industrial Environment AC-DC Converters >100 W VEW-Family 1500/3000 W AC-DC Converters VEW-Family 3 Phases Single output 110 V-AC and 230 V AC input * 3750: Ving input to. output isolation * Wide power range *. Excellent line/oad regulation High level of electromagnetic compatibility Safety. according to IEC 950. an @ Table of Contents Page TYPO SUIVEY oo. cccce cee teecnceeettaetesteserastereesenteeneaes 11-77 Description . Safety and Installation Instructions ............ceee 11-78 Electromagnetic compatibility EMC ......0. ee 11-79 Electrical input and Output Data .... we Operation IMstructions ......00. ce eee eeen eee eee Mounting Instructions ...0..00 ce eee ete eeeeenecnrenees Input and Output Terminais Immunity to Environmental Conditions ..........0.0.0.. 11-85 Mechanical Data ..........:c:ccccccessessecseseeeertcssesaesnertaees 11-86 Type Key and Product Marking ........0. cece 11-87 Type Survey Table 1: Type survey Output Input voltage range Rated power Type designation Us nom fe max lonom Gimin-. Gimax Ps tot {VOC} Ta = 50C [A] |. Ta = 60C [A] Ty: = 50C 2 300 210 VEW 1000: 600 W VEW 1000-02 600 420 85...132/170...265 V AC | 1200 W VEW 2100-02 5 300 210 jumper select 1500 W VEW 1000-05 600 420 1 and 3 phases 3000 W VEW 2100-05 12 125 87.5 VEW 2100: 1500 W VEW 1000-12 - 250 175 170...265 V AC 3000 W VEW 2100-12 15 100 70 3-phases only 1500 W VEW 1000-15 200 140 47...63 Hz 3000 W VEW 2100-15 24 63 44.1 PF = 0.95 1500 W VEW 1000-24 125 87.5 fo 3000 W _ VEW 2100-24 36 42 T 29.4 1500 W VEW 1000-36 pS | \ 48 | 32 22.4 1500 W VEW 1000-48 | | | 63 44.1 3000 W VEW 2100-48 i Description The VEW series of switching power supplies is a single out- put series of AC-DC converters. Compact size and high re- liability make the VEW series an excellent choice when a very low profile is required. Five standard single output rat- ings are available, all with universal input (auto selectable). The units are provided with inhibit control, programmable output voltage, sense lines and output undervoltage moni- tor. Key applications Factory automation, technical equipment, measuring appa- ratus, computer, display and communications equipment. Edition 1/96 - Melcher AG MELCHER 11-77 ar Be me| i... Output PF undervoltage t+) VEW-Family AG-DC Converters >100 W Industrial Environment ' L r Fuse 5 = V4 1 Loe 28 a 3 8 a == Eo 25 3 = | Fuse 5 & 3 > g LL . g ac = 5 3 E N Oo _ O) i ACG oc - Current p=") EG sharing ' oT | ; I vercurren P| protection REV OQ : WO i PWM com eo Oscillator | I So Overwoltage i ! i inhibi and therma O | control protection TOG | CNT OC * Only with 3-phases types Fig. 1 Block diagram Safety and Installation Instructions Safety If the cutput circuit of an AC-DC converter is operator-ac- cessible according to the IEC 950 related safety standards, it shall be an SELV circuit (Safety Extra Low Voltage circuit, i.e. a circuit, separated from mains by at least basic insula- tion, that is so designed and protected that under normal and single fault conditions, the voltage between any two conductors and between any conductor and earth does not exceec 60 V DC). in the following section an interpretation is provided of the IEC 950 safety standard with respect to the safety status of the outout circuit. However, it is the sole responsibility of the installer or user to assure the compliance with the relevant and apolicable safety standards: If the AC-DC converter is installed acoording to the relevant safety regulations, its output is considered to be an SELV circuit up to a nominal output voltage of 36 V, provided the output is connected to ground according to the relevant safety standard, a suitable input line fuse is installed and an adequate voltage limiting device is connected across the output. detection 7 Installation instruction Installation of the power supply must strictly follow the na- tional safety regulations. To observe the safety require- ments according to EN 6OS50/IEC 950, the module shall be connected via the female connector or terminal block. Other installation methods may not meet the safety require- ments. At least one external fuse, installed in the wiring to the input is essential! 