M-Family DC-DC Converters <100 W 50 W DC-DC (AC-DC) Converters Rugged Environment M-Family Class I Equipment Single output: series AM...LM 1000 Dual output: series AM...LM 2000 Triple output: series AM...LM 3000 Class II Equipment (double insulation) Single output: series CMZ/DMZ/LMZ 1000 Dual output: series CMZ/DMZ/LMZ 2000 Triple output: series CMZ/DMZ/LMZ 3000 * Extremely wide input voltage range suitable for battery (and AC) operation * Efficient input filter and built-in surge and transient suppression circuitry * 4 kVrms input to output electric strength test * Outputs individually isolated and controlled * Outputs fully protected against overload Safety according to IEC 950 LGA C 7.1 Table of Contents ........................................... Page Description .................................................................. 7 - 2 Type Survey ................................................................ 7 - 3 Safety and Installation Instructions ............................. 7 - 4 Functional Description ................................................. 7 - 6 Electrical Input Data .................................................... 7 - 7 Electrical Output Data ................................................. 7 - 9 EMC and Immunity to Input Transients ..................... 7 - 13 Supplementary Data ................................................. 7 - 15 Description of Options ............................................... 7 - 16 Immunity to Environmental Conditions ...................... 7 - 22 Mechanical Data ....................................................... 7 - 24 Type Key and Product Marking ................................. 7 - 25 Description The M-family of DC-DC (AC-DC) converters represents a broad and flexible range of power supplies for use in advanced industrial electronic systems. Features include high efficiency, reliability, low output voltage noise and excellent dynamic response to load/line changes due to individual regulation of each output. to output isolation is provided. The modules are designed and built according to the international safety standard IEC 950 and have been approved by the safety agencies LGA (Germany) and UL (USA). The UL Mark for Canada has been officially recognized be regulatory authorities in provinces across Canada. The converter inputs are protected against surges and transients occuring at the source lines. An input over- and undervoltage cut-out circuitry disables the outputs if the input voltage is outside the specified range. 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 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 with pin 23 to enable the outputs. LED indicators display the status of the converter and allow visual monitoring of the system at any time. Full input to output, input to case, output to case and output 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 71 C but the case temperature should 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 inch rack systems according to DIN 41494, or be chassis mounted. Case: aluminium, black finish, self cooling. Dimensions: 38.7 x 111.2 x 168.5 mm. Weight: 770 g. 7-2 MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Rugged Environment DC-DC Converters <100 W M-Family Type Survey Options see "Descriptions of Options" General note The type survey tables provide an overview of the basic input and output configurations. More than 500 different types have been manufactured providing different output configurations and customized specialities. Please consult Melcher's field sales engineers for specific