Cassette Style DC-DC Converters 50 Watt DC-DC Converters H Series H Series Wide input voltage ranges up to 60 V DC 1, 2 or 3 outputs up to 48 V DC 3 kV DC I/O electric strengh test voltage * Wide input voltage range suitable for battery operation * Efficient input filter and built-in surge and transient suppression circuitry * Outputs individually isolated * Outputs fully protected against overload Safety according to IEC/EN 60950 LGA 111 4.37" 3U Summary The H series of DC-DC converters represents a broad and flexible range of power supplies for use in advanced electronic systems. Features include high efficiency, reliability and reasonable output voltage noise. The converter inputs are protected against surges and transients occuring at the source lines. An input over- and undervoltage cut-out circuitry disables the outputs if the input voltage is outside the specified range. All outputs are open- and short-circuit proof and are protected against overvoltages by means of built-in suppressor diodes. The outputs can be inhibited by a logic signal applied to the connector pin 2 (i). If the inhibit function is not used pin 2 should be connected to pin 23 to enable the outputs. LED indicators display the status of the converter and allow visual monitoring of the system at any time. Full input to output, input to case, output to case and output to output isolation is provided. The modules are designed and built according to the international safety standard IEC/EN 60950 and have been approved by the safety Table of Contents 39 1.54" 8 TE 168 6.6" agencies LGA (Germany) and UL (USA). The UL Mark for Canada has been officially recognized by regulatory authorities in provinces across Canada. The case design allows operation at nominal load up to 50C in a free air ambient temperature. If forced cooling is provided, the ambient temperature may exceed 50C but the case temperature should remain below 80C under all conditions. A temperature sensor generates an inhibit signal which disables the outputs if the case temperature TC exceeds the limit. The outputs are automatically re-enabled when the temperature drops below the limit. Various options are available to adapt the converters to individual applications. The modules may either be plugged into 19 inch rack systems according to DIN 41494, or be chassis mounted. Page Page Summary .......................................................................... 1 Type Survey and Key Data .............................................. 2 Type Key .......................................................................... 2 Functional Description ...................................................... 3 Electrical Input Data ......................................................... 4 Electrical Output Data ...................................................... 5 Auxiliary Functions ........................................................... 8 Electromagnetic Compatibility (EMC) ............................ 10 Mechanical Data ............................................................ 11 Immunity to Environmental Conditions ........................... 12 Safety and Installation Instructions ................................ 12 Description of Options .................................................... 15 Accessories .................................................................... 19 Edition 5/5.2000 1/19 Cassette Style DC-DC Converters H Series Type Survey and Key Data Table 1: Type survey Input Voltage Range and Efficiency 1 Output 1 Output 2 Output 3 Uo nom Io nom [V DC] [A] Uo nom Io nom [V DC] [A] Uo nom Io nom [V DC] [A] Option Ui min...Ui max 8...15 V DC 2 h min [%] Ui min...Ui max 14...30 V DC 2 h min [%] Ui min...Ui max 28...60 V DC 2 h min [%] 5.1 12.0 15.0 24.0 48.0 8.0 4.0 3.4 2.0 1.0 - - - - 12H1001-2R 12H1301-2R 12H1501-2R 12H1601-2R 12H1901-2R 2 73 79 80 81 83 24H1001-2R 24H1301-2R 24H1501-2R 24H1601-2R 24H1901-2R 2 75 82 82 83 85 48H1001-2R 48H1301-2R 48H1501-2R 48H1601-2R 48H1901-2R 2 76 82 83 85 86 12.0 15.0 2.0 1.7 12.0 15.0 2.0 1.7 - - 12H2320-2 12H2540-2 79 80 24H2320-2 24H2540-2 80 81 48H2320-2 48H2540-2 82 83 5.1 5.1 5.0 5.0 12.0 15.0 0.7 0.6 12.0 15.0 0.7 0.6 12H3020-2 12H3040-2 77 77 24H3020-2 24H3040-2 78 79 48H3020-2 48H3040-2 79 80 V2, V3 D1...D8 -7 1Efficiency 2 measured at Ui nom and Io nom Input voltage range 12H1901-2R: 9...15 V DC, 24H1901-2R: 18...30 V DC, 48H1901-2R: 36...60 V DC Type Key and Product Marking Type Key 48 H 2 5 40 -2 R D V Input voltage range Ui : 8...15 V DC ............. 12 14...30 V DC ............. 24 28...60 V DC ............. 48 Series .............................................................................. H Number of outputs ...................................................... 1...3 Output 1, Uo1 nom : 5.1 V 12 V 15 V 24 V 48 V ............... 0 ............... 3 ............... 5 ............... 6 ............... 9 Single output modules ................................................... 01 12 V ............. 20 Output 2 and 3, Uo2 nom, Uo3 nom: 15 V ............. 40 Options and features: Ambient temperature range TA -10...50C ..................... -2 Extended temperature range TA -25...71C .................... -7 Output voltage control input (single output modules only)R Save data signal (D1...D8, to be specified) ..................... D 1 ACFAIL signal (V2, V3, to be specified) ........................... V 1 1 Option D excludes option V and vice versa Example: Edition 5/5.2000 48H1501-2RD3: DC-DC converter, input voltage range 28...60 V, providing output with 15 V/3.4 A; equipped with an output voltage control input and undervoltage monitoring. 