Rugged Environment DC-DC Converters >100 Watt 150 Watt DC-DC Converters K Series K Series Input to output isolation Single output: AK...EK 1000 Double output: AK...EK 2000 * Extremely wide input voltage range * Input over- and undervoltage lock-out * Efficient input filter and built-in surge and transient suppression circuitry * 4 kVrms input to output electric strength test * Fully isolated outputs * Outputs open- and short-circuit proof * No derating over entire operating temperature range Safety according to IEC/EN 60950 LGA C 111 4.4" 3U 80 3.2" 16 TE Summary The K series of DC-DC converters represents a broad and flexible range of power supplies for use in advanced electronic systems. Features include high efficiency, high reliability, low output voltage noise and excellent dynamic response to load/line changes. The converter inputs are protected against surges and transients occuring at the source lines. An input over- and undervoltage lock-out circuitry disables the outputs if the input voltage is outside the specified range. Certain types include an inrush current limitation preventing circuit breakers and fuses from being damaged at switch-on. All outputs are open- and short-circuit proof and are protected against overvoltages by means of a built-in suppressor diode. The outputs can be inhibited by a logic signal applied to the connector pin 18 (i). If the inhibit function is not used pin 18 must be connected with pin 14 to enable the outputs. LED indicators display the status of the converter and allow visual monitoring of the system at any time. Table of Contents 168 6.6" 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 standards IEC/EN 60950 and have been approved by the safety 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 71C in a free air ambient temperature. If forced cooling is provided, the ambient temperature may exceed 71C but the case temperature must remain below 95C 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" rack systems according to DIN 41494, or be chassis mounted. Page Page Summary .......................................................................... 1 Type Survey and Key Data .............................................. 2 Type Key .......................................................................... 3 Functional Description ...................................................... 4 Electrical Input Data ......................................................... 5 Electrical Output Data ...................................................... 7 Auxiliary Functions ......................................................... 14 Electromagnetic Compatibility (EMC) ............................ 18 Immunity to Environmental Conditions ........................... 20 Mechanical Data ............................................................ 21 Safety and Installation Instructions ................................ 22 Description of Options .................................................... 25 Accessories .................................................................... 31 MELCHER The Power Partners. Edition 4/4.99 1/31 K Series DC-DC Converters >100 Watt Rugged Environment Type Survey and Key Data Non standard input configurations or special custom adaptions are available on request. See also: Commercial Information: Inquiry Form for Customized Power Supply. Table 1a: Type survey AK Output 1 Output 2 Input Voltage Options Uo nom [V DC] Io nom [A] 2 Uo nom [V DC] Io nom [A] 2 Ui min...Ui max 8...35 V DC hmin [%] 5.1 12.0 15.0 24.0 20.0 10.0 8.0 5.0 - - AK 1001-7R AK 1301-7R AK 1501-7R AK 1601-7R 78 80 80 82 24.0 4 30.0 4 48.0 4 5.0 4.0 2.5 - - AK 2320-7R AK 2540-7R AK 2660-7R 78 79 79 12.0 15.0 24.0 5.0 4.0 2.5 12.0 5 15.0 5 24.0 5 5.0 4.0 2.5 AK 2320-7R AK 2540-7R AK 2660-7R 78 79 79 -9 E3 D V6 P T B1 B2 Table 1b: Type survey BK, FK, CK Output 1 Input Voltage Range and Efficiency 1 Output 2 Options Uo nom [V DC] Io nom [A] 2 Uo nom [V DC] Io nom [A] 2 Ui min...Ui max 14...70 V DC hmin [%] Ui min...Ui max 20...100 V DC hmin [%] Ui min...Ui max 28...140 V DC hmin [%] 5.1 12.0 15.0 24.0 25.0 12.0 10.0 6.0 - - BK 1001-7R BK 1301-7R BK 1501-7R BK 1601-7R 79 81 82 84 FK 1001-7R FK 1301-7R FK 1501-7R FK 1601-7R 80 82 85 86 CK 1001-7R CK 1301-7R CK 1501-7R CK 1601-7R 79 82 84 86 24.0 4 30.0 4 48.0 4 6.0 5.0 3.0 - - BK 2320-7R BK 2540-7R BK 2660-7R 80 80 80 FK 2320-7R FK 2540-7R FK 2660-7R 81 83 84 CK 2320-7R CK 2540-7R CK 2660-7R 80 82 84 12.0 15.0 24.0 6.0 5.0 3.0 12.0 5 15.0 5 24.0 5 6.0 5.0 3.0 BK 2320-7R BK 2540-7R BK 2660-7R 80 80 80 FK 2320-7R FK 2540-7R FK 2660-7R 81 83 84 CK 2320-7R CK 2540-7R CK 2660-7R 80 82 84 -9 E3 D V6 P T B1 B2 Table 1c: Type survey DK, EK Output 1 1 2 3 4 5 6 Output 2 Input Voltage Range and Efficiency 1 Options Uo nom [V DC] Io nom [A] 2 Uo nom [V DC] Io nom [A] 2 Ui min...Ui max 44...220 V DC hmin [%] Ui min...Ui max 67...385 V DC hmin [%] 5.1 12.0 15.0 24.0 25.0 12.0 10.0 6.0 - - DK 1001-7R DK 1301-7R DK 1501-7R DK 1601-7R 79 83 86 87 EK 1301-7R EK 1501-7R EK 1601-7R 84 84 84 24.0 4 30.0 4 48.0 4 6.0 5.0 3.0 - - DK 2320-7R DK 2540-7R DK 2660-7R 81 82 85 EK 2320-7R EK 2540-7R EK 2660-7R 81 80 83 12.0 15.0 24.0 6.0 5.0 3.0 12.0 5 15.0 5 24.0 5 6.0 5.0 3.0 DK 2320-7R DK 2540-7R DK 2660-7R 81 82 85 EK 2320-7R EK 2540-7R EK 2660-7R 81 80 83 -9 E3 D V6 P T B1 B2 Efficiency at Ui nom and Io nom. If the output voltages are increased above Uo nom via R-input control, option P setting, remote sensing or option T, the output currents should be reduced accordingly so that Po nom is not exceeded. Option E only for CK, DK, EK types. Series connection of output 1 and 2. Second output semi-regulated. Option V for K 1001 types only. MELCHER The Power Partners. Edition 4/4.99 2/31 Rugged Environment DC-DC Converters >100 Watt K Series Type Key Type Key C K 2 5 40 -7 E R P D V T B1 Input voltage range Ui: 8...35 V DC 14...70 V DC 20...100 V DC 28...140 V DC 44...220 V DC 67...385 V DC ............... A .............. B .............. F .............. C .............. D .............. E Series ............................................................................... K Number of outputs ....................................................... 1...2 Single output units: Nominal voltage output 1 (main output), Uo1 nom 5.1 V ....... 0, 1, 2 12 V ............... 3 15 V ........... 4, 5 24 V ............... 6 other voltages ........... 7, 8 Other specifications for single output modules ...... 01...99 Symmetrical double output units: Nominal voltage output 1/output 2, Uo1/2 nom 12 V/12 V 1 (24 V series connection) 15 V/15 V 1 (30 V series connection) 24 V/24 V 1 (48 V series connection) other symmetrical voltages ............. 20 ............. 40 ............. 60 ...... 70...99 Operational ambient temperature range TA: -25...71C .............. -7 -40...71C .............. -9 customer specific ........ -0...-6 Auxiliary functions and options: Inrush current limitation .................................................... E Output voltage control input ............................................ R Potentiometer (output voltage adjustment) ...................... P Save data signal (D0...DD, to be specified) .................... D ACFAIL signal (V0, V2, V3, to be specified) .................... V Current sharing ................................................................ T Cooling plate standard case .......................................... B1 Cooling plate for long case 220 mm .............................. B2 1 2 3 4 5 3 2 2 4 4, 5 External wiring of main and second output depending upon the desired output configuration (see: R-Function for Different Output Configurations). Feature R excludes option P and vice versa. Option E available for CK, DK and EK types. Option D excludes option V and vice versa. Option V available for K 1001 type. Example: CK 2540-7PD3: DC-DC converter, input voltage range 28...140 V, double output, each providing 15 V/ 5 A, equipped with potentiometer and undervoltage monitoring option. Ambient temperature -25...71C. MELCHER The Power Partners. Edition 4/4.99 3/31 K Series DC-DC Converters >100 Watt Rugged Environment Functional Description The input voltage is fed via an input fuse, an input filter, and an inrush current limiter 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 and output filter. 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. The second output of double output units is controlled by the main output but has independent current limiting. If the main output is driven into current limitation, the second output voltage will fall as well and vice versa. P 03057 16 R 26 Vi+ 18 i Y 28 20 D/V 2 4 12 S+ 4 8 Vo- Y 10 3 Vi- Vo+ 6 Output filter Y 22 T Control circuit Input filter Forward converter (approx. 