requirements. The best technical solution will carefully be considered and a detailed proposal submitted. Table 1a: Class I equipment Output 1 Output 2 Output 3 Uo nom I o nom V DC A Uo nom Io nom V DC A Uo nom Io nom V DC A 5.1 12.0 15.0 24.0 48.0 8.0 4.0 3.4 2.0 1.0 12.0 15.0 2.0 1.7 12.0 15.0 2.0 1.7 5.1 5.1 5.0 5.0 12.0 15.0 0.7 0.6 12.0 15.0 0.7 0.6 Input Voltage Range and Efficiency 1 Ui min...Ui max 8...35 V DC min % Ui min... Ui max 14...70 V DC min % Ui min... Ui max 20...100 V DC Option min % AM 1001-7R AM 1301-7R AM 1501-7R AM 1601-7R AM 1901-7R 72 79 79 81 81 BM 1001-7R BM 1301-7R BM 1501-7R BM 1601-7R BM 1901-7R 74 80 81 83 83 FM 1001-7R FM 1301-7R FM 1501-7R FM 1601-7R FM 1901-7R 74 80 81 82 83 -9 P D0...D9 V0,V2,V3 A AM 2320-7 AM 2540-7 77 78 BM 2320-7 BM 2540-7 79 80 FM 2320-7 FM 2540-7 80 79 H F AM 3020-7 AM 3040-7 75 75 BM 3020-7 BM 3040-7 76 76 FM 3020-7 FM 3040-7 76 76 U Table 1b: Class I equipment Output 2 Output 3 Uo nom I o nom V DC A Uo nom Io nom V DC A Uo nom Io nom V DC A 5.1 12.0 15.0 24.0 48.0 8.0 4.0 3.4 2.0 1.0 12.0 15.0 2.0 1.7 12.0 15.0 2.0 1.7 5.1 5.1 5.0 5.0 12.0 15.0 0.7 0.6 12.0 15.0 0.7 0.6 Input Voltage Range and Efficiency 1 Ui min...Ui max 28...140 V DC min % Ui min... Ui max 44...220 V DC min % Ui min... Ui max 88...372 V DC (85...264 V AC) Option min % CM 1001-7R CM 1301-7R CM 1501-7R CM 1601-7R CM 1901-7R 74 80 82 82 82 DM 1001-7R DM 1301-7R DM 1501-7R DM 1601-7R DM 1901-7R 74 81 82 83 83 LM 1001-7R LM 1301-7R LM 1501-7R LM 1601-7R LM 1901-7R 73 79 78 81 81 -9 E P D0...D9 V0,V2,V3 CM 2320-7 CM 2540-7 79 80 DM 2320-7 DM 2540-7 80 80 LM 2320-7 LM 2540-7 77 78 A H CM 3020-7 CM 3040-7 76 76 DM 3020-7 DM 3040-7 77 76 LM 3020-7 LM 3040-7 73 71 F U Table 2: Class II equipment (double insulation) 1 Output 1 Output 2 Output 3 Uo nom I o nom V DC A Uo nom Io nom V DC A Uo nom Io nom V DC A 5.1 12.0 15.0 24.0 48.0 8.0 4.0 3.4 2.0 1.0 12.0 15.0 2.0 1.7 12.0 15.0 2.0 1.7 5.1 5.1 5.0 5.0 12.0 15.0 0.7 0.6 12.0 15.0 0.7 0.6 Input Voltage Range and Efficiency 1 Option Ui min...Ui max 28...140 V DC min % Ui min... Ui max 44...220 V DC min % Ui min... Ui max 88...372 V DC (85...264 V AC) min % CMZ 1001-7R CMZ 1301-7R CMZ 1501-7R CMZ 1601-7R CMZ 1901-7R 74 80 82 82 82 DMZ 1001-7R DMZ 1301-7R DMZ 1501-7R DMZ 1601-7R DMZ 1901-7R 74 81 82 83 83 LMZ 1001-7R LMZ 1301-7R LMZ 1501-7R LMZ 1601-7R LMZ 1901-7R 73 79 78 81 81 -9 E P D0...D9 V0,V2,V3 CMZ 2320-7 CMZ 2540-7 79 80 DMZ 2320-7 DMZ 2540-7 80 80 LMZ 2320-7 LMZ 2540-7 77 78 A H CMZ 3020-7 CMZ 3040-7 76 76 DMZ 3020-7 DMZ 3040-7 77 76 LMZ 3020-7 LMZ 3040-7 73 71 F U Efficiency measured at Ui nom and I o nom Notes: EM types with an input voltage range of 67...385 V DC are available upon request Remarks: LM types may be operated in AC mode within a frequency range of 47...440 Hz and LMZ types within a frequency range of 47...65 Hz. Edition 2/96 - (c) Melcher AG MELCHER The Power Partners. 7-3 7.1 Output 1 M-Family DC-DC Converters <100 W Rugged Environment Safety and Installation Instructions Safety For safety reasons, the power supply modules must be wired via the female connector H11 (according to DIN 41612, see section "Accessories") in order to meet national and international safety requirements! If the output circuit of a DC-DC converter is operator-accessible according to the IEC 950 related safety standards, it shall be an SELV circuit (Safety Extra Low Voltage circuit, i.e. a circuit, separated from mains by at least basic insulation, that is so designed and protected that under normal and single fault conditions, the voltage between any two conductors and