2/19 Cassette Style DC-DC Converters H Series Functional Description The input voltage is fed via an input filter to the input capacitor. This capacitor sources a single transistor forward converter. Each output is powered by a separate secondary winding of the main transformer. The resultant voltages are rectified and their ripples smoothed by a power choke. The control logic senses the main output voltage Uo1 and generates, with respect to the maximum admissible output currents, the control signal for the primary switching transistor. This signal is fed back via a coupling transformer. The auxiliary outputs Uo2 and Uo3 are unregulated. Each auxiliary output's current is sensed and transferred to the main control circuit using a current transformer. If one of the outputs is driven into current limit, the other outputs will reduce their output voltages as well because all output currents are controlled by the same control circuit. 03067 1 Main control circuit 1 29 Forward converter approx. 70 kHz 32 Y 26 1 5 D/V 14 R 17 G 23 Input filter Vi- i 20 Y Vi+ 2 CMKT 14 Current limitation output 2 17 CMKT 8 Current limitation output 3 11 Y Y Y Single output modules H1000 (R input) Fig. 1 DC-DC converter block diagram Edition 5/5.2000 3/19 Cassette Style DC-DC Converters H Series Electrical Input Data General conditions: - TA = 25C, unless TC is specified. - Connector pins 2 and 23 interconnected, R input not connected. Table 2: Input data Input 12H Characteristics Ui Conditions Operating input voltage Io = 0...Io nom T ...TC max ..H1901-2R C min min Input current U i nom, Io nom 1 Pi 0 No-load input power: Single output Double output Triple output Ui nom I o1,2,3 = 0 Idle input power inhibit mode Peak inrush current Ui = Ui max RS = 0 2 TC = 25C Pi inh I inr p 3 t inr r Rise time t inr h Time to half value Ri Input resistance Ci Input capacitance TC = 25C Ui abs Input voltage limits without any damage 24H max min 15 14 15 18 8 9 Ui nom Nominal input voltage Ii typ 48H typ max min 30 28 30 36 typ 24 48 5.0 2.5 1.3 1.5 6 6 1 4 4 1.5 6 6 Unit 60 V DC 60 12 1 4 4 max 1 4 4 A 1.5 6 6 2 2 2 380 380 350 60 50 20 110 75 40 40 80 W A s 175 m 2200 3300 750 1200 190 300 F 0 20 0 40 0 80 V DC 1 With multiple output modules, the same condition for each output applies. R S = source resistance 3I inr p = U i /(R s + Ri ) 2 Input Under-/Overvoltage Lock-out Input Fuse If the input voltage remains below 0.8 Ui min or exceeds 1.1 Ui max (approx. values), an internally generated inhibit signal disables the output(s). When checking this function the absolute maximum input voltage rating Ui abs must be carefully considered (see table: Electrical Input Data). Between Ui min and the undervoltage lock-out level the output voltage may be below the value defined in table: Output data (see: Technical Information: Measuring and Testing). The modules do not incorporate any fuse. External fuses installed in the wiring to the inputs are essential. Table 3: Recommended fuse types Series Schurter type 12H SPT 24H SPT 48H SPT 10 A Part number 250 V 0001.2514 8A 250 V 0001.2513 3.15 A 250 V 0001.2509 Reverse Polarity The unit is not protected against reverse polarity at the input. (Reverse polarity will cause the external fuse to blow.) Edition 5/5.2000 4/19 Cassette Style DC-DC Converters H Series Electrical Output Data General conditions - TA = 25C, unless TC is specified. - Connector pins 2 and 23 interconnected, R input not connected. Table 4a: Output data Output 5.1 V Characteristics Uo1 Output voltage Conditions U i nom, I o nom min 1 5.00 Uo2/3 Uo2/3 P Ui min...Ui max Io2/3 = 0 Output current limitation response uo1/2/3 Output Switch. freq. Ui nom, Io nom 1 voltage IEC/EN 61204 Total noise BW = 20 MHz Static line regulation DUo2/3 U DUo1 Ic DUo2/3 Ic U i min...U i max TC min...TC max 11.76 12.24 11.10 12.90 typ max Unit 14.70 15.30 V 13.90 16.10 13.80 17.25 21 25 25 31 see: Type Survey and Key Data see fig.: Typical output voltage Uo1 versus output currents I o 30 50 60 100 50 80 60 200 70 200 75 200 50 U i min...U i nom U i nom...U i max I o nom 1 100 100 150 150 150 150 see: H2320/H3020 = DUo 2/3 vers. Io 2/3 see: H2540/H3040 = DUo 2/3 vers. Io 2/3 - Static load regulation U i nom I o = I o nom...0 2 Static cross load regulation 3 min - Io L DUo2/3 I 5.20 typ 15 V max 7.5 Output current DUo1 I min - Output overvoltage protection Io nom DUo1 U 12 V max - Uo2/3 0 Uo1 P typ 50 5 U i nom Io = Io nom...0 4 15 10 30 - see: H2320/H3020 = DUo 2/3 vers. Io 2/3 24 V 48 V 15 mVpp mV 45 see: H2540/H3040 = DUo 2/3 vers. Io 2/3 Table 4b: Output data Output 1 2 3 4 Characteristics Conditions Uo1 Output voltage U i nom, I o1 nom Uo P Overvoltage prot. min typ 23.52 max min 24.48 47.04 41 Io1 nom Output current Io1 L Output current limitation response U i min...U i max TC min...TC max uo1/2/3 Output Switch. freq. Ui nom, Io nom 1 voltage IEC/EN 61204 Total noise BW = 20 MHz DUo1 U Static line regulation DUo1 I Static load regulation U i nom I o1 = I o1 nom...0 U i min...U i nom U i nom...U i max I o1 nom typ max Unit 48.96 V 85 see: Type Survey and Key Data see: Typical output voltage Uo1 versus output currents Io 30 50 20 40 75 200 35 150 150 150 150 150 mVpp mV With multiple output modules, the same condition for each output applies. Condition for specified output. With multiple output modules, other output(s) loaded with constant current Io = Io