120 kHz) 1 30 32 14 S- Y 24 - Fig. 1 Block diagram of single output converters AK...EK 1000 + P 03058 16 R Vi+ 26 18 i Y 28 20 D 2 4 14 Vo1- Y 4 Y 6 Output 2 filter 3 Vi- 12 Vo1+ Output 1 filter Y 22 T Control circuit Input filter Forward converter (approx. 110 kHz) 1 30 32 8 Y Y 10 24 Fig. 2 Block diagram of symmetrical double output converters AK...EK 2000 1 2 3 4 Transient suppressor (VDR) in CK, DK, EK, FK types Transient suppressor (diode) in AK, BK, CK, FK types Inrush current limiter in CK, DK, EK types (NTC or Opt. E), -9 versions exclude the NTC Input fuse MELCHER The Power Partners. Edition 4/4.99 4/31 Vo2+ - + Vo2- Rugged Environment DC-DC Converters >100 Watt K Series Electrical Input Data General Conditions - TA = 25C, unless TC is specified. - Pin 18 connected to pin 14, Uo adjusted to Uo nom (option P); R input not connected. - Sense line pins S+ and S- connected to Vo+ and Vo- respectively. Table 2a: Input data Input AK Ui Operating input voltage U i nom Nominal input voltage Io = 0...Io nom TC min...TC max Ii Input current Ui nom, Io nom 1 P i0 No-load input power Ui min...Ui max 2.5 2.5 2.5 P i inh Idle input power unit inhibited 1.5 1.5 1.5 Ri Input resistance TC = 25C R NTC NTC resistance 2 Ci Input capacitance U i RFI Conducted input RFI U i abs typ 8 max min 35 14 max min 70 20 30 48 9.0 6.0 3.75 65 100 830 EN 55022 U i nom, I o nom typ 15 3 Input voltage limits without damage typ FK Conditions Radiated input RFI min BK Characteristics V DC A 300 450 1200 B B A B 0 W m A 40 100 3 A 0 Unit 70 3 1250 max 80 0 1800 F 100 V DC Table 2b: Input data Input CK Conditions min Ui Operating input voltage 28 U i nom Nominal input voltage Io = 0...Io nom TC min...TC max Ii Input current Ui nom, Io nom 1 P i0 No-load input power Ui min...Ui max 2.5 2.5 2.5 P i inh Idle input power unit inhibited 1.5 1.5 1.5 Ri Input resistance TC = 25C R NTC NTC Ci Input capacitance U i RFI Conducted input RFI Radiated input RFI U i abs 1 2 3 4 Input voltage limits without damage max min 140 44 min 220 67 typ 110 220 1.6 0.8 170 1000 400 B B B 0 W m 3200 260 B 154 V DC A 180 1600 660 max 385 60 800 0 max 3.0 150 EN 55022 U i nom, I o nom typ EK Characteristics resistance 2 typ DK 210 400 F 400 V DC B B 400 4 0 With double output modules, both outputs loaded with Io nom. Valid for -7 versions with NTC, (-9 versions exclude the NTC). Initial switch-on cycle. Subsequent switch-on/off cycles increase the inrush current peak value. AK, BK and FK types have no NTC (inrush current limiter) fitted. 1 s max., duty cycle 1% max. Input Transient Protection A suppressor diode or a VDR (depending upon the input voltage range) together with the input fuse and a symmetrical input filter form an effective protection against high input transient voltages which typically occur in most installations, but especially in battery driven mobile applications. tremely wide input range is required. The EK input range for 110 V batteries has been designed and tested to meet this requirement. Nominal battery voltages in use are: 12, 24, 36, 48, 60, 72, 110 and 220 V. In most cases each nominal value is specified in a tolerance of -30%...+25%. The CK, DK, EK modules incorporate an NTC resistor in the input circuitry which - at initial turn on - reduces the peak inrush current value by a factor of 5...10 to protect connectors and switching devices from damage. Subsequent switch-on cycles within short periods will cause an increase of the peak inrush current value due to the warming-up of the NTC resistor. See also: E option. In certain applications, surges according to RIA 12 are specified in addition to those defined in IEC 571-1. The power supply must not switch off during these surges and since their energy can practically not be absorbed an ex- MELCHER The Power Partners. Inrush Current Limitation Edition 4/4.99 5/31 K Series DC-DC Converters >100 Watt Rugged Environment Input Inrush Current Characteristic Input Fuse A fuse mounted inside the converter protects the module against severe defects. This fuse may not fully protect the module when the input voltage exceeds 200 V DC! In applications where the converters operate at source voltages above 200 V DC an external fuse or a circuit breaker at system level should be installed! Ii inr [A] 05108 150 Table 3: Fuse Specification 1 100 Module Fuse type Fuse rating AK 1 BK 1 CK 2 DK 2 EK 2 FK 2 fast-blow fast-blow slow-blow slow-blow slow-blow slow-blow Little fuse 314 Little fuse 314 SPT SPT SPT SPT Fuse size 6.3 x 32 mm 2 30.0 A, 125 V 25.0 A, 125 V 12.5 A, 250 V 8 A, 250 V 4 A, 250 V 16 A, 250 V CK EK DK 50 Fuse size 5 x 20 mm Static Input Current Characteristic Ii (A) 0 04044 20.00 2 1 3 t [ms] Fig. 5 Typical inrush current versus time at Ui max, Rext = 0. For AK, BK and FK as well as for application related values use the formula given in Inrush Current Peak Value to get realistic results. 10.00 AK Input Under-/Overvoltage Lock-out If the input voltage remains below approx. 0.8 Ui min or exceeds approx. 1.1 Ui max, an internally generated inhibit signal disables the output(s). When checking this function the absolute maximum input voltage rating U i abs should be considered! 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). BK FK CK 1.00 DK EK 0.40 1 2 3 4 5 Ui ____ Ui min Hold-up Time versus relative Input Voltage Fig. 3 Typical input current versus relative input voltage t h (ms) 04045 Inrush Current Peak Value EK 100.00 The inrush current peak value (initial switch-on cycle) can be determined by following calculation: (See also: Input Inrush Current Characteristic) Ui source Iinr p = ---------------- (Rs ext + Ri + RNTC) CK/FK DK 10.00 AK BK 05109 Rs ext Iinr p Ri RNTC 1.00 + Ui source Ci int 0.10 Fig. 4 Equivalent circuit for input impedance Reverse Polarity The units are not protected against reverse polarity at the input to avoid unwanted power losses and may be damaged. MELCHER The Power Partners. 1 2 3 4 5 6 Ui ____ Ui min Fig. 6 Typical hold-up time th versus relative input voltage Ui /Ui min. The DC-DC converters require an external series diode in the input path if other loads are connected to the same input supply lines. Edition 4/4.99 6/31 Rugged Environment DC-DC Converters >100 Watt K Series Electrical Output Data General Conditions - TA = 25C, unless TC is specified. - Pin 18 (i) connected to pin 14 (S-/Vo1-), Uo adjusted to Uo nom (option P), R input not connected. - Sense line pins 12 (S+) and 14 (S-) connected to Vo1+ and Vo1- respectively. Table 4a: Output data single output modules AK/BK Output AK/BK 1001 5.1 V Characteristics Conditions min typ max Uo Output voltage Ui nom, Io nom 5.07 5.13 Uo P Overvoltage protection (suppressor diode) Io nom Output current 1 Io L Output current limit 4 Ui min...Ui max uo7 Output Switching freq. voltage Total noise Ui nom, Io nom IEC/EN 61204 BW = 20 MHz 5 6 7 12.07 min typ max 14.91 15.09 AK/BK 1601 24.0 V min typ max 23.86 24.14 7.6 21 26.5 43.5 20.0/25.0 10.0/12.0 8.0/10.0 5.0/6.0 21/26 10.2/12.2 8.2/10.2 Unit V A 5.2/6.2 10 5 5 5 60 40 30 50 mVpp Ui min...Ui nom Ui nom...Ui max Io nom 15 25 30 30 DUo I Static load regulation Ui nom, Io = (0.1...1) Io nom 20 25 30 40 uo d 5 Dynamic load regulation Ui nom, Io = Io nom 1/2 Io nom IEC/EN 61204 220 110 150 130 0.6 0.6 0.5 1 ms TC min...TC max 0...I o nom -0.2 -1 -1 -1 mV/K a Uo 4 min typ max 11.93 AK/BK 1501 15.0 V DUo u Static line regulation td 5 1 Ui min...Ui max TC min...TC max AK/BK 1301 12.0 V Voltage deviation Recovery time Temperature coefficient of output voltage 6 mV If the output voltages are increased above Uo nom through R-input control, option P setting, remote sensing or option T, the output current should be reduced accordingly so that Po nom is not exceeded. See: Output voltage regulation of single output units. See: Dynamic load regulation of Uo1. Negative temperature coefficient (0...