page 1
gen
Contents
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Overview of Xgen series
Part numbering system
Installation considerations
Xgen DOs and DON’Ts
Theory of operation
Xgen configuration
powerMod
operation
powerMod
signals
powerPac
operation
powerPac
(global) signals
powerPac
options
Power ratings
Reliability
Safety
EMC
Connectors
Mechanical specifications
Configuring Xgen
The Xgen series allows users to instantly configure high efficiency, off-line power sup-
plies. Although very small in size, (40.4mm high, 260mm long and either 89mm or
127mm wide) the Xgen series provides up to 1,200W of output power. The chassis has
4 or 6 slots and can provide up to 12 isolated outputs.
A complete power supply is configured by selecting and inserting up to six same length
slide-in output assemblies called powerMods incorporating high efficiency switching
techniques and leading edge technologies from Excelsys and available in a wide array
of output voltages and power levels. The net result is a power supply that offers the
advantages of a custom supply, but is assembled from standard and modular building
blocks continuing the Excelsys tradition of industry leading configurable power supplies.
Manufactured in world class power supply facilities under Excelsys control, the Xgen
series is completely user configurable. If output requirements change, i.e., more power
or a different output voltage is needed, upgrading is easy: simply unlock a single screw
and replace the slide-in powerMod assembly with the preferred alternative. Allowing
additional flexibility, powerMods can be connected in parallel to increase output power,
or in series for higher voltages (subject to staying within isolation ratings and giving due
consideration to any SELV requirements.
A user-friendly interface on connector J3 of each powerMod provides control and out-
put sequencing capability, in addition to useful status indicators. Please consult our
Excelsys applications team if you have other special requirements.
The Xgen series power supplies combine feature-laden front-ends (powerPacs) with
slide-in output converters (powerMods). The plug-together architecture facilitates
‘instant’ custom power solutions with industry leading 15W/in
3
power density and up to
90% conversion efficiency. Available in two package sizes, with a variety of application
specific powerPacs, the Xgen series provides a standard off-the-shelf solution for spe-
cific application requirements.
The tables overleaf summarise various model families in the Xgen series together with
a summary of the outline specifications for each model.
Designers’ Manual
This Xgen Designers’ Manual has been prepared by Excelsys experts to assist
suitably qualified engineers and technicians in understanding the correct
system design practices necessary to achieve maximum versatility and
performance from any of the Xgen series family of products.
Section 1
Overview of Xgen series
www.excelsys.com
page 2
powerPacs
General Applications (4slot package, 89mm wide)
Family
X
lite
MODEL
XLA
XLB
XLC
XLD
Watts
200W
400W
600W
750W
powerMods
MODEL
Xg1
Xg2
Xg3
Xg4
Xg5
Vmin
1.0
1.5
4.0
8.0
8.0
5.0
V1
V2
Vnom
2.5
5.0
12.0
24.0
48.0
24.0
24.0
24.0
Vmax
3.6
6.0
15.0
30.0
58.0
30.0
28.0
28.0
Imax
50A
40A
20A
10A
6A
5A
3A
3A
Imin
0A
0A
0A
0A
0A
0A
0A
0A
Type
A
A
A
A
A
A
B
Watts
125W
200W
240W
240W
288W
120W
72W
72W
General Applications (6slot package, 127mm wide)
Family
X
cite
MODEL
XCA
XCB
XCC
XCD
XCE
Watts
400W
700W
1000W
1200W
1340W
Xg7
Xg8
5.0
5.0
See Section 12:Power Ratings for detailed
powerMod
ratings
Medical Applications (4slot package, 89mm wide)
Family
X
mite
MODEL
XMA
XMB
XMC
XMD
Watts
200W
400W
600W
750W
Medical Applications (6slot package, 127mm wide)
Family
X
vite
MODEL
XVA
XVB
XVC
XVD
XVE
Watts
400W
700W
1000W
1200W
1340W
Standard Features
• Input Voltage: 85V to 264Vac 47 to 63 Hz
• Outputs: 6 slots (up to 12 outputs)
• Full power output to 40°C; Derating to 70°C
• Low inrush current
• Conducted EMI meets EN 55022 Level B
• AC Fail status signal
• Output Sequencing capability
• Global shutdown capability
• Overcurrent protection standard on all outputs.
• Overvoltage protection on all
powerMod
outputs
• Overtemperature limiting on all
powerMods
• Safety Agency Approvals: CE Mark, UL, CSA
• DC OK (Power Good) status signal
• Wide output voltage adjustment range
• RoHS compliant
Optional Features
• Thermal Signals suite (Over Temp and FanFail signals)
• Reversed fan airflow direction
High Temperature (6slot package, 127mm wide)
Family
X
hite
MODEL
XHA
XHB
Watts
400W
600W
Section 2
Part numbering system
Low Acoustic Noise (4slot package, 89mm wide)
Family
X
kite
MODEL
XKA
XKB
XKC
Watts
200W
400W
600W
The part numbering system (explained below) clearly identi-
fies which
powerMods
are factory installed into particular
powerPacs.
