MODULE RATING WITH MODEL NUMBERS: UE Z 1 - X X X X X X14
NOTE: ENERGY HAZARDS15
THERMAL DERATING GUIDELINE15
MAXIMUM POWER VS. AC LINE15
LABEL / CONNECTION DIAGRAM17
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LAMBDA
Power Supply
Installation Manual
INTRODUCTION
The “UltraFlex” is a product family of fan-cooled, multi-output, power factor corrected switch
mode power supplies. The flexible design offers a high quality, cost-effective solution for the
high volume OEM market.
CERTIFICATION
Lambda certifies that this product meets published specifications at the time of shipment from
the factory.
WARRANTY
This power supply is warranted against defects in material and workmanship for a period of
three years from date of shipment. During this period Lambda will either repair or replace this
product at the discretion of Lambda . No other warranty is implied or given.
APPLICABILITY
This manual applies to the UltraFlex UF1500 Series power supply. Manual part no.
IMUE1500.
PART NUMBER CONFIGURATION
UEZ1-_______
UltraFlex
Case Code
Global Signals Output Module Codes [SEE PAGE 14]
EN55022 Level B, FCC20780 Class A Cond. EMI
INSTALLATION MANUAL
This manual contains important information regarding the proper installation and operation of
the power supply mounted inside the host equipment.
SAFETY AGENCY APPROVALS
The UltraFlex power supply series complies with the following regulatory specifications:
UL1950, IEC950, CSA 22.2 No.950, EN60950. This product is certified and allowed to carry
UL combined Canada/U.S. Recognized Component Mark, DEMKO.
CE Marked in accordance with the Low Voltage directive (73,23/EEC) as amended by the CE
Marking directive (93/68/EEC).
NOTE: CE Mark does not include compliance to either EMC or medical device directives.
PLEASE READ THE SAFETY AND INSTALLATION INSTRUCTIONS BEFORE
INSTALLATION OR USE OF THIS PRODUCT.
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SAFETY SYMBOL:
This symbol indicates dangerous voltages present within the power supply. Isolation
transformers should be used between the AC mains and the power supply if work is to be
carried out with the safety covers removed.
GENERAL SAFETY INSTRUCTIONS
The UltraFlex power supply series is designed for use within other equipment or enclosures.
Access is restricted to authorized personnel only.
For safe installation and operation of this product, carefully follow the instructions below:
A.Do not install, operate or test this product near water, and do not spill any liquid on it.
B.Do not touch the product when the input supply is connected.
C.Do not operate this product unless it is in a secure position.
D.When cleaning the product, make sure the input supply is disconnected and use only a
damp cloth.
E.Never push objects of any kind into the product through slots in its case, as this could
result in electric shock or a fire hazard.
F.Slots in the product case are designed for ventilation and must not be obstructed when
the product is installed and/or operated.
G.Make sure the unit is supplied only by a power source of the type indicated on its label.
H.When securing the product, do not use screws that infringe the maximum penetration
depth specified on the mechanical drawing within this handbook.
I.The unit covers are designed only to protect skilled personnel from hazards. They must
not be used as part of the external covers of any equipment where they may be
accessible to operators, since, under full load conditions, parts of the unit chassis may
reach temperatures in excess of those considered safe for operator access.
J.All servicing, repair and testing of this product must be carried out by competent
personnel who are familiar with the hazards of AC/DC line operated equipment and with
the particular dangers associated with switched mode power supplies.
K.AFTER DISCONNECTING THE AC SOURCE, ALLOW 5 MINUTES BEFORE
TOUCHING THE UNIT TO ALLOW CAPACITORS WITHIN THE UNIT TO
DISCHARGE.
L.The low-voltage output from the power supply unit shall not be user-accessible as
defined in EN 60950.
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M.A protective earth must be provided for safety in accordance with EN60950.
WARNING: It is essential that the earth grounding terminal of this product be securely
connected to earth (hard-wired) by the end user.
