VoxPower VCCR300 Series User Manual

Single output conduction cooled dc/dc

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VCCR300 Series
USER MANUAL
Single Output Conduction Cooled DC/DC
_______________________________________________________________________________________________
The VCCR300 series user manual has been prepared by our design team to assist qualified engineers in correctly
designing in the VCCR300 product into their application to achieve the best reliability and performance possible.
All specifications are believed to be correct at time of publishing. Vox Power Ltd reserves the right to make changes to any of its products and to change or improve any part of the
specification, electrical or mechanical design or manufacturing process without notice. Vox Power Ltd does not assume any liability arising out of the use or application of any of its products
and of any information to the maximum extent permitted by law. No license, express or implied, by estoppel or otherwise, to any intellectual property rights is granted by this document or
by any products of Vox Power Ltd. VOX POWER LTD DISCLAIMS ALL WARRANTIES AND REPRESENTATIONS OF ANY KIND WHETHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO,
IMPLIED WARRANTIES OF SUITABILITY, FITNESS FOR PURPOSE, MERCHANTABILITY AND NONINFRINGEMENT.
Please consult your local distributor or Vox Power directly to ensure that you have the latest revision before using the product and refer to the latest relevant user manual for further information
relating to the use of the product. Unless specifically otherwise agreed in writing by Vox Power, products sold by Vox Power are not intended for use in connection with life support systems,
human implantations, nuclear facilities or systems, aircraft spacecraft, military or naval missile, ground support or control equipment used for the purpose of guidance navigation or direction
of any aircraft spacecraft or military or naval missile or any other application where product failure could lead to loss of life or catastrophic property damage. The user will indemnify and hold
Vox Power harmless from any loss, cost or damage resulting from its breach of the provisions.

VCCR300 Series Overview

The VCCR300 series of conduction cooled power supplies have been designed to provide a rugged and highly reliable DC/DC power source that
can deliver a silent 300 Watts of power in a 7.43 x 4.6 x 1-inch low profile package. The input voltage has a wide range of 33.6V to 160V which covers
the full requirements for the standard 48V, 72V, 96V and 110V railway battery voltages outlined in EN50155 and suitable for a variety of Battery
Electric Vehicle (BEV) and other demanding industrial applications. The high efficiency design minimises heating resulting in a wide operating
temperature range of -40°C to +70°C (+85°C 10 mins) with minimal cooling requirement. Output voltages of 12V, 24V, 36V and 48V are available
with a wide adjustment range of 90% to 125%. Protections including over-voltage, over-current and over-temperature are provided while DC_OK
and warning signals indicate the status of the PSU. An adjustable droop mode current share allows multiple units to be paralleled while sharing the
load equally. Internal fusing and 10ms full power holdup are included as standard. A remote shutdown signal can place the unit in a low power
standby mode and the input undervoltage level can be adjusted to meet application requirements. The series meets the requirements of the latest
railway standards (EN50155), MIL-STD-810G (Shock & Vibration) and is approved to the latest industrial safety standards (IEC/UL62368-1 3
EMC emissions and immunity exceed the requirements of EN50121-3-2, EN55035 and EN55032 class B. As with all Vox products, our world class
sales, applications and engineering teams are available to support design-in of the VCCR300 series.
Page 1 of 20
Vox Power Limited | Unit 2, Red Cow Interchange Estate, Ballymount, Dublin 22, D22 Y8H2, Ireland | T +353 1 4591161 |
Ruggedised
for long term reliability
7.43" x 4.6" x 1"
Low Profile
300W | 600W | 900W
Scalable
33.6-160V
DC
Wide input voltage range
Fan-less
Reliable
DOC-MN-009-03, VCCR300 User Manual
RD
Edition).
www.vox-power.com

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Summary of Contents for VoxPower VCCR300 Series

  • Page 1: Vccr300 Series Overview

    VCCR300 Series Overview The VCCR300 series of conduction cooled power supplies have been designed to provide a rugged and highly reliable DC/DC power source that can deliver a silent 300 Watts of power in a 7.43 x 4.6 x 1-inch low profile package. The input voltage has a wide range of 33.6V to 160V which covers the full requirements for the standard 48V, 72V, 96V and 110V railway battery voltages outlined in EN50155 and suitable for a variety of Battery Electric Vehicle (BEV) and other demanding industrial applications.
  • Page 2: Table Of Contents