This is also clearly indicated on the output label
situated on top of the power supply.
Full specifications for each model are given in the relevant
family datasheets,
Low Acoustic Noise (6slot package, 127mm wide)
Family
X
qite
MODEL
XQA
XQB
XQC
Watts
400W
900W
1200W
Factory use only
X C D 1 2 3 4 5 6 P 03 A
Model(a)
Power(b)
Slot A powerMod (c)
Slot B powerMod
Slot C powerMod
Sum of option codes(d)
‘-’,P for a configured unit (e)
Slot F powerMod
Slot E powerMod
Slot D powerMod . . . . . . . . .
Medical Low Acoustic Noise (4slot package, 89mm wide)
Family
X
rite
MODEL
XRA
XRB
XRC
Watts
200W
400W
600W
Medical Low Acoustic Noise (6slot package, 127mm wide)
Family
X
zite
MODEL
XZA
XZB
XZC
Watts
400W
900W
1200W
(a)Letter refers to relevant Xgen family ‘C’ for cite, ‘V’ for vite etc
(b)Letter refers to power level within family, D for 1200W in Xcite
(c)Number refers to powerMod type. ‘1’ for Xg1, ‘2’ for Xg2 etc, ‘0’ if unused
(d)Number refers to Option codes, -01 for temps alarms, -02 for reverse fan
(e)‘P’ for configured (voltage settings etc), ‘-’ for non configured
See Section 12:Power Ratings for detailed
powerPac
ratings
page 3
Section 3
Installation considerations
Xgen series models may be mounted on any of three sur-
faces using standard M4 screws. The chassis comes with four
mounting points on the base; maximum allowable torque is
2Nm. The maximum penetration depth is 6mm. Additionally,
the fleximount
TM
system on both side walls of the powerPac
chassis facilitates flexible mounting. See Section 17 for further
information.
When selecting a mounting location and orientation, the unit
should be positioned so air flow is not restricted. Maintain a
50mm minimum clearance at both ends of the Xgen power
supply and route all cables so airflow is not obstructed. The
standard unit draws air in on the input side and exhausts air
out the load side. If airflow ducting is used, avoid sharp turns
that could create back pressure. The fan moves 8.78 CFM of
air.
Avoid excessive bending of output power cables after they are
connected to the Xgen
powerMods.
For high-current outputs,
use cable-ties to support heavy cables and minimize mechan-
ical stress on output studs. Be careful not to short-out to
neighboring output studs. Xgen
powerMods
are supplied with
spring washers on all output screws. These (or equivalents)
should be used and thread locking compounds are not
required. The maximum torque recommended on output con-
nectors is 4Nm. Avoid applications in which the unit is
exposed to excessive shock or vibration levels that exceed
the specified levels. In such applications, a shock absorption
mounting design is required.
• Do not restrict airflow to the unit. The cooling fan draws air
into the unit and forces it out at the output terminals.
• Always ensure that output screws are properly torqued
before applying power to the
powerPac.
• Positive and Negative power cables should be run next to
each other to minimize inductance.
• Wait 4 minutes after shutting off power before inserting or
removing
powerMods.
• Xgen assemblies do not have user serviceable components.
They must be returned to the factory for repairs. Contact
Customer Service for a RMA number before returning the
unit. Do not attempt to repair or modify the power supply in
any manner other than the exchange of
powerMods
as
described in this Designers’ Manual.
• Use proper size wires to avoid overheating and excessive
voltage drop.
Section 5
Theory of operation
The Xgen is comprised of an appropriate
powerPac
and a
selection of
powerMod
DC output modules selected to deliver
the exact volts and amps requirements of the the system
designer. See Operational Block Diagram below.
The Xgen
powerPac
modules consist of a fan-cooled semi-
enclosed chassis containing circuitry for an off-line single
phase AC front end, EMI filter, cooling fan, customer interface
and associated housekeeping circuits. Input AC mains voltage
(L1/N, L2 and GND) is applied to an IEC320 type input con-
nector and then through an EMI filter designed to meet EN
55022 Level B. For medical applications, the EMI filter also
ensures the the power supply meets the low earth leakage
current requirements of EN60601-1
At start-up, inrush current is limited by an active soft-start cir-
cuit integrated with the power rectifier circuitry. This stage is
then followed by a high frequency switching input current
shaping boost converter feeding the ZVS (Zero Voltage
Switching) resonant switching stage. The ZVS stage supplies
power to a variety of
powerMod
assemblies that provide the
desired low voltage, regulated outputs. Conversion in the out-
put assemblies is achieved by the most advanced high effi-
ciency converters resulting in reduced size for magnetics and
capacitors; excellent line and load regulation; wide adjustment
range for output and low EMI/RFI emission.
