H Series Data Sheet 50 Watt DC-DC Cassette Converters Features Wide input voltage ranges up to 60 VDC 1, 2, or 3 outputs up to 48 VDC Class I equipment * 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 111 4.37" 3U 39 1.54" 8TE Safety according to IEC/EN 60950 168 6.6" Description The H series of DC-DC converters represents a broad and flexible range of cassette 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. 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. safety agencies TUV and UL (USA and Canada). The case design allows operation at nominal load up to 50 C in a free air ambient temperature. If forced cooling is provided, the ambient temperature may exceed 50 C, but the case temperature should remain below 80 C 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 converters may either be plugged into 19-inch rack systems according to DIN 41494, or be chassis mounted. 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 converters are designed and built according to the international safety standard IEC/EN 60950 and have been approved by the Table of Contents Page Page Description ....................................................................... 1 Model Selection ............................................................... 2 Part Number Description and Product Marking ............... 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 REV. MAR 27, 2006 Page 1 of 19 www.power-one.com H Series Data Sheet 50 Watt DC-DC Cassette Converters Model Selection Table 1: Model types 1 2 Input Voltage Range and Efficiency 1 Output 1 Output 2 Output 3 Vo nom Io nom [VDC] [A] Vo nom Io nom [VDC] [A] Vo nom Io nom [VDC] [A] Option Vi min to V max 8 to 15 VDC 2 min [%] Vi min to Vi max 14 to 30 VDC 2 min [%] Vi min to Vi max 28 to 60VDC 2 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 to D8 -7 Efficiency measured at Vi nom and Io nom Input voltage range 12H1901-2R: 9 to 15 VDC, 24H1901-2R: 18 to 30 VDC, 48H1901-2R: 36 to 60 VDC Model numbers highlighted in yellow or shaded are not recommended for new designs. Part Number Description and Product Marking Type Key Input voltage range Vi: 48 H 2 5 40 -2 R D V 8 to 15 VDC ............. 12 14 to 30 VDC ............. 24 28 to 60 VDC ............. 48 Series ............................................................................... H Number of outputs .................................................... 1 to 3 Output 1, Vo1 nom: 5.1 V 12 V 15 V 24 V 48 V ............... 0 ............... 3 ............... 5 ............... 6 ............... 9 Single output modules ................................................... 01 Output 2 and 3, Vo2 nom, Vo3 nom: 12 V ............. 20 15 V ............. 40 Options and features: Ambient temperature range TA -10 to 50 C .................. -2 Extended temperature range TA -25 to 71 C ................. -7 Output voltage control input (single output modules only)R Save data signal (D1 to 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: 48H1501-2RD3: DC-DC converter, input voltage range 28 to 60 V, providing output with 15 V/3.4 A; equipped with an output voltage control input and undervoltage monitoring. REV. MAR 27, 2006 Page 2 of 19 www.power-one.com H Series Data Sheet 50 Watt DC-DC Cassette Converters 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 Vo1 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 Vo2 and Vo3 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 5 D/V 14 R 17 G Forward converter approx. 70 kHz 23 Input filter Vi- i 20 Y Vi+ 2 32 Y 26 CMKT 14 Current limitation output 2 17 CMKT 8 Current limitation output 3 11 Y 1 Y Y Single output modules H1000 (R input) Fig. 1 DC-DC converter block diagram REV. MAR 27, 2006 Page 3 of 19 www.power-one.com H Series Data Sheet 50 Watt DC-DC Cassette Converters Electrical Input Data General conditions: - TA = 25 C, unless TC is specified. - Connector pins 2 and 23 interconnected, R input not connected. Table 2: Input data Input 12H Characteristics Vi Conditions Operating input voltage Io = 0 to Io nom T to TC max ..H1901-2R C min min Input current Vi nom, Io nom 1 Pi 0 No-load input power: Single output Double output Triple output Vi nom I o1,2,3 = 0 Idle input power inhibit mode Peak inrush current Vi = Vi 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 = 25 