-3 mV/cell and K) available on request Measured according to IEC/EN 61204 sub clause 3.10 with a probe acc. to annex A of the same standards. (see: Technical Information: Measuring and Testing) MELCHER The Power Partners. Edition 4/4.99 7/31 K Series DC-DC Converters >100 Watt Rugged Environment Table 4b: Output data double output modules AK/BK Output (Outputs connected in Series) Characteristics Conditions Uo Output voltage Uo P Overvoltage protection (suppressor diode) Io nom Output current 1 3 4 5 6 7 Ui nom, Io nom Ui min...Ui max TC min...TC max typ max min typ max AK/BK 2660 48 V (2 x 24 V) min typ max Unit 24.0 2 30.0 2 48.0 2 38 48 74 5.0/6.0 4.0/5.0 2.5/3.0 A mVpp V Output current limit 4 Ui min...Ui max uo7 Output Switching freq. voltage Total noise 3 Ui nom, Io nom IEC/EN 61204 BW = 20 MHz 10 5 5 60 60 70 DUo u Static line regulation Ui min...Ui nom Ui nom...Ui max Io nom 15 15 20 DUo I Static load regulation Ui nom, Io = (0.1...1) Io nom 25 25 35 uo d 5 Dynamic load regulation Ui nom, Io= Io nom 1/2 Io nom IEC/EN 61204 180 160 100 0.3 0.2 0.2 ms -2 -2 -2 mV/K a Uo 2 min AK/BK 2540 30 V (2 x 15 V) Io L td 5 1 AK/BK 2320 24 V (2 x 12 V) Voltage deviation Recovery time Temperature coefficient of output voltage 6 TC min...TC max 0...I o nom 5.2/6.2 4.2/5.2 2.7/3.2 mV If the output voltages are increased above Uo nom through R-input control, option P setting, remote sensing or option T, the output current should be reduced accordingly so that Po nom is not exceeded. Series connection for Uo nom = 24 V, 30 V or 48 V, see: R-Function for Different Output Configurations. Shortest possible wiring for series connection at the connector. See: Output voltage regulation of single output units. See: Dynamic load regulation of Uo1 and Uo2 . Negative temperature coefficient (0...-3 mV/cell and K) available on request. Measured according to IEC/EN 61204 sub clause 3.10 with a probe acc. to annex A of the same standards. (See: Technical Information: Measuring and Testing.) MELCHER The Power Partners. Edition 4/4.99 8/31 Rugged Environment DC-DC Converters >100 Watt K Series Table 4c: Output data double output modules AK/BK Output (Outputs independently loaded) 1 AK/BK 2320 12 V/12 V Characteristics Conditions Output 1 Uo Output voltage Ui nom, Io nom 2 Uo P Overvoltage protection (suppressor diode) min Io nom Output current 3 Ui min...Ui max TC min...TC max Io L Output current limit 4 uo9 Output Switching freq. Ui nom, Io nom voltage IEC/EN 61204 Total noise BW = 20 MHz Ui min...Ui max Output 2 typ max 11.93 AK/BK 2540 15 V/15 V 12.07 min typ max 11.82 12.18 Output 1 min Output 2 typ max 14.91 15.09 min typ 14.78 19 19 24 24 5.0/6.0 5.0/6.0 4.0/5.0 4.0/5.0 5.2/6.2 5.2/6.2 4.2/5.2 max Unit 15.23 V A 4.2/5.2 10 10 10 10 50 20 50 20 DUo u Static line regulation Ui min...Ui nom Ui nom...Ui max Io nom 30 DUo I Static load regulation Ui nom, Io = (0.1...1) Io nom 5 50 uo d 6 Dynamic load regulation Ui nom, Io = Io nom 1/2 Io nom IEC/EN 61204 80 80 0.2 0.2 ms TC min...TC max 0...I o nom -1 -1 mV/K td 6 a Uo Voltage deviation Recovery time Temperature coefficient of output voltage 7 30 30 mVpp 8 50 30 mV 8 Table 4d: Output data double output modules AK/BK Output (Outputs independently loaded) 1 Characteristics AK/BK 2660 24 V/24 V Conditions Output 1 min Uo Output voltage Uo P Overvoltage protection (suppressor diode) Io nom Output current 3 Io L uo 9 Ui nom, Io nom 2 Ui min...Ui max TC min...TC max Output current limit 4 Ui min...Ui max Output Switching freq. voltage Total noise Ui nom, Io nom IEC/EN 61204 BW = 20 MHz DUo u Static line regulation typ 23.86 1 Output 2 max min typ 24.14 23.64 max Unit 24.36 V 37 37 2.5/3.0 2.5/3.0 2.7/3.2 3 A 2.7/3.2 5 5 60 30 Ui min...Ui nom Ui nom...Ui max Io nom 40 70 mVpp 40 mV 6 8 Static load regulation Ui nom, Io = (0.1...1)Io nom 5 uo d 6 Dynamic load regulation Ui nom, Io = Io nom 1/2 Io nom IEC/EN 61204 50 0.2 ms TC min...TC max 0...I o nom -1 mV/K td 6 a Uo Recovery time Temperature coefficient of output voltage 7 MELCHER The Power Partners. 4 5 DUo I Voltage deviation 2 Edition 4/4.99 9/31 7 8 9 Depending upon the desired output configuration the wiring should be made as shown in: R-Function for Different Output Configurations. Same conditions for both outputs. If the output voltages are increased above Uo nom via R-input control, option P setting, remote sensing or option T, the output currents should be reduced accordingly so that Po nom is not exceeded. See: Output voltage regulation of single output units. Condition for specified output. Other output loaded with constant current Io = Io nom See: Dynamic load regulation of Uo1 and Uo2 . Negative temperature coefficient (0...-3 mV/cell and K) available on request. See: Output Voltage Regulation of Double Output Modules. Measured according to IEC/EN 61204 sub clause 3.10 with a probe acc. to annex A of the same standards. (see: Technical Information: Measuring and Testing) K Series DC-DC Converters >100 Watt Rugged Environment Table 4e: Output data single output modules CK...EK Output CK...DK 1001 5.1 V Characteristics Conditions min Uo Output voltage Ui nom, Io nom 5.07 Uo P Overvoltage protection (suppressor diode) Io nom Output current 1 typ Output current limit 4 Ui min...Ui max uo7 Output Switching freq. voltage Total noise Ui nom, Io nom IEC/EN 61204 BW = 20 MHz max min typ CK...EK 1501 15.0 V max 5.13 11.93 Ui min...Ui max TC min...TC max Io L CK...EK 1301 12.0 V min typ 12.07 14.91 CK...EK 1601 24.0 V max min typ 15.09 23.86 max Unit 24.14 V 7.6 21 26.5 43.5 25.0 12.0 10.0 6.0 A mVpp 26 12.2 10.2 6.2 10 5 5 5 50 40 30 50 DUo u Static line regulation Ui min...Ui nom Ui nom...Ui max Io nom 15 25 30 30 DUo I Static load regulation Ui nom, Io = (0.1...1) Io nom 20 25 30 40 uo d 5 Dynamic load regulation Ui nom, Io = Io nom 1/2 Io nom IEC/EN 61204 td 5 a Uo Voltage deviation Recovery time Temperature coefficient of output voltage 6 mV 100 100 100 80 0.3 0.5 0.4 0.3 ms -1 -1 -1 -2 mV/K TC min...TC max 0...Io nom Table 4f: Output data double output modules CK...EK Output (Outputs connected in Series) Characteristics Conditions Uo Output voltage Ui nom, Io nom Uo P Overvoltage protection (suppressor diode) Io nom Output current 1 Output current limit 4 Ui min...Ui max uo7 Output Switching freq. voltage Total noise 3 Ui nom, Io nom IEC/EN 61204 BW = 20 MHz 3 4 5 6 7 typ max CK...EK 2540 30 V (2 x 15 V) min typ max CK...EK 2660 48 V (2 x 24 V) min typ max Unit 24.0 2 30.0 2 48.0 2 38 48 74 6.0 5.0 3.0 A mVpp 6.2 5.2 V 3.2 15 15 20 100 120 120 DUo u Static line regulation Ui min...Ui nom Ui nom...Ui max Io nom 40 30 50 DUo I Static load regulation Ui nom, Io = (0.1...1) Io nom 40 30 40 uo d 5 Dynamic load regulation Ui nom, Io = Io nom 1/2 Io nom IEC/EN 61204 100 100 100 0.3 0.5 0.4 ms TC min...TC max 0...Io nom -2.2 -2.2 -2.6 mV/K a Uo 2 min Ui min...Ui max TC min...TC max Io L td 5 1 CK...EK 2320 24 V (2 x 12 V) Voltage deviation Recovery time Temperature coefficient of output voltage 6 mV If the output voltages are increased above Uo nom through R-input control, option P setting, remote sensing or option T, the output current should be reduced accordingly so that Po nom is not exceeded. Series connection for Uo nom = 24 V, 30 V or 48 V, see: R-Function for Different Output Configurations. Shortest possible wiring for series connection at the connector. See: Output voltage regulation of single output units. See: Dynamic load regulation of Uo1 and Uo2 . Negative temperature coefficient (0...-3 mV/cell and K) available on request Measured according to IEC/EN 61204 sub clause 3.10 with a probe acc. to annex A of the same standards. (See Technical Information: Measuring and Testing.) MELCHER The Power Partners. Edition 4/4.99 10/31 Rugged Environment DC-DC Converters >100 Watt K Series Table 4g: Output data double output modules CK...EK Output (Outputs independendtly loaded) 1 CK...EK 2320 12 V/12 V Output 1 CK...EK 2540 15 V/15 V Characteristics Conditions Uo Output voltage Ui nom, Io nom 2 Uo P Overvoltage protection (suppressor diode) Failure in control circuit 19 19 24 24 Ui min...Ui max TC min...TC max 6.0 6.0 5.0 5.0 A mVpp min Io nom Output current 3 Io L uo 9 Output current limit 4 Ui min...Ui max typ 11.93 Output 2 max 6.2 Output Switching freq. Ui nom, Io nom voltage IEC/EN 61204 Total noise BW = 20 MHz min typ 12.07 11.82 max Output 1 min typ 12.18 14.91 6.2 max Output 2 min typ 15.09 14.78 5.2 max Unit 15.22 V 5.2 5 5 5 5 75 25 100 25 DUo u Static line regulation Ui min...Ui nom Ui nom...Ui max Io nom 30 DUo I Static load regulation Ui nom, Io = (0.1...1) Io nom 5 100 uo d 6 Dynamic load regulation Ui nom, Io = Io nom 1/2 Io nom IEC/EN 61204 100 80 0.3 0.2 ms TC min...TC max 0...Io nom -1.1 -1.1 mV/K td 6 a Uo Voltage deviation Recovery time Temperature coefficient of output voltage 7 40 30 8 100 40 mV 8 Table 4h: Output data double output modules CK...EK Output (Outputs independently loaded) 1 Characteristics CK...EK 2660 24 V/24 V Conditions Output 1 min Uo Output voltage Uo P Overvoltage protection (suppressor diode) Io nom Output current 3 Io L uo 9 Output current limit 4 Ui nom, Io nom 2 Output Switching freq. Ui nom, Io nom voltage IEC/EN 61204 Total noise BW = 20 MHz DUo u Static line regulation 23.86 Ui min...Ui max T C min...T C max Ui min...Ui max typ 1 Output 2 max min typ 24.14 23.64 max Unit 24.36 V 37 3.0 3.0 A 5 5 mVpp 100 25 3.2 3.2 Ui min...Ui nom, Ui nom...Ui max, Io nom 30 50 mV 6 8 Static load regulation Ui nom, Io = (0.1...1) Io nom5 uo d 6 Dynamic load regulation Ui nom, Io = Io nom 1/2 Io nom IEC/EN 61204 50 0.2 ms T C min...T C max 0...Io nom -1.3 mV/K td 6 a Uo Recovery time Temperature coefficient of output voltage 7 MELCHER The Power Partners. 