Roal RCB600 Manuale utente

The RCB and MCB series user manual has been prepared

by the Roal Electronics design team to assist qualified engineers

in correctly implementing the products 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 Roal Electronics 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 Roal Electronics SpA.

RCB600 and MCB600 series overview

The RCB600 and MCB600 switch mode power supply series offers truly unrivalled power density, providing 600 W at 25 W/in3

in a 5” x 3”x 1U package. They are the ultimate power solutions for system designers as they address the pressing demands

for more power within less space. Providing multiple isolated outputs, the series carry full UL60601 (MCB600) and UL60950 2nd

edition (RCB600) 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 mains signal (AC_OK) and a global inhibit signal (GINH) that

can disable all outputs simultaneously, comes as standard on all models.

A built in fan, which speed is automatically controlled, ensures the unit proper cooling in any operating condition maintaining

at minimum fan RPM and, in turn, acoustic noise.

Output modules are currently available in single output types with models covering voltage ranges from 1.5 V to 58 V and

currents up to 25 A. All outputs can be connected in parallel or in a series resulting in a voltage range of up to 232 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.

RCB600, MCB600

User Manual

RCB600 AND MCB600 SERIES OVERVIEW

RCB600 and MCB600 series overview......................................................................... 1

Models and ordering information................................................................................ 3

Installation Notes .................................................................................................... 4

Theory of operation ................................................................................................. 5

Input module operation............................................................................................ 6

Signalling ............................................................................................................... 9

Output module operation.........................................................................................11

Advanced output module features.............................................................................14

Seriesed outputs ....................................................................................................17

Outputs in parallel configuration...............................................................................18

Mechanical dimensions and mounting........................................................................22

Connectors ............................................................................................................23

Configuring your power supply .................................................................................24

Safety...................................................................................................................29

EMC compliance……………………………………………………………………………………………………………………..27

Reliability ..............................................................................................................31

CONTENTS

Models and ordering information

The RCB/MCB600 part numbering system is easily comprehensible following the scheme in the table below.

A power unit part number can also be easily accessed through the descriptive label placed on its top surface (see picture

below). Simply add to the unit part number the letters visible through the lid holes following the order indicated by the lines.

Each letter identifies the selected output module fitted in the correspondent slot.

Part Number: MCB600-ABCC

The following table contains all the characteristic parameter of each Output Module, OP-x, and is a useful guide in identifying

the optimal configuration for every application.

Output

Module

Nominal

Voltage Rated

current Voltage

Adjustment Load

Regulation Line

Regulation OVP Output

Power

5 V

25.0 A 1.5 to 7.5 V ±50 mV ±0.1 %VNOM 9.5 V 125 W

12 V

15 A 4.5 to 15 V ±100 mV ±0.1 %VNOM 18 V 150 W

24 V

7.5 A 9 to 30 V ±150 mV ±0.1 %VNOM 36 V 150 W

48 V

3.75 A 18 to 58 V ±300 mV ±0.1 %VNOM 66 V 150 W

0 (zero)

Unused slots

Example: For an MCB600 with 5 V at 25 A (Module A in slot 1), 12 V at 12.5 A (Module B in slot 2) and 24 V at 12.5 A

(Module C x 2 in slot 3 and slot 4), use “MCB600-ABCC”.

CONFIGURATIONS AND ORDERING INFORMATION

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 and 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 authorized personnel only. Contact Roal

Electronics SpA 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, UL60601-1, EN60601-1,

IEC60601-1, 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

Mounting the unit can be done 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

To prolong the life of the unit, use in dust free environment.

If units are damaged during transit, contact your sales agent or Roal Electronics 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

Equipment class I

Installation category II

Pollution degree 2

Material group IIIb (Indoor use only)

Flammability rating 94V-2

IP rating IP10

RoHS compliance 2002/95/EC

INSTALLATION NOTES

Theory of operation

The diagram below outlines the topology and major internal components of a fully assembled system. Four output slots are

provided and can be populated by any combination of output modules (OP-A, OP-B, OP-C, OP-D). The remaining components

in the block diagram are housed in the input module.

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 (L) 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 EN61000-3-2. 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 capacitors 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 (ZVS) 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.

A built in fan, which speed is automatically controlled, ensures the unit proper cooling in any operating condition maintaining

at minimum its RPM and, in turn, acoustic noise. The control function directly correlate the fan supply voltage to the control

voltage derived from the half bridge current sense resistor. The secondary control input is derived from a non-linear

temperature sensor located near the rectifiers on the main board.

THEORY OF OPERATION

Input module operation

Start-up and shut-down

The RCB600 and MCB600 input modules operate from a universal input voltage range and start automatically upon application

of adequate AC mains voltage (>84 VRMS). 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.