nom. Condition for non-specified output, individually tested, other output(s) loaded with constant current Io = Io nom. Multiple output modules. Edition 5/5.2000 5/19 Cassette Style DC-DC Converters H Series 05119 Uo2/3 [V] Output Protection Each output is protected against overvoltages which could occur due to a failure of the internal control circuit. Voltage suppressor diodes (which under worst case condition may become a short circuit) provide the required protection. The suppressor diodes are not designed to withstand externally applied overvoltages. Overload at any of the outputs will cause a shut-down of all outputs. Uo1 Uo1 nom Uo2/3 0 13 Io1 nom 0.5 * Io1 nom Io1 = 0 A 12 05022 Io nom IoL1 IoL2,IoL3 1.0 .95 11 0 0.25 0.5 0.75 1.0 Io2/3 Io2/3 nom Fig. 3 H2320/H3020: DUo2/3 (typ.) versus Io2/3 with different Io1 Io1 Io2,Io3 0.5 05120 Uo2/3 [V] Uo2/3 0 16 Io1 nom 0 0.5 1.0 1.2 Io Io nom 0.5 * Io1 nom Io1 = 0 A 15 Fig. 2 Typical output voltage Uo1 versus output currents Io Parallel and Series Connection Main outputs of equal nominal voltage can be connected in parallel. It is important to assure that the main output of a multiple output module is forced to supply a minimum current of 0.1 A to enable correct operation of its own auxiliary outputs. 14 0 0.25 0.5 0.75 1.0 Io2/3 Io2/3 nom Fig. 4 H2540/H3040: DUo2/3 (typ.) versus Io2/3 with different Io1 Outputs one and two of a double output unit may be connected in parallel without a minimum current requirement at the main output. Outputs two and three of a triple output unit can be connected in parallel. In parallel operation, one or more of the main outputs may operate continuously in current limitation which will cause an increase in case temperature. Consequently, a reduction of the max. ambient temperature by 10 K is recommended. Main or auxiliary outputs can be connected in series with any other output of the same or another module. In series connection, the maximum output current is limited by the lowest current limit. Output ripple and regulation values are added. Connection wiring should be kept as short as possible. If output terminals are connected together in order to establish multi-voltage configurations, e.g. +5.1 V, 12 V etc. the common ground connecting point should be as close as possible to the connector of the converter to avoid excessive output ripple voltages. Edition 5/5.2000 6/19 Cassette Style DC-DC Converters Thermal Considerations H Series Io /Io nom Caution: The installer must ensure that under all operating conditions TC remains within the limits stated in the table: Temperature specifications. Notes: Sufficient forced cooling or an additional heat sink allows TA to be higher than 50C (e.g. 65C) if TC max is not exceeded. For -2 units at an ambient temperature TA of 65C with only convection cooling, the maximum permissible current for each output is approx. 50% of its nominal value as per figure. Forced cooling 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 05032 If a converter is located in free, quasi-stationary air (convection cooling) at the indicated maximum ambient temperature TA max (see table: Temperature specifications) and is operated at its nominal input voltage and output power, the temperature measured at the Measuring point of case temperature TC (see: Mechanical Data) will approach the indicated value TC max after the warm-up phase. However, the relationship between TA and TC depends heavily on the conditions of operation and integration into a system. The thermal conditions are influenced by input voltage, output current, airflow and temperature of surrounding components and surfaces. TA max is therefore, contrary to TC max, an indicative value only. Convection cooling TC max TA min 40 50 60 70 80 TA [C] Fig. 5 Output current derating versus temperature for -2 units. Thermal Protection A temperature sensor generates an internal inhibit signal which disables the outputs if the case temperature exceeds TC max. The outputs are automatically re-enabled if the temperature drops below this limit. Output Response The reaction of the outputs is similar whether the input voltage is applied or the inhibit is switched low. An output voltage overshoot will not occur when the module is turned on or off. Output Uo nom 0.95Uo nom 05025 0.1 0 tr t tf th Ui 1 t 0 Inhibit Fig. 6 Output response as a function of input voltage (on/off switching) or inhibit control 1 t 0 Table 5: Output response time tr and tf Type of Converter t r at Po = 0 and t f at Po = Po nom typ max t r and t f at Po = 3/4 Po nom typ max t r at Po = Po nom typ max H1001-2R H1301-2R H1501-2R H1601-2R H1901-2R 3 5 3 8 35 7 15 7 20 90 3 8 5 15 50 7 20 15 35 140 5 10 15 20 85 15 30 40 60 220 H2320-2 H2540-2 10 8 30 20 15 10 40 30 25 20 70 50 H3020-2 H3040-2 30 20 75 60 45 30 120 80 75 50 200 140 Unit ms Conditions: R input not used. For multiple output modules the figures indicated in the table above relate to the output which reacts slowest. All outputs are resistively loaded. Variation of the input voltage within Ui min...Ui max does not influence the values. Edition 5/5.2000 7/19 Cassette Style DC-DC Converters H Series Auxiliary Functions i Inhibit for Remote On and Off Iinh [mA] The outputs of the module may be enabled or disabled by means of a logic signal (TTL, CMOS, etc.) applied between the inhibit input i and the negative pin of output 1 (Vo1-). In systems with several units, this feature can be used, for example, to control the activation sequence of the converters. If the inhibit function is not required, connect the inhibit pin 2 to pin 23 to enable the outputs (active low logic, fail safe). For output response refer to: Output Response. 