4 5 50 DUo I Voltage deviation 2 3 37 Edition 4/4.99 11/31 7 8 9 Depending upon the desired output configuration the wiring should be made as shown in: R-Function for Different Output Configurations. Same conditions for both outputs. If the output voltages are increased above Uo nom via R-input control, option P setting, remote sensing or option T, the output currents should be reduced accordingly so that Po nom is not exceeded. See: Output voltage regulation of single output units. Condition for specified output. Other output loaded with constant current Io = Io nom . See: Dynamic load regulation of Uo1 and Uo2.. Negative temperature coefficient (0...-3 mV/cell and K) available on request. See: Output Voltage Regulation of Double Output Modules. Measured according to IEC/EN 61204 sub clause 3.10 with a probe acc. to annex A of the same standards. (Se:e Technical Information: Measuring and Testing.) K Series DC-DC Converters >100 Watt Rugged Environment Thermal Considerations Output Protection 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. 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. A red LED indicates the overload condition. Caution: The installer must ensure that under all operating conditions TC remains within the limits stated in the table Temperature specifications. With option T (current sharing), all units share the current approximately equally. Notes: Sufficient forced cooling or an additional heat sink allows TA to be higher than 71C (e.g. 85C) if TC max is not exceeded. For -7 or -9 units at an ambient temperature TA of 85C with only convection cooling, the maximum permissible current for each output is approx. 40% of its nominal value as per figure. Io /Io nom 05089 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 Single or double output units with equal nominal output voltage can be connected in parallel without any precautions using option T. Single output units and/or main and second outputs of double output units can be connected in series with any other (similar) output. Note: - Parallel connection of double output units should always include both, main and second output to maintain good regulation of both outputs. - Not more than 5 units should be connected in parallel. - Series connection of second outputs without involving their main outputs should be avoided as regulation may be poor. Forced cooling 1.0 Parallel or Series Connection of Units - The maximum output current is limited by the output with the lowest current limitation if several outputs are connected in series. Convection cooling 05072 Uo1 TC max Uo1d Ur Ur Uo1d td TA min 50 60 70 80 90 100 t Uo2 Fig. 7 Output current derating versus temperature for -7 and -9 units. Thermal Protection It is recommended that continuous operation under simultaneous extreme worst case conditions of the following three parameters be avoided: Minimum input voltage, maximum output power and maximum temperature. The Power Partners. Uo2d t 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. MELCHER td TA [C] Io1/Io1 nom Io2/Io2 nom 1 0.5 <10 s <10 s 0 Fig. 8 Typical dynamic load regulation of Uo1 and Uo2 Edition 4/4.99 12/31 t Rugged Environment DC-DC Converters >100 Watt Output Voltage Regulation of Single or Double Output Modules with Outputs 1 and 2 Connected in Series K Series [V] Uo2 05106 15.75 Io1 = 5.00 A Io1 = 3.75 A Io1 = 2.50 A Io1 = 1.25 A Io1 = 0.50 A Uo Uo nom 05098 15.50 0.98 15.25 15.00 14.75 0.5 Io1 14.50 IoL 14.25 Io Io nom 0 1.0 0.5 14.00 0 1 2 3 4 5 6 7 Io2 [A] Io nom Fig. 9 Uo1 vs. Io1 (typ.) of single output units AK...EK Fig. 11 AK...EK 2540: DUo2 (typ.) vs. Io2 with different I01 Output Voltage Regulation of Double Output Modules Output 1 is under normal conditions regulated to Uo1 nom, independent of the output currents. Uo2 is dependent upon the load distribution. If both outputs are loaded with more than 10% of Io nom, the deviation of Uo2 remains within 5% of the value of Uo1. The following 3 figures show the regulation with varying load distribution. If Io1 = Io2 or the two outputs are connected in series, the deviation of Uo2 remains within 1% of the value of Uo1 provided that a total load of more than 10% of Io nom is applied. Two outputs of a single K 2000 module connected in parallel will behave like the output of a K 1000 module; the paralleled output is fully regulated. No precautions are necessary in using the R-input and the test sockets. [V] Uo2 05107 26.0 Io1 = 3.0 A Io1 = 2.0 A Io1 = 1.0 A Io1 = 0.5 A Io1 = 0.3 A 25.5 25.0 24.5 24.0 23.5 [V] Uo2 23.0 05105 12.6 0 Io1 = 6.0 A Io1 = 4.5 A Io1 = 3.0 A Io1 = 1.5 A Io1 = 0.6 A 12.4 12.2 11.6 11.4 11.2 2 3 4 5 6 7 8 Io2 [A] Io nom Fig. 10 AK...EK 2320: DUo2 (typ.) vs. Io2 with different I01 MELCHER The Power Partners. 1.5 2 2.5 3 Io nom 11.8 1 1 3.5 Fig. 12 AK...EK 2660: DUo2 (typ.) vs. Io2 with different I01 12.0 0 0.5 Edition 4/4.99 13/31 4 Io2 [A] K Series DC-DC Converters >100 Watt Rugged Environment Auxiliary Functions i Inhibit for Remote On and Off Sense Lines Note: With open i input: Output is disabled (Uo = off). (Only for single output units 5.1 V, 12 V, 15 V, 24 V) 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 18 to pin 14 to enable the outputs (active low logic, fail safe). For output response refer to: Hold-up Time and Output Response. This feature enables for compensation of voltage drops across the connector contacts and if necessary, across the load lines. If the sense lines are connected at the load rather than directly at the connector, the user should ensure that Uo max (between Vo1+ and Vo1-) is not exceeded. We recommend connecting the sense lines directly at the female connector. 06031 Vo+ Vi+ i I inh U inh Fig. 13 Definition of Uinh and Iinh. Table 5: Inhibit characteristics Characteristic Conditions min Uinh Inhibit Uo = on voltage Uo = off Ui min...Ui max -50 0.8 2.4 50 Iinh Inhibit current Uinh = 0 tr Rise time tf Fall time Iinh [mA] typ max Unit V -400 30 A ms depending on Io Uinh = 0.8 V To ensure correct operation, both sense lines (S+ and S-) should be connected to their respective power outputs (Vo1+ and Vo1-) and the voltage difference between any sense line and its respective power output pin (as measured on the connector) should not exceed the following values: Table 6: Maximum voltage compensation allowed using sense lines Vo- Vi- For further information, please refer to: Application Notes. Output voltage Total voltage difference between sense lines and their respective outputs Voltage difference between Vo- and S- 5.1 V < 0.5 V < 0.25 V 12 V, 15 V < 1.0 V < 0.25 V If the output voltages are increased above Uo nom via R-input control, option P setting, remote sensing or option T, the output currents must be reduced accordingly so that Po nom is not exceeded. Note: The output terminals Vo1+ and Vo1- must always be connected to the load before connecting the sense lines S+ and S-, otherwise the unit will be damaged. Uinh = 2.4 V 06032 2.0 1.6 1.2 0.8 Uo = on 0.4 Uo = off 0 -0.4 -0.8 -50 -30 -10 0 10 30 50 Uinh [V] Fig. 14 Typical inhibit current I inh versus inhibit voltage U inh 06001 Uo /Uo nom 1 0.1 0 t tr tf Inhibit 1 0 t Fig. 15 Typical output response as a function of inhibit control MELCHER The Power Partners. Edition 4/4.99 14/31 Rugged Environment DC-DC Converters >100 Watt K Series Programmable Output Voltage (R-Function) As a standard feature, the modules offer an adjustable output voltage, identified by letter R in the type designation. The control input R (pin 16) accepts either a control voltage Uext or a resistor Rext to adjust the desired output voltage. When not connected, the control input automatically sets the output voltage to Uo nom. a) Adjustment by means of an external control voltage Uext between pin 16 (R) and pin 14: The control voltage range is 0...2.75 V DC and allows an output voltage adjustment in the range of approximately 0...110% Uo nom. Uo Uext = ------ * 2.5 V (approximate formula) Uo nom b) Adjustment by means of an external resistor: - If the output voltages are increased above Uo nom via Rinput control, option P setting, remote sensing or option T, the output current(s) should be reduced accordingly so that Po nom is not exceeded. - The R-input (as well as option P) is related to the main output. - With double output units the second output follows the value of the controlled main output. Resistor values as indicated for the single output units should be used. - For correct output voltage adjustment of double output units the external wiring of the outputs should be according to: R-Function