11-78 MELCHER Edition 1/96 - Melcher AG The Power PartnersIndustrial Environment AC-DC Converters >100 W VEW-Family Electromagnetic compatibility EMC Immunity A metal oxide VDR together with an input fuse and an input but especially in battery driven mobile applications. The filter ferm an effective protection against high input tran- | VEW family has been successfully tested to the following sient voltages which typically occur in most installations, specifications: Table .2: Immunity type tests Electrostatic IEC 801-2 4 air discharge 15 kVp 1/50 ns 330 2 10 positive and yes | 1 discharge (1991-04) to frame 10 negative : discharges Fast transient/ | IEC 801-4 3 i/c, +if-i 2000 V, 5/50 ns 50.92 1 min positive yes | 1 burst (1988) 1 min negative bursts per coupling mode Transient IEC 801-5 4 i/c 4000 V, 1.2/50 ps 12Q | Spos.and5neg. |yes?| 1 (Draft 1993-01) impulses per | coupling mode ' Normal operation, no deviation from specifications 2 No load 3j = input, o = output, c = case Emission Internal input filtering keeps the conducted noise of the units within the frequency range of 10 KHz to 30 MHz below level B according to EN 55011 and EN 55022 standards (CISPR 11/22 respectively). Refer also to table "Input Data". Electrical Input and Output Data General Condition: T, = 25C unless otherwise specified. Table 3: Input data Uirate 1 Rated input voltage 100-120/200-240 jumper select 200-240 ' VAC u Input voltage range 85...132/170...265 jumper select | 170...265 ' f Line frequency 47...63 Hz fh Input current 2 100/200 V AC 22/11 -/8.4 A hor Inrush current (max.) 100/200 V AC 30/60 ~/40 PF | Power Factor? - 0.95 hieak Leakage current (max.) 100/200 V AC 0.6/0.8 -/1.0 mA Urri | Input RFI level EN 5501 1/22 B B : VEW 2100: three phases mains supply 2 At rated input and output Editior: 1/96 - Melcher AG MELCHER 11-79 Phe Power Partners mm| @... VEW-Family AC-DC Converters >100 W Industrial Environment General Condition: T, = 25C unless otherwise specified. Table 4a: Output data 1500 W types Type _| VEW1pe0-02 | VEW 1000-05 |v | Vews000-18 | Unit, Crasaoheeliie: ee ee nS | ae : Usnon | Output voltage 2 5 12 15 Vv ; Adjustable voitage range (progr.) +20 (0...120) % fy max Maximum output current 7, = 50C 300 i 300 125 100 A to nam | Nominal output current Ts = 60C 210 | 210 87.5 70 U, __| Ripple-noise * max. 100 | 100 200 200 | mVpp AUsii | Line regulation +0.4 % AU,; | Load regulation 0...100% +0.6 fot Overcurrent protection 2 105...130 |_Uo1 _| Overvottage protection 24.28 | 60.70 | 144.168 | 18.0..21.0 Vv lor Rise time ' max. 20 ms th min Hoid-up time ' 100/200 V AC 20/20 in Efficiency ' (typ.) 65 | 80 at | 82 % Remote sensing provided CNT |: Inhibit control (remote on/off) provided | PE DC power fail signal provided Outputs in series connection possible [ Outputs in parallel connection possible, with current sharing facility Cooling forced air (fan built in) General Condition: Ta = 25C unless otherwise specified Table 4b: Output data 1500 W types Type Re EW 1000-24 | VEW Unit Characteristics Peete - - Usnom | Output voltage 24 v | Adjustable voltage range (progr.) +20 (0...120) % lomax | Maximum output current 7, = 50C 63 42 32 A lonom | Nominal output current 7, = 60C: 441 29.4 22.4 Uy Ripple-noise ' max. 200 400 400 mVpp AUg. | Line regulation 85...264 V +0.4 % AU; + Load regulation 0...100% +0.6 lo Overcurrent protection 2 105...130 ) Us. Overvoltage protection 28.8...33.6 | 