between any conductor and earth does not exceed 60 V DC). In the following section an interpretation is provided of the IEC 950 safety standard with respect to the safety status of the output circuit. However, it is the sole responsibility of the installer or user to assure the compliance with the relevant and applicable safety standards. Since the M-family DC-DC converters provide double or reinforced insulation between input and output, based on an input voltage of 250 V AC and 400 V DC, only operational insulation between the AC mains and the input of the DCDC converter is needed according to the following table. If the table below is observed, the output of a DC-DC converter is considered to be an SELV circuit up to a nominal output voltage of 36 V. Table 3: Insulation concept Nominal mains supply voltage (AC) 250V 7.1 1 Minimum required grade of isolation, to be provided by the AC-DC front end, including mains supplied battery charger Maximum Minimum required safety output status of the front end voltage output circuit from the front end Minimum required grade of isolation between the input and the output provided by the DC-DC converter Resulting safety status of the DC-DC output Operational 400 V 1 Reinforced, based on AC 250 V and DC 400 V 1 SELV circuit Primary circuit With LMZ converters, the maximum rated output voltage of the front end is 250 V according to IEC 950. AM...LM types correspond to class I equipment, while the C/D/LMZ types correspond to class II equipment. In class I equipment the connector protective earthing pin is leading while it is omitted in class II equipment (no protective earthing is required). Class II equipment provides reinforced insulation between input and output circuitry and also between input and case. There are two class II Y-capacitors connected in series between input and output circuitry instead of having Y-capacitors connected to the case. During the production process, all transformers and each of the fully assembled modules are individually tested for electric strength and earth continuity (see "Supplementary Data"). All electric strength tests are performed as factory tests. The UL 1950 recognition limits the maximum ambient operational temperature of the standard modules to TA = TA max -15 K. Option U allows the operation in applications where the full operational temperature range according to the relevant data sheet and UL 1950 recognition is required. Important Advice Electric strength tests should not be repeated in the field. Improper test methods, for example overshooting or oscillating test voltages, voltage slopes exceeding 1 kV/s, internal Y-capacitors not carefully discharged, etc. can cause severe damage to switching devices and ICs. Melcher AG will not honour any guarantee/warranty claims resulting from high voltage field tests. 7-4 MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Rugged Environment DC-DC Converters <100 W Installation Instructions Installation of the power supply must strictly follow the national safety regulations. To observe the safety requirements according to EN 60950/IEC 950, the module shall be connected via the female connector type H11 (see section "Accessories"). Other installation methods may not meet the safety requirements. A second fuse should be installed in the wiring to pin 29 if: - Local requirements demand an individual fuse in each source line M-Family - Input to earth impedance is high or undefined - Phase and neutral of the mains are not defined (AC-DC converters) Reverse polarity at the input of A...D/FM and C/DMZ types will cause