Section 4
Xgen DOs and DON’Ts
• Always fill all output slots of the Xgen. If a slot is not filled
with a
powerMod,
it should be filled with an Empty Slot Cover
(part numbers XB1,XB2 or XB3). Empty Slot covers are plas-
tic assemblies whose main function is to fill up an empty slot.
Excessive airflow escape from an empty slot may degrade
thermal performance, and result in overheating and damage
to the Xgen unit. Refer to Section 12 for optimum positioning
of
powerMods.
• Do not unplug
powerMods
while input power is applied to
the powerPac. The Xgen series is not designed for hot-plug
applications.
page 4
At initial power-up, the Xgen outputs are disabled to eliminate
inrush current and a low-power flyback converter operating
with PWM currentmode control converts the high voltage DC
bus into regulated low voltage to power the internal house-
keeping circuits and cooling fans. Once the bus potential is
within operating parameters, the AC Fail signal is activated
indicating that the input power is OK, and allows the installed
powerMod
outputs to come up. An auxiliary bias supply of 5
Vdc rated at 250mA is provided for peripheral use on inter-
face connector J2. In the case of medically approved sup-
plies, this bias supply has medical isolation (4000VAC).
Outputs may be either globally enabled or inhibited via con-
tact closure signals applied to J2.
1. Front-panel potentiometer adjustment
2. Remote resistive programming
3. Remote voltage programming
See diagrams for details on external connections to the V trim
pin (J3 pin3) required for remote voltage programming.
Section 6
Configuration
(and Reconfiguration)
powerMods
may be easily added, replaced, or moved by slid-
ing the assemblies in or out of a powerPac chassis.
Prior to removing or installing a
powerMod
module, remove
power from the
powerPac
and wait 4 minutes. Failure to do
so can result in personal injury and/or damage to the supply.
Take standard ESD precautions when handling
powerMods.
Configuring the Xgen is as easy as 1,2,3!.
1. Select the appropriate powerMods for your application.
2. Calculate your power requirements
3. Select your appropriate powerPac for power and applica-
tion from the wide range of powerPacs listed on page 2.
See Section 18 for Configuration examples
Removing
powerMods
powerMods
may be removed by removing the screw on the
top surface. Once this screw has been removed the
powerMod
will slide out of the chassis. Once a
powerMod
has
been removed, the empty slot MUST be filled with either
another
powerMod
or an employ slot cover. If the slot is left
empty, it will provide an airflow escape and may cause inad-
vertent shutdown of the unit
.
Installing
powerMods
powerMods
may be installed in empty slots by simply sliding
in the new
powerMod,
pushing the module ‘home’ until the
mounting bracket lines up with the hole in the Top Panel, then
securing the module with the M3 x 6 countersunk screw pro-
vided. Power and interface connections can be made after
the
powerMod
has been installed.
powerMods
may be paralleled for more power using bus bars
(paralleling Links) across the positive and negative output ter-
minals. See Section 7
Remote Voltage Programming using a Voltage Source
Using an external Voltage source (Vcontrol), the
powerMod
output voltage may be adjusted over a wide range. The
powerMod
output voltage may be programmed by referring to
the Voltage Programming graph and applying formula below
to set the
powerMod
output voltage to the required level.
Voutput = K x Vcontrol
(1)
The appropriate K factor for different powerMods are in
Voltage Programming table.
Important: Vcontrol must not exceed 2.5V.
e.g. Vnom of Xg3 is 12V, trim range is 3.6V to 15.0V
Voltage Programming Table
powerMod
Xg1
Xg2
Xg3
Xg4
Xg5
K
1.5
2.5
6.25
12.5
24.25
Section 7
powerMod
operation
The Xgen series of products have been designed to allow
maximum flexibility in meeting the unique requirements of
individual users. The inherent flexibility resulting from modu-
larity concepts is further enhanced by this flexibility. Although
the products are very versatile, care should always be taken
to ensure that the proper procedures are followed.