    Contents VCCR300 Series Overview Contents Part Numbers and Ordering Information Installation Notes Product Operation User controls Efficiency Performance Mechanical Dimensions and Mounting Safety EMC Compliance Reliability Installing your VCCR300 Product Page 2 of 20 Vox Power Limited | Unit 2, Red Cow Interchange Estate, Ballymount, Dublin 22, D22 Y8H2, Ireland | T +353 1 4591161 | www.vox-power.com...
  • Page 3: Part Numbers And Ordering Information

    Part Numbers and Ordering Information SUMMARY SPECIFICARIONS Efficiency RATED RATED Model RATED VCCR300-12 10.8 VCCR300-24 21.6 12.5 VCCR300-36 32.4 8.33 VCCR300-48 43.2 6.25 Vin = 110V, Vo = V , 100% load. PART NUMBERING SYSTEM SERIES VCCR300 Factory use Standard nominal output voltage 12/24/36/48 Contact your Distributor or Vox Power representative for information regarding non-standard requirements Page 3 of 20...
  • Page 4: Installation Notes

    Installation Notes The instructions in this manual and all warning labels on the product must be followed carefully. PRODUCT USE Vox Power Ltd products are not intended for use in connection with life support systems, human implantations, nuclear facilities or systems, aircraft, spacecraft, military or naval missile, ground support or control equipment used for the purpose of guidance navigation or direction of any aircraft, spacecraft or military or naval missile or any other application where product failure could lead to loss of life or catastrophic property damage.
  • Page 5 Installationshinweise Die Anweisungen in dieser Anleitung und alle Warnhinweise auf dem Produkt sind sorgfältig zu befolgen. PRODUKTVERWENDUNG Produkte von Vox Power Ltd sind nicht vorgesehen für den Gebrauch in Zusammenhang mit Lebenserhaltungssystemen, menschliche Implantaten, Nuklearanlagen oder -systemen, Flugzeugen, Raumfahrzeugen, militärischen Lenkflugkörpern, boden- oder steuerungstechnischem Gerät für den Einsatz zum Zwecke der Navigation oder Lenkung von Flugzeugen, Raumfahrzeugen oder Lenkflugkörpern oder sonstigen Anwendungen, bei denen ein Produktversagen zum Tode oder zu katastrophalen Schäden führen kann.
  • Page 6 Instrucciones de instalación Las instrucciones de este manual y las etiquetas de advertencia del producto se deben seguir estrictamente. USO DEL PRODUCTO Los productos de Vox Power Ltd no están destinados a su conexión a sistemas de soporte vital, implantaciones en personas, instalaciones o sistemas nucleares, aviones, vehículos espaciales, misiles militares o navales, equipamiento de soporte o control terrestre utilizado para guiar la navegación o la dirección de aviones, vehículos espaciales o misiles militares o navales o cualquier otra aplicación en las que una avería del producto pudiera provocar la pérdida de vidas o daños catastróficos en propiedades.
  • Page 7 Remarques relatives à l'installation Les instructions de ce manuel et les étiquettes d'avertissement présentes sur le produit doivent être respectées scrupuleusement. UTILISATION DU PRODUIT Les produits Vox Power Ltd ne sont pas destinés à être utilisés dans des systèmes de survie, des implants chirurgicaux, des installations ou systèmes nucléaires, des aéronefs, des engins spatiaux, des missiles militaires ou navals, des équipements de soutien au sol ou de commande utilisés à...
  • Page 8 Note per l’installazione Seguire scrupolosamente le istruzioni del presente manuale e le indicazioni di tutte le etichette di avvertenza presenti sul prodotto. USO DEL PRODOTTO I prodotti Vox Power Ltd non sono previsti per l’uso in relazione a sistemi di supporto delle funzioni vitali, impianti su esseri umani, impianti o centrali nucleari, aeroplani, veicoli spaziali, missili navali o per usi militari, apparecchiature di controllo o supporto di sistemi terrestri impiegati per la guida o l’orientamento di qualsiasi aerodina, missili navali oppure per usi militari o veicoli spaziali o qualunque altra applicazione in cui un guasto al prodotto potrebbe comportare la perdita di vite o danni catastrofici alle cose.
  • Page 9 Informações sobre a instalação As instruções neste manual e em todas as etiquetas de aviso afixadas no produto devem ser cuidadosamente observadas UTILIZAÇÃO DO PRODUTO Os produtos da Vox Power Ltd não se destinam a ser utilizados em sistemas de suporte de vida, sistemas para implantação no corpo humano, instalações ou sistemas nucleares, aeronaves, naves espaciais, mísseis militares ou navais, equipamento de suporte no solo ou de controlo para fins de guiamento de navegação ou orientação de aeronaves, naves espaciais ou mísseis militares ou navais ou quaisquer outras aplicações onde a falha do produto possa conduzir à...
  • Page 10: Product Operation