2.0 1.6 1.2 0.8 Uo = off 0 -0.4 Vo+ I inh i -0.8 -50 U inh -30 0 10 -10 30 50 Uinh [V] Fig. 8 Typical inhibit current I inh versus inhibit voltage U inh Vo- Vi- Uo = on 0.4 06031 Vi+ Uinh = 2.4 V Uinh = 0.8 V 06032 Note: With open i input: Output is disabled (Uo = off). Fig. 7 Definition of Uinh and Iinh. Table 6: Inhibit data Characteristics U inh Uo = on Inhibit input voltage to keep output voltage I inh Uo = off Inhibit current Conditions min U i min...U i max TC min...TC max Uinh = 0 -60 typ max Unit -50 0.8 V DC 2.4 50 -100 -220 A R-Control for Output Voltage Adjustment Note: With open R input, Uo Uo nom. Vo1+ As a standard feature, single output modules offer an adjustable output voltage identified by letter R in the type designation. R2 The output voltage Uo1 can either be adjusted with an external voltage (Uext) or with an external resistor (R1 or R2). The adjustment range is approximative 0...110% of Uo nom. For output voltages Uo > Uo nom, the minimum input voltage according to Electrical Input Data increases proportionally to Uo /Uo nom. R1 Vo1+ R + Uext 06087 Uref 4000 + - G Fig. 9 Voltage adjustment with external voltage Uext a) Uo 0...110% Uo nom, using Uext between R (14) and G (17): Uo Uext Uext 2.5 V * ----- Uo Uo nom * ----- Uo nom 2.5 V Caution: To prevent damage, Uext should not exceed 8 V, nor be negative. Edition 5/5.2000 06088 Uref 4000 + - R G Fig. 10 Voltage adjustment with external resistor R1 or R2 b) Uo 0...100% Uo G (17): nom, using R1 between R (14) and R1 Uo Uo nom * ----------- R1 + 4000 c) Uo Uo nom...Uo max, 4000 * Uo R1 ---------- Uo nom - Uo using R2 between R (14) and Vo1+ (20): Uo max = Uo nom + 10% 4000 * Uo * (Uo nom - 2.5 V) R2 ------------------------ 2.5 V * (Uo - Uo nom) Uo nom * 2.5 V * R2 Uo -------------------------------- 2.5 V * (R2 + 4000 ) - Uo nom * 4000 Caution: To prevent damage, R2 should never be less than 47 k. Note: R inputs of n units with paralleled outputs may be paralleled, too, but if only one external resistor is to be used, its value should be R1/n, or R2/n respectively. 8/19 Cassette Style DC-DC Converters H Series Table 7a: R1 for Uo < Uo nom (conditions: Ui nom, Io nom, rounded up to resistor values E 96); R 2 = Uo nom = 5.1 V Uo [V] R1 [k] 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 0.432 0.976 1.65 2.61 3.83 5.76 8.66 14.7 30.1 200.0 Uo nom = 12 V Uo [V] R1 [k] Uo nom = 15 V Uo [V] R1 [k] Uo nom = 24 V Uo [V] R1 [k] Uo nom = 48 V Uo [V] R1 [k] 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 2.0 4.0 6.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 4.0 6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0 22.0 8.0 12.0 16.0 20.0 24.0 28.0 32.0 36.0 40.0 44.0 0.806 1.33 2.0 2.87 4.02 5.62 8.06 12.1 20.0 44.2 0.619 1.47 2.67 4.53 6.04 8.06 11.0 16.2 26.1 56.2 0.806 1.33 2.0 2.87 4.02 5.62 8.06 12.1 20.0 44.2 0.806 1.33 2.0 2.87 4.02 5.62 8.06 12.1 20.0 44.2 Table 7b: R 2 for Uo > Uo nom (conditions: Ui nom, Io nom, rounded up to resistor values E 96); R1 = Uo nom = 5.1 V Uo [V] R2 [k] 5.15 5.20 5.25 5.30 5.35 5.40 5.45 5.50 Uo nom = 12 V Uo [V] R 2 [k] 464 215 147 110 90.9 78.7 68.1 61.9 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 13.0 13.2 Uo nom = 15 V Uo [V] R 2 [k] 1780 909 619 464 383 316 274 249 200 169 15.2 15.4 15.6 15.8 16.0 16.2 16.4 16.5 1470 750 511 383 332 274 237 226 Uo nom = 24 V Uo [V] R2 [k] 24.25 24.50 24.75 25.00 25.25 25.50 25.75 26.00 26.25 26.40 3160 1620 1100 825 715 590 511 453 402 383 Uo nom = 48 V Uo [V] R 2 [k] 48.5 49.0 49.5 50.0 50.5 51.0 51.5 52.0 52.5 52.8 6810 3480 2370 1780 1470 1270 1100 953 845 806 Display Status of LEDs Uo1 > 0.95...0.98Uo1 adj 06090 OK i Ui Ui uv Ui min Ui max Uo1 > 0.95...0.98Uo1 adj Ui ov Fig. 11 LEDs "OK" and "i" status versus input voltage Conditions: Io Io nom, TC TC max, Uinh 0.8 V Ui uv = undervoltage lock-out, Ui ov = overvoltage lock-out Ui abs Uo1 < 0.95...0.98Uo1 adj Io LED "OK" status versus output current Conditions: U i min...U i max, TC TC max, U inh 0.8 V TC LED "i"versus case temperature Conditions: U i min...U i max, I o I o nom, U inh 0.8 V Ui inh LED "i"versus U inh Conditions: U i min...U i max, I o I o nom, TC TC max OK Io nom IoL i TC max TPTC threshold Uinh threshold i -50 V LED off Edition 5/5.2000 +0.8 V +2.4 V LED Status undefined +50 V LED on 9/19 Cassette Style DC-DC Converters H Series Electromagnetic Compatibility (EMC) A suppressor diode together with an input filter form an effective protection against input transient voltages which typically occur in most installations, but especially in battery driven mobile applications. The H series has been successfully tested to the following specifications: Electromagnetic Immunity Table 8: Immunity type tests 1 2 3 Phenomenon Standard 1 Level Coupling mode 2 Value applied Waveform Source imped. Test procedure Electrostatic discharge (to case) IEC/EN 61000-4-2 2 contact discharge 4000 Vp 1/50 ns 330 10 positive and 10 negative discharges yes A Electromagnetic IEC/EN field 61000-4-3 x antenna 20 V/m AM 80% 1 kHz n.a. 26...1000 MHz yes A Electrical fast transient/burst IEC/EN 61000-4-4 1 direct, i/c, +i/-i 500 Vp bursts of 5/50 ns 2.5 / 5 kHz over 15 ms; burst period: 300 ms 50 1 min positive 1 min negative transients per coupling mode yes Surge IEC/EN 61000-4-5 1 i/c 500 Vp 1.2/50 s 12 5 pos. and 5 neg. surges per yes +i/-i 2 In Peroper. form. 3 A Related and previous standards are referenced in: Technical Information: Standards. i = input, o = output, c = case. A = Normal operation, no deviation from specifications, B = Normal operation,temporary deviation from specs possible. Electromagnetic Emissions Table 9: Emissions at Ui nom and Io nom Series Standard CISPR 11/EN 55011, 1991 CISPR 22/EN 55022, 1987 30 MHz 30 MHz 12H <A <B 24H <B <B 48H <B <B Edition 5/5.2000 10/19 Cassette Style DC-DC Converters H Series Mechanical Data European Projection 09050 6TE 12.1 32 29 26 23 20 17 14 8 11 2 5 Dimensions in mm. Tolerances 0.3 mm unless otherwise indicated. 