43.2...50.4 [ 57 6...67.2 Vv be Rise time ' max. 20 ms | tamin _ Hold-up time 1 100/200 V AC 20/20 n Efficiency ' (typ.) 83 | 83 | 84 % Ss Remote sensing provided CNT Inhibit control (remote on/off) provided | Pr DC power fail signal provided Po Outputs in series connection possible | Outputs in parallel connection possible, with current sharing facility j | Cooling forced air (fan built in) 4 1 At rated input and output 2 Constant current limiting with automatic recovery. However, after 30 sec overcurrent with output voltage below output voltage monitor threshold, the unit switches off and can only be turned on again by brief removal of the input voltage 3 Output will be shut down. Turn-on only by brief removai of the input voltage 11-80 MELCHER The Power Partners, Edition 1/96 - Melcher AGindustria! Environment AC-DC Converters >100 W General Condition: T, = 25C unless otherwise specified Table 4c: Output data 3000 W types VEW-Family Type | vewatoooz | Unit Characteristics ee a / : Us nom | Output voltage 2 5 12 Vv ; Adjustable voltage range (progr.) +20 (0...120) % lomax | Maximum output current 7, = 50C 600 600 250 A | fonom | Nominal output current Ta = 60C 420 420 175 U, Ripple-noise ' max. 100 100 200 mVpp AU,u | Line regulation 85...264 V +0.4 % Alp, | Load regulation 0...100% +0.6 | lot Overcurrent protection 2 105...130 Uo Overvoltage protection > 2.4.2.8 6.0...7.0 14.4...16.8 Vv lor Rise time ' max. 50 ms thmin | Hold-up time? 100/200 V AC 20/20 | 7 | Efficiency * (typ.) 65 80 81 % $ Remote sensing | provided CNT | Inhibit control (remote on/off) | provided PF DC power fail signal provided Outputs in series connection possible Outputs in paratiel connection possibie, with current sharing facility j Cooling forced air (fan built in) General Condition: T, = 25C unless otherwise specified Table 4d: Output data 3000 W types Us nor, | Output voltage 15 24 48 v Adjustable voltage range (progr.) +20 (0...120) % lomax | Maximum output current. Ts = 50C 200 125 63 A lonom | Nominal output current Ta = 60C 140 87.5 444 Us Ripple-noise max. | 200 200 400 mVpp AUyu | Line regulation 85...264 V +0.4 % AUs1 Load regulation 0...100% +0.6 Job Overcurrent protection 2 105...130 Uoe Overvoitage protection? 18...21 28.8...33.6 | 57.6...67.2 Vv tor Rise time ' max. 50 ms thmin | Hold-up time! 100/200 V AC 20/20 n | Efficiency (typ.) 82 83 | 84 % is | Remote sensing provided CNT | Inhibit control (remote on/off) provided _ . PF ' DC power fail signal provided , ; Outputs in series connection possible Outputs in paratiel connection possible, with current sharing facility L | Cooling forced air (fan built in} 1 At rated input and output 2 Constant current limiting with automatic recovery. However, after 30 sec overcurrent with output voltage below output voltage monitor threshold, the unit switches off and can only be turned on again by brief removal of the input voltage 3 Qutput will be shut down. Turn-on only by brief removal of the input voltage Edition 1/96 - Melcher AG MELCHER 11-81 The Power Partners. nm || .. VEW-Family AC-DC Converters >100 W industrial Environment Operation Instructions AC Input Voltage Range Selection The VEW 1000 models provide jumper selection. The VEW 2100 models require three phases mains of 3 x 170...265 V AC. Input Open Phase Detection (VEW 2100) lf one of the the three input line phases becomes open, or falls below 160 V AC, the output will be shut down within 5 seconds. The unit is reactivated by short removal of the in- put lines. Inrush Current Limiting Device This series is provided with an inrush current limiting de- vice. However it will not be operating if activated more than once in any 5 seconds. Output Power Rating The relation between the rated output power P, and the ambient temperature 7, is shown in