Cosel DBS100A User manual

DC-DC Converters Bus Converter
-
Power Module Type
1 Connection for Standard Use DBS-13
2.1 Wiring input pin DBS-13
2.2 Wiring output pin DBS-14
Instruction Manual
3.1 Overcurrent protection DBS-14
3.2 Overvoltage protection DBS-15
3.3 Thermal detection/Thermal protection DBS-15
3.4 Inverter operation monitor DBS-15
3.5 Remote ON/OFF DBS-15
3.6 Remote sensing DBS-16
3.7 Adjustable voltage range DBS-16
3.8 Isolation DBS-17
3 Function DBS-14
4.1 Series operation DBS-17
4.2 Parallel operation/Master-slave operation DBS-17
4.3 N+1 redundant operation DBS-18
4 Series and Parallel Operation DBS-17
5 Cleaning DBS-18
2 Wiring Input/Output Pin DBS-13
DBS-12
June 26, 2020

2 Wiring Input/Output Pin
1 Connection for
Standard Use
¡In order to use the power supply, it is necessary to wire as shown
in Fig.1.1 and external components in table1.1.
¡Short the following pins to turn on the power supply.
-VIN RC1, +VOUT +S, -VOUT -S
Reference: 3.5 ”Remote ON/OFF”
3.6 ”Remote sensing”
¡The DBS Series handles only the DC input.
Avoid applying AC input directly.
It will damage the power supply.
¡Operate with the conduction cooling(e.g. heat radiation from the
aluminum base plate to the attached heat sink).
Reference ”Derating”
+
Heatsink
o
C
Cin
FG
RC1 -S
+VOUT
-VOUT
-VIN
+VIN
+S
Y
C
Load
F1
DC
input
Noise
filter
Fig.1.1 Connection for standard use
Table 1.1 External components
No. Symbol component Reference
1 F1 Input fuse 2.1 (1) ”External fuse”
2 CY
Primary decoupling capacitor
2.1 (2) ”Noise lter/
Decoupling capacitor”
3xNoise lter
4 Cin
External capacitor on the input side 2.1 (3) ”External capacitor on the input side”
5 Co External capacitor on the output side 2.2 ”Wiring output pin”
6xHeatsink ”Derating”
2.1 Wiring input pin
(1) External fuse
¡Fuse is not built-in on input side. In order to protect the unit, install
the normal blow type fuse on input side.
¡When the input voltage from a front end unit is supplied to multiple
units, install the normal blow type fuse in each unit.
Table 2.1 Recommended fuse(Normal-blow type)
Model DBS100A / 150A DBS200B DBS400B DBS700B
Rated current 5A 3A 5A 10A
(2) Noise lter/Decoupling capacitor
¡Install an external noise lter and a decoupling capacitor CYfor
low line-noise and for stable operation of the power supply.
¡Install a correspondence lter, if a noise standard meeting is re-
quired or if the surge voltage may be applied to the unit.
¡Install a primary decoupling capacitor CY, with more than 470pF,
near the input pins(within 50mm from the pins).
¡When the total capacitance of the primary decoupling capacitor is
more than 8800pF, the nominal value in the specication may not
be met by the Hi-Pot test between input and output.
In this case, it is that a capacitor should be installed between out-
put and FG.
(3) External capacitor on the input side
¡Install an external capacitor Cin between +VIN and -VIN input pins
for low line-noise and for stable operation of the power supply.
DBS100A / 150A:more than 47μF
DBS200B:more than 0.1μF
DBS400B / 700B:more than 0.33μF
¡When the line impedance is high or the input voltage rise quickly
at start-up(less than 10μs), install a capacitor Cin between +VIN
and -VIN input pins(within 50mm from pins).
DBS200B:more than 22μF
DBS400B / 700B:more than 47μF
(4) Input voltage rang/Input current range
¡The specication of input ripple voltage is shown as below.
Ripple voltage DBS100A / 150A:less than 10Vp-p
DBS200B / 400B / 700B:less than 20Vp-p
¡Make sure that the voltage uctuation, including the ripple voltage,
will not exceed the input voltage range.
¡Use a front end unit with enough power, considering the start-up
current Ip of this unit.
t
Ripple
voltage
time
Input voltage [V]
Input voltage range
Fig.2.1 Input voltage ripple
DC-DC Converters Bus Converter
-
Power Module Type
Instruction Manual
DBS-13 June 26, 2020