N. PREVENTION OF ACCESS BY THE USER: This apparatus is intended to be
accessible to authorized personnel only. Ensure that user access to this product, when
installed in a host equipment, complies with EN60950. Failure to do this will invalidate
the approval given to this apparatus.
O.WARNING: All outputs used are SELV as defined in EN60950 Clause 2.3. As such, all
outputs must only be connected to circuits compliant with the requirements of SELV
complying EN60950 Clause 2.3. circuits. Other usage will invalidate any approval given
to this apparatus.
P.EARTH TERMINAL MARKING:
IMPORTANT: If in the end use equipment the incoming mains cable earth wire
connects directly to the "GND" connection on the UltraFlex unit without being
interrupted or junctioned on its way to that connection, then this connection is the main
protective earth of the system. To comply with EN60950, UL1950, and CSA-22.2-950
requirements, this terminal must be marked with as defined in IEC417 No. 5019a.
The customer should therefore affix an adhesive label which will pass the 15 second
rub test (IEC950 section 1.7.15) showing the above symbol adjacent to the earth
connection. This symbol must only be used at the first interruption/connection of the
incoming earth wire.
INPUT FUSE
The AC power source line is protected by an internal ceramic body fuse contained within the
power supply enclosure located in the neutral side. Only qualified service personnel should
replace the internal fuse (no user access).
Notes:
1. Replace the input fuse in the unit with same type and rating. Fusing requirements are
shown in Table #1. Caution: Primary fuse is located in the neutral side.
2. Additional customer supplied fuse is required in the “Line side”, same as in Table #1.
3. Internal fuses (no user access) F506, F601, rated 4A/250v Very Fast-Acting Type.
TABLE #1
MODELOUTPUT
FUSE VALUENOTES
POWER
UF15001500W25A/600VBussmann fast
acting KTK-25
or equivalent
RECEIPT AND UNPACKING
On receipt, the unit should be unpacked carefully and checked for transit damage. If the unit is
damaged, do not apply power or install the unit--seek specialist advice. Read the rating label
located on the power supply to verify that the unit has the correct input and output ratings and
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part number. All electrical tests performed on the unit prior to installation must be carried out
by a qualified person familiar with AC/DC powered equipment and having the specialized
knowledge required of the hazards associated with switched mode power supplies. This is
particularly essential if the unit covers are removed, which exposes many devices operating at
line voltage and some operating at peak voltages of up to 400 volts.
MOUNTING REQUIREMENTS AND COOLING
The mechanical outline drawing, contained within this pamphlet, provides the necessary
installation dimensions required for customer mounting and space allocation.
IMPORTANT: Use M4 screws for mounting. Screws must not penetrate more than 1/8”(3
MM) into the power supply. The UF1500 units have integral cooling fans and can be mounted
in any position. However mounting orientation should not oppose the system forced air
direction, the natural convection, or system cooling draft air flow. Furthermore, the power
supply air intakes and exhaust slots must not be obstructed. The intake air temperature should
be limited to allow the unit to operate in accordance with the thermal derating envelope of the
electrical specifications.
INPUT POWER CONNECTIONS
The input power terminal block is located on the chassis end that also includes the fans.
Safety earth ground is to be connected to the grounding post adjacent to the input power
terminal block.
The terminal functions are clearly shown on the top label of the unit.
Connections should be made using correctly sized wire gauges and colors as per applicable
electrical codes.
AC INPUT
Line:Black
Neutral:White
Ground:Green
The ground connection must be made to a well defined, low impedance ground (protective
ground). Connections must not have loose strands and the insulation must cover the wire up
to the block itself. Interface terminal lugs must be fastened properly.
AC INPUT AND OUTPUT POWER RATINGS
85-265 Vac, 47-63 Hz. The input current will be limited to 20A max.
1200W @100 Vac 60 oC derate output power to 75%
1500W @170 Vac 70 oC derate output power to 50%
Note: Refer to Table 3 and Graphs 1 & 2 on pages 13 and 14 respectively.