fig. 2. If the power sup- ply is used at an ambient temperature of 10...60C, the output power is derated to 70% of the rated value. Output Voltage Adjustment The output voltage may be adjusted within +20% of Up nom by means of the internal potentiometer. If the output voltage setting should be excessively high, the overvoltage protec- tion circuit may shut-down the output. Sense Lines (S) Remcte sensing provides compensation of voltage drops between power supply and load, caused by connectors and load eeding wires. The sense lines should consist of shielded cables or be twisted. If remote sensing is not reqiured, the +S should be connected to the +V and the -S to the V terminals respectively applying shortest possible links. The compensation range is 20% Of Up nom- Output Undervoltage Monitor (PF) If the output voltage drops below 75...80% of its set value, the monitoring circuit consisting of an opto-coupler with an open collector output (Vce max = 30 V, Ic max = 20 MA), gen- erates across an external pull-up resistor a power fail signal (a logic "H", high signal). Output Overvoltage Protection, Fan Monitor If the built-in overvoltage protection circuit becomes active, the output is shut down and a reset can only be achieved by brief removal of the input voltage after a minimum interval time. VEW 2100: Should one of this built-in fans stop, the output is shut down and the output undervoltage monitor (PF) activated. Po [%} 100 70 50 QO 25 Th -10 0 10 20 30 40 50 60 70 [C] Fig. 2 Output power vs. ambient temperature Output Overload Protection An overload condition at the output will cause the protection circuit to turn into its foldback characteristic. After removal of overload, the unit will return to normal operation auto- matically. Therma! Protection If the temperature inside the module should exceed approx. 85...95C, the thermal protection circuit will shut down the power supply. Having turned-off and cooled down the power supply, it will automatically reset when re-powering the input. Inhibit (CNT, TOG) signal (TTL, CMOS etc.) or a mechanical contact applied to the inhibit input which is isolated from input and output by means of an opto-coupler. This provides independency from other voltages polarity. If the inhibit function is not re- quired, connect the inhibit input CNT to return pin TOG to enable the output (active low logic, fail safe). Table 5: Inhibit characteristics | Characteristic Conditions | min typ max | Unit ' Upn | Inhibit | Up=on | Usmin-.Usmex| ~0.7 08 V voltage | Up = off | 20 7 gn | Inhibit sink curr. Ugn= 0 35 mA =o : ! t a CNT Cinh ( E Vion Ni sTOG Fig. 3 Definition of inhibit voltage and current MELCHER Edition 1/96 - Melcher AG The Power PartnersIndustrial Environment AC-DC Converiers >100 W VEW-Family Outputs Connected in Series Two or more units supplying the same or different output voltages may be connected in series. The value of the maximum output current to be taken is defined by that unit providing the lowest current limiting value. It should be as- sured that the outputs do not feed backwards into each other caused by their different rise/fall times at switch-on/ off cycles by adding reverse polarity diodes across each output Outputs Connected in Parallel, Current Sharing (PC) Two or more units supplying equivalent output voltages may be connected in parallel to enhance the total output power. It has to be assured that ail output voltages are set to identical values before parallel wiring takes place. The load feeding fines should all be of identical specification. One o the PC pins of each unit should be interconnected with a C pin of the paraliel connected units. The units then show approximately equal load currents. % oO Programmable Output Voltage (PV, COM) Control by an extemal voltage: The