the fuse to blow. In E/LM and LMZ types a series diode will protect the module. A series diode is not incorporated in A...D/FM and C/DMZ types to avoid unwanted power loss. Whenever the inhibit function is not required, pin 2 (i) should be connected to pin 23 to enable the output(s). Table 4: H11 connector pin allocation 2 3 4 C/D/LMZ 1000 Pin Ident A...LM 2000 Pin Ident C/D/LMZ 2000 Pin Ident A...LM 3000 Pin Ident C/D/LMZ 3000 Pin Ident Inhibit control input 2 i 2 i 2 i 2 i 2 i 2 i Safe Data or ACFAIL 5 D or V 5 D or V 5 D or V 5 D or V 5 D or V 5 D or V Output voltage (positive) 8 Vo1+ 8 Vo1+ 8 8 8 Vo3+ 8 Vo3+ Output voltage (negative) 11 Vo1- 11 Vo1- 11 11 11 Vo3- 11 Vo3- Control input + 1 14 R 14 R Control input - 17 G 17 G Output voltage (positive) 14 Vo2+ 14 Vo2+ 14 Vo2+ 14 Vo2+ Output voltage (negative) 17 Vo2- 17 Vo2- 17 Vo2- 17 Vo2- Output voltage (positive) 20 Vo1+ 20 Vo1+ 20 Vo1+ 20 Vo1+ 20 Vo1+ 20 Vo1+ Output voltage (negative) 23 Vo1- 23 Vo1- 23 Vo1- 23 Vo1- 23 Vo1- 23 Vo1- Protective 1 A...LM 1000 Pin Ident earthing 2 26 26 26 DC input voltage 3 29 Vi+ 29 Vi+ 29 Vi+ 29 Vi+ 29 Vi+ 29 Vi+ DC input voltage 32 Vi- 32 Vi- 32 Vi- 32 Vi- 32 Vi- 32 Vi- AC input voltage 4 29 N 29 N 29 N 29 N 29 N 29 N AC input voltage 32 P 32 P 32 P 32 P 32 P 32 P This function is not simultaneously available with option P Leading pin (pregrounding) A/B/C/D/E/FM and C/DMZ types LM/LMZ types Degree of Protection Condition: Female connector fitted to the unit IP 40: All units, except those with options P, A, K, D or V with potentiometer adjustment. IP 30: All units, except those with option P, D or V with potentiometer adjustment. IP 20: All units fitted with options which include potentiometer setting. Leakage Currents and Insulation Please refer to "Supplementary Data" Edition 2/96 - (c) Melcher AG MELCHER The Power Partners. 7-5 7.1 Electrical Determination M-Family DC-DC Converters <100 W Rugged Environment Functional Description mary switching transistor. This signal is fed back via a coupling transformer. The input voltage is fed via an input fuse, an input filter, a rectifier 3 and an inrush current limiter 4 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 an 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 pri- The auxiliary outputs Uo2 and Uo3 are individually regulated by means of secondary switching transistors. Each auxiliary output's current is sensed 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. P 2 5 5 Main control circuit 14 5 17 20 Y Output 1 filter 29 23 3 MKT Forward converter approx. 70 kHz 2 Input filter Fuse 1 4 14 Control circuit Output 2 filter 17 MKT 8 32 Control circuit Output 3 filter 11 26 7.1 Y Fig. 1a DC-DC (AC-DC) converter block diagram, class I equipment P Y Y 2 5 5 Main control circuit 14 5 17 20 Output 1 filter 29 23 3 4 Forward converter approx. 70 kHz 2 Input filter Fuse 1 32 14 Control circuit Output 2 filter 17 8 Control circuit Output 3 filter 11 Fig. 1b DC-DC (AC-DC) converter block diagram, class II equipment (double insulation) 7-6 1 Transient suppressor (VDR) in C/D/E/F/LM and C/D/LMZ Transient suppressor diode in A/B/C/FM and CMZ types 3 Bridge rectifier in LM/LMZ, series diode in EM types 4 Inrush current limiter (NTC) in C/D/E/LM and C/D/LMZ types (option E: refer to the description of option E) 5 Single output modules A...LM 1000 and C/D/LMZ 1000 with feature R 2 MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Rugged Environment DC-DC Converters <100 W M-Family Electrical Input Data General conditions: - TA = 25C, unless TC is specified. - Connector pins 2 and 23 interconnected, with