Voltage Adjustment
The Xgen series has been designed with maximum user flexi-
bility as a key objective. With regards to voltage adjustment
this has been achieved by the wide range of adjustment on
each of the
powerMod
models. Voltage adjustment may be
achieved by:
Example
Using a powerMod Xg4, what external voltage must be
applied to Vtrim pin in order to set powerMod output voltage
to 20V.
page 5
PowerMod
Vmin
Vnom
Vmax
Imax
II
limit
adjust
Min
Max
Current
Limit
Onset
SC*
I foldback
Vtrim
range
Min
Max
Itrim
range
Min
Max
OVP 1
OVP 2
Remote
Sense
J3 Signals
Tracking
Latching
% of Vset % of Vmax
+Sense
Vtrim
Inhibit
+PG
+Sense
Vtrim
Inhibit
+PG
+Sense
Vtrim
Inhibit
+PG
+Sense
Vtrim
Inhibit
+PG
+Sense
Vtrim
Inhibit
+PG
+PG
-PG
Inhibit
Common
-Sense
Itrim
Enable
-PG
-Sense
Itrim
Enable
-PG
-Sense
Itrim
Enable
-PG
-Sense
Itrim
Enable
-PG
-Sense
Itrim
Enable
-PG
0A
Xg1
1.5V
2.5V
3.6V
50A
55.0A
55.0A
Yes
58.0A
1.0V
3.9V
0A
110-115%
55.0A
110-125%
0.5V
0A
Xg2
3.2V
5.0V
6.0V
40A
44.0A
44.0A
Yes
46.0A
1.5V
6.6V
0A
110-115%
44.0A
110-125%
0.5V
0A
Xg3
6.0V
12.0V
15.0V
20A
22.0A
22.0A
Yes
23.0A
3.6V
16.5V
0A
110-115%
22.0A
110-125%
0.5V
0A
Xg4
12.0V
24.0V
30.0V
10A
11.0
11.0A
Yes
12.0A
7.2V
30.0V
0A
110-115%
11.0
110-125%
0.5V
0A
Xg5
28.0V
48.0V
58.0V
6A
6.6A
6.6A
Yes
7.0A
7.2V
58.0V
0A
110-115%
6.6A
110-125%
0.5V
5.5A
Xg7
5.0V
24.0V
30.0V
5A
No
6.0A
No
No
No
No
110-125%
No
3.3A
Xg8
V1
5.0V
24.0V
28.0V
3A
No
4.0A
No
No
No
No
110-125%
No
V1
+PG
-PG
Inhibit
Common
V2
+PG
-PG
Inhibit
Common
3.3A
Xg8
V2
5.0V
24.0V
28.0V
3A
No
4.0A
No
No
No
No
110-125%
Voutput = 20V, K=12.5
Using equation (1); Voutput/K=Vcontrol
20V/12.5 = 1.6V.
Vcontrol = 1.6V
Remote Voltage Programming using a Resistor.
The
powerMod
output voltage can be adjusted downward
using a remote potentiometer,or reduced, using an external
resistance.
Calculation of the the external resistance depends on the
actual initial voltage setting of the
powerMod
(via the onboard
potentiometer). The preferred method is to set the
powerMod
voltage to its maximum rating. e.g. Xg4 set to 30V. This will
allow the widest possible adjustment range of the output volt-
age.
powerMod
set to V
max
For modules Xg1 and Xg2
R
trim
= [3700V
out
- 250K]
[2.5K-V
out
]
(2)
For powerMod Xg1 and Xg2
R
trim
= V
out
[(3700 +10KVp(1-Vp)] -K(100Vp+67.5)
K(Vp +0.675) -V
out
(3)
For powerMod Xg3, Xg4 and Xg5
R
trim
= V
out
[(3700 +10KVp(1-Vp)] -K(100Vp+127.50) (4)
[K(Vp +1.275) -V
out
where Vp is the
powerMod
setpoint voltage expressed as a
proportion of the total trim range.
Vp =(V
set
-V
min
)
(V
max
-V
min
)
(5)
Example.
To set
powerMod
Xg4 to 15V when
powerMod
Vset is 21V
Using equation (5) Vp = (21-12)
(30-12)
Vp =0.5
K= 12.5
Vout =15V
Using equation (4)
R
trim
= V
out
[(3700 +10KVp(1-Vp)] -K(100Vp+127.5)
[K(Vp +1.275) -V
out
]
Rtrim = 7478 ohm
The power rating of the trim resistor can be as low at 100mW
Example.
Using a
powerMod
Xg4, determine the resistance value to be
applied to V
trim
pin in order to set
powerMod
output voltage to
20V.
K for Xg4 = 12.5
Vout = 20V
Using equation (2)
R
trim
= 6300 ohm
Alternatively if the
powerMod
voltage is set to new level via
the on-board potentiometer to another level e.g. 21V then the
following formula must be used to calculate the value of R
trim
Over Current Protection (OCP)
A variety of over current protection methods are possible with
the Xgen series. See the
powerMod
table which indicates the
available current limit modes on each
powerMod.
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