Range of input voltage
Ip
Input voltage [V]
Input current [A]
Fig.2.2 Input current characteristics
(5) Operation with AC input
¡The DBS series handles only for the DC input.
A front end unit(AC/DC unit) is required when the DBS series is
operated with AC input.
(6) Reverse input voltage protection
¡Avoid the reverse polarity input voltage. It will break the power
supply.
It is possible to protect the unit from the reverse input voltage by
installing an external diode.
AC
/DC
AC
DBS Load
AC
DBS Load
DC
DBS Load
YES
NO
YES
Fig.2.3 Use with AC input
DC INDC IN
-VIN
+VIN
-VIN
+VIN
(a) (b)
Fig.2.4 Reverse input voltage protection
2.2 Wiring output pin
¡Install an external capacitor Co between +VOUT and -VOUT pins
for stable operation of the power supply.
Recommended capacitance of Co is shown in Table 2.2.
¡Select the high frequency type capacitor. Output ripple and start-
up waveform may be inuenced by ESR
-
ESL of the capacitor and
the wiring impedance.
¡Install a capacitor Co near the output pins(within 100mm from the
pins).
Table 2.2 Recommended capacitance Co [μF]
Model DBS100A
DBS150A DBS200B DBS400B DBS700B
Output voltage (V)
3.3 x2200 6800 x
5 2200 2200 4700 x
7.5 x2200 4700 x
12 1000 1000 2200 2200
13.8 1000 xxx
15 1000 x2200 x
18 x x 2200 x
24 470 x820 2200
28 x x 820 2200
36 xxx2200
48 xxx1000
When using power supply at -20Cor less, the recommended capaci-
tance becomes 3 times.
¡The specied ripple and ripple noise are measured by the method
introduced in Fig.2.5.
FG
Cin
2200pF
＋
100mm
＋VIN
－VIN
FG
＋VOUT
－VOUT
－S
＋S
0.1 F
Co
＋
RC1
2200pF
Measuring board
DBS100A/150A/200B/400B
Load
DC
input
Oscilloscope
BW:20MHz
FG
Cin
2200pF
＋
100mm
＋VIN
－VIN
FG
＋VOUT
－VOUT
－S
＋S
0.1 F
Co
＋
RC1
2200pF
Measuring board
DBS700B
Load
DC
input
Oscilloscope
BW:100MHz
1.5m 50
Coaxial Cable
R=50W
C=0.01

F
R
C
Fig.2.5 Method of Measuring Output Ripple and Ripple Noise
3 Function
3.1 Overcurrent protection
¡Overcurrent protection is built-in and comes into effect over 105%
of the rated current.
Overcurrent protection prevents the unit from short circuit and
overcurrent condition. The unit automatically recovers when the
fault condition is cleared.
DC-DC Converters Bus Converter
-
Power Module Type
Instruction Manual
DBS-14
June 26, 2020

Table 3.1 Specication of TMP, IOG
No. Item TMP IOG
1 Function
Normal operation ”H” Normal operation ”L”
Overheat detection ”L” Malfunction of inverter ”H”
2 Base pin -S
3 Level voltage ”L” 0.5Vmax at 5mA
4 Level voltage ”H” 5V typ
5 Maximum sink current 10mA max
6
Maximum applicable voltage 35V max
3.5 Remote ON/OFF
¡Remote ON/OFF circuit is built-in on both side of input(RC1) and
output(RC2
-
RC3).
Output can be controlled by either circuit.
(1) Input side remote ON/OFF(RC1)
¡The ground pin of input side remote ON/OFF circuit is ”-VIN” pin.
Between RC1 and -VIN: Output voltage is ON at ”Low” level or
short circuit(0 - 1.0V).
Between RC1 and -VIN: Output voltage is OFF at ”High” level or
open circuit(3.5 - 7.0V).
When RC1 is ”Low” level, fan out current is 0.3mA typ. When Vcc
is applied, use 3.5 [Vcc [7V.
When remote ON/OFF function is not used, please short between
RC1 and -VIN.
¡When the DPF-DPG series(Power factor & harmonic correc-
tor module) is used as a front end unit, connect between RC1
pin and ENA pin on DPF-DPG for the start-up time of the
DBS200B/400B/700B control. Please contact us for details.
-
VIN
RC1
Vcc
or
Relay
or
Transistor IC
Rc
Fig.3.2 RC1 connection example
(2) Output side remote ON/OFF(RC2-RC3)
Table 3.2 Specication of output side remote ON/OFF(RC2-RC3)
No. Item RC2-RC3
1 Wiring method Fig.3.3 (a) Fig.3.3 (b) Fig.3.3 (c)
2 Function
Power ON ”H” Power ON ”H” Power ON ”L”
3 Base pin RC2 -S -S and RC2
4 Power ON Open
(0.1mA max)
Short
(0.5V max)
5 Power OFF Short
(3mA min)
Open
(0.1mA max)
¡When the output voltage drops at overcurrent, the average output
current is reduced by hiccup operation of power supply.
3.2 Overvoltage protection
¡The overvoltage protection circuit is built-in. The DC input should
be shut down if overvoltage protection is in operation. The mini-
mum interval of DC recycling for recovery is for 2 to 3 minutes().
The recovery time varies depending on input voltage and input
capacity.
Remarks:
Please note that devices inside the power supply might fail when
voltage more than rated output voltage is applied to output termi-
nal of the power supply. This could happen when the customer
tests the overvoltage performance of the unit.
3.3 Thermal detection/Thermal protection
¡Thermal detection(TMP) and protection circuit are built-in.
¡When overheat is detected, thermal detection signal(TMP) turns
”L” from ”H”.
TMP circuit is designed as shown in Fig.3.1, and specication is
shown as in Table 3.1.
¡When overheating continues after detecting the TMP signal, the
output will be shut down by the thermal protection circuit.
When this function comes into effect, input voltage should be shut
off, and eliminate all possible causes of overheat condition and
lower the temperature of the unit to the normal level.
3.4 Inverter operation monitor
¡By using the inverter operation monitor(IOG), malfunction of the
inverter can be monitored.
When inverter operation is in following mode 1or 2, IOG signal
turns ”H” from ”L” within 1 second.
IOG circuit is designed as shown in Fig.3.1 and specification is
shown in Table 3.1.
1Malfunction of inverter.
2The output voltage drops by 60% or less of the rated voltage.
3When output wattage is decreased radically to less than 10% of
rated wattage.
6V typ
22kW
TMP
or
IOG
-S
Fig.3.1 TMP, IOG circuit
DC-DC Converters Bus Converter
-
Power Module Type
Instruction Manual
DBS-15 June 26, 2020

