Cassette Style
100 Watt AC-DC Converters
S Series PFC
100 Watt AC-DC Converters with PFC
Input voltage range from 85...264 V AC
1 or 2 isolated outputs up to 48 V DC
4 kV AC I/O electric strength test voltage
•
Universal input voltage range
•
Power factor
>0.95,
harmonics
<IEC/EN
61000-3-2
•
Input over- and undervoltage lock-out
•
Efficient input filter and built-in surge and transient
suppression circuitry
•
Fully isolated outputs
•
Outputs overload, open- and short-circuit proof
•
No derating over entire operating temperature range
Safety according to IEC/EN 60950
LGA
S Series
111
4.4"
3U
60
2.4"
12 TE
168
6.6"
Summary
The S 4000/S 5000 series of AC-DC converters represents
a flexible range of power supplies for use in advanced elec-
tronic systems. Features include full power factor correc-
tion, high efficiency, high reliability, low output voltage noise
and excellent dynamic response to load/line changes.
The converter inputs are protected against surges and tran-
sients occurring at the source lines. An input over- and
undervoltage lock-out circuitry disables the outputs if the
input voltage is outside the specified range. Inrush current
limitation is included preventing circuit breakers and fuses
from being damaged at switch-on.
All outputs are overload, open- and short-circuit proof and
are protected against overvoltages by means of a built-in
suppressor diode. The outputs can be inhibited by a logic
signal applied to the connector pin 18 (i). If the inhibit func-
tion is not used pin 18 must be connected to pin 14 to en-
able the outputs.
LED indicators display the status of the converter and allow
visual monitoring of the system at any time.
Full input to output, input to case, output to case and output
to output isolation is provided. The modules are designed
and built according to the international safety standards
IEC/EN 60950 and have been approved by the safety
agencies LGA (Germany) and UL (USA). The UL Mark for
Canada has been officially recognized by regulatory au-
thorities in provinces across Canada.
The case design allows operation at nominal load up to
71°C in a free air ambient temperature. If forced cooling is
provided, the ambient temperature may exceed 71°C but
the case temperature must remain below 95°C under all
conditions.
A temperature sensor generates an inhibit signal which
disables the outputs if the case temperature
T
C
exceeds
the limit. The outputs are automatically re-enabled when
the temperature drops below the limit.
Various options are available to adapt the converters to in-
dividual applications.
The modules may either be plugged into 19" rack systems
according to DIN 41494, or be chassis mounted.
Important:
These products are intended to replace the LS 1000 and
LS 2000 in order to comply with IEC/EN 61000-3-2.
Table of Contents
Page
Page
Electromagnetic Compatibility (EMC) ............................ 15
Immunity to Environmental Conditions ........................... 17
Mechanical Data ............................................................ 18
Safety and Installation Instructions ................................ 19
Description of Options .................................................... 22
Accessories .................................................................... 27
Summary .......................................................................... 1
Type Survey and Key Data .............................................. 2
Type Key .......................................................................... 2
Functional Description ...................................................... 3
Electrical Input Data ......................................................... 4
Electrical Output Data ...................................................... 6
Auxiliary Functions ......................................................... 11
Edition 01/01.2001
1/27
Cassette Style
Type Survey and Key Data
100 Watt AC-DC Converters
S Series PFC
Non standard input/output configuration or special custom adaptions are available on request. See also:
Commercial Infor-
mation: Inquiry Form for Customized Power Supply.
Table 1: Type survey LS
Output 1
U
o nom
I
o nom
[V DC]
[A]
2
5.1
12.0
15.0
24.0
24.0
3
30.0
3
48.0
3
12.0
15.0
24.0
1
2
Output 2
U
o nom
I
o nom
[V DC]
[A]
2
Input Voltage Range
U
i min
...U
i max
85...255 V AC
6
LS 4001-7R
LS 4301-7R
LS 4501-7R
LS 4601-7R
LS 5320-7R
LS 5540-7R
LS 5660-7R
Efficiency
1
h
min
[%]
77
81
83
83
81
81
81
81
81
81
3
Options
16.0
8.0
6.5
4.2
4.0
3.2
2.0
4.0
3.2
2.0
12.0
4
15.0
4
24.0
4
4.0
3.2
2.0
-9
E
D
V
5
P
T
B1
B2
LS 5320-7R
LS 5540-7R
LS 5660-7R
Efficiency at
U
i nom
and
I
o nom
.
If the output voltages are increased above
U
o nom
via R-input
control, option P setting, remote sensing or option T, the output
currents must be reduced accordingly so that
P
o nom
is not ex-
ceeded.