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EMI
(Conducted)
The UltraFlex power supply has internal EMI filtering, and complies with EN55022 level B, as
well as FCC Docket 20780 Part 15, Subpart J Class A. The end system wiring and grounding
can influence the conducted and radiated EMI pattern. The customer may require additional
EMI filtering to meet system requirements. If problems are encountered, the customer should
contact Lambda’s Application Engineering Staff.
INPUT TRANSIENT/ESD PROTECTION
The UltraFlex is designed to withstand surges, line transients, and ESD as specified in the
following documents:
Surge:IEEE-C62.41, Category A3;
EN61000-4-5 Class 4; L-L: 2KV, L-Gnd: 4KV, Criterion B.
Fast Transients: EN61000-4-4, Level 3, Criterion B.
ESD:EN61000-4-2, Level 3, Criterion B.
Input Dips and Variations: IEC1000-4-11, Criterion B.
Radiated Immunity:EN61000-4-3, Level 3, 10 V/M.
REMOTE SENSE
Remote sense is provided for each output to compensate for load cable drops from the power
supply to the sense points. To meet specifications and output voltage set point of the output
modules, the sense lines must be connected to the load or locally to the power supply output
terminals. The remote sense connections are available on the signal connector. See Table 2
below for the appropriate pin numbers.
J2 pin 4 +Positive Remote Sense Output 2
J2 pin 5 - Negative Remote Sense Output 2
The following rules should be observed when using remote sense:
1)Use a twisted pair of 20-24 AWG wires for remote sense leads.
2)Route the sense leads away from any high current conductors or devices
(motors, transformers, etc.) to avoid pick-up, as this may cause ripple or stability
problems on the power supply.
3)Never disconnect the power supply output power connections with the remote
sense still connected to the load. This may damage the internal remote sense
pick-up resistors.
4)The total voltage drop on the output cables must be limited to less that 0.5V.
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OUTPUT VOLTAGE ADJUSTMENT (TRIMMING)
Voltage adjust potentiometers are provided for all outputs. The potentiometers are located
adjacent to the output connections of the power supply. Use a non-conductive trim-pot
adjustment tool. Turn clockwise to increase the voltage.
NOTE: Always monitor the corresponding output voltage while turning the potentiometer.
CURRENT LIMIT PROTECTION
All outputs are protected by constant-current limiting circuitry. The overcurrent limits are set at
the factory between 110-150% for single outputs. The overcurrent limit settings for the dual
output modules are as follows: Output #1: 110- 150% of rated load; Output #2: 110-150% of
rated load. Removing the overload automatically restores the output voltage. On Dual Output
Modules - if Output #1 is in current limit, Output #2 voltage will also decrease.
OVERVOLTAGE PROTECTION (OVP)
When any single output module voltage reaches 120-130% of nominal voltage, that channel
will shut down. When any dual output module reaches 120-140% of nominal voltage, both
outputs of the dual module will shut down. OVP on 2V outputs is factory set to 3-3.5V, and
OVP on 3.3V outputs is set to 4.3-4.8V. OVP activates the internal shutdown latch of the
module until the AC input power is recycled OFF to ON to clear the latch and resume normal
operation, once the OVP problem has been corrected.
OUTPUT LOAD REGULATION
(NO LOAD/FULL LOAD/NO LOAD)Single output modules 0.4% maximum.
The UltraFlex output voltages will remain within specified regulation for a minimum of 16msec
after loss of applied power on the AC input at full load and nominal output voltage.
TURN-OFF/TURN-ON
Turn-off/turn-on output voltage - transient overshoot is less than 3% of nominal voltage during
the application or removal of input voltage under any condition of turn-on, turn-off, including
inhibit or enable.
TURN ON TIME
All outputs shall be within voltage regulation limits within 1 second of application of AC power.
NOISE AND RIPPLE
UltraFlex output modules meet the following specifications with a 20MHz bandwidth. Care
must be taken when conducting the following measurements:
Single output modules: 2-5V, <1000W: <50mV pk –pk.
terminals with two – 2700 uf capacitors located at this point.
> 5V: <1% pk–pk.