(a) (b) (c)
ON
POWER
RC2
RC3
AUX
OFF
-S
typ
12V 150W
2.2kW
ON
POWER
RC2
RC3
AUX
OFF
-S
typ
12V 150W
2.2kW
typ
12V 150W
2.2kW
ON
POWER
RC2
RC3
AUX
OFF
-S
Fig.3.3 RC2
-
RC3 connection example
¡Make sure that sink current of output side remote ON/OFF circuit
should be less than 12mA.
(3) Auxiliary power supply for remote ON/OFF(AUX)
¡AUX is built in for operating the output side remote ON/OFF
(RC2-RC3).
If AUX is not used for RC2-RC3, AUX can be used for IOG or
TMP signal output by opto coupler.
¡Short protection resistance(2.2kW) is built in.
Output voltage decreases as the output current increases.
(AUX voltage at open circuit: 15V max)
3.6 Remote sensing
(1) When the remote sensing function is not in use
¡When the remote sensing function is not in use, it is necessary to
conrm that pins are shorted between +S & +VOUT and between
-S & -VOUT.
¡Wire between +S & +VOUT and between -S & -VOUT as short as
possible.
Loop wiring should be avoided.
This power supply might become unstable by the noise coming
from poor wiring.
(2) When the remote sensing function is in use
¡Twisted-pair wire or shield wire should be used for sensing wire.
¡Thick wire should be used for wiring between the power supply
and a load.
Line drop should be less than 0.5V.
Voltage between +VOUT and -VOUT should remain within the
output voltage adjustment range.
¡If the sensing patterns are short, heavy-current is drawn and the
pattern may be damaged.
The pattern disconnection can be prevented by installing the pro-
tection parts as close as a load.
+S
-S
+VOUT
-VOUT
OUT Co Load
Short at pin root
+
Fig.3.4 Connection when the remote sensing is not in use
+S
-S
+VOUT
-VOUT
OUT Load
Wire as close as possible
Co
+
Fig.3.5 Connection when the remote sensing is in use
3.7 Adjustable voltage range
¡Output voltage is adjustable by the external potentiometer or by
applied voltage externally.
The adjustable range is 60 - 110% of the rated output voltage.
¡When the output voltage adjustment is used, note that the over-
voltage protection circuit operates when the output voltage sets
too high.
(1) Adjusting method by external resistor
¡By connecting the external potentiometer(VR1) and resistors(R1,
R2), output voltage becomes adjustable, as shown in Fig.3.6, rec-
ommended external parts are shown in Table 3.3.
¡The wiring to the potentiometer should be as short as possible.
The temperature coefficient becomes worse, depending on the
type of a resistor and potentiometer. Following parts are recom-
mended for the power supply.
Resistor Metal lm type, coefcient of less than �100ppm/C
Potentiometer Cermet type, coefcient of less than �300ppm/C
¡When the output voltage adjustment is not used, open the TRM
pin and VB pin respectively.
RB
10kW
-
+
RA
15kWReference
voltage 2.5V
VR1
R2
R1
TRM
VB
+S
+VOUT
-VOUT
-S
Control Amp.
of rated
voltage
Fig.3.6 Output voltage control circuit
DC-DC Converters Bus Converter
-
Power Module Type
Instruction Manual
DBS-16
June 26, 2020