20.5 3.27 Mounting holes for retaining clips V 1.6 2TE Male connector H 11 according to DIN 41 612 100 0.6 Front plate 20 103 M 3; depth = 4 mm (chassis mount) Rear face 127 159.4 Measurement point for case temperatureTC 22 68 168.5 0.5 173.7 0.5 Main face Mounting plane of connector H11 (11.6) 88 111.2 0.8 3U 38.7 Back plate 17.25 12.17 7.09 31.5 0.1 0 30.48 25.40 94.5 0.1 95 0.5 o 3.5 o 4.0 0 OK (LED green) Inhibit i (LED red) Potentiometer (option D or V) Fig. 12 DC-DC converter in case H02, weight 770 g (approx.) Case aluminium, black finish and self cooling. Edition 5/5.2000 11/19 Cassette Style DC-DC Converters H Series Immunity to Environmental Conditions Table 10: Mechanical stress Test method Standard Test conditions Status Damp heat steady state IEC/DIN IEC 60068-2-3 MIL-STD-810D section 507.2 Temperature: Relative humidity: Duration: 40 2 C Ea Shock (half-sinusoidal) IEC/EN/DIN EN 60068-2-27 MIL-STD-810D section 516.3 Acceleration amplitude: Bump duration: Number of bumps: 15 gn = 147 m/s2 11 ms 18 (3 each direction) Eb Bump (half-sinusoidal) IEC/EN/DIN EN 60068-2-29 MIL-STD-810D section 516.3 Acceleration amplitude: Bump duration: Number of bumps: 10 gn = 98 m/s2 16 ms 6000 (1000 each direction) Fc Vibration (sinusoidal) IEC/EN/DIN EN 60068-2-6 MIL-STD-810D section 514.3 Acceleration amplitude: 0.15 mm (10...60 Hz) 2 gn = 20 m/s2 (60...150 Hz) 10...150 Hz 3.75 h (1.25 h each axis) Ca Unit not operating 93 +2/-3 % 21 days Frequency (1 Oct/min): Test duration: Unit operating Table 11: Temperature specifications, values given are for an air pressure of 800...1200 hPa (800...1200 mbar) Temperature Standard -2 Characteristics TA 1 Ambient temperature 1 min max min max Unit Operational 2 -10 50 -25 71 C -10 80 -25 95 -25 100 -40 100 temperature 3 TC Case TS Storage temperature 1 Option -7 Conditions Not operational MIL STD 810D section 501.2 and 502.2. 2 See: Thermal considerations. 3 Overtemperature lock-out at TC >95C (PTC). Table 12: MTBF Values at specified Case Temperature Module Types Ground Benign Unit 40C MTBF 1 H1000 H2000 H3000 384'000 306'000 270'000 h 1 Calculated in accordance with MIL-HDBK-217E (calculation according to edition F would show even better results) Safety and Installation Instructions 10028 Connector pin Allocation The connector pin allocation table defines the electrical potentials and the physical pin positions on the H11 connector. Pin no. 26, the protective earth pin present on all 12H...48H DC-DC converters is leading, ensuring that it makes contact with the female connector first. 32 29 26 23 20 17 14 11 8 5 2 Fig. 13 View of male H11 connector. Table 13: H11 connector pin allocation and designation Electrical Determination H1000 Pin H2000 Ident Inhibit control input Safe Data or ACFAIL 2 5 i D or V 2 5 Output voltage (positive) Output voltage (negative) 8 11 Vo1+ Vo1- 8 11 Control input + Control input - 14 17 R G Output voltage (positive) Output voltage (negative) 1 Pin Output voltage (positive) Output voltage (negative) 20 23 Protective earthing 1 26 DC input voltage DC input voltage 29 32 Vo1+ Vo1- H3000 Ident i D or V Ident 2 5 i D or V 8 11 Vo3+ Vo3- 14 17 Vo2+ Vo2- 14 17 Vo2+ Vo2- 20 23 Vo1+ Vo1- 20 23 Vo1+ Vo1- 26 Vi+ Vi- Pin 29 32 26 Vi+ Vi- 29 32 Vi+ Vi- Leading pin (pregrounding) Edition 5/5.2000 12/19 Cassette Style DC-DC Converters H Series Installation Instructions Cleaning Agents The H series DC-DC converters are components, intended exclusively for inclusion within other equipment by an industrial assembly operation or by professional installers. Installation must strictly follow the national safety regulations in compliance with the enclosure, mounting, creepage, clearance, casualty, markings and segregation requirements of the end-use application. See also: Technical Information: Installation and Application. In order to avoid possible damage, any penetration of liquids (e.g. cleaning fluids) is to be prevented, since the power supplies are not hermetically sealed. Connection to the system shall be made via the female connector H11 (see: Accessories). Other installation methods may not meet the safety requirements. All DC-DC converters are provided with pin no. 26 ( ), which is reliably connected with their case. For safety reasons it is essential to connect this pin with the protective earth of the supply system if required in: Safety of operator accessible output circuit. Ensure that a unit failure (e.g. by an internal short-circuit) does not result in a hazardous condition. See also: Safety of operator accessible output circuit. To prevent excessive current flowing into the unit (e.g. by an internal short-circuit), an external fuse suitable for the application and in compliance with the local requirements should be installed in the wiring to one or both input pins (no. 29 and/or no. 32). See also: Input Fuse. Important: Whenever