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</= 5V, 1000W: <200mV pk-pk directly on the output terminals;
<50mV pk-pk measured 5 inches away from the output
Dual output modules: <1% pk-pk.
DYNAMIC LOAD TRANSIENT RESPONSE
A 25% step load change will result in an output deviation (overshoot or undershoot) of less
than 3% of nominal output voltage (150mV for <5V outputs, 400mV for the </= 5V 1000W
module). Output voltage will recover to within 1% of set value within 300ms (500us for the
</=5V 1000W module.) Slew rate not to exceed 1A/us.
DYNAMIC CROSS REGULATION
The effect of dynamic cross regulation on any fully loaded auxiliary channel for a load step
change of 25% from a 75% base value on the highest rated channel, at a slew rate not to
exceed 1A/us, shall be less than 0.1% for single output modules and less than 3% for dual
output modules. The summation of the individual module powers must not exceed the total
rated power of the UF1500. This measurement is to be performed with all other channels
loaded to 50% of rated load.
TEMPERATURE COEFFICIENT
The output voltage will change less than .02% per oC over the ambient temperature range of
0-50oC. (After 30 minute warm-up).
NO LOAD OPERATION
Operation at no load will not cause damage to the UltraFlex supply, however the output
voltages may be outside the regulation band. A 1 Ampere preload is required on the highest
rated output for a dual output module.
OVER TEMPERATURE SHUTDOWN
The power supply is self-protected against over-temperature conditions. A thermal shutdown
requires re-cycling of the input voltage to restore output. The fan will continue to operate
during thermal shutdown.
OPERATING ENVIRONMENT
The power supply is designed to meet the performance parameters defined above when
operated within the following conditions:
Temperature:0 to 50o C; -20oC Start-Up, 30 Minutes to perform
within specifications.
Humidity:10% - 90% Non-condensing
Altitude:0 – 10,000 ft. Operating
The power supply will not be damaged during transit and storage when subjected to the
following conditions:
Temperature:-40oC to +85oC
Humidity:90% Non-condensing
Altitude:40,000 ft. (12Km)
SIZE AND WEIGHT
H" x W" x L":5”x5.125”x11”
WEIGHT:5.7lbs. + 0.5lbs. / used slot; maximum # of slots = 10.
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COOLING
Integral fans provide forced-air cooling to ensure safe operation under all environmental
conditions. Care must be taken not to obstruct intake and exhaust ports.
SHOCK & VIBRATION
The UltraFlex power supply meets the performance requirements of IEC68-2-27; 15g, 11ms
half-sine pulses.
The UltraFlex power supply meets the performance requirements of IEC68-2-64 with a
frequency range of 20 - 2000Hz and acceleration of 6 Grms for a minimum of 30 minutes.
PACKAGE DROP
The UltraFlex packaging has been tested per National Safe Transit Association Project 1A.
RELIABILITY PREDICTION
Reliability prediction MTBF by stress method per Bellcore TR-NWT-000332 Issue 4 (reliability
prediction procedure for electronic equipment).
The following signals are provided as a standard feature on the UF1500 via J3. Logic level
signal outputs are via open drain Mosfets (60VDC/100mA max ratings). Pull up resistors are
required. Signals are referenced to the Signal Common terminal (J3 Pin 3) on the interface
connector.
5V DC Standby Output (J3 pin 1):
Isolated 5VDC/0.3A output available whenever the input power is applied. This output is not
affected by inhibit signals. Load regulation less than or equal to 5%.
Global Output Good LED Drive (J3 pin 2):
An open drain output to light an external LED indicator. If any output equipped with a DC
output good option fails, this signal goes low. An internal 390 ohm series resistor limits the
current through the LED.
Global Output Good (J3 pin 4):
When all output modules which have Output Good signals are within specification, this signal
is high. If any output fails, this signal goes low.
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Fan Stop/Thermal Alarm (J3 pin 5):
Logic signal goes low if the fan stops; or in the event of overheating, at least 10mS prior to a
thermal shutdown of the supply. Signal remains low until fault is cleared. If a thermal shutdown
has occurred, the input power must be re-cycled to restore output.