option P: Uo = Uo nom, R input not connected. Table 5a: Input data Input AM Characteristics Conditions Ui Input voltage range I o = 0...Io nom Ui nom Nominal input voltage TC min...TC max Ii Input current U i nom, Io nom 2 Pi 0 No-load input power: Single output Double output Triple output Ui nom I o1,2,3 = 0 Idle input power inhibit mode Pi inh I inr p 6 Peak inrush current t inr r Rise time t inr h Trailing edge half-life Ri Input resistance Ci Input capacitance min U i abs Input voltage limits without any damage max min 35 14 8 typ FM max min 70 20 CM/CMZ typ max min 100 28 typ 15 30 50 60 4.0 2.0 2.0 1.0 1 7 6 1.5 9 9 1 7 6 1.5 Ui = Ui max RS = 0 3 TC = 25C TC = 25 C typ BM 1.5 9 9 1 7 6 1.5 9 9 1.5 400 1.5 500 50 40 170 100 60 140 Unit 140 V DC A 1.5 9 9 W 1.5 400 60 87.5 1 7 6 max 170 W 4 A s 60 280 250 824 4 m 2600 4000 670 1100 370 600 370 600 F 0 40 0 80 0 120 0 160 V DC Table 5b: Input data DM/DMZ Characteristics Conditions Ui Io = 0...Io nom TC min...TC max Input voltage range min Input current Ui nom , Io nom 2 Pi 0 No-load input power: Single output Double output Triple output Ui nom Io1,2,3 = 0 Pi inh Idle input power I inr p 6 Peak inrush current t inr r Rise time t inr h Trailing edge half-life Ri Input resistance 44 Ci Input capacitance Ui abs Input voltage limits without any damage min typ 67 385 min typ max Unit 85 264 V AC 1 88 372 V DC 110 220 310 0.55 0.275 0.20 1 7 6 1.5 9 9 1 7 6 1.5 Ui = Ui max RS = 0 3 TC = 25C LM/LMZ max 220 inhibit mode TC = 25C EM max - Ui nom Nominal input voltage Ii typ 110 1.5 9 9 1 7 6 1.5 4 160 40 4 250 1.5 9 9 W 1.5 W 60 40 4 A s 300 240 2000 4 A 900 2400 4 6200 4 m 140 270 140 270 140 270 F 0 400 5 - 400 400 - 400 400 V DC - - - - 0 284 V AC 1 In AC powered mode: LM types: 47...440 Hz; LMZ types: 47...65 Hz With multiple output modules, the same condition for each output applies. 3 R = source resistance. S 4 Value for initial switch-on cycle. 5 1 s max., duty cycle 1% max. 6 I inr p = U i /(R s + Ri ) 2 Edition 2/96 - (c) Melcher AG MELCHER The Power Partners. 7-7 7.1 Input M-Family DC-DC Converters <100 W Input fuse A fuse holder containing a slow-blow type fuse (Dimension: 5 x 20 mm) is mounted in the converter's back plate. The fuse protects the module against severe defects. It may not fully protect the module at input voltages exceeding 200 V DC. In applications where the converters operate at DC source voltages above 200 V DC, an external fuse or a circuit breaker at system level should be installed. For applications where the fuse should be inaccessible: see option F. Input Under-/Overvoltage Cut-out If the input voltage remains below 0.8 Ui min or exceeds 1.1Ui max (approx. values), an internally generated inhibit signal disables the output(s). When checking this function the absolute maximum input voltage rating Ui abs must be carefully considered (see table "Input Data"). I i [A] Rugged Environment Table 6: Fuse types (slow-blow) Series Schurter type Part number AM 1000...3000 SPT 10 A 250 V 0001.2514 BM 1000...3000 SPT 8 A 250 V 0001.2513 SPT 5 A 250 V 0001.2511 CM/CMZ 1000...3000 FM 1000...3000 SPT 3.15 A 250 V 0001.2509 DM/DMZ 1000...3000 EM 1000...3000 LM/LMZ 1000...3000 SPT 2.5 A 0001.2508 250 V Inrush Current The C...LM and C/D/LMZ (excluding FM) modules incorporate a NTC resistor in the input circuitry which (during the initial switch-on cycle) limits the peak inrush current to avoid damage to connectors and switching devices. Subsequent switch-on cycles within a short interval will cause an increase of the peak inrush current due to the warming up of the NTC