriesed units will not produce beat frequencies Ripple and Noise The ripple and noise figures stated in the datasheet are defined based on a standard measuring method To obtain the same results the same test setup must be used and care must be taken to eliminate any parasitic noise pickup The diagram below shows details of the setup and also sources of noise pickup 50 Ohm coax soldered directly across
24. input module is operating correctly To ensure safety the following abnormal conditions may cause the entire unit to latch off which will disable the 5V bias supply e Over temperature of any part of the unit e Over voltage on the output e Internal over current device failure AC mains signal ACOK Output An ACOK signal is provided to indicate to the user that the AC mains voltage is applied and the input module is operating correctly The output signal is driven from an internal operational amplifier as shown in the following diagram Under normal operating conditions this signal gives a warning of Sms before the output voltage falls below the power good threshold However to ensure safety the following abnormal conditions may cause the entire unit to latch off without an ACOK warning e Over temperature of any part of the unit e Over voltage on the output e Internal over current device failure Power Good signals PG1 PG4 Output Each output module provides a power good PG signal to indicate when the output voltage is above approximately 90 10V of the preset voltage for that module Each PG signal on an output module is internally connected through an opto isolator to the signals circuit which buffers the signal through a PNP transistor with a 10k pull down resistor as shown 5V 11 PG1 1 PG 3 The LED on the front of each module gives a visual PG3 5 confirmation of the PG status PG4 7 Note that r
25. it instead of a voltage source to adjust the current limit while continuing to use an amplifier to measure the output current An example circuit is shown above right In this case Ver will control the current limit while the amplified Icontroi signal will provide a measurement of the output current Remote sensing Remote sensing is available on all output modules and can be used to compensate for any voltage drop in the main power leads between the power supply and the load To implement remote sensing connect the positive sense pin S connector J5 2 to the positive side of the remote load and the negative sense pin S connector J5 1 to the negative side of the remote load The voltage will be regulated at the points where the sense cables are connected Twisted sense cables Active protection against worn out power cables or accidental power cable removal is provided and prevents damage to the unit in each case An internal circuit measures the voltage between S to V and S to V when this voltage exceeds the thresholds specified in the datasheet the output voltage is 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 diff
26. module SELV precautions Where series combinations of output modules exceed 60 V the output can no longer be considered SELV Safety Extra Low Voltage and hence the final equipment manufacturer must provide suitable protection for both users and service personnel Paralleled outputs NEVO output modules of the same type can be paralleled in any number within the same chassis to achieve higher output Currents WARNING Energy hazards may arise when individual modules are paralleled See the Safety section for more details For best performance the output voltages of each paralleled module should be adjusted as close as possible Follow the procedure below to achieve the most accurate results Output Module Output Module Output Module A B Cc S V V S lout S V V S lout S V V S lout Voltmeter Voltmeter 1 Connect all the negative power cables together 2 Adjust the first module A to the desired voltage 3 Connect a voltmeter between the positive terminal of the first module A and the positive terminal of the second module B and adjust the second module B until the voltmeter reads 0 000 volts 4 Repeat step 3 for the remaining modules always using the positive terminal of the first module A as the reference When paralleled the outputs can operate in two distinct modes Normal parallel mode or Share parallel mode Normal parallel mode For normal parallel mode the positive power cables should be co