for Different Output Configurations, depending upon the desired output configuration. - In case of parallel connection the output voltages should be individually set within a tolerance of 1 - 2%. Depending upon the value of the required output voltage the resistor shall be connected Either: Between pin 16 and pin 14 (Uo < Uo nom) to achieve an output voltage adjustment range of approximately 0...100% Uo nom R 16 Warning: Vi- Vo1- Vi+ Vo1+ - Uext shall never exceed 2.75 V DC. - The value of R'ext shall never be less than the lowest value as indicated in table R'ext for (Uo > Uo nom) to avoid damage to the unit! + Uext S- 14 or: Between pin 16 and pin 12 (Uo > Uo nom) to achieve an output voltage adjustment range of approximately 100...110% Uo nom. 05074 Vo1+ Vi+ S+ 12 R'ext R 16 S- 14 Remarks: - The R-Function excludes option P (output voltage adjustment by potentiometer). Rext Vo1- Vi- Fig. 16 Output voltage control for single output units AK...EK 1000 by means of the R input Table 7a: Rext for Uo < Uo nom; approximative values (Ui nom, Io nom, series E 96 resistors); R'ext = Uo nom = 5.1 V Uo (V) Rext [k] 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 0.422 1.0 1.62 2.16 3.83 5.61 9.09 14.7 28.7 196 Uo nom = 12 V Uo [V] 1 2 3 4 5 6 7 8 9 10 11 4 6 8 10 12 14 16 18 20 22 Uo nom = 15 V Uo [V] 1 Rext [k] 0.825 1.3 1.96 2.87 3.83 5.62 8.28 12.1 19.6 42.2 2 4 6 8 9 10 11 12 13 14 4 8 12 16 18 20 22 24 26 28 Uo nom = 24 V Uo [V] 1 Rext [k] 0.56 1.47 2.61 4.64 6.19 8.25 11.0 16.2 26.1 56.2 4 6 8 10 12 14 16 18 20 22 Rext [k] 8 12 16 20 24 28 32 36 40 44 0.825 1.33 1.96 2.87 3.83 5.61 8.25 12.1 19.6 46.4 Table 7b: R'ext for Uo > Uo nom; approximative values (Ui nom, Io nom, series E 96 resistors); Rext = Uo nom = 5.1 V Uo [V] 5.15 5.2 5.25 5.3 5.35 5.4 5.45 5.5 1 R'ext [k] 422 215 147 110 90.9 75 61.9 56.2 Uo 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 13.0 13.2 Uo nom = 12 V Uo nom = 15 V [V] 1 [V] 1 24.2 24.4 24.6 24.8 25.0 25.2 25.4 25.6 26.0 26.4 R'ext [k] 1780 909 623 464 383 316 286 234 196 162 Uo 15.2 15.4 15.6 15.8 16.0 16.2 16.4 16.5 30.4 30.8 31.2 31.6 32.0 32.4 32.8 33.0 Uo nom = 24 V Uo [V] 1 R'ext [k] 1470 750 511 383 316 261 237 215 24.25 24.5 24.75 25.0 25.25 25.5 25.75 26.0 26.25 26.4 R'ext [k] 48.5 49.0 49.5 50.0 50.5 51.0 51.5 52.0 52.5 52.8 First column: single output units or double output units with separated outputs, second column: outputs in series connection MELCHER The Power Partners. Edition 4/4.99 15/31 3160 1620 1100 825 681 562 511 464 422 383 K Series DC-DC Converters >100 Watt Rugged Environment R-Function for Different Output Configurations 06004 Vo2+ 4 Vo2+ 6 Vo2- 8 Vo2- 10 Vo1+ Vo1- + Uo1 2 1 12 - 14 Rext R 24 V 30 V 48 V Vo2+ Vo2- Vo2- 4 Vo2+ 6 Vo2- 8 Vo2- 10 Vo1+ 12 Vo1- 14 R 16 16 6 1 Uo2 12 Vo1- 14 R 16 - Uo1 10 Vo1+ 1 -12/-15/-24 V 8 + Vo2+ 4 Vo2+ 6 Vo2- 8 Vo2- 10 Vo1+ 12 Vo1- 14 R 16 Vo2+ 6 Vo2- 8 Vo2- 10 Vo1+ 12 Vo1- 14 Uo1 Rext R 12 V 15 V 24 V 12 V 15 V 24 V 2 1 + 1 1 R'ext A ceramic multilayer capacitor connected across the output lines reduces ripple and spikes. Shortest possible wiring for series connection at the female connector + 1 - Remarks: Double output units fitted with H-15 connectors have the output pins of the second output, pins 4/6 and 8/10, internally paralleled. 16 Fig. 17e AK...EK 2000 with H15 connector. R-input for output voltage control. Wiring of main and second output for two output voltages Uo1 and Uo2: 12 V/12 V or 15 V/15 V or 24 V/24 V, the outputs are galvanically isolated. The Power Partners. Uo1 - R'ext MELCHER +12/+15/+24 V Fig. 17d AK...EK 2000 with H15 connector. R-input for output voltage control. Wiring of main and second output for two output voltages Uo1 and Uo2: +12 V and +24 V or +15 V and +30 V or +24 V and +48 V. + Uo2 + Uo2 Rext 1 4 06007 +24/+30/+48 V 0V 06008 Vo2+ R'ext Fig. 17b AK...EK 2000 with H15 connector. R-input for output voltage control. Wiring for output voltage 12 V or 15 V or 24 V with main and second output connected in parallel. R'ext Fig. 17c AK...EK 2000 with H15 connector. R-input for output voltage control. Wiring of main and second output for two symmetrical output voltages Uo1 and Uo2: 12 V or 15 V or 24 V. 1 - 2 +12/+15/+24 V Rext 12 V Uo1 15 V 24 V 06006 0V 4 + Rext R'ext Fig. 17a AK...EK 2000 with H15 connector. R-input for output voltage control. Wiring for output voltage 24 V or 30 V or 48 V with main and second output connected in series. Vo2+ 06005 Vo2+ It is recommended that pins 4/6 and 8/10 be directly paralleled at the female connector as well to reduce the voltage drop across the connector. Please note: Uo2 varies depending upon its own load and the load on output 1. Edition 4/4.99 16/31 Rugged Environment DC-DC Converters >100 Watt K Series Display Status of LEDs 06002 Uo1 > 0.95...0.98Uo1 adj OK i Io L Ui Ui uv Ui min Ui max Ui ov Uo1 > 0.95...0.98Uo1 adj Fig. 18 LEDs "OK", "i" and "Io L"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 OK Io L Io nom Io LEDs "OK" and "Io L"status versus output current Conditions: Ui min...Ui max, TC TC max, Uinh 0.8 V TC LED "i"versus case temperature Conditions: Ui min...Ui max, Io Io nom, Uinh 0.8 V Ui inh LED "i"versus Uinh Conditions: Ui min...Ui max, Io Io nom, TC TC max IoL i TC max TPTC threshold Uinh threshold i -50 V LED off +0.8 V +2.4 V LED Status undefined +50 V LED on Test Sockets (Main output only) Test sockets for measuring the output voltage U o1 are located at the front of the module. The positive test socket is protected by a series resistor (see: Functional Description, block diagrams). The voltage measured at the test sockets is approximetly 30 mV lower than the value measured at the output terminals. In case of double output units externally connected in series for Uo = 24 V, 30 V or 48 V the monitored output voltage is 12 V, 15 V or 24 V respectively. MELCHER The Power Partners. Edition 4/4.99 17/31 K Series DC-DC Converters >100 Watt Rugged Environment Electromagnetic Compatibility (EMC) A suppressor diode or a metal oxide VDR (depending upon the type) together with an input fuse and an input filter form an effective protection against high input transient voltages which typically occur in most installations, but especially in battery driven mobile applications. The K series has been successfully tested to the following specifications: Electromagnetic Immunity Table 8: Immunity type tests Phenomenon Standard 1 Voltage surge IEC 60571-1 Supply related surge RIA 12 Level Coupling mode 2 i/c, +i/-i Test procedure 100 1 pos. and 1 neg. voltage surge per coupling mode yes A 0.2 1 positive surge yes A 5 5 pos. and 5 neg. impulses yes B 800 Vp 100 s 1500 Vp 50 s 3000 Vp 5 s 4000 Vp 1 s 100 ns 2/20/2 ms 1.5 * Ubatt 0.1/1/0.1 s 960 Vp 10/100 s D 1800 Vp 5/50 s E 3600 Vp 0.5/5 s F 4800 Vp 0.1/1 s 8400 Vp 0.05/0.1 s 1800 Vp 5/50 s +i/-i +i/c, -i/c G Electrostatic discharge (to case) Source imped. 7000 Vp C Indirect coupled transient Waveform 3.5 * Ubatt A4 B Direct transient Value applied H +o/c, -o/c, 3600 Vp 0.5/5 s 4800 Vp 0.1/1 s L 8400 Vp 0.05/0.1 s contact discharge 8000 Vp 1/50 ns 330 A 15000 Vp 10 positive and 10 negative discharges yes air discharge antenna 10 V/m AM 80% 1 kHz n.a. 26...1000 MHz yes A 900 5 MHz yes A Electromagnetic IEC/EN field 61000-4-3 3 Electromagnetic ENV 50204 field, pulse modulated Surge IEC/EN 61000-4-5 Conducted disturbances 1 2 3 4 5 IEC/EN 61000-4-6 5 J 4 IEC/EN 61000-4-4 100 K IEC/EN 61000-4-2 Electrical fast transient/burst In Peroper. form. 3 50% duty cycle, 200 Hz repetition frequency 4 capacitive, o/c 2000 Vp 1 min positive 1 min negative transients per coupling mode yes A 4000 Vp bursts of 5/50 ns 2.5/5 kHz over 15 ms; burst period: 300 ms 50 i/o, +i/-i direct 2000 Vp 1.2/50 s 12 5 pos. and 5 neg. surges per coupling mode yes A 2 150 0.15...80 MHz yes A 3 i/c 4 +i/-i 3 i, o, signal wires 10 Vrms (140 dBV) AM 80% 1 kHz 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. Only met with extended input voltage range of CK (48 V battery) and EK (110 V battery) types. These units are available on customer's request. Standard DK units (110 V battery) will not be damaged, but overvoltage lock-out will occur during the surge. Under normal operation temporary deviation from specifications possible. Test in progress, please consult factory. Note: Previous standards are referenced in: Technical Information: Standards. MELCHER The Power Partners. Edition 4/4.99 18/31 Rugged Environment DC-DC Converters >100 Watt K Series Electromagnetic Emission u [dBV] 07037 90 [dBV/m] 50 07077 A 80 A 70 40 B B 60 30 50 40 20 30 20 10 10 Fig. 19 Typical disturbance voltage (quasi-peak) at the input according to CISPR 11/22 and EN 55011/22, measured at Ui nom and Io nom. MELCHER The Power Partners. 