C Ui abs Input voltage limits without any damage 24H max min 15 14 15 18 8 9 Vi 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 VDC 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 VDC 1 With multiple output modules, the same condition for each output applies. R S = source resistance 3I inr p = Vi /(R s + Ri ) 2 Input Under-/Overvoltage Lockout Input Fuse If the input voltage remains below 0.8 Vi min or exceeds 1.1 Vi max (approx. values), an internally generated inhibit signal disables the output(s). When checking this function the absolute maximum input voltage rating Vi abs must be carefully considered (see table: Electrical Input Data). Between Vi min and the undervoltage lockout level the output voltage may be below the value defined in table: Output data (see: Technical Information: Measuring and Testing). The converters do not incorporate any fuse. External fuses installed in the wiring to the inputs are essential. Table 3: Recommended fuse types Series 12H Schurter type 250 V Part number SPT 10 A 0001.2514 24H SPT 8A 250 V 0001.2513 48H SPT 3.15 A 250 V 0001.2509 Reverse Polarity The converter is not protected against reverse polarity at the input. (Reverse polarity will cause the external fuse to blow.) REV. MAR 27, 2006 Page 4 of 19 www.power-one.com H Series Data Sheet 50 Watt DC-DC Cassette Converters Electrical Output Data General conditions - TA = 25 C, unless TC is specified. - Connector pins 2 and 23 interconnected, R input not connected. Table 4a: Output data Output 5.1 V Characteristics Vo1 Output voltage Conditions Vi nom, I o nom min 1 5.00 Vo2/3 Vo2/3 P Vi min to Vi max Io2/3 = 0 Output current limitation response Vo1/2/3 Output Switch. freq. Vi nom, Io nom 1 voltage IEC/EN 61204 Total noise BW = 20 MHz Vi min to Vi max TC min TC max to Vo1 U Vo2/3 U Static line regulation Vo1 I Static load regulation Vi nom I o = I o nom to 0 2 Static cross load regulation 3 min 11.76 12.24 11.10 12.90 typ max Unit 14.70 15.30 V 13.90 16.10 13.80 - Io L Vo2/3 Ic 5.20 typ 15 V max 7.5 Output current Vo1 Ic min - Output overvoltage protection Io nom Vo2/3 I 12 V max - Vo2/3 0 Vo1 P typ 17.25 21 25 25 31 see: Type Survey and Key Data see fig.: Typical output voltage Vo1 versus output currents Io Vi min to Vi nom Vi nom to Vi max I o nom 1 30 50 60 100 50 80 60 200 70 200 75 200 50 100 100 150 150 150 150 see: H2320/H3020 = Vo 2/3 vers. Io 2/3 see: H2540/H3040 = Vo 2/3 vers. Io 2/3 50 - Vi nom Io = Io nom to 0 4 5 15 10 30 - see: H2320/H3020 = Vo 2/3 vers. Io 2/3 24 V 48 V 15 mVpp mV 45 see: H2540/H3040 = Vo 2/3 vers. Io 2/3 Table 4b: Output data Output 1 2 3 4 Characteristics Conditions Vo1 Output voltage Vi nom, I o1 nom Vo P Overvoltage prot. min typ 23.52 max min 24.48 47.04 41 Io1 nom Output current Io1 L Output current limitation response Vi min to Vi max TC min to TC max Vo1/2/3 Output Switch. freq. Vi nom, Io nom 1 voltage IEC/EN 61204 Total noise BW = 20 MHz Vo1 U Static line regulation Vo1 I Static load regulation Vi nom I o1 = I o1 nom to 0 Vi min to Vi nom Vi nomto Vi max I o1 nom typ max Unit 48.96 V 85 see: Type Survey and Key Data see: Typical output voltage Vo1 versus output currents Io 30 50 20 40 75 200 35 150 150 150 150 150 mVpp mV With multiple-output models, the same condition for each output applies. Condition for specified output. With multiple output models, 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 models. REV. MAR 27, 2006 Page 5 of 19 www.power-one.com H Series Data Sheet 50 Watt DC-DC Cassette Converters Output Protection 05119 Vo2/3 [V] 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. Vo1 Vo1 nom Vo2/3 0 13 Io1 nom 0.5 * Io1 nom Io1 = 0 A 12 05022 Io nom IoL1 11 IoL2,IoL3 1.0 .95 0 0.25 0.75 0.5 1.0 Io2/3 Io2/3 nom Fig. 3 H2320/H3020: Vo2/3 (typ.) versus Io2/3 with different Io1 Io1 Io2,Io3 0.5 05120 Vo2/3 [V] Vo2/3 0 16 Io1 nom 0.5 * Io1 nom 0 0.5 1.0 1.2 Io Io nom Io1 = 0 A 15 Fig. 2 Typical output voltage Vo1 versus output currents Io 14 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 converter is forced to supply a minimum current of 0.1 A to enable correct operation of its own auxiliary outputs. 