output voltage can be externally controlled between zero and 120% of rated output voltage (0...120% regulation range) by applying an external control voitage between pins PV and COM. The relationship between contral volt- age and output voltage can be found in figure 4. Setting ac- curacy is within +2%. If the output voltage is regulated to below of 10% of nominal voltage, the output power has to be derated linearily to zero according to figure 5. Response time to control voltage changes is between 200...300 ms depending on load. The maximum contro! voltage change over time should stand below 1 V/ms. Attention: If this function is not used, short PV and REF pin! Control by an external resistor: The output voltage can be controlled by an external potentiometer connected to the pins PV, REF and COM as shown in figure 7. The pin REF is hereby feeding a control voltage. The regulation range is 0...100%. Should a range of 0...120% be necessary, then the output voltage must be set to the maximum by using the adjustment potentiometer 120 T : . | (short PV and REF pin betore doing so!} ~ Attention: If this function is not used, short PV and REF pin! 100 LL Master-Slave operation: 80 One unit can control the voltage of the other units by inter- & connecting them as shown in figure 8. o | s 2 60 Ley uel 2 | -S oI -s [@] a com [[@} - com [eH ra o 40 .___| eel eH ke} [ | REF ||@]] REF [1h | - Pv [eH + Pv [I@BH 20 T el T el 0 Fig. 6 Fig. 7 1 2 3 4 5 6 Control voltage Output voltage control by an external voltage Output voltage control by an external variable resis- Fig. 4 tor Programmable output voltage function folly nom p > PC + OF E SO PV Master ' hoot ' 100 sy Ree ~o L lo een ee ence ceeeee cee : | 80 Lo porrettceeecern cc eeeey 3 fSD PC + O a ' | 0) PV Slave Load 40 -O | Lo PUTT s secre | 20 OPC +O | 0 tal oto C PV Slave 20 40 60 80 100 ! A | . Output voltage (%) ' M4 Fig. 5 Nene eee ' Derating curve tor programmable output voltage Fig. 8 Master slave operation Edition 1/96 - Melcher AG 11-83 @) MELCHER the Fowes|e VEW-Family AC-DC Converters >100 W Industrial Environment Grounding Recommendations A single power supply should be wired to the AC input by interconnecting the ACG (AC Ground) terminal with the FG (Frame Ground) terminal and both together to the protec- tive earth. With several modules connected in parallel, EMC and leak- age currents in accordance with safety standard recom- mendations may no longer be met. In such cases, an exter- Input filter of VEW 1000 AC input: L AC input: N AC Ground: ACG Frame Ground: FG PS 1 PS 2 PS3 ACG ACG ACG Ln lFG| | LN /FG] | LN LFG Lojias 5< | | | Notas | 9 +o LL Fig. 9a Block diagram of VEW 1000 input filter and input wiring of paralle! connected modules using an external noise filter nal noise filter should be added in order to minimize RFI noise and to avoid summarization of the individual leakage currents caused by each module's filter. Therefore the ACG terminals (AC Ground) should not be connected. The FG terminals (Frame Ground) must be connected directly to the protective earth (see fig. 3a and 3b). Input filter of VEW 2100 AC input: 11 i " = AC input: L2 t = = } ' be / tik / :} ' Tr i. [ / t ACinput. 19 O+tst ie 1 = AC Ground: ACG eo + ' Frame Ground: FG O : PS 1 PS 2 PS3 L2 ACG L2 ACG L2 ACG u11L3iF@] {i+ lis !Fa] |i lL3!re Lio BS | L2o 5 0 i L | L30] tis C +0 Fig. 9b Block diagram of VEW 2100 3-phase input filter and input wiring of parallel connected modules using an external noise filter Mounting Instructions eee | |O Q| | |O CG} | O| _ 2! ol le ~A LL. EXC) 6 @ fo S-8 fee ors W277iT fire YIPLETTTTT ETT) ee tiat Mounting A Mounting B Mounting C Mounting D Standard not permissible Fig. 10 Mounting instructions Table 8: Output derating by mounting method PC} | MeuntingA | MountingB | 40 100% 