resistor. Refer also to option E description. Ii [A] 10.00 A...FM LM 400 BM 7.1 350 AM AM 300 50; 250 BM FM 1.00 FM 40; 200 LM/LMZ CM/CMZ EM 30; 150 DM/DMZ EM LM/LMZ DM/DMZ 20; 100 10; 0.10 1 2 3 4 5 6 U i DC ________ U i min DC CM/CMZ 50 t [ms] 0 0 Fig. 2 Typical input current versus relative input voltage at nominal output load 7-8 0.2 0.5 0.4 1.0 0.6 1.5 0.8 2.0 1.0 2.5 1.2 3.0 1.4 3.5 1.6 A...EM LM 4.0 Fig. 3 Typical inrush current at initial switch-on cycle and at Ui max [DC] versus time MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Rugged Environment DC-DC Converters <100 W M-Family Electrical Output Data General conditions - TA = 25 C, unless TC is specified. - Connector pins 2 and 23 interconnected, Uo = Uo nom (option P), R input not connected. Table 7: Output data Characteristics Conditions Uo Output voltage U i nom, I o nom Uo L Overvoltage prot. I o nom Io nom Output current Io L Output current limitation response 1 12 V 15 V 24 V 48 V min typ max min typ max min typ max min typ max min typ max 5.07 5.13 11.93 7.5 12.07 14.91 21 U i min... U i max TC min...TC max u o1/2/3 Output voltage noise U i nom, I o nom 1 Bandwidth = u o1 20 MHz u o2/3 Uo U Static line regulation U i min... U i nom U i nom... Ui max I o nom 1 Uo I 5.1 V Static load regulation U i nom I o = I o nom...0 2 15.09 23.86 25 24.14 47.72 41 Unit 48.28 V 8 mVrms 85 see tables 1 and 2 see fig. 4 2 4 3 6 3 6 3 6 15 30 25 50 35 70 40 80 60 120 40 80 40 80 40 80 10 30 12 50 15 60 15 60 6 25 13 50 17 60 30 80 0 15 0 20 0 30 0 40 4 50 100 mVpp 15 60 mV 60 150 Uo Ic Static cross load regulation 4 U i nom I o = I o nom...0 3 uo d Dynamic load regulation 220 110 150 130 150 td Dynamic load regulation time constant U i nom, Io = 1/0.33/1*I o nom 2 fig. 5 0.6 0.6 0.5 1 2 ms u o dc Dynamic cross load regulation 4 +10 -100 +10 -75 +10 -140 +20 -200 - mV t dc Dynamic cross load reg. time constant 4 U i nom, Io = 1/0.33/1*I o nom 3 fig. 5 0.05 0.5 0.2 0.3 0.5 0.7 1 2 - ms Uo Output voltage deviation versus case temperature TC min...TC max 0.02 0.02 0.02 0.02 0.02 %/K 1.0 2.4 3.0 4.8 9.6 mV/K - 1 With multiple output modules, the same condition for each output applies. Condition for specified output. With multiple output modules, other output(s) loaded with constant current Io = Io nom . 3 Condition for non-specified output, individually tested, other output(s) loaded with constant current I = I o o nom. 4 Multiple output modules. 2 Output Protection Each output is protected against overvoltages which could occur due to a failure of the internal control circuit. Voltage suppressor diodes (which under worst case condition may become a short circuit) provide the required protection. The suppressor diodes are not designed to withstand externally applied overvoltages. Overload at any of the outputs will cause a shut-down of all outputs. A red LED indicates the overload condition of the respective output. Parallel and Series Connection Main outputs of equal nominal voltage can be connected in parallel. It is important to assure that the main output of a multiple output module is forced to supply a minimum current of 0.1 A to enable correct operation of its own auxiliary outputs. In parallel operation, one or more of the main outputs may operate continuously in current limit which will cause an increase in case temperature. Consequently, a reduction of the max. ambient temperature by 10 K is recommended. Main or auxiliary outputs can be connected in series with any other output of the same or another module. In series connection, the maximum output current is limited by the lowest current limit. Output ripple and regulation values are added. Connection wiring should be kept as short as possible. If output terminals are connected together in order to establish multi-voltage configurations, e.g. +5.1 V, 12 V etc. the common ground connecting point should be as close as possible to the connector of the converter to avoid excessive output ripple voltages. Auxiliary outputs should never be connected in parallel! Edition 2/96 - (c) Melcher AG MELCHER The Power Partners. 