0 0.25 0.5 0.75 1.0 Io2/3 Io2/3 nom Fig. 4 H2540/H3040: Vo2/3 (typ.) versus Io2/3 with different Io1 Outputs one and two of a double-output model may be connected in parallel without a minimum current requirement at the main output. Outputs two and three of a triple-output model 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 maximum 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 converter. 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. REV. MAR 27, 2006 Page 6 of 19 www.power-one.com H Series Data Sheet 50 Watt DC-DC Cassette Converters Thermal Considerations 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 50 C (e.g. 65 C) if TC max is not exceeded. For -2 units at an ambient temperature TA of 65 C 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 converter is turned on or off. Output Vo nom 0.95Vo nom 05025 0.1 0 tr t tf th Vi 1 Fig. 6 Output response as a function of input voltage (on/off switching) or inhibit control t 0 Inhibit 1 Type of Converter t 0 Table 5: Output response time tr and tf 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 Vi min to Vi max does not influence the values. REV. MAR 27, 2006 Page 7 of 19 www.power-one.com Auxiliary Functions i Inhibit for Remote On and Off Iinh [mA] 2.0 Vinh = 2.4 V Vinh = 0.8 V 06032 Note: With open i input: Output is disabled (Vo = off). 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. 1.6 1.2 0.8 0.4 Vo = on Vo = off 0 06031 -0.4 Vo+ Vi+ i -0.8 -50 I inh -30 -10 0 10 30 50 Vinh [V] Fig. 8 Typical inhibit current I inh versus inhibit voltage Vinh Vinh Vo- Vi- Fig. 7 Definition of Vinh and Iinh. Table 6: Inhibit data Characteristics Vinh Inhibit input voltage to keep output voltage I inh Inhibit current Vo = on Vo = off Conditions min Vi min to Vi max TC min to TC max -50 Vinh = 0 -60 typ 2.4 Vo1+ R + Vext + - 4000 R + - R1 G Fig. 10 Voltage adjustment with external resistor R1 or R2 b) Vo 0 to 100% Vo nom, using R1 between R (14) and G (17): 4000 * Vo R1 ---------- Vo nom - Vo c) Vo Vo nom to Vo max, using R2 between R (14) and Vo1+ (20): Vo max = Vo nom + 10% G Fig. 9 Voltage adjustment with external voltage Vext 4000 * Vo * (Vo nom - 2.5 V) R2 ------------------------ 2.5 V * (Vo - Vo nom) a) Vo 0 to 110% Vo nom, using Vext between R (14) and G (17): Vo Vext Vext 2.5 V * ----- Vo Vo nom * ----- Vo nom 2.5 V Caution: To prevent damage, Vext should not exceed 8 V, nor be negative. REV. MAR 27, 2006 06088 R1 Vo Vo nom * ----------- R1 + 4000 06087 Vref 4000 A Vref R2 The output voltage Vo1 can either be adjusted with an external voltage (Vext) or with an external resistor (R1 or R2). The adjustment range is approximative 0 to 110% of Vo nom. For output voltages Vo > Vo nom, the minimum input voltage according to Electrical Input Data increases proportionally to Vo/Vo nom. VDC -220 Vo1+ As a standard feature, single-output models offer an adjustable output voltage identified by letter R in the type designation. Unit 0.8 50 -100 R-Control for Output Voltage Adjustment Note: With open R input, Vo Vo nom. max Vo nom * 2.5 V * R2 Vo -------------------------------- 2.5 V * (R2 + 4000 ) - Vo nom * 4000 Caution: To prevent damage, R2 should never be less than 47 k. Note: R inputs of n models 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. Page 8 of 19 www.power-one.com H Series Data Sheet 50 Watt DC-DC Cassette Converters Table 7a: R1 for Vo < Vo nom (conditions: Vi nom, Io nom, rounded up to resistor values E 96); R 2 = Vo nom = 5.1 V Vo [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 Vo [V] R1 [k] Vo nom = 15 V Vo [V] R1 [k] Vo nom = 24 V Vo [V] R1 [k] Vo nom = 48 V Vo [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 Vo > Vo nom (conditions: Vi nom, Io nom, rounded up to resistor values E 96); R1 = Vo nom = 5.1 V Vo [V] R 2 [k] 5.15 5.20 5.25 5.30 5.35 5.40 5.45 5.50 Vo nom = 12 V Vo [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 Vo nom = 15 V Vo [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 Vo nom = 24 V Vo [V] R 2 [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 Vo nom = 48 V Vo [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 Vo1 > 0.95 to 0.98Vo1 adj 06090 OK i Ui Vi uv Vi min Vi max Vo1 > 0.95 to 0.98Vo1 adj Vi ov Fig. 11 "OK" and "i" status versus input voltage LEDs Conditions: Io Io nom, TC TC max, Vinh 0.8 V Vi uv = undervoltage lockout, Vi ov = overvoltage lockout Vi abs Vo1 < 0.95 to 0.98Vo1 adj OK Io nom Io LED "OK" status versus output current Conditions: Vi min to