    Product Operation System overview The diagram below outlines the topology and major internal components of a VCCR300 power supply. The DC input is fused in the positive line and filtered before being boosted to an appropriate DC voltage. The integrated EMI filter attenuates high frequency current emissions to levels below EN55032 class B and provides protection from input disturbances.
  • Page 11 No Load Power Consumption The VCCR300 series has an extremely low no-load power consumption of <1.5W. To achieve this the unit enters burst mode when the output power is below 3W. When in burst mode the output ripple frequency will reduce significantly.
  • Page 12 Output Transient Response The VCCR300 series uses the latest current mode control algorithms to achieve a fast (<1mS) and stable response to dynamic loading. Where large dynamic loading and tight voltage deviation specification are required, additional low impedance external capacitance should be placed at the load.
  • Page 13: User Controls

    User Controls Output voltage adjustment (VOUT_ADJ) Common (SCOM) The output voltage can be adjusted by connecting VOUT_ADJ to COM (J2 This is the return reference for the following secondary side controls. pin 1 to pin 2) through an external resistor according to the formula below, VOUT_ADJ, DC_OK, WARN, IOUT &...
  • Page 14: Efficiency Performance

    Efficiency Performance The efficiency of the VCCR300 product is dependent on parameters such as input voltage, output power and on the model. The plots below show typical efficiencies of a VCCR300 product for the standard output voltages. The plots cover the full load and input voltage range. TYPICAL EFFICIENCIES Typical efficiency (48V Load (W)
  • Page 15: Mechanical Dimensions And Mounting

    Mechanical Dimensions and Mounting Baseplate temperature measurement point Chassis base material: Aluminium, Anodised Chassis cover material: Steel, Powder coated CONNECTORS AND PINOUT J3 - DC output voltage J2 - User Controls J1 - DC input voltage WAGO 2626-1102/020-004 WAGO 713-1425/037-000, Mating: WAGO 713-1105/037-047 WAGO 2626-1103/020-004 Function Function...
  • Page 16: Safety

    Safety The VCCR300 unit has been designed to comply with the Low Voltage Directive DIR 2014/35/EU (LVD), the EMC Directive DIR 2014/30/EU and DIR 2011/65/EU regarding the restriction of certain hazardous substances and is CE marked to show its compliance. When correctly installed (per the installation instructions in this manual) in a limited access environment the VCCR300 comply with the requirements of IEC/EN/UL/CSA 62368-1:2018 and EN50155:2021.
  • Page 17: Emc Compliance

    EMC Compliance To support compliance of the final system design with the EMC directive 2014/30/EU, the VCCR300 PSU has been designed and tested to the following standards. ELECTROMAGNETIC COMPLIANCE – EMISSIONS Phenomenon Port Reference Standards Test Details EN50155:2021 cl.13.4.9 30MHz to 1GHz. Radiated emissions, EN50121-3-2:2016 cl.7 Enclosure...
  • Page 18: Reliability

    Reliability The VCCR300 series has been designed to be extremely rugged and reliable. All opto-couplers have been eliminated from the design, only a minimum number of high reliability electrolytic capacitors are used, and the internal assembly is covered with a protective coating. The series has undergone extensive testing, including HALT and Environmental testing.
  • Page 19: Installing Your Vccr300 Product

    Installing your VCCR300 Product The VCCR300 power supply is designed to be used as part of an end-system in a restricted environment and therefore should only be accessible to qualified and trained personnel. Persons attempting to install a unit must have the necessary knowledge and training before doing so. Incorrect installation may cause damage to the power supply and may affect the warranty.
  • Page 20 Connecting units in parallel VCCR300 units of the same type can be paralleled in any number to achieve higher output currents. To parallel the outputs simply connect all the positive power cables together and all the negative power cables together. No other external circuitry is necessary. For best performance and increased reliability, it is recommended to enable share mode on each unit (See “User Controls: Share Mode (Droop)”...

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