the inhibit function is not in use, pin no. 2 (i) should be connected to pin no. 23 (Vo1-) to enable the output(s). Do not open the modules, or guarantee will be invalidated. Make sure that there is sufficient air flow possible for convection cooling. This should be verified by measuring the case temperature when the unit is installed and operated in the end-use application. The maximum specified case temperature TC max shall not be exceeded. See also: Thermal Considerations. Standards and approvals 12H...48H DC-DC converters correspond to class I equipment. All types are UL recognized according to UL 1950, UL recognized for Canada to CAN/CSA C22.2 No. 950-95 and LGA approved to IEC/EN 60950 standards. The units have been evaluated for: * Building in * Supplementary insulation between input and case and double or reinforced insulation between input and output, based on 250 V AC and 400 V DC * Operational insulation between output(s) and case * Operational insulation between the outputs * The use in a pollution degree 2 environment * Connecting the input to a primary or secondary circuit with a maximum transient rating of 2500 V. The DC-DC converters are subject to manufacturing surveillance in accordance with the above mentioned UL, CSA, EN and with ISO 9001 standards. Protection Degree Condition: Female connector fitted to the unit. IP 40: All units, except those with option D or V with potentiometer. IP 20: All units fitted with option D or V with potentiometer. Isolation The electric strength test is performed as a factory test in accordance with IEC/EN 60950 and UL 1950 and should not be repeated in the field. Power-One will not honour any guarantee/warranty claims resulting from electric strength field tests. If the end-product is to be UL certified, the temperature of the main isolation transformer should be evaluated as part of the end-product investigation. Table 14: Isolation Characteristic Electric strength test voltage Input to case Input to output Output to case Output to output Unit Required according to IEC/EN 60950 1.5 3.0 1 0.5 - kVrms 2.1 4.2 1 0.7 - kV DC Actual factory test 1 s 2.8 5.6 1 1.4 0.3 AC test voltage equivalent to actual factory test 2.0 4.0 1 1.0 0.2 kVrms >300 >300 >300 >100 2 M Insulation resistance at 500 V DC 1 2 In accordance with IEC/EN 60950 only subassemblies are tested in factory with this voltage. Tested at 300 V DC. For creepage distances and clearances refer to: Technical Information: Safety. Edition 5/5.2000 13/19 Cassette Style DC-DC Converters H Series Safety of operator accessible output circuit If the output circuit of a DC-DC converter is operator accessible, it shall be an SELV circuit according to the IEC/EN 60950 related safety standards. Since the H series DC-DC converters provide double or reinforced insulation between input and output, based on a rated primary input voltage of 250 V AC and 400 V DC only operational insulation is needed between the AC mains and the input of the DC-DC converter. This means that there is no need for an electrical isolation between the AC mains circuit and the DC-DC converter input circuit to cause the output of an H series DC-DC converter to be an SELV cir- cuit. Only voltage adaption and rectification to the specified input voltage range of the DC-DC converter is needed. The following table shows some possible installation configurations, compliance with which causes the output circuit of the DC-DC converter to be an SELV circuit according to IEC/EN 60950 up to a configured output voltage (sum of nominal voltages if in series or +/- configuration) of 36 V. However, it is the sole responsibility of the installer to assure the compliance with the relevant and applicable safety regulations. More information is given in: Technical Information: Safety. Table 15: Safety concept leading to an SELV output circuit Conditions Front end Nominal supply voltage DC-DC converter Minimum required grade Nominal DC output of isolation, to be provided voltage from the by the AC-DC front end, front end including mains supplied battery charger Mains Operational (i.e. there is 250 V AC no need for electrical isolation between the mains supply voltage and theDC-DC converter input voltage) 1 2 3 Result Minimum required Measures to achieve the safety status of the specified safety status of front end output the output circuit circuit 400 V 1 (The Primary circuit rated voltage between any input pin and earth can be up to 250 V AC or 400 V DC) Double or reinforced insulation, based on 250 V AC and 400 V DC (provided by the DC-DC converter) and earthed case 2 400 V Supplementary insulation, based on 250 V AC and 400 V DC and double or reinforced insulation, based on the maximum nominal output voltage from the front end (both provided by the DC-DC converter) and earthed case 3 Unearthed hazardous voltage secondary circuit Safety status of the DC-DC converter output circuit SELV circuit The front end output voltage should match the specified operating input voltage range of the DC-DC converter. The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC/EN 60950. The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC/EN 60950. If the converter case shall not be connected with earth, the front end output circuit has to be insulated from earth according to the relevant safety standard by at least basic insulation, based on the maximum nominal output voltage from the front end, and insulated from the converter case by at least supplementary insulation, based on the