500 200 100 1000 [MHz] 0 50 f [MHz] 30 20 30 10 5 2 1 0.5 0.1 0.05 0.02 0.01 0 Fig. 20 Typical radiated electromagnetic field strength (quasipeak) according to CISPR 11/22 and EN 55011/22, normalized to a distance of 10 m, measured at Ui nom and Io nom. Edition 4/4.99 19/31 K Series DC-DC Converters >100 Watt Rugged Environment Immunity to Environmental Conditions Table 9: 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: 100 gn = 981 m/s2 6 ms 18 (3 each direction) Unit 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: 40 gn = 392 m/s2 6 ms 6000 (1000 each direction) Unit operating Fc Vibration (sinusoidal) IEC/EN/DIN EN 60068-2-6 MIL-STD-810D section 514.3 Acceleration amplitude: Unit operating Frequency (1 Oct/min): Test duration: 0.35 mm (10...60 Hz) 5 gn = 49 m/s2 (60...2000 Hz) 10...2000 Hz 7.5 h (2.5 h each axis) Ca Unit not operating 93 +2/-3 % 56 days Fda Random vibration wide band Reproducibility high IEC 60068-2-35 DIN 40046 part 23 Acceleration spectral density: Frequency band: Acceleration magnitude: Test duration: 0.05 g n2 /Hz 20...500 Hz 4.9 gn rms 3 h (1 h each axis) Unit operating Kb Salt mist, cyclic (sodium chloride NaCl solution) IEC/EN/DIN IEC 60068-2-52 Concentration: Duration: Storage: Storage duration: Number of cycles: 5% (30C) 2 h per cycle 40C, 93% rel. humidity 22 h per cycle 3 Unit not operating Table 10: Temperature specifications, valid for an air pressure of 800...1200 hPa (800...1200 mbar) Temperature Characteristics TA 1 2 3 Ambient temperature 1 Standard -7 min max min max Unit Operational 2 -25 71 -40 71 C -25 95 -40 95 -40 100 -55 100 temperature 3 TC Case TS Storage temperature 1 Option -9 Conditions Non operational MIL-STD-810D section 501.2 and 502.2. See: Thermal Considerations. Overtemperature lock-out at TC >95C (PTC). Table 11: MTBF Values at specified case temperature MTBF 1 Device 1 2 Module types Ground benign 40C AK...EK 500'000 hours 2 Ground fixed 40C 70C 150'000 Ground mobile 50C Unit 50'000 h 80'000 500'000 Calculated in accordance with MIL-HDBK-217F. Statistical values, based on an average of 4300 working hours per year and in general field use, over 3 years. MELCHER The Power Partners. Edition 4/4.99 20/31 DC-DC Converters >100 Watt K Series 7 TE 159 7.0 10.3 12.1 20.3 Dimensions in mm. Tolerances 0.3 mm unless otherwise indicated. 29.9 19.7 Test jacks (+/-) Option P (Uo) Option D (Uto) Option D (Uti) 9.5 4.5 LED i (red) Gravitational axis 6.5 Measuring point of case temperature TC 51.5 89 111 (3U) 4.5 9 TE 3.27 30.3 Mechanical Data 09002 Rugged Environment LED OK (green) LED IoL (red) = O 3.5 = O 4.1 50 42 171.93 (DIN 41494) 80 Front plate d Back plate 168.5 0.5 11.8 Main face 25.9 European Projection Note: - d 15 mm, recommended minimum distance to next part to ensure proper air circulation at full output power. 7 TE 3.27 5 50 5 - free air locations: the module should be mounted with fins in vertical position to achieve a maximum air flow through the heat sink. 158 4 TE 09003 Fig. 21 Case K02 with heatsink, case aluminium, black finish and self cooling, weight: Approx. 1.55 kg 101 111 (3U) M4 Measuring point of case temperature TC 17.3 47.2 133.4 168 0.5 171.93 (DIN 41494) Fig. 22 Case K02 with option B1 (cooling plate),case aluminium, black finish and self cooling, weight: Approx. 1.15 kg MELCHER The Power Partners. Edition 4/4.99 21/31 5 Note: Long case with S-type heatsink or cooling plate B2, elongated by 60 mm for 220 mm rack depth, is available on request. (No LED's and no test jacks.) K Series DC-DC Converters >100 Watt Rugged Environment Safety and Installation Instructions Connector Pin Allocation The connector pin allocation table defines the electrical potentials and the physical pin positions on the H15/H15 S4 connector. Pin no. 24, the protective earth pin present on all AK...FK DC-DC converters is leading, ensuring that it makes contact with the female connector first. 10010 10010 Fixtures for connector retention clips V (see Accessory Products) Fixtures for connector retention clips V (see Accessory Products) 30/32 32 4/6 4 Type H15 Type H15 S4 Fig. 23 View of module's male connectors Table 12: H15 and H15 S4 connector pin allocation Pin No. Connector type H15 S4 Connector type H 15 AK 1000 (all), BK...EK 1001 AK 2000 Vo1+ Output 1 Vo2+ Output 2 Vo1- Output 1 Vo2- Output 2 S+ Sense Vo1+ Output 1 4 6 12 Vo1+ Vo2+ Output 1 Vo1- Vo1- Vo2+ Output 2 Vo2- Output 1 S+ Sense Vo2- Output 2 Vo1+ Output 1 14 S- Sense Vo1- Output 1 S- Sense Vo1- Output 1 16 R1 Control of U o1 R1 Control of U o1 R1 Control of U o1 R1 Control of U o1 18 i Inhibit i Inhibit i Inhibit i Inhibit 20 D3 Save data D Safe data D Save data D Save data V3 ACFAIL T Current sharing T Current sharing T Current sharing T Current sharing 22 24 2 Protective earth Protective earth 26 28 32 Protective earth Vi+ Vi+ Input Vi+ Input Vi- Input Vi- Input Vi- Feature R excludes option P and vice versa; 2 Vi+ Input or Neutral Vi- Input Vi- Leading pin (pregrounding); Protective earth Vi+ Input Vi+ 30 1 BK...EK 2000 Vo1+ 8 10 BK...EK 1301/1501/1601 3 Vi- Input or Phase Option D excludes option V and vice versa. Installation Instructions The K 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. An input fuse is built-in in the connection from pins no. 30 and 32 (Vi-) of the unit. Since this fuse is designed to protect the unit in case of an overcurrent and does not necessarily cover all customer needs, an external fuse suitable for the application and in compliance with the local requirements might be necessary in the wiring to one or both input potentials, pins nos. 26 and 28 and/or nos. 30 and 32. Connection to the system shall be made via the female connector H15 (see: Accessories). Other installation methods may not meet the safety requirements. Important: Whenever the inhibit function is not in use, pin no. 18 (i) should be connected to pin no. 14 (S-/ Vo1-) to enable the output(s). The DC-DC converters are provided with pin no. 24 ( ), 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 unless specified in: Safety of operator accessible output circuit. Do not open the modules, or guarantee will be invalidated. MELCHER The Power Partners. Edition 4/4.99 22/31 Rugged Environment DC-DC Converters >100 Watt Due to high current values, all AK...FK units provide two internally parallel connected contacts for certain paths (pins 4/6, 8/10, 26/28 and 30/32 respectively). It is recommended to connect load and supply to both female connector pins of each path in order to keep the voltage drop across the connector pins to an absolute minimum and to not overstress the connector contacts if currents are higher than approx. 8 A. The connector contacts are rated 8 A over the whole temperature range. K Series Standards and approvals All DC-DC converters correspond to class I equipment. They 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. 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. The units have been evaluated for: * Building in, * Basic insulation between input and case and double or reinforced insulation between input and output, based on 150 V AC/DC (AK and BK) or 250 V AC and 400 V DC (CK, DK, EK, FK), * The use in a pollution degree 2 environment, * Connecting the input to a primary or secondary circuit which is subject to a maximum transient rating of 2500 V. 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. The DC-DC converters are subject to manufacturing surveillance in accordance with the above mentioned UL, CSA, EN and with ISO 9001 standards.Cleaning Agents Check for hazardous voltages before altering any connections. In order to avoid possible damage, any penetration of cleaning fluids is to be prevented, since the power supplies are not hermetically sealed. 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. Protection Degree Condition: Female connector fitted to the unit. Cleaning Agents In order to avoid possible damage, any penetration of cleaning fluids is to be prevented, since the power supplies are not hermetically sealed. IP 30: All units except those with option P, and except those with option D or V with potentiometer. IP 20: All units fitted with option P, or with option D or V with potentiometer. Isolation The electric strength test is performed as factory test in accordance with IEC/EN 60950 and UL 1950 and should not be repeated in the field. Melcher will not honour any guarantee claims resulting from electric strength field tests. Table 13: Isolation Characteristic Electric strength test voltage Required according to IEC/EN 60950 AK, BK CK, DK EK, FK Actual factory test 1 s AC test voltage equivalent to actual factory test Insulation resistance at 500 V DC 1 2 AK, BK CK, DK EK, FK Input to case Input to output Output to case Output to output Unit 1.0 2.0 1 0.5 - kVrms 1.4 2.8 1 0.7 - kV DC 1.5 3.0 1 0.5 - kVrms 2.1 4.2 1 0.7 - kV DC 2.8 5.6 1 1.4 0.14 2.0 4.0 1 1.0 0.1 kVrms >300 >300 >300 >100 2 M In accordance with IEC/EN 60950 only subassemblies are tested in factory with this voltage. Tested at 150 V DC. For creepage distances and clearances refer to: Technical Information: Safety. MELCHER The Power Partners. Edition 4/4.99 23/31 K Series DC-DC Converters >100 Watt Rugged Environment 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. 