KEPCO HSF 3.3-10PFC User manual

©2010, KEPCO, INC 1
Data subject to change without notice 228-1532 REV 9
KEPCO, INC. " 131-38 SANFORD AVENUE " FLUSHING, NY. 11355 U.S.A. " TEL [phone] " FAX [phone]
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INSTRUCTION MANUAL
KEPCO An ISO 9001 Company. HSF-PFC
50W SERIES
KEPCO SINGLE OUTPUT 50 WATT
HOT SWAP PLUG-IN POWER SUPPLIES
I — INTRODUCTION
The Kepco HSF-PFC 50 Watt series hot swappable, high
frequency switching, plug-in power supplies with built in
power factor correction employ forward conversion and are
designed to operate in a fault tolerant power system with
either a-c or d-c input. A thermistor soft-start circuit limits
start-up surge. A built-in forced current share circuit and
OR-ing diodes allow configuration for hot-swap and paral-
lel-redundant N+1 operation.
These power supplies are designed to be installed in
Kepco’s RA 19-(X)B Rack Adapters (Figure 2). RA 19-6B
accepts up to six 150W units, RA 19-7B accepts up to three
150W units, and up to four 50W or 100W units and RA 19-
8B accepts up to eight 50W or 100W units. The applicable
RA 19-(X)B Operator Manual can be downloaded from the
Kepco web site at:
www.kepcopower.com/support/opmanls.htm#ra19-xb
All input/output connections are through a 24 pin connector
that plugs into the rack adapter. All external connections
are made through the rack adapter.
Six models may be selected for outputs of 3.3, 5, 12, 15,
24, or 48V (see Table 1).
When the input is cut off, the output is maintained for 15
milliseconds minimum. If the power supply shuts down due
to an output overvoltage condition, it is then necessary to
wait 30 seconds minimum before turning the unit on again.
EMI filtering is designed to meet FCC Class B rating and
VDE 0871 Class B rating. Table 1 lists specifications for
each model of the HSF-PFC 50 Watt Series. See “SPECI-
FICATIONS” on page 4 for common specifications.
OPTIONS. Options are identified by suffix: T (-PFCT)
offers improved efficiency, less weight, and the addition of
a 28V, 50W model; C (-PFCC) offers current monitoring
via an integral current sensing resistor (includes option T),
X (-PFCX) offers remote on/off (includes option T); and Y
(-PFCY) includes options C, X and T.
TABLE 1. OUTPUT RATINGS AND SPECIFICATIONS, HSF-PFC 50W SERIES
MODEL HSF
3.3-10PFC
HSF
5-10PFC
HSF
12-4.3PFC
HSF
15-3.5PFC
HSF
24-2.2PFC
HSF
28-1.8PFC(4)
HSF
48-1.1PFC
OUTPUT VOLTS, d-c (NOMINAL) 3.3V 5V 12V 15V 24V 28V 48V
ADJUSTMENT RANGE 2.8 - 3.4V 4.3 - 5.3V 11.4 - 12.6V 13.5 - 16.2V 22.5 - 25.5V 22.4 - 30.2V 44.0 - 52.0V
OUTPUT CURRENT (NOMINAL)(1) 10A 10A 4.3A 3.5A 2.2A
(3.2A Peak)(6) 1.8A 1.1A
CURRENT LIMIT(2) 13.1A min 10.5A min 4.5A min 3.6A min 3.3A min
(2.3A min)(7) 1.9A min 1.15A min
OUTPUT POWER (MAX.)(3) 33W 50W 51.6W 52.5W 52.8W 50.4W 52.8W
SHORT CIRCUIT CURRENT(2) 16A 12.6A 5.6A 5.4A 6.2A 1.7A 2.4A
RIPPLE AND NOISE
(mV p-p)
0-40°C, 10-100%
LOAD
switching (typ) 80 80 100 100 100 150 130
spike noise
(d-c—50MHz) 120 120 150 150 150 200 200
OVERVOLTAGE SETTING
(25 °C, NOM. INPUT) 3.9 - 5.1V 5.7 - 6.4V 13.5 - 15.5V 16.8 - 18.8V 26.8 - 30.3V 32.0 - 35.0V 54.8 - 59.9V
SENSE RESISTOR (RS) value(5) 0.01 Ohm 0.01 Ohm 0.02 Ohm 0.03 Ohm 0.05 Ohm 0.05 Ohm 0.1 Ohm
(1) Derates same as Output Power.
(2) Current Limit is rectangular. After the overload is removed,
output is automatically restored.
(3) See power derating curve, Figure 3.