maximum nominal mains voltage. The converter case is then considered to be a double insulated accessible part ~ Mains ~ Max. 250 V AC or 400 V DC AC-DC front end Fuse + Battery Fuse Max. 250 V AC or 400 V DC 10024 DC-DC converter SELV - Earth connection Fig. 14 Schematic safety concept. Use earth connection as per table: Safety concept leading to an SELV output circuit. Use fuse according to: Installation Instructions. Edition 5/5.2000 14/19 Cassette Style DC-DC Converters H Series Description of Options Table 16: Survey of options Option 1 2 Function of Option Characteristic -7 Extended operational ambient temperature range TA = -25...71C D1 Input and/or output undervoltage monitoring circuitry Safe data signal output (D1...D8) V12 Input and output undervoltage monitoring circuitry ACFAIL signal according to VME specifications ( V2, V3) Option D excludes option V and vice versa Only available with main output voltage Uo1 = 5.1 V -7 Extended Temperature Range Option -7 extends the operational ambient temperature range from -10...50C (standard) to -25...71C. The power supplies provide full nominal output power with convection cooling. D Undervoltage Monitor The input and/or output undervoltage monitoring circuit operates independently of the built-in input undervoltage lockout circuit. A logic "low" (JFET output) or "high" signal (NPN output) is generated at pin 5 as soon as one of the monitored voltages drops below the preselected threshold level Ut. The return for this signal is Vo1- (pin 23). The D output recovers when the monitored voltage(s) exceed(s) U t+U h. The threshold level U t is adjustable by a potentiometer, accessible through a hole in the front cover. Option D exists in various versions D1...D8 as shown in the following table. Table 17: Undervoltage monitor functions Output type JFET NPN 1 2 Monitoring Ui U o1 Typical hysteresis U h [% of U t ] for U t min...U t max U hi U ho Minimum adjustment range of threshold level U t U ti U to D1 D5 no yes - 3.5 V...48 V 1 - 2.3...1 D2 D6 yes no U i min...U i max 1 - 3.0...0.5 - D3 D7 yes yes U i min...U i max D4 D8 no yes - 1 0.95...0.98 U o1 2 0.95...0.98 U o1 2 3.0...0.5 "0" - "0" Threshold level adjustable by potentiometer (not recommended for mobile applications) Fixed value between 95% and 98% of Uo1 (tracking) 11006 JFET output (D1...D4): Vo1+ U i , U o1 status D output, U D U i or U o1 < U t low, L, U D 0.4 V at I D = 2.5 mA U i and U o1 > U t + U h high, H, I D 25 A at U D = 5.25 V Rp ID Input Connector pin D is internally connected via the drainsource path of a JFET (self-conducting type) to the negative potential of output 1. UD 0.4 V (logic low) corresponds to a monitored voltage level (Ui and/or Uo1) <Ut. The current ID through the JFET should not exceed 2.5 mA. The JFET is protected by a 0.5 W Zener diode of 8.2 V against external overvoltages. D UD Vo1- Fig. 15 Options D1...D4, JFET output 11007 NPN output (D5...D8): Vo1+ U i , U o1 status D output, U D U i or U o1 < U t high, H, I D 25 A at U D = 40 V U i and U o1 > U t + U h low, L, U D 0.4 V at I D = 20 mA Edition 5/5.2000 Rp Input Connector pin D is internally connected via the collectoremitter path of a NPN transistor to the negative potential of output 1. UD 0.4 V (logic low) corresponds to a monitored voltage level (Ui and/or Uo1) >Ut + Uh. The current ID through the open collector should not exceed 20 mA. The NPN output is not protected against external overvoltages. UD should not exceed 40 V. ID D UD Vo1- Fig. 16 Options D5...D8, NPN output 15/19 DC-DC Converters Threshold tolerances and hysteresis: UD If Ui is monitored, the internal input voltage after the input filter is measured. Consequently this voltage differs from the voltage at the connector pins by the voltage drop Ut i across the input filter. The value of Uti depends upon the input voltage range, threshold level Ut , temperature and input current. The input current is a function of the input voltage and the output power. H Series DUti Uhi 11021 Po = 0 Po = 0 Po = Po nom UD high Po = Po nom Cassette Style UD low Ui Uti Fig. 17 Definition of Uti, Uti and Uhi (JFET output) Input voltage monitoring NPN UD UD high 11008 3 3 3 3 UD low t 0 ID ID high ID low 0 t JFET UD UD high UD low 0 t th1 tlow min4 tlow min4 Uo1 Uo1 nom 1 0.95 tlow min4 thigh min th1 t 0 Ui [V DC] Uti +Uhi Uti t 0 Input voltage failure Input voltage sag Switch-on cycle Output voltage monitoring NPN UD UD high Switch-on cycle and subsequent input voltage failure 2 3 3 UD low t 0 ID ID high ID low 0 t JFET UD UD high UD low 0 t tlow min4 1 Uo1 2 Uo1 nom Uto +Uho Uto 3 t 0 4 n.a. With output voltage monitoring the hold-up time t h = 0 The D signal remains high if the D output is connected to an external source. t low min = 40...200 ms, typically 80 ms Output voltage failure Fig. 18 Relationship between Ui, Uo1, UD, ID and Uo1/Uo nom versus time. Edition 5/5.2000 16/19 Cassette Style DC-DC Converters H Series Formula for threshold level for desired value of t h: V ACFAIL signal (VME) Available for units with Uo1 = 5.1 V. This option defines an undervoltage monitoring circuit for the input or the input and main output voltage equivalent to option D and generates the ACFAIL signal (V signal) which conforms to the VME standard. The low state level of the ACFAIL signal is specified at a sink current of I V = 48 mA to U V 0.6 V (open-collector output of a NPN transistor). The pull-up resistor feeding the open-collector output should be placed on the VME backplane. After the ACFAIL