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 35 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 14: Safety concept leading to an SELV output circuit Conditions Front end Nominal supply voltage DC-DC converter Minimum required grade Nominal DC of isolation, to be provided output voltage by the AC-DC front end, from the front end including mains supplied battery charger Mains Operational (i.e. there is 150 V AC no need for electrical isolation between the mains supply voltage and the DC-DC converter input voltage) 100 V (The Primary circuit nominal voltage between any input pin and earth can be up to 150 V AC or DC) AK BK Mains 250 V AC 400 V (The nominal voltage between any input pin and earth can be up to 250 V AC or 400 V DC) CK DK EK FK 400 V Basic Double or reinforced 1 2 3 4 Minimum required Types safety status of the front end output circuit Unearthed hazardous voltage secodary circuit AK BK CK DK EK FK Result Measures to achieve the specified safety status of the output circuit Safety status of the DC-DC converter output circuit Double or reinforced insulation, based on the mains voltage and 2 (provided by the DC-DC converter) and earthed case 3 SELV circuit Supplementary insulation, based on 250 V AC and double or reinforced insulation 2 (provided by DC-DC converter) and earthed case 3. Earthed hazardous voltage secondary circuit Double or reinforced insulation 2 (provided by the DC-DC converter) earthed case 3 60 V SELV circuit Operational insulation (provided by the DC-DC converter) 4 120 V TNV-3 circuit Basic insulation (provided by the DC-DC converter) 4 The front end output voltage should match the specified input voltage range of the DC-DC converter. Based on the maximum nominal output voltage from the front end. The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC/EN 60950. Earthing of the case is recommended, but not mandatory. Max. 150 V AC or DC for AK, BK Max. 250 V AC or 400 V DC for CK, DK, EK, FK ~ Mains ~ + AC-DC front end Fuse Battery Fuse Max. 150 V AC or DC for AK, BK Max. 250 V AC or 400 V DC for CK, DK, EK, FK Fig. 24 Schematic safety concept. Use earth connection as per table: Safety concept leading to an SELV output circuit. Use fuse if required by the application. See also: Installation Instructions. MELCHER The Power Partners. 10044 Edition 4/4.99 24/31 DC-DC converter SELV - Earth connection Rugged Environment DC-DC Converters >100 Watt K Series Description of Options Table 15: Survey of options Option Function of Option Characteristics -9 Extended operational ambient temperature range TA = -40C...71C E Electronic inrush current limitation circuitry Active inrush current limitation for CK, DK, EK P1 Potentiometer for fine adjustment of output voltage Adjustment range +10/-60% of Uo nom excludes R input D2 Input and/or output undervoltage monitoring circuitry Safe data signal output (Versions D0...DD) V23 Input (and output) undervoltage monitoring circuitry ACFAIL signal according to VME specs (Versions V0, V2, V3) T B1/B2 1 2 3 Current sharing Interconnect T-pins if paralleling outputs (5 units max.) Cooling plate Replaces standard heat sink, allowing direct chassis-mounting Function R excludes option P and vice versa. Option D excludes Option V and vice versa . Only available if main output voltage U o1 = 5.1. 10017 Input Filter Option -9 extends the operational ambient temperature range from -25...71C (standard) to -40...71C. The power supplies provide full nominal output power with convection cooling. Option -9 excludes inrush current limitation by NTC. Converter -9 Extended Temperature Range Control FET E Inrush Current Limitation CK/DK/EK types may be supplemented by an electronic circuit (option E, replacing the standard built-in NTC) to achieve an enhanced inrush current limiting function (not available with AK/BK/FK types). If fitted with option E (inrush current limitation) together with option D6, input voltage monitoring, the CK units meet the CEPT/ETSI standards for 48 V DC supply voltages according to prETS 300132-2, version 4.2, date 9312. Option D6, externally adjustable via potentiometer, is necessary to disable the converter at input voltages below actual service voltage ranges, avoiding an excessive input current when the input voltage is raised slowly according to prETS 300132-2. Option D6 threshold level should be adjusted to 36.0...40.5 V for 48 V nominal supply systems or 44.0...50.0 V for 60 V nominal supply systems (refer also to description of option D). The D output should be connected to the inhibit input. Please contact Melcher if applications do not permit potentiometer setting. RS Ci RI Fig. 25 Option E block diagram 11039 I [A] CapacitorCi fully charged Ui /RV Normal operation (current limiting circuit is fully conducting) Ii = Pi /Ui 0 t [ms] <30 0 RV: Current limiting resistance = RS + RI = 15 Fig. 26 Inrush current with option E Table 16: Inrush current characteristics with option E Characteristics CK DK EK Unit Ui nom, Io nom Input voltage 60 110 220 V P Potentiometer Iinr p Peak inrush current 6.8 7.4 14.6 A t inr Inrush current duration 18 14 16 ms The potentiometer provides an output voltage adjustment range of +10/-60% of Uo nom and is accessible through a hole in the front cover. This feature enables compensation of voltage drops across the connector and wiring. Option P is not recommended if units are connected in parallel. Ui max, Io nom Input voltage 140 220 380 V Iinr p Peak inrush current 9.3 14.5 25.3 A t inr Inrush current duration 20 14 12 ms Precaution: Subsequent switch-on cycles at start-up are limited to max. 10 cycles during the first 20 seconds (cold unit) and at continuing on/off (TC = 95C) max. 1 cycle every 8 sec. MELCHER The Power Partners. Option P excludes the R-function. With double output units both outputs are affected by the potentiometer setting (doubling the voltage setting if the outputs are in series). If the output voltages are increased above Uo nom via R-input control, option P setting, remote sensing or option T, the output current(s) should be reduced accordingly so that Po nom is not exceeded. Edition 4/4.99 25/31 K Series DC-DC Converters >100 Watt T Current Sharing 11003 This option ensures that the output currents are approximately shared between all paralleled modules hence increasing system reliability. To use this facility, simply interconnect the T pins of all modules and make sure, that pins 14, the S- pins (K 1000) or the Vo1- pins (K 2000) are also connected together. The load leads should have equal length and cross section to ensure equal voltage drops. Not more than 5 units should be connected in parallel. If output voltage adjustment is requested we strongly recommend to use the R-input instead of option P, as with option P the required setting accuracy is difficult to achieve. The output voltages must be individually set prior to paralleling to within a tolerance of 1...2% or the R pins should be connected together. Vi+ Rugged Environment Vo+ 2 1 Vo+ Load Vo- Vo+ Vo- Vo+ Vo- Fig. 27 An example of poor wiring for connection in parallel Vo2+ 11036 S+ Vo2- T 1 Module 3 T S- Vo1+ Vi- Vo- Vo1- Vi+ Vo+ Vo2+ 2 S+ Vo2- T T 1 Module 3 S- Vo- Vo1+ Vo1- 1 max. 5 units in parallel connection max. 5 units in parallel connection 1 2 3 Leads should have equal length and cross sections and should run in the same cable loom. Diodes recommended in redundant operation only DC common point Fig. 29 Paralleling of double output units using option T with Power Bus Fig. 28 Paralleling of single output units using option T with the sense lines connected at the load MELCHER The Power Partners. 