4
5
6
Series connection of output 1 and 2, see:
R-Function for differ-
ent output configurations.
Second output semi-regulated.
Option V for LS 4000 types with 5 V outputs.
For DC-input please ask your local Power-One partner.
Type Key
Type Key
Input voltage range
U
i
: 85...255 V AC .............................. L
Series ............................................................................... S
Number of outputs (4 for single, 5 for double outputs) 4...5
Single output units:
Nominal voltage output 1 (main output),
U
o1 nom
5.1 V .................................................... 0, 1, 2
12 V ............................................................. 3
15 V ......................................................... 4, 5
24 V ............................................................. 6
other voltages .......................................... 7, 8
Other specifications for single output modules ....... 01...99
Symmetrical double output units:
Nominal voltage output 1/output 2,
U
o1/2 nom
12 V/12 V
1
(24 V series conn.) .................. 20
15 V/15 V
1
(30 V series conn.) .................. 40
24 V/24 V
1
(48 V series conn.) .................. 60
other symmetrical voltages ................. 70...99
Operational ambient temperature range
T
A
:
–25...71°C .................................................. -7
–40...71°C .................................................. -9
customer specific .................................. -0...-6
Auxiliary functions and options:
Inrush current limitation ............................... E
Output voltage control input ........................ R
2
Potentiometer (output voltage adjustment) .. P
2
Save data signal (D0...DD, to be specified) D
3
ACFAIL signal (V2, V3) ................................ V
3, 4
Current sharing ............................................ T
Cooling plate standard case ...................... B1
Cooling plate for longe case 220 mm ........ B2
1
L S 5 5 40 -7 E R P D V T B1
2
3
4
External wiring of main and second output depending upon the desired output configuration (see:
R-Function for different output con-
figurations).
Feature R excludes option P and vice versa.
Option D excludes option V and vice versa.
Option V available for LS 4000 types with 5V output.
2/27
Edition 01/01.2001
Cassette Style
Functional Description
100 Watt AC-DC Converters
S Series PFC
The input voltage is fed via an input fuse, an input filter, a
rectifier and an inrush current limiter to a single transistor
boost converter. This converter provides a sinusoidal input
current (IEC/EN 61000-3-2, class D equipment) and sour-
ces a capacitor with a voltage of 360-370 V DC. This ca-
pacitor sources a single transistor forward converter.
Each output is powered by a separate secondary winding
of the main transformer. The resultant voltages are rectified
and their ripples smoothed by a power choke and an output
filter. The control logic senses the main output voltage
U
o1
and generates, with respect to the maximum admissible
output currents, the control signal for the primary switching
transistor.
The second output of double output units is controlled by
the main output, but has independent current limiting. If the
main output is driven into current limitation, the second out-
put voltage will fall as well and vice versa.
P
03001
Forward converter (approx. 80 kHz)
26
N∼ 28
1
Y
Boost converter (PFC)
Input filter
360 V DC
4
Output
filter
C
i
+
Y
Control circuit
16
18
20
22
12
4
6
8
10
R
i
D/V
T
S+
Vo+
3
Y
Vo–
2
P~ 30
32
24
Y
14 S–
Fig. 1
Block diagram of single output converters LS 4000
P
–
+
03002
Forward converter (approx. 80 kHz)
N~ 26
28
1
Y
Boost converter (PFC)
Input filter
Output 1
filter
C
i
+
360 V DC
4
Y
Control circuit
16
18
20
22
R
i
D
T
12 Vo1+
14 Vo1–
4
Vo2+
6
8
Vo2–
10
3
Y
P~ 30
32
Y
24
Y
Output 2
filter
2
Y
Fig. 2
Block diagram of symmetrical double output converters LS 5000
1
2
3
4
–
+
Transient suppressor (VDR)
Inrush current limiter (NTC or Opt. E), -9 versions exclude the NTC
Input fuse
Hold-up capacitor
Edition 01/01.2001
3/27
Cassette Style
Electrical Input Data
100 Watt AC-DC Converters
S Series PFC
General Conditions
–
T
A
= 25°C, unless
T
C
is specified.
– Pin 18 connected to pin 14,
U
o
adjusted to
U
o nom
(option P); R input not connected.
– Sense line pins S+ and S– connected to Vo+ and Vo– respectively.