signal has gone low, the VME standard requires a hold-up time t h of at least 4 ms before the 5.1 V output drops to 4.875 V when the 5.1 V output is fully loaded. This hold-up time t h should be provided by an external input capacitance. Consequently the working input voltage and the threshold level U t i should be adequately above the minimum input voltage Ui min of the converter so that enough energy is remaining in this capacitance. If the input voltage is below the required level, an external hold-up capacitor (C i ext) should be added. Table 18: Available internal input capacitance and factory potentiometer setting of U ti with resulting hold-up time. Types 12H 24H 48H Unit Ci min 2.2 0.75 0.19 mF Ut i 9.5 19.5 39 V DC th 0.19 0.87 0.89 ms Option V operates independently of the built-in input undervoltage lock-out circuit. A logic "low" signal is generated at pin 5 as soon as one of the monitored voltages drops below the preselected threshold level Ut. The return for this signal is Vo1- (pin 23). The V output recovers when the monitored 2 * Po * (t h + 0.3 ms) * 100 ---------------------- + Ui min2 C i min * U ti = Formula for additional external input capacitor 2 * Po * (t h + 0.3 ms) * 100 C i ext = --------------------- - Ci min * (U ti 2 - U i min2) where as: C i min = minimum internal capacitance [mF], according to the table below C i ext = external input capacitance [mF] Po = output power [W] = efficiency [%] th = hold-up time [ms] U i min = minimum input voltage [V] U ti = threshold level [V] Remarks: The threshold level Uti of option V2 and V3 is adjusted during manufacture to a value according to table Undervoltage monitor functions, section Option D. A decoupling diode should be connected in series with the input to avoid the input capacitance discharging through other loads connected to the same source voltage. voltage(s) exceed(s) Ut + Uh. The threshold level Ut is adjustable by a potentiometer accessible through a hole in the front cover. Versions V2 and V3 are available as shown below. Table 19: Undervoltage monitor functions V output (VME compatible) V2 V3 1 2 Monitoring Ui U o1 yes no yes yes Typical hysteresis U h [% of U t ] for U t min...U t max U hi U ho Minimum adjustment range of threshold level U t U ti U to U i min...U i max 1 U i min...U i max 1 - 0.95...0.98 U o1 2 3.0...0.5 - 3.0...0.5 "0" Threshold level adjustable by potentiometer (not recommended for mobile applications) Fixed value between 95% and 98% of Uo1 (tracking), output undervoltage monitoring is not a requirement of VME standard 11009 V output (V2, V3): Vo1+ Ui, Uo1 status V output, UV U i or U o1 < U t low, L, U V 0.6 V at I V = 50 mA U i and U o1 > U t + U h high, H, I V 25 A at U V = 5.1 V Edition 5/5.2000 Rp Input Connector pin V is internally connected to the open collector of a NPN transistor. The emitter is connected to the negative potential of output 1. U V 0.6 V (logic low) corresponds to a monitored voltage level (U i and/or Uo1) < U t. The current I V through the open collector should not exceed 50 mA. The NPN output is not protected against external overvoltages. U V should not exceed 80 V. IV V UV Vo1- Fig. 19 Output configuration of options V2 and V3 17/19 DC-DC Converters Threshold tolerances and hysteresis: H Series UV If Ui is monitored, the internal input voltage is measured after the input filter. Consequently this voltage differs from the voltage at the connector pins by the voltage drop U ti across input filter and rectifier. The value of U ti depends upon the input voltage range, threshold level U t , temperature and input current. The input current is a function of input voltage and output power. DUti Uhi 11023 Po = 0 Po = 0 Po = Po nom UV high Po = Po nom Cassette Style UV low Ui Uti Fig. 20 Definition of Uti, Uti and Uhi Input voltage monitoring V2 UV UV high t low min 2 t low min 2 t low min 2 3 3 3 11010 4 4 2 2 UV low t 0 t low min V3 UV UV high 3 t low min 3 3 UV low t 0 th 1 th 1 Uo1 5.1 V 4.875 V 2.0 V 0 t Ui [V DC] Uti + Uhi Uti t 0 Input voltage failure Input voltage sag Switch-on cycle Switch-on cycle and subsequent input voltage failure Output voltage monitoring V2 UV UV high 4 UV low 4 t 0 V3 UV UV high t low min 3 2 3 4 UV low 0 t Uo1 5.1 V 4.875 V 2.0 V 0 t 1 Ui 2 3 Uti + Uhi Uti 4 t 0 VME request: minimum 4 ms t low min = 40...200 ms, typically 80 ms UV level not defined at Uo1 < 2.0 V The V signal drops simultaneously with the output voltage, if the pull-up resistor RP is connected to Vo1+. The V signal remains high if RP is connected to an external source. Output voltage failure Fig. 21 Relationship between U i, Uo1, U V, I V and Uo1 /Uo nom versus time. Edition 5/5.2000 18/19 Cassette Style DC-DC Converters H Series Accessories A variety of electrical and mechanical accessories are available including: - Front panels for 19" rack mounting, Schroff and Intermas systems. - Mating H11 connectors with screw, solder, fast-on or press-fit terminals. - Connector retention facilities. - Code key system for connector coding. - Flexible H11 PCB for mounting of the unit onto a PCB. - Chassis mounting plates for mounting the 19" cassette to a chassis/wall where only frontal access is given. - Universal mounting bracket for DIN-rail or chassis mounting. For more detailed information please refer to Accessory Products. H11 female connector, Code key system Front panels Flexible H11 PCB Universal mounting bracket for DIN-rail mounting. Mounting plate, Connector retention clips Edition 5/5.2000 19/19