Input Power Fail Signal (J3 pin 6):
Following the loss of input power, this signal provides at least 5mS warning prior to any output
going outside of it's regulation band when adjusted to Vo nominal at full load. The signal goes
"Low" when input power is lost. Signal "High" on fault available as a special option.
Global Inhibit (J3 pin 8):
A TTL compatible signal will turn off all output modules, depending upon the setting of the
Inhibit/Select function (See below.) The outputs are less than 0.5V while inhibited at no load.
Inhibit/Select (J3 pin 10):
When open circuit, Global Inhibit is Active Low. When this input is shorted to signal common
(Pin 3), Global Inhibit is active high.
OUTPUT MODULE SIGNALS & FEATURES
Output module options are available only with single output modules. Logic Level signal
outputs are via open collector NPN transistors (40VDC/10mA max ratings) except the Module
Inverter OK signal which is 20VDC/4mA. Pull up resistors are required.
Signals are referenced to the -Remote Sense terminal. (J1 pin 10)
+Remote Sense (J1 pin 1- single output module, J2 pin 3 & 4 – dual output module):
Compensates for load cable drop from power supply to sense point (.25V per terminal.) To
meet regulation the remote sense must be connected to the load or locally to the power
supply.
Remote Voltage Adjust (J1 pin 2):
This input signal may be used for remote adjustment of the output +/- 10% of nominal via
external resistive or current input. Requires external potentiometer (10K ohms) between +/remote sense terminals with the wiper to remote voltage adjust pin.
Margin (J1 pin 3):
Margining +/- 5% of nominal output voltage. Requires an external switch (normally open,
SPDT) connected to the +/- remote sense terminals with switch common connected to Margin
input.
Current Sharing (J1 pin 4):
Active current sharing provides Load Sharing between two or more similar output modules to
within 10% of each output’s rated current. The current share node automatically disconnects if
a module inverter fault is detected. Modules with this option share current proportionally to
their maximum current ratings. Current sharing between modules is accomplished by
connecting J1 pin 4 of each module together. A single remote sense point must be used. The
individual output voltages must be set to within 1% of each other to ensure the outputs are
within a 2% capture window. Refer to Lambda application note AN-018 for additional details.
High Module Signal (J1 pin 5):
When outputs are connected in parallel and the current share option is employed, only the
module with the highest output voltage will have a logic high signal (useful for system
diagnostics). This is an open collector output signal.
A TTL "low" level signal can be applied to disable outputs to <0.5V at no load.
Output Good Signal (J1 pin 7):
This signal goes low if output deviates by - 4% from factory settings.
Module Inverter O.K. Signal (J1 pin 8):
If an output module inverter fault is detected this output goes high. This signal causes the
current-share node to disconnect. Maximum ratings for the output transistor are 20V/4mA.
Current Monitor (J1 pin 9):
This is an analog signal proportional to the output current, 0-2VDC (2VDC at max output
current). From 20%-100% of current rating the accuracy will be within 10% of the max rated
current value.
Compensates for load cable drop from power supply to sense point (.25V per terminal.) To
meet module specifications the remote sense must be connected to the load or locally to the
power supply.
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MODULE RATING WITH MODEL NUMBERS: UE Z 1 - X X X X X X
Module Code
Modules Overcurrent Protection are set between 110 – 120% of max current.
Certain modules are capable of providing hazardous energy (240VA) according to
output voltage setting. Therefore, consideration should be given to electrical energy
hazards from these outputs
THERMAL DERATING GUIDELINE
for UltraFlex UF1500 Power Supply Series
Derating UF1500 Series
120
100
80
60
40
20
% Output Power
0
-60-40-20020406080
MAXIMUM POWER VS. AC LINE
for UltraFlex UF1500 Power Supply
Temperature [C
Continuous Output Power Derating
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1500
1400
watts)
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OUTLINE DRAWING
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LABEL / CONNECTION DIAGRAM
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