(4) 28V Model available with T, C, X and Y Options only.
(5) Sense resistor Included with C and Y models only.
(6) Peak current and thermal protection applicable to some 24V models:
standard (no options) and C option only.See Figure 1 for peak power
requirements.
(7) For 24V Model,s T, X and Y options only.

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II — FEATURES
FRONT PANEL ACCESS. The front panel provides a
power ON/OFF switch controlling input power and a “VDC
ON” light which indicates when the unit is operating.
NOTE: The ON/OFF switch must be set to OFF before
removing unit from rack adapter. The front panel “MAS-
TER ON” LED lights when 1) the unit operates indepen-
dently, or 2) the unit is used in parallel redundant
configurations while a) the output is less than 10% of
nominal or b) the output is within 10% to 100% of nominal
and the unit is functioning as a master. In parallel redun-
dant configurations, the module with the highest voltage
functions as the master. The other units are slaves, and
track the output voltage of the master. Refer to Current
Share Bus (CSB) on page 3 for details. (The MASTER
ON LED is not used on 3.3V model; it is always off.) The
front panel Vadj trimmer provides adjustment of the output
voltage within the limits specified in Table 1; test points
connected to the +S and –S lines are available at the front
panel for measuring the output.
FORCED CURRENT SHARE CIRCUIT. (Not avail-
able on 3.3V model.) When units are configured for N+1
parallel redundant operation, it is desirable for current to
be divided equally among the paralleled supplies. When
the CSB (Current Share Bus) lines of paralleled HSF-PFC
units are connected together, the load current is forced to
divide equally between all paralleled units. If one unit fails,
the remaining units will continue to supply the load, and
the load current will be divided equally among the remain-
ing operating units. The failed unit is automatically isolated
from the circuit by a built-in isolation diode. Refer to Cur-
rent Share Bus (CSB) on page 3 for details.
FIGURE 1. 24V MODEL PEAK CURRENT REQUIREMENTS
FIGURE 2. HSF-PFC 50 WATT POWER SUPPLIES (8) INSTALLED IN RA 19-8B RACK ADAPTER
REMOTE ON-OFF. Remote on-off (X and Y models
only) is via ±RC assigned to pins of the RA 19-(X)B I/O
connector: off = no voltage, short circuit, or 0 to 0.8V, on =
4.5 to 12.5V (or 12.5 to 24.5V via 1.5K Ohms). To reverse
on-off polarity contact Kepco. There is no isolation
between ±RC, d-c output and alarm circuit. Refer to the
applicable RA 19-(X)B Manual for details.
CURRENT MONITOR. Current monitor (C and Y mod-
els only) is via ±IMON assigned to pins of the RA 19-
(X)B I/O connector: Monitored Output Current (Amps) =
Voltage drop across Rs (Volts) / Rs (Ohms) (see Table 1),
where voltage drop across Rs is measured across ±
IMON pins (requires millivoltmeter, range 0 to 200mV).
Accuracy is ±10%; contact Kepco if greater accuracy is
required. There is no isolation between ±IMON, alarm cir-
cuit and d-c output. Refer to the applicable RA 19-(X)B
Manual for details.
3043527
I1
I2
T
t
D=(t/T)
Some 24V Models (standard (no options) and Option C)
can supply Peak current listed in Table 1 if the four condi-
tions listed below are met. These models include thermal
protection, voltage shutdown type. Restart by removing
a-c input; after sufficient cooling, reapply a-c input (wait
at least 30 seconds).
1. Time: t ≤ 10 Seconds
2. I1≤ Peak Current (Amperes)
3. Effective Current:
≤Rated current (Amperes)
4. Effective Power P ≤Maximum Power (Watts)
(output RMS current x output voltage)
DI1
2ID–()I2 2
×+

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090310 228-1532 REV 9 3
ALARM CIRCUIT. The HSF-PFC includes an isolated
internal relay offering normally closed and normally open
contacts referenced to an isolated common. These con-
tacts are rated for 1A at 30V d-c and 0.5A at 125V a-c.
These contacts may be used to configure “close on failure”
or “open on failure” alarm circuits. (Refer to the Series
RA 19-(X)B Manual for alarm configurations for multiple
HSF-PFC power supplies.) Any condition which causes the
unit to be out of specified voltage/current ranges (including
overvoltage, overcurrent, overtemperature, open sense
line, ac input line failure, etc.) results in an alarm.
KEYING. Keying of the HSF-PFC is established at the
factory. The output voltage determines which keyway is
open. When the corresponding rack adapter key (pin) is
installed by the user, only a power supply of the correct
voltage can be inserted in the rack adapter slot.