4.1 Series operation
¡Series operation is available by connecting the outputs of two or
more power supplies, as shown below. Output current in series con-
nection should be lower than the lowest rated current in each unit.
Power
supply
Power
supply
Power
supply
Power
supply
LoadLoadLoad
(a)
(b)
Fig.4.1 Examples of series operation
4.2 Parallel operation/Master-slave operation
¡Parallel operation is available by connecting the units as shown in
Fig.4.2.
¡As variance of output current drew from each power supply is
maximum 10%, the total output current must not exceed the value
determined by the following equation.
(Output current in parallel operation)
=(the rated current per unit) X(number of unit) X0.9
When the number of units in parallel operation increases, input
current increase at the same time. Adequate wiring design for in-
put circuitry is required, such as circuit pattern, wiring and current
capacity for equipment.
In parallel operation, the maximum operative number of units is 11.
Table 3.3 Recommended value of external potentiometer & resistor
No. Adjustable range [%] Number of unit External parts value [W]
VR1 R1 R2
1
�5
Single
5k
75k
1k2 2sets 36k
3 3sets 24k
4
�10
Single
5k
36k
9105 2sets 18k
6 3sets 12k
(2) Adjusting method by applying external voltage
¡By applying the voltage externally at TRM, output voltage become
adjustable.
¡Output voltage is calculated by the following equation.
(Output voltage)
= (Applied voltage externally) X(Rated output voltage)
¡The output adjustment range for DBS700B is shown in Fig.3.7.
Input Voltage [V]
200V
100
105
110
2500
0
60
Output Voltage [%]
Fig.3.7 DBS700B Output Voltage Adjustment Range
3.8 Isolation
¡For a receiving inspection, such as Hi-Pot test, gradually
increase(decrease) the voltage for a start(shut down). Avoid using
Hi-Pot tester with the timer because it may generate voltage a few
times higher than the applied voltage, at ON/OFF of a timer.
4 Series and Parallel
Operation
DC-DC Converters Bus Converter
-
Power Module Type
Instruction Manual
DBS-17 June 26, 2020

Co
+
Co
+
R1
R2
Co
+
VR1
VB
-VOUT
CB
TRM
+VOUT
+S
-S
VB
-VOUT
CB
TRM
+VOUT
+S
-S
VB
-VOUT
CB
TRM
+VOUT
+S
-S
Load
The output voltage rises
when VR1 is adjusted
for the resistance
between 1and 2to
lower.
Fig.4.2 Examples of parallel operation
¡When output voltage adjustment is not in use. TRM wiring, R1, R2
and VR are not necessary.
¡Thick wire should be used for wiring between the power supply
and load, and line drop should be less than 0.3V.
¡When the output-line impedance is high, the power supply is be-
come unstable.
Use same length and thickness(width) wire(pattern) for the current
balance improvement.
¡Connect each input pin for the lowest possible impedance.
¡When the number of the units in parallel operation increases, input
current increases. Adequate wiring design for input circuitry such
as circuit pattern, wiring and current for equipment is required.
¡Connect the sensing line and the power line by one point after
connecting each power supply’s sensing pins(+S, -S). In multiple
operation, sensing wires should be connected between each units
for the muster connection to a load.
¡Output current should be 10% or more of the total of the rated
output current in parallel operation. If less than 10%, the IOG sig-
nal might become unstable, and output voltage slightly increasing
(max5%).
¡IOG signal might be unstable for one second when the units are
turned on in parallel operation.
4.3 N+1 redundant operation
¡It is possible to set N+1 redundant operation for improving reliabil-
ity of power supply system.
¡Purpose of redundant operation is to ensure stable operation in
the event of single power supply failure.
Since extra power supply is reserved for the failure condition, so
total power of redundant operation is equal to N-1.
¡Clean the product with a brush. Prevent liquid from getting into the
product.
Do not soak the product into liquid.
¡Do not stick solvent to a name plate or a resin case.
(If solvent sticks to a name plate or a resin case, it will cause
to change the color of the case or to fade letters on name plate
away.)
¡After cleaning, dry them enough.
5 Cleaning
DC-DC Converters Bus Converter
-
Power Module Type
Instruction Manual
DBS-18
June 26, 2020