27. must exceed maximum short circuit output current Eg Output 1 25A 1 25 31 25Amps 2 Direct equivalents may be used for any connector parts 3 All cables must be rated 105 C min equivalent to UL1015 Configuring your power supply The NEVO600 power supply is designed to be used as part of an end system in a restricted environment and therefore should only be accessible to qualified and trained personnel Persons attempting to configure a unit must have the necessary knowledge and training before doing so Incorrect configuration may cause damage to the power supply and may affect the warranty of the power supply Output power modules may be added replaced or moved by strictly following the sequence of operations described below Please contact Vox Power or your distributor for assistance in configuring your power supply STEP 1 Remove the power connection and all other connections from the power supply WARNING Leave the unit to stand for a minimum of 3 minutes after removing all power and other connections from the unit before attempting to configure or re configure the power supply Always remove the power before handling the unit During operation the external surface of the unit can become hot Leave to stand for 10 minutes to allow the unit to cool down before handling the unit Dangerous voltages are present within the power supply Covers may only be removed by qualified personnel when the power supply has been disconnec
28. nd all warning labels on the product must be followed carefully Safety All power supplies must be installed correctly in a controlled environment which restricts access to any unauthorised personnel Equipment and system manufacturers must protect service personnel against unintentional contact with the output terminals Hazards If series and or parallel combinations of outputs exceed safe voltage and or energy levels the final equipment manufacturer must provide appropriate protection for both users and service personnel Health and safety To comply with section 6 of the health and safety at work act a label that is clearly visible to service personnel must be placed on the final equipment which warns that surfaces of the power supply may be hot and should not be touched when the product is operating Fusing The power supply has internal single pole fusing in the L Live line Servicing The power supply contains no user serviceable parts Repairs must be carried out by authorised personnel only Contact Vox Power Ltd for further information Cooling For proper cooling of the power supply the air intake and outlet must not be impeded Allow 50 mm clearance at both ends and position cabling appropriately Avoid excessive back pressure in the general system or when using ducting to navigate hot air out of the system Earth terminal marking To comply with the requirements of UL60950 1 EN60950 1 IEC60950 1 CSA22 2 no 60950 1 UL60
29. nnected together and the negative power cables should be connected together No other connections are required as shown in the diagram below Output Module Output Module Output Module A B c S V V S Ictri S V V S Ictri S V V S Ictri Volts ImaxA ImaxB ImaxC Amps In this mode the highest adjusted output module will supply all of the load current until it s current limit is reached If the load demand exceeds this level the output voltage will drop to the level of the next highest adjusted module and that module will begin to supply the load current while the first module continues delivering full current This process repeats for 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 modules 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 adjusted modules only delivering current during peak load demand Share parallel mode In Share parallel mode the outputs are paralleled as before and the Icontrol pin for each module is connected together as shown in the diagram below Output Module Output Module Output Module Mimi ara ee A B C Vet rr OE S V V S Ictri S V V S Ictrl S V V S Ictri Volts KA
30. onents of a fully assembled system Four output slots are provided and can be populated by any combination of output modules The remaining components in the block diagram are housed in the input module ACTIVE PFC BOOST STAGE OUTPUT SLOT D HOLDUP CAPACITOR RECTIFIER OUTPUT SLOT C amp ACTIVE INRUSH CONTROL ZVS TRANSFORMER DRIVE TRANSFORMER OUTPUT SLOT B SIGNALS ACOK INHIBIT POWER GOOD EMI FILTER OUTPUT SLOTA The input module is responsible for receiving the AC mains line voltage and converting it to an appropriate DC voltage whilst providing protection from AC line disturbances and preventing excessive EMI emissions and current harmonics The integrated EMI filter attenuates high frequency current emissions to levels below EN55022 class B It also provides single pole fusing in the live conductor and protection from line disturbances as outlined in EN61000 Inrush current is controlled 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 prevents overloading of the input stage while maintaining high power factor The output of the PFC stage charges the hold up electrolytic capaci
31. ply COM N E Circuit 2 Circuit 1 7 Ja Negative Output Ed l sa CIRCUIT 1 J5 Sense Sense Voltage Control Current Control Share Out COM 5V local bias supply MATING PART DETAILS DETAILS MANUFACTURER HOUSING TERMINAL J1 MAINS INPUT 3 Pin 5 08mm with Friction Lock 18 24 AWG MOLEX 010013036 8701031 J2 GLOBAL SIGNALS 12 Pin 2mm with Friction Lock 24 30 AWG MOLEX 511101260 503948051 J3 J4 1 OUTPUT POWER TERMINAL TAB SIZE 6 35mmx0 8mm VARIOUS VARIOUS J5 OUTPUT SIGNALS 6 Pin 1 25mm with Friction lock 28 32 AWG MOLEX 1510210600 30058800 Notes 1 Terminal and Wire current rating