Vi max, TC TC max, Vinh 0.8 V TC LED "i"versus case temperature Conditions: Vi min to Vi max, I o I o nom, Vinh 0.8 V Vi inh LED "i"versus Vinh Conditions: Vi min to Vi max, I o I o nom, TC TC max IoL i TC max TPTC threshold Vinh threshold i -50 V LED off REV. MAR 27, 2006 +0.8 V +2.4 V LED Status undefined +50 V LED on Page 9 of 19 www.power-one.com H Series Data Sheet 50 Watt DC-DC Cassette Converters 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 to 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 2 +i/-i 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 Vi 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 REV. MAR 27, 2006 Page 10 of 19 www.power-one.com Mechanical Data European Projection 09050 6TE 12.1 32 29 26 23 20 17 14 8 11 5 2 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 31.5 0.1 0 30.48 25.40 94.5 0.1 95 0.5 17.25 12.17 7.09 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. REV. MAR 27, 2006 Page 11 of 19 www.power-one.com Immunity to Environmental Conditions Table 10: Mechanical stress Test method Standard Test conditions Ca Damp heat steady state IEC/DIN IEC 60068-2-3 MIL-STD-810D section 507.2 Temperature: Relative humidity: Duration: 40 2 C 93 +2/-3 % 21 days Converter not operating Status 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) Converter operating 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 to 60 Hz) 2 gn = 20 m/s2 (60 to 150 Hz) 10 to 150 Hz 3.75 h (1.25 h each axis) Frequency (1 Oct/min): Test duration: Table 11: Temperature specifications, values given are for an air pressure of 800 to 1200 hPa (800 to 1200 mbar) Temperature Standard -2 Characteristics 1 TA Ambient temperature 1 TC Case temperature 3 TS Storage temperature 1 Option -7 Conditions min max min max Unit Operational 2 -10 50 -25 71 C -10 80 -25 95 -25 100 -40 100 Not operational MIL STD 810D section 501.2 and 502.2. 2 See: Thermal considerations. 3 Overtemperature lockout at TC >95 C (PTC). Table 12: MTBF Values at specified Case Temperature Model Types Ground Benign Unit 40 C 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 to 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) REV. MAR 27, 2006 Page 12 of 19 www.power-one.com H Series Data Sheet 50 Watt DC-DC Cassette Converters 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 cassette failure (e.g. by an internal shortcircuit) does not result in a hazardous condition. See also: Safety of operator accessible output circuit. To prevent excessive current flowing into the cassette (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 airflow 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 to 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 TUV 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 VAC and 400 VDC * 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 honor 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 - kVDC 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 VDC 1 2 In accordance with IEC/EN 60950 only subassemblies are tested in factory with this voltage. Tested at 300 VDC. For creepage distances and clearances refer to: Technical Information: Safety. REV. MAR 27, 2006 Page 13 of 19 www.power-one.com H Series Data Sheet 50 Watt DC-DC Cassette Converters Safety of operator accessible output circuit If the output circuit of a DC-DC converter is operator accessible, it shall be a 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 VAC and 400 VDC 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 a SELV circuit. Only voltage adaptation 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 a 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 a SELV output circuit Conditions Front end 1 2 3 DC-DC converter Result Minimum required safety status of the front end output circuit Measures to achieve the specified safety status of the output circuit Safety status of the DC-DC converter output circuit -400 V 1 (The rated voltage between any input pin and earth can be up to 250 VAC or 400 VDC) Primary circuit Double or reinforced insulation, based on 250 VAC and 400 VDC (provided by the DC-DC converter) and earthed case 2 SELV circuit -400 V Unearthed hazardous voltage secondary circuit Supplementary insulation, based on 250 VAC and 400 VDC, 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 Nominal