CONNECTIONS: The 24-pin I/O connector is designed
to mate with the corresponding connector in the Series RA
19-(X)B Rack Adapter.
FIGURE 3. % OUTPUT POWER RATING VS.
AMBIENT TEMPERATURE
(+) SENSE, (–) SENSE: These lines are provided to com-
pensate for voltage drops in the load connecting wires. The
Sense lines must be connected to their respective (+) and
(–) output terminals, either at the load or at the rack
adapter (see Rack Adapter Manual). The connection
ensures the most accurate error tracking. Error compensa-
tion in the connecting wires is up to 0.25 Volts per lead for
all models.
NOTE:
The Sense lines must be connected for the
HSF-PFC Power supply to work properly!
OUTPUT (+), OUTPUT (–): HSF-PFC power supply d-c out-
put.
CURRENT SHARE BUS (CSB): (Not available on 3.3V
model.) Connecting the CSB lines of HSF-PFC power sup-
plies operating in a parallel configuration causes output
current to be shared equally. (See Rack Adapter Manual
for additional information on parallel configurations.). For
current sharing to work properly the outputs of all paralleled
units must be within 250 mV (max) of each other and each
unit must be operating at between 10% to 100% of rated
output. If current to the load goes below 10% for each unit
in current share mode, all MASTER ON lights may go on
(see load effect specifications); this indicates that forced
current share is no longer working, units are simply in cur-
rent share mode. (If forced current sharing at less than
10% nominal current per supply is needed, contact Kepco
application engineering.) Remote sensing is recom-
mended. For master/slave operation to work properly each
unit should be adjusted to 40 mV (optimum) less than the
next paralleled unit (unit 1 is adjusted to VOUT
, unit 2 to
VOUT – 40mV, and unit 3 to VOUT – 80mV, etc. If the master
fails, the unit 2 will become the new master). The 40 mV
difference can be reduced to a minimum of 25 mV as
needed to parallel many units and still keep all units within
250 mV of each other. Adjust the outputs using Vadj trim-
mer on front panel.
• Optimum difference among output voltages of par-
alleled units: 40mV
• Maximum difference among output voltages of
paralleled units: 250 mV
• Minimum difference among output voltages of par-
alleled units: 25 mV
ALARM: The Alarm NC (normally closed) - Open on Fail-
ure and Alarm NO (normally open) - Close on Failure lines
are relay contacts referenced to Alarm Common. If the unit
fails, the path between Alarm NC - Open on Failure and
Alarm Common opens, the path between Alarm NO - Close
on Fail and Alarm Common is a short circuit. Figure 4 illus-
trates typical Close on Fail and Open on Fail circuits to give
a failure indication if any one of a number of power supplies
fail.
INPUT POWER: Line (either a-c or d-c source power), Neu-
tral and Ground (chassis)

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III — SPECIFICATIONS
The following specifications apply to all HSF-PFC 50 Watt
Series models (also refer to Table 1). Other models are
also available; consult your Kepco representative for their
specifications.
INPUT:
Voltage: 120V a-c/240V a-c nominal; Range 95-265V
a-c; 125-370V d-c. (polarity insensitive)
Frequency: Nominal 50-60 Hz; Range 47-440Hz (at
440Hz leakage current exceeds UL/VDE safety
spec.limit).
Current (nominal output at rated load):
0.8A rms max. (100-120 Va-c input, 100% load)
0.4A rms max. (200-240 Va-c input, 100% load)
3.3V Model:
0.7A rms max @100 - 120V a-c:
0.35A rms max. @200 - 240V a-c:
Initial Turn-on Surge: cold start 25 °C (First surge
only, not including the current flow into the EMI fil-
ter)
14A typ. (100 V a-c, 100% load);
28A typ. (200 Va-c, 100% load).
Brownout Voltage: 85V a-c, 110V d-c.
Switching Frequency: 140KHz typical, nominal load.
STABILIZATION:
Source Effect: Range 95-132V a-c or
190-265V a-c, 0.2% typ.; 0.3% max.
Load Effect: Range 10%-100% load
0.5% typ.; 1.5% max.
Temperature Effect: Range 0oto 40oC
0.5% typ.; 1.0% max.
Combined Effect: 0.9% typ.; 1.8% max. (includes
source, load, and temperature effects).
Time Effect (1/2 hr-8 hr at 25oC):
0.2% typ.; 0.5% max.