32. s lengths and loop areas should be minimised Where cables must enter or exit the enclosure good high frequency 100nF decoupling capacitors of sufficient voltage rating should be connected to the cables as close to the entry exit point as possible For further details or assistance contact Vox Power Reliability The Nevo series has undergone extensive testing including HALT and Environmental testing Reliability data is collected on an ongoing basis Please contact Vox Power or your distributor for the most up to date reliability data Vox Power Ltd reserves the right to change or improve any part of the specification electrical or mechanical design or manufacturing process without notice Please consult your local distributor or contact Vox Power to ensure that you have the latest specification before using your product For other information relating to the use of the product please refer to the latest NEVO user manual Vox Power reserves the right to make changes without notice to any of its products Vox Power does not assume any liability arising out of the use or application of any of its products and of any information to the maximum extent permitted by law No license express or implied by estoppel or otherwise to any intellectual property rights is granted by this document or by any conduct of Vox Power VOX POWER DISCLAIMS ALL WARRANTIES AND REPRESENTATIONS IN PARTICULAR ALL OTHER WARRANTIES CONDITION OR TERMS RELATING TO SUITABIL
33. sholds are exceeded the entire unit may latch off with no ACOK warning To re enable the unit the AC mains must be disconnected for approximately 2 minutes Power derating NEVO600 units must always be operated within its stated operating limits Equipment manufacturers and other users must take appropriate deratings into account at all times when specifying a unit for the intended application If in doubt contact your sales representative or Vox Power for assistance There are two main deratings for NEVO power supplies temperature and input line voltage Temperature deratings apply to both input and output modules while line deratings apply only to the input module For temperature the derating for both input and output modules is 2 5 of maximum rated power per degree Celsius above 50 C While for input line voltage the derating for the input module only is 0 55 of maximum rated power per volt below 180Vrms These deratings can be calculated using the following conditional equations Input voltage derating Equation for line derating If Vin lt 180 Pout Prated Line derating factor 22 Prated 1 0 0055 180 Vin ee ge Otherwise Pout Prated 170 Input voltage l Temperature Derating Equation for temp derating If temp gt 50C 5 Pout Prated Temp derating factor O Prated 1 Temp 50 0 025 L O Otherwise Q Pout Prated 10 30 Temperature Depending on the application conditions
34. ted from the mains supply voltage for more than 3 minutes Covers must be replaced and all screws secured properly before reconnecting to the mains voltage STEP 2 Remove all screws There are 2 screws at the fan side 5 screws on the sides and 8 on the top 2 for each slot The lid can now be removed Ensure that all the output modules are loose from the lid before removing the lid Side x 5 STEP3 Once the lid is removed modules can be removed and replaced as required The 15 pin header on the output module plugs directly into the connector on the printed circuit board Each connector is keyed to prevent improper insertion Insert the output module and ensure it is pushed down properly Do not remove the plastic cover on the front end of the unit Plastic Cover STEP 4 Once the modules are replaced and the new configuration is complete and the lid can be closed again A blanking plate must always be used whenever a slot does not contain an output module Attach blanking plates to the lid before closing it Ensure the plastic cover is in place before closing the lid again When closing the lid ensure that each output module slots properly into its corresponding slot in the lid Insert all the screws and tighten to 1NM Do not over tighten Each Output Module must slot id ae properly into corresponding slot in lid WARNING Do not apply power to the power supply before replacing the lid