supply voltage 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 -250 VAC Operational (i.e. there is no need for electrical isolation between the mains supply voltage and the DC-DC converter input voltage) 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 VAC or 400 VDC Fuse 10024 + AC-DC front end Battery Fuse Max. 250 VAC or 400 VDC DC-DC converter SELV - Earth connection Fig. 14 Schematic safety concept. Use earth connection as per table: Safety concept leading to a SELV output circuit. Use fuse according to: Installation Instructions. REV. MAR 27, 2006 Page 14 of 19 www.power-one.com Description of Options Table 16: Survey of options Option -7 D 1 V12 1 2 Function of Option Characteristic Extended operational ambient temperature range TA = -25 to 71C Input and/or output undervoltage monitoring circuitry Safe data signal output (D1 to D8) 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 Vo1 = 5.1 V -7 Extended Temperature Range Option -7 extends the operational ambient temperature range from -10 to 50 C (standard) to -25 to 71 C. 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 Vt. The return for this signal is Vo1- (pin 23). The D output recovers when the monitored voltage(s) exceed(s) Vt+Vh. The threshold level Vt is adjustable by a potentiometer, accessible through a hole in the front cover. Option D exists in various versions D1 to D8 as shown in the following table. Table 17: Undervoltage monitor functions Output type JFET NPN D5 no yes - 3.5 V to 48 V 1 - 2.3 to 1 D2 D6 yes no Vi min to Vi max 1 - 3.0 to 0.5 - 0.95 to 0.98 Vo1 2 3.0 to 0.5 "0" 0.95 to 0.98 Vo1 2 - "0" D4 2 Typical hysteresis Vh [% of Vt ] for Vt min to Vt max Vhi Vho Minimum adjustment range of threshold level Vt Vti Vto D1 D3 1 Monitoring Vi Vo1 D7 yes D8 no yes Vi min to Vi max 1 - yes Threshold level adjustable by potentiometer (not recommended for mobile applications) Fixed value between 95% and 98% of Vo1 (tracking) 11006 JFET output (D1 to D4): Vo1+ Connector pin D is internally connected via the drainsource path of a JFET (self-conducting type) to the negative potential of output 1. VD 0.4 V (logic low) corresponds to a monitored voltage level (Vi and/or Vo1) <Vt. 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. Vi , Vo1 status D output, VD Vi or Vo1 < Vt low, L, VD 0.4 V at I D = 2.5 mA Vi and Vo1 > Vt + Vh high, H, I D 25 A at VD = 5.25 V Rp Input ID D VD Vo1- Fig. 15 Options D1 to D4, JFET output 11007 NPN output (D5 to D8): Vo1+ Connector pin D is internally connected via the collectoremitter path of an NPN transistor to the negative potential of output 1. VD - 0.4 V (logic low) corresponds to a monitored voltage level (Vi and/or Vo1) >Vt + Vh. The current ID through the open collector should not exceed 20 mA. The NPN output is not protected against external overvoltages. VD should not exceed 40 V. Vi , Vo1 status D output, VD Vi or Vo1 < Vt high, H, I D 25 A at VD = 40 V Vi and Vo1 > Vt +Vh low, L, VD 0.4 V at I D = 20 mA REV. MAR 27, 2006 Input Rp ID D VD Vo1- Fig. 16 Options D5 to D8, NPN output Page 15 of 19 www.power-one.com Threshold tolerances and hysteresis: Vti VD If Vi 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 Vt i across the input filter. The value of Vti depends upon the input voltage range, threshold level Vt , temperature, and input current. The input current is a function of the input voltage and the output power. Vhi 11021 Po = Po nom Po = 0 Po = 0 Po = Po nom VD high VD low Vi Vti Fig. 17 Definition of Vti, Vti and Vhi (JFET output) Input voltage monitoring NPN VD VD high 11008 3 3 3 3 VD low t 0 ID ID high ID low 0 t JFET VD VD high VD low 0 t th1 tlow min4 tlow min4 Vo1 Vo1 nom 1 0.95 tlow min4 thigh min th1 t 0 Vi [V DC] Vti +Vhi Vti t 0 Input voltage failure Input voltage sag Switch-on cycle Output voltage monitoring NPN VD VD high Switch-on cycle and subsequent input voltage failure 2 3 3 VD low t 0 ID ID high ID low 0 t JFET VD VD high VD low 0 t tlow min4 Vo1 Vo1 nom Vto +Vho Vto 1 2 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 to 200 ms, typically 80 ms Output voltage failure Fig. 18 Relationship between Vi, Vo1, VD, ID and Vo1/Vo nom versus time. REV. MAR 27, 2006 Page 16 of 19 www.power-one.com H Series Data Sheet 50 Watt DC-DC Cassette Converters Formula for threshold level for desired