RECOVERY CHARACTERISTICS: A step load
change from 50% to 100% produces less than +4% output
excursion. Recovery occurs to within +1% of the original
setting in <1 ms (load change tr or tfequal to or greater
than 50µsec).
START-UP TIME: 500 ms. maximum.
HOLDUP TIME:
40 ms. typ., 20 ms. min. (100V a-c);
50 ms. typ., 25 ms. min. (240V a-c).
FIGURE 4. TYPICAL ALARM CIRCUIT DIAGRAMS
DIELECTRIC STRENGTH:
Between input and output:
2KV a-c for one minute.
Between input and output with Y-capacitor removed:
3KV a-c for one minute.
Between input and case (ground):
2KV a-c for one minute.
INSULATION RESISTANCE: Between input and
ground, output and ground, input and output:
100 Megohms min. (500V d-c).
LEAKAGE CURRENT
(UL method, 120V a-c): 0.24 mA maximum.
(VDE method, 240V a-c): 0.48 mA maximum.
POWER FACTOR:
0.99 typ. at 100V a-c,
0.95 typ. at 200V a-c
SAFETY: Units are designed to meet UL60950 3rd Edi-
tion, CSA 22.2 No. 60950 and EN 60950 and are CE
marked per the Low Voltage Directive (LVD), 73/23/EEC
and 93/68/EEC. [The standards do not apply with DC
input operation]

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EMI: Designed to meet FCC Class B (100-120V a-c) and
VDE 0871 Class B (220-240V a-c).
VIBRATION: (non-operating, one hour on each one of
the three axes):
5-10 Hz, 10 mm amplitude.
10-55 Hz, 2g acceleration.
SHOCK: (non-operating, one-half sinusoidal pulse, three
shocks to each axis):
Acceleration: 20g
Duration: 11ms +5ms
OPERATING TEMPERATURE: See Figure 3.
STORAGE TEMPERATURE: -40oC to +75oC.
RELATIVE HUMIDITY: Operating and storage:
up to 95% (wet bulb temp. <35oC non-condensing).
FUSE: Slow Blow, 2A, 250V; (5 x 20 mm),
Littelfuse, P/N 215002PG;
Kepco P/N 541-0137.
DIMENSIONS: See Figure 6.
WARRANTY: 5 years.
IV — INSTALLATION
MOUNTING THE POWER SUPPLY. Refer to Figure
2 and insert HSF-PFC power supply into selected slot of
RA 19-(X)B Rack adapter until power supply front panel is
flush with rack adapter chassis and secure with front panel
Phillips head mounting screw.
CONNECTIONS. All connections are made at the rear
panel of the RA 19-(X)B Rack Adapter (see applicable RA
19-(X)B Operator Manual). Connect the load to the applica-
ble ± DC OUTPUT terminals. AC input power to each slot
is applied via two INPUT POWER terminal blocks as indi-
cated on the rack adapter rear panel. Make sure to connect
the AC input Neutral, Line and Ground wires to the respec-
tive terminals of the terminal blocks.
REMOVAL. To remove a power supply, first use the
POWER switch to turn off the unit. Then loosen the mount-
ing screw and extract the unit from the RA 19-(X)B Rack
Adapter.
V — OPERATION
Turn the unit on using the front panel POWER switch (see
Figure 5). CAUTION: DO NOT repeatedly toggle the
POWER on/off switch as this may cause unit to fault.
FIGURE 5. COMPONENT LOCATIONS
When output voltage is available, the green VDC ON LED
is on. While monitoring output voltage at the front panel
test points, the Output Voltage Adjust trimmer allows
adjustment of the output voltage.
Master/slave parallel configurations of one or more HSF-
PFC power supplies are covered in the applicable RA 19-
(X)B Rack Adapter manual.
The MASTER ON LED (amber) goes on under any of the
following three conditions:
• Independent operation.
• Operation in a parallel master/slave configuration
to indicate which unit is the master
• Operation in a parallel master/slave configuration
to indicate that a slave unit is no longer within the
proper specifications for paralleled units. Slave 1
should be optimally adjusted to 40mV less than
master, slave 2 adjusted to 40mV less than slave
1, etc. The maximum allowable difference
between paralleled units is 250mv. The minimum
allowable difference between paralleled units is
25mV. If a slave exceeds these limits, the MAS-
TER ON light goes on.
NOTE: MASTER ON LED not used on 3.3V
model: always OFF.
Additional information for various parallel and alarm config-
urations can be found in the applicable RA 19 Rack
Adapter manual referenced on page 1.

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FIGURE 6. HSF-PFC 50W POWER SUPPLY OUTLINE DRAWING