100% 50 100% 100% 60 70% 70% 11-84 MELCHER Edition 1/96 - Melcher AG The Power PartaersIndusirial Environment AC-DC Converters >100 W VEW-Family Input and Output Terminals LED (on) AC input L AC input N 230 V AC: open [ A 115 VAC: short Fig. 17 Terminal designation of VEW 1000 / Ug adjustment : (potentiometer) B ' +8 Sense oa > ' Ol. TKK @ COM Return for PV REF Source for PV PV Output voltage control PC Current sharing TOG Return for CNT and PF | CNT Inhibit PF Power fail signal Ug adjustment (potentiometer) (me at) L1 AC input | 12 AC input {@5)} | 3 Ac input Co) | ACG AC Ground l @ LED (on) +5 Sense gS ga (@) - () 4+V bo (Oo) Sense COM Retum for PV REF Source for PV PV Output voltage control Gg as ga v co@O ae" ae Ns PC Current sharing TOG Return for CNT and PF & FG Frame Ground CNT Inhibit PF Power fail signal Fig. 12 Terminal designation of VEW 2100 Immunity to Environmental Conditions Table 7: Mechanical stress Damp heat Temperature: 40C Operating steady state Relative humidity: 30...95-3+2 % Shock (half-sinusoidal) Acceleration amplitude: 20 gn = 196.2 m/s? Operating Vibration (sinusoidal) Frequency (1 Oct/min): 10...55 Hz Operating Maximum vibration amplitude: 0.83 mm (55 Hz) Acceleration amplitude: 2 Gn = 19.6 m/s? | Test duration: 3h (1h each axis) Table 8: Temperature Ta | Ambient temperature U min... Ui max ! -10 60 C Tc | Case temperature Ts | Storage temperature fy = 0. oom -10 85 _ Te Not operational -30 85 | | Edition 1/96 - Meicher AG MELCHER 11-85 he Power Partners. a| i } 11.2 VEW-Family AC-DC Converters >100 W Industrial Environment Table 9: MTBF values MTBF | Ground Benign MTBF according to MiL-HDBK-217E i Te = 40C VEW 1 000 types _ 48'000 h VEW 2100 types 33'000 h Table 10: Isolation Test | Input to output | inputtocase | Output tocase | Unit | Electric strenght test voltage (1 min) VEW 200/440/1 000 3750 2500 500 VAC - Electric strenght test voltage (1 min) VEW 2100 2500 2500 500 | Isolation resistance (500 V DC) all types >100 >100 >100 | MQ Table 11: Safety approvals Safety Approvals PUL 1950") CSA 1402 | TUV' - VEW 1000-05, 24 x x x VEW 2100 - x - 1 EN 60590 Mechanical Data 3 Dimensions in mm. Tolerances +1 mm unless otherwise indicated. European Projection 300 + 1.0 151 260:+05 25 | 45 ~ t i a @ _6- | a 1 { | | a | | eo: i Bh of th e- e- 77.5 05 9.5x8=76 L115 see a = - | of | | 4-M8 g Tee & oo 8 (er OF Ae Boot 9 o 1 aa i 1 g ! B | | | , PBB + I bi o ! i ' | | 22 max S I \ 1 | | ef 9M | 8 3| 4@ ee ! , f) g = = i | | [oy a | ol Yoo 1 ee | i 5 q i ! { - | 6.8 aq ~ 4 | ! 21,530.50] 23 Fig. 13 VEW 1000, weight 7 kg 2gmax 11-86 MELCHER The Power Partners. Edition 1/96 - Melcher AGIndustrial Environment AC-DC Converters >100 W VEW-Family 300 + 1.0 451 260 +05 125 | 45 max ' | ot 6- 8 6- & oe S 5 Roe 1 4-M4 | M4 o oe e 260 105 ot = |. 8 as gi can Bo 1 1 po ' ! g 9 |! 1 ! I \ 1 | Ho 5 1 | fo) + g | g 1 b | a ! Ho o wo}g) fo ! oy jo! lslg ! ae | | : | i | i -" | ! ' & a | . I mo - 4-M4 on bottom side Lo Be =P o SoM 28m Fig. 14 VEW 2100, weight 14 kg Type Key and Product Marking Type Key VEW 1000 - 12 FAMily ccccccccccesssssssecssesssessesevceecsssessesseesesesittessenseseen VEW JS} |! BlAINK ooo. eee ce ete ete cen eens ceeeseeeeseaecneeteneettasensesneseneeenstaeees Nominal output power [W] .....0. eee 1000, 2100 | DSN ieee ccenee teens ene ecenereesnemaerserieseteeceereenaeeantatrages Nominal output voltage [V] .....0.0. cece creer 2...48 _ Example: VEW 1000-12 = AC-DC converter providing 12 V/125 A, 1500 W output, output undervoitage monitor and inhibit control. Produkt Marking Label: Type designation, applicable safety approvals and recognition marks, specific type designation, input voltage range, nominal output voltage and current and pin allocation. Edition 1/96 - Meicher AG MELCHER 11-87 The Power Partners. mi