value of t h: V ACFAIL signal (VME) Available for units with Vo1 = 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 VV -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 Vt i should be adequately above the minimum input voltage Vi 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 Vti with resulting hold-up time. Types 12H 24H 48H Unit Ci min 2.2 0.75 0.19 mF Vt i 9.5 19.5 39 VDC th 0.19 0.87 0.89 ms Option V operates independently of the built-in input undervoltage lockout circuit. A logic "low" signal is generated at pin 5 as soon as one of the monitored voltages drops below the preselected threshold level Vt. The return for this signal is Vo1- (pin 23). The V output recovers when 2 * Po * (t h + 0.3 ms) * 100 ---------------------- + Vi min2 C i min * V ti = Formula for additional external input capacitor 2 * Po * (t h + 0.3 ms) * 100 C i ext = --------------------- - Ci min * (Vti 2 - Vi 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] Vi min = minimum input voltage [V] Vti = threshold level [V] Remarks: The threshold level Vti 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. the monitored voltage(s) exceed(s) Vt + Vh. The threshold level Vt 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 Vi Vo1 yes no yes yes Typical hysteresis Vh [% of Vt ] for Vt min to Vt max Vhi Vho Minimum adjustment range of threshold level Vt Vti Vto Vi min to Vi max 1 Vi min to Vi max 1 - 0.95 to 0.98 Vo1 2 3.0 to 0.5 - 3.0 to 0.5 "0" Threshold level adjustable by potentiometer (not recommended for mobile applications) Fixed value between 95% and 98% of Vo1 (tracking), output undervoltage monitoring is not a requirement of VME standard 11009 V output (V2, V3): Vo1+ Connector pin V is internally connected to the open collector of an NPN transistor. The emitter is connected to the negative potential of output 1. VV 0.6 V (logic low) corresponds to a monitored voltage level (Vi and/or Vo1) < Vt. The current I V through the open collector should not exceed 50 mA. The NPN output is not protected against external overvoltages. VV should not exceed 80 V. Vi, Vo1 status low, L, VV 0.6 V at I V = 50 mA Vi and Vo1 > Vt + Vh high, H, I V 25 A at VV = 5.1 V Input V VV V output, UV Vi or Vo1 < Vt REV. MAR 27, 2006 Rp IV Vo1- Fig. 19 Output configuration of options V2 and V3 Page 17 of 19 www.power-one.com Threshold tolerances and hysteresis: VV If Vi 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 Vti across input filter and rectifier. The value of Vti depends upon the input voltage range, threshold level Vt, temperature, and input current. The input current is a function of input voltage and output power. Vti Vhi 11023 Po = Po nom Po = 0 Po = 0 Po = Po nom VV high VV low Fig. 20 Definition of Vti, Vti and Vhi Input voltage monitoring V2 VV VV high t low min 2 t low min 2 t low min 2 3 Vi Vti 3 3 11010 4 4 t low min 2 t low min 2 VV low t 0 V3 VV VV high 3 3 3 VV low t 0 th Vo1 5.1 V 4.875 V 1 th 1 2.0 V 0 t Vi [VDC] Vti + Vhi Vti t 0 Input voltage failure Input voltage sag Switch-on cycle Switch-on cycle and subsequent input voltage failure Output voltage monitoring V2 VV VV high 4 VV low 4 t 0 V3 VV VV high t low min 3 2 3 4 VV low 0 t Vo1 5.1 V 4.875 V 2.0 V 0 t Vi 1 Vti + Vhi Vti 3 2 4 t 0 VME request: minimum 4 ms t low min = 40 to 200 ms, typically 80 ms VV level not defined at Vo1 < 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 Vi, Vo1, VV, I V and Vo1 /Vo nom versus time. REV. MAR 27, 2006 Page 18 of 19 www.power-one.com H Series Data Sheet 50 Watt DC-DC Cassette Converters 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 Mounting plate, Connector retention clips Front panels Flexible H11 PCB Universal mounting bracket for DIN-rail mounting. NUCLEAR AND MEDICAL APPLICATIONS - Power-One products are not designed, intended for use in, or authorized for use as critical components in life support systems, equipment used in hazardous environments, or nuclear control systems without the express written consent of the respective divisional president of Power-One, Inc. TECHNICAL REVISIONS - The appearance of products, including safety agency certifications pictured on labels, may change depending on the date manufactured. Specifications are subject to change without notice. REV. MAR 27, 2006 Page 19 of 19 www.power-one.com