Typical timing values: t1= 300 ms, t2= 50 ms, t3= 25 ms, t4= 15 ms, t5= 5 ms (minimum), t6= 100 ms

When the AC mains voltage is removed, the internal hold-up capacitors will supply power to the load for typically 20 ms (t4+t5)

at maximum power. The “ACOK” signal will go low at least 5 ms 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 100 ms, after the output modules have turned off.

Hold-up

For short line disturbances (<20 ms), 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.

Idle power

The idle power of the RCB/MCB 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 thresholds

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.

INPUT MODULE OPERATION

Power De-rating

The RCB600 and MCB600 units must always be operated within its stated operating limits. Equipment manufacturers and other

users must take appropriate de-ratings into account at all times when specifying a unit for the intended application. If in

doubt, contact your sales representative or Roal Electronics for assistance.

There are two main de-ratings for the RCB/MCB power supplies, environment temperature and input line voltage. Temperature

de-ratings apply to both input and output modules, while line de-ratings apply only to the input module.

For temperature, the de-rating 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 de-rating for the input module only is 0.83% (of maximum rated power) per

Volt below 120 VRMS. These de-ratings can be calculated using the following conditional equations;

Equation for line de-rating:

If Vin < 120 VRMS,

Pout = Prated*Line de-rating factor

= Prated*(1-(0.0083*(120-Vin))

Otherwise,

Pout = Prated

Equation for temperature de-rating:

If temp > 50 °C,

Pout = Prated*Temp derating factor

= Prated*(1-(Temp-50)*0.025)

Otherwise,

Pout = Prated

Depending on the application conditions, one or both of the de-ratings may apply. Where both apply, the de-rating factors

given above can be multiplied together to obtain the total derating factor.

Example: What are the RCB600 input and output module deratings at 60 °C at 100 V line?

Input power rating = Prated*Line de-rating factor*Temp de-rating factor

Output power rating = Prated*Temp de-rating factor

Line derating factor = (1-(0.0083*(120-Vin)) = (1-(0.0083*(120-100)) = 0.83

Temperature de-rating factor = (1-(Temp-50)*0.025) = (1-(60-50)*0.025) = 0.75

Input power rating = 600*0.83*0.75 = 373.5 W

Output B/C/D power rating = 150*0.75 = 112.5 W

Output A power rating = 125*0.75 = 93.75 W

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 an RCB/MCB600 over the full line voltage and load 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: Estimate the efficiency of an RCB600-AABC, at 160 VRMS input and 100 W load on each output?

1. Define load efficiencies for each output module at specified load and 220 VRMS.

2. Define change in efficiency from 220 VRMS to 160 VRMS for each output module.

3. Sum the values from step one and two for each output module.

4. Calculate the average efficiency for the total system.

Step Details Slot 1

OP-A Slot 2

OP-A Slot 3

OP-B Slot 4

OP-C

1 Є220 (Load chart) 0.85 0.85 0.88 0.88

2 ∆Є(220-160) (Line chart) -0.01 -0.01 -0.01 -0.01

3 Єx= Є220 + ∆Є(220-160) 0.84 0.84 0.87 0.87

4 ЄAVE = (Є1+ Є2+ Є3+ Є4)/4 0.855

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.

All of the signals are referenced to the bias supply common rail (COM) and external control and/or monitoring circuits can

easily be powered and directly 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 4000 VAC

Signals to Chassis 250 VDC

Signals to Output 250 VDC

+5V bias supply (Power Unit)

A +5 V bias supply that can deliver up to 200 mA is provided as standard on all units. This supply is available whenever the AC

mains voltage is connected and the input module is operating correctly. To ensure safety, the following abnormal conditions

may cause the entire unit to latch off, which will disable the +5 V bias supply:

Over temperature of any part of the unit

Over voltage on the output

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 5 ms 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:

Over temperature of any part of the unit

Over voltage on the output

Internal over current (device failure)

Pin Name Description

1 PG1 Power Good Slot 1

2 INH1 Inhibit

3 PG2 Power Good Slot 2

4 INH2 Inhibit

5 PG3 Power Good Slot 3

6 INH3 Inhibit

7 PG4 Power Good Slot 4

8 INH4 Inhibit

9 GINH Global Inhibit

10 ACOK AC mains signal

11 +5V Global 5V Bias

12 COM Common

SIGNALS

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%

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 10 kΩ pull down resistor, as shown here on

the side.

The LED on the front of each module gives a visual

confirmation of the PG status.

Note that remote adjustments of the output voltage using the

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.

Output Inhibits _ INH1-INH4, GINH (Input)

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, tOff = 100 µs and

tOn = 8 ms.

To inhibit each output module individually, GINH should be connected to COM, and +5 V 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 +5 V, 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. +5 V on any INH input will disable all outputs.

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