11037 Load Load Vi- Power bus + - Edition 4/4.99 26/31 Rugged Environment DC-DC Converters >100 Watt K Series 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 20 as soon as one of the monitored voltages drops below the preselected threshold level Ut. The return for this signal is Vo1-. The D output recovers when the monitored voltage(s) exceed(s) U t + Uh. The threshold levels U ti and U to are either adjustable by a potentiometer, accessible through a hole in the front cover, or factory adjusted to a fixed value specified by the customer. Option D exists in various versions D0...DD as shown in the following table. Table 17: Undervoltage monitor functions Output type JFET NPN Monitoring Ui Uo1 D1 D5 no yes - 3.5...40 V 1 D2 D6 yes no Ui min...Ui max 1 - D7 yes yes Ui min...Ui max D8 no yes - (0.95...0.985 Uo1) 2 D0 D9 no yes - 3.5...40 V 3 yes no Ui min...Ui max 3 4 - 3 4 DD yes Ui min...Ui max 34 34 yes yes Ui min...Ui max yes yes Ui min...Ui max 1 (0.95...0.985 Uo1 )2 D3 2 1 D4 yes 1 Typical hysteresis Uh [% of Ut] for U t min...U t max U hi U ho Minimum adjustment range of threshold level U t U ti U to 3.5...40 V3 (0.95...0.985 Uo1 )2 3.5...40 V 1 - 2.5...0.6 3.4...0.4 - 3.4...0.4 "0" - "0" - 2.5...0.6 3.4...0.4 - 3.4...0.4 2.5...0.6 3.4...0.4 "0" 3.4...0.4 2.5...0.6 Threshold level adjustable by potentiometer Fixed value tracking if Uo1 is adjusted via R-input, option P or sense lines. The threshold level permanently adjusted according to customer specification 2% at 25C. Any value within the specified range is basically possible but causes a special type designation in addition to the standard option designations (D0/D9 respectively)! Adjusted at Io nom JFET output (D0...D4): 11006 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. 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 Vo1+ Rp Input ID D UD Vo1- Fig. 30 Option D1...D0: JFET output, ID 2.5 mA 11007 NPN output (D5...DD): Vo1+ 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. 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 Rp Input ID D UD Vo1- Fig. 31 Option D5...DD: NPN output, Uo1 40 V, ID 20 mA Table 18: D-output logic signals U i < U t resp. U o < U t U i > U t + U h resp. U o > U t Configuration D1, D2, D3, D4, D0 low high JFET D5, D6, D7, D8, D9, DD high low NPN Version of D MELCHER The Power Partners. Edition 4/4.99 27/31 DC-DC Converters >100 Watt 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 DU ti across the input filter. The threshold levels of the D0 and D9 options are factory adjusted at nominal output current Io nom and at TA = 25C. The value of DU ti depends upon the input voltage range (CK, DK, ..), threshold level Ut, temperature and input current. The input current is a function of the input voltage and the output power. Rugged Environment DUti Uhi 11021 Po = 0 Po = 0 Po = Po nom UD high Po = Po nom K Series UD low Ui U ti Fig. 32 Definition of Uti, Ut i and Uhi (JFET output) D-signal with respect to input and output voltage versus time: 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 Uo1 Uo1 nom Uto +Uho Uto 1 t 0 3 Output voltage failure Fig. 33 Relationship between Ui, Uo1, UD, Uo1/Uo nom versus time MELCHER The Power Partners. 2 Edition 4/4.99 28/31 4 Hold-up time see section Electrical Input Data With output voltage monitoring, hold-up time th = 0. The signal will remain high if the D output is connected to an external source. t low min = 100...170 ms, typically 130 ms. Rugged Environment DC-DC Converters >100 Watt K Series V ACFAIL signal (VME) Available for units with Uo1 = 5.1 V. Formula for the external input capacitor: This option defines an undervoltage monitoring circuit for the input or input and main output voltage (Uo1 nom = 5.1 V only) equivalent to option D and generates an ACFAIL signal (V signal) which conforms to the VME standard. 2 * Po * (t h + 0.3 ms) * 100 Ci ext = ---------------------- - Ci min h * (Uti 2 - Ui min2) 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 back plane. 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 output is fully loaded. This hold-up time t h is provided by the internal input capacitance. Consequently the working input voltage and the threshold level U ti should be adequately above the minimum input voltage Ui min of the converter so that enough energy is remaining in the input capacitance. If the input voltage is below the required level, an external hold-up capacitor (Ci ext) should be added. Formula for threshold level for desired value of t h: Uti = where as: C i min = C i ext = Po = h = th = U i min = U ti = 1 internal input capacitance [mF] external input capacitance [mF] output power [W] efficiency [%] hold-up time [ms] minimum input voltage [V] 1 threshold level [V] Min. input voltage according to Electrical Input Data. For output voltages Uo > Uo nom, the minimum input voltage increases proportionally to Uo/Uo nom. Remarks: Option V2 and V3 can be adjusted by potentiometer to a threshold level between Ui min and Ui max. A decoupling diode should be connected in series with the input of AK...FK converters to avoid the input capacitance discharging through other loads connected to the same source voltage. 2 * Po * (t h + 0.3 ms) * 100 --------------------- + Ui min2 Ci min * h Table 19: Available internal input capacitance and factory potentiometer setting of Uti with resulting hold-up time Types AK BK FK CK DK EK Unit Ci min 0.83 0.3 1.2 0.66 0.26 0.21 mF Ut i 9.5 19.5 39 39 61 97 V DC th 0.1 0.1 3.4 1.1 1.1 2.7 ms Option V operates independently of the built-in input undervoltage lock-out circuit. A logic "low" signal is generated at pin 20 as soon as one of the monitored voltages drops below the preselected threshold level U t. The return for this signal is Vo1-. The V output recovers when the monitored voltage(s) exceed(s) U t + U h . The threshold level U ti is either adjustable by potentiometer, accessible through a hole in the front cover, or adjusted during manufacture to a determined customer specified value. Versions V0, V2 and V3 are available as shown below. Table 20: Undervoltage monitor functions V output (VME compatible) Monitoring Ui U o1 V2 yes no U i min...U i max 1 - 3.4...0.4 - V3 yes yes U i min...U i max 1 0.95...0.985 U o1 2 3.4...0.4 "0" V0 yes no U i min...U i max 3 4 - 3.4...0.4 - 3.4...0.4 "0" yes 1 4 Typical hysteresis Uh [% of Ut] for U t min...U t max U hi U ho Minimum adjustment range of threshold level U t U ti U to yes U i min...U i max 34 0.95...0.985 U o1 2 Threshold level adjustable by potentiometer. 2 Fixed value between 95% and 98.5% of Uo1 (tracking). 3 Adjusted at Io nom. Fixed value, resistor-adjusted (2% at 25C) acc. to customer's specifications; individual type number is determined by Melcher. V output (V0, V2, V3): 11009 Vo1+ 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 60 V. Ui, Uo1 status 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 The Power Partners. Input V UV V output, UV U i or U o1 < U t MELCHER Rp IV Vo1- Fig. 34 Output configuration of options V0, V2 and V3 Edition 4/4.99 29/31 DC-DC Converters >100 Watt Threshold tolerances and hysteresis: 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 DU ti across the input filter. The threshold level of option V0 is adjusted during manufacture at Io nom and TA = 25C. The value of DU ti depends upon the input voltage range (AK, BK, ...), threshold level U t , temperature and input current. The input current is a function of input voltage and output power. Input voltage monitoring V2 UV UV high DUti Uhi 11023 Po = 0 Po = 0 Po = Po nom UV high UV low Ui Fig. 35 Uti Definition of Uti, Uti and Uhi t low min 2 t low min 2 t low min 2 3 Rugged Environment Po = Po nom K Series 3 3 4 11010 4 UV low t 0 t low min 2 t low min 2 V3 UV UV high 3 3 3 UV low t 0 th Uo1 5.1 V 4.875 V 1 th 1 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 1 2 4 UV low 4 3 t 0 V3 UV UV high t low min 3 2 3 4 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. 4 UV low 0 t Uo1 5.1 V 4.875 V 2.0 V 0 t Ui Uti + Uhi Uti t 0 Output voltage failure Fig. 36 Relationship between U i, Uo1, U V, I V and Uo1/Uo nom versus time. MELCHER The Power Partners. Edition 4/4.99 30/31 Rugged Environment DC-DC Converters >100 Watt K Series B1/B2 Cooling Plate (see: Mechanical Data) Where a cooling surface is available, we recommend the use of a cooling plate (option B1) instead of the standard heatsink. The mounting system should ensure sufficient cooling capacity to guarantee that the maximum case temperature TC max is not exceeded. The cooling capacity is calculated by: (100% - h) PLoss = ---------- (Uo * Io) h Efficiency h see Type survey Elongated case for 220 mm rack depth: Option B2 Accessories A variety of electrical and mechanical accessories are available including: - Front panels for 19" rack mounting, Schroff and Intermas systems. - Mating H15/H15 S4 connectors with screw, solder, faston or press-fit terminals. - Connector retention facilities. - Code key system for connector coding. - 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. Front panels H15 female connector, code key system Mounting plate (option B1 essential), connector retention clips Universal mounting bracket for DIN-rail mounting. MELCHER The Power Partners. Edition 4/4.99 31/31