Table 2: Input data
Input
Characteristics
Conditions
min
85
230
0.55
9.0
3.5
480
3200 4000
80
EN 55022
U
i nom
,
I
o nom
–400
–400
100
B
B
400
400
V DC
V
p
120
µF
10
5
mΩ
A
rms
W
LS
typ
max
255
Unit
V AC
3,4
U
i
U
i nom
I
i
P
i0
P
i inh
R
i
R
NTC
C
i
U
i RFI
U
i abs
Operating Input voltage
Nominal Input voltage
Input current
No-load input power
Idle input power
Input resistance
NTC resistance
2
Input capacitance
Conducted input RFI
Radiated input RFI
Input voltage limits
without damage
I
o
= 0...I
o nom
T
C min
...T
C max
U
i nom
,
I
o nom 1
U
i min
…
U
i max
unit inhibited
T
C
= 25°C
1
2
3
4
With double output modules, both outputs loaded with
I
o nom
.
Valid for -7 versions with NTC, (-9 versions exclude the NTC). Initial switch-on cycle. Subsequent switch-on/off cycles increase the in-
rush current peak value.
AC frequency range 47...63 Hz.
For DC-input please ask your local Power-One partner.
Input Fuse
A fuse mounted inside the converter protects the module
against severe defects. (If operated from a DC-source this
fuse may not fully protect the module when the input volt-
age exceeds 200 V DC! In applications where the convert-
ers operate at source voltages above 200 V DC an external
fuse or a circuit breaker at system level should be installed!)
Reverse Polarity Protection
Should the input voltage to the unit be supplied from a DC
source the built-in bridge rectifier provides reverse polarity
protection. (For DC-input operation, please consult your lo-
cal Power-One partner.)
Inrush Current Limitation
The modules of the versions -7, incorporate an NTC resis-
tor in the input circuitry which – at initial turn on – reduces
the peak inrush current value by a factor of 5...10 to protect
connectors and switching devices from damage. Subse-
quent switch-on cycles within short periods will cause an
increase of the peak inrush current value due to the warm-
ing-up of the NTC resistor. See also:
E option.
Inrush Current Peak Value
The inrush current peak value (initial switch-on cycle) can
be determined by following calculation:
U
i rms
•
√2
I
inr p
= ––––––––––––––––
(R
s ext
+
R
i
+
R
NTC
)
04001
Table 3: Fuse Specification
Module
LS
1
1
Fuse type
slow-blow
Fuse rating
SP T
4 A, 250 V
Fuse size 5
×
20 mm
Input Under-/Overvoltage Lock-out
If the input voltage remains below approx. 65 V AC or ex-
ceeds approx. 280 V AC an internally generated inhibit sig-
nal disables the output(s). When checking this function the
absolute maximum input voltage rating
U
i abs
should be
considered! Between
U
i min
and the undervoltage lock-out
level the output voltage may be below the value defined in
table:
Output data
(see:
Technical Information: Measuring
and Testing).
Input Transient Protection
A VDR together with the input fuse and a symmetrical input
filter form an effective protection against high input tran-
sient voltages.
R
s ext
I
inr p
R
i
R
NTC
C
i
U
i rms
Fig. 3
Equivalent circuit diagram for input impedance.
Edition 01/01.2001
4/27
Cassette Style
Input Inrush Current Characteristic
I
inr
[A]
100 Watt AC-DC Converters
Static Input current Characteristic
04006
S Series PFC
130
100
l
i
[A
rms
]
3
2.5
2
1.5
1
04005
U
i
= 255 V
rms
U
i
= 115 V
rms
50
0.5
50
100
150
200
250
U
i
[V AC]
300
Fig. 6
Input current versus input voltage at I
o nom
Power Factor, Harmonics
1
0
1
2
3
t
[ms]
Power factor correction is achieved by controlling the input
current waveform synchronously with the input voltage
waveform. The power factor control is active under all oper-
ating conditions.
Power Factor
1
0.95
04004
Fig. 4
Theoretical input inrush current versus time at U
i
255 V
rms
and 115 V
rms
, R
ext
= 0.
Harmonic Currents
The harmonic distortion is well below the limits specified in
IEC/EN 61000-3-2, class D.
I
i [mA/W]
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0
3
5
7
9
11
13
15
17
19
Harm.
Limit class D according
to IEC/EN 61000-3-2
04042
0.9
0.85
0.8
0.75
0.7
0
0.2
0.4
0.6
U
i
= 230 V AC
U
i
= 85 V AC
0.8
1
I
o
/I
o nom
Fig. 7
Power factor versus output current at U
i
230 V AC and
85 V AC.
Fig. 5
Harmonic currents at the input, IEC/EN 61000-3-2,
class D. U
i
= U
i nom
, I
o
= I
o nom
.
Edition 01/01.2001
5/27
PCB Design
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