35. the following standards Parameter Standard Level Emissions Radiated electric field EN55011 EN55022 FCC B Conducted emissions EN55011 EN55022 FCC B Harmonic distorsion EN61000 3 2 Compliant Flicker and fluctuation EN61000 3 3 Compliant Immunity Electrostatic discharge EN61000 4 2 15 kV air 8 kV contact 4 Radiated RFI EN61000 4 3 10 V m 2 Fast transient burst EN61000 4 4 4 kV 4 Input line surges EN61000 4 5 1 kV L N 2 kV L E 3 Conducted RFI EN61000 4 6 10 V 4 Power freq Magnetic field EN61000 4 8 10 A m 3 Voltage dips EN61000 4 11 EN55024 Compliant For radiated and conducted emissions compliance of the final system relies on proper installation of the PSU component The installation guidelines detailed below should be followed Installation guidelines for EMC NEVO units should be mounted within a metal enclosure using the mounting fixtures provided If the application enclosure is not metal then a metal ground plate should be used to mount both the power supply and the load Decoupling the loads to the chassis or ground plate with suitably rated 100nF capacitors can assist in reducing emissions Both input and output cables should be fixed as close as possible to the ground plate or metal enclosure Also input and output cables should be separated as much as possible Output power and sense cables should be twisted pairs and routed parallel to each other Do not twist sense and power cables together All cable
36. tors which store enough energy to allow the system to continue operating during minor line disturbances These are the only electrolytic capacitors in the entire power supply and to further increase system reliability long life and high temperature capacitors are used A highly efficient zero voltage switching circuit is used to drive the medically isolated transformer from the hold up capacitors The output modules connect to the transformer secondary and provide safe isolated power to a high performance synchronous rectifier power converter which is controlled using the latest analog control technology to produce superior output performance in an extremely reduced size Input module operation Startup amp shut down The NEVO input modules operate from a universal input voltage range and start automatically upon application of adequate AC mains voltage gt 84Vrms After a short delay the global 5V bias supply starts and the ACOK signal goes high to indicate that the mains voltage is present and input stage is operating correctly Once the ACOK signal is high the output modules turn on and deliver power to the application loads The power good signals will indicate that the output voltages are within specification The diagram below shows the normal start up shut down sequence and gives typical timings AC Mains te d EE ty 5Vbias SR ta ty ACOK lt gt R t5 4 3 Output Voltage gt Typical timing values t 300 ms L
37. tput Define load efficiencies for each output module at the specified load and 220V Define change in efficiency from 220Vrms to 160Vrms for each output module Sum the values from step one and two for each output module Calculate the average efficiency for the total system 220 Load chart NE 220 160 Line chart Ex E220 AE 220 160 Eave Ej r E gt aie E iz 4 Signalling To reduce cabling in the end system all major input and output signals and the global 5V bias supply are wired to a single signals circuit that is accessed through the connector J2 located at the output side of the chassis as shown in the diagram below Description Power Good Inhibit Power Good Inhibit Power Good Inhibit Power Good Inhibit Global inhibit AC mains signal Global 5V Bias Common VO ON AU BRWN H e O N All of the signals are referenced to the bias supply common rail COM and external control and or monitoring circuits can be easily powered and interfaced to the PSU through this connector The entire signals circuit is fully medically isolated and can be considered a SELV output The table below lists the isolation voltages Signals isolation voltages Signals to Input Signals to Chassis Signals to Output 5V bias supply Power A 5V bias supply that can deliver up to 200mA is provided as standard on all units This supply is available whenever the AC mains voltage is connected and the
38. utput modules are connected to external power sources such as batteries or other power supplies certain precautions must be observed to prevent damage to the unit The outputs should never be directly connected to to external power sources without some form of reverse current protection such as an external diode or controlled mosfet If protection is not used large reverse currents which will ultimately result in damage to the unit will occur especially when the AC mains is disconnected Output module Average and Peak power All modules have an average and peak power rating The average power of each unit must at all times remain below it s specified limit However each output can deliver up to 150 of it s average power rating for a maximum of 5 seconds at 50 duty cycle subject to the current limit not being exceeded and subject to the overall average power drawn being less than the specified average power rating including any input derating due to temperature or line voltage The available peak power is a function of the output voltage and 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 amp Shut down All outputs are designed to have a re
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