7-9 7.1 Uo nom Output DC-DC Converters <100 W Uo1 Uo1 nom Io nom Rugged Environment U o IoL1 = M-Family uod = = IoL2,IoL3 1.0 .95 uod = td AM...LM and C/D/LMZ td Io1 t Io2,Io3 0.5 I o/I o nom 3/3 2/3 1/3 0 0.5 1.0 1.2 Io Io nom 0 t 10 s 10 s Fig. 5 Control deviation of Uo versus dynamic load change Fig. 4 Typical output voltage Uo1 versus output currents Io Output Current Allocation for special Types Output currents differing from those given for standard types (as per "Type Survey") can be provided. A maximum output power of 50 W should be considered, if an ambient temperature range of -25...71 C is required. The maximum permissible output currents are indicated in the table below. If (upon customer's request) output voltages are different from standard values, the relevant output currents have to be adapted accordingly. With reduced maximum ambient temperature or with forced cooling, the total output power may exceed 50 W. Customized configurations always need to be checked by a feasibility study first. Please ask Melcher's sales engineers for a proposal appropriate to your specific needs. 7.1 Table 8: Current allocation with special types Output voltage all types Uo1/2/3 nom [V] Output 1 all types I o1 max [A] Output 2 A...LM 2000 I o2 max [A] Output 2 A...LM 3000 I o2 max [A] Output 3 A...LM 3000 I o3 max [A] TA [C ] TC [C ] 5.1 12 15 24 8.0 4.0 3.4 2.0 4.0 2.0 1.7 1.0 1.8 (2.5 1 ) 1.5 1.2 0.7 1.5 1.2 1.0 0.5 -25...71 -25...95 5.1 12 15 24 10.0 5.0 4.0 2.5 4.5 2.5 2.0 1.3 2.1 (2.8 1 ) 1.7 1.5 0.9 1.8 1.5 1.3 0.7 -25...60 -25...90 5.1 12 15 24 11.0 6.0 4.6 3.0 5.0 3.0 2.3 1.5 2.4 (3.0 1 ) 2.0 1.7 1.0 2.0 1.7 1.5 0.8 -25...50 -25...85 2 1 2 Special high current components required, Temperature U i min has to be increased Inhibit (i Input) The outputs of the module may be enabled or disabled by means of a logic signal (TTL, CMOS, etc.) applied to the inhibit input. If the inhibit function is not required, connect the inhibit pin 2 to pin 23 to enable the outputs (active low logic, fail safe). The reference for the inhibit signal is the negative pin of output 1. Iinh [mA] 2.0 Uinh= 0.8 V Uinh= 2.4 V 1.6 Vi+ 1.2 Vo+ 0.8 i Iinh Vo- -0.4 -0.8 -50 Fig. 6 Definition of inhibit voltage and current 7 - 10 Uo = off 0 Uinh Vi- Uo = on 0.4 -40 -30 -20 -10 0 10 20 30 40 50 Uinh [V] Fig. 7 Typical inhibit current I inh versus inhibit voltage U inh MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Rugged Environment DC-DC Converters <100 W M-Family Table 9: Inhibit data Characteristics Conditions Uinh Inhibit input voltage causing output voltage being... I inh Inhibit current switched on min U i min... Ui max -50 Uinh = 0 -60 switched off typ 2.4 Hold-up Time and Output Response When the input voltage is switched off the output voltage will remain high for a certain hold-up time th (fig. 8) before the output voltage falls below 0.95 Uo nom . To achieve the hold-up times indicated in fig. 9, A/B/C/D/FM and C/DMZ modules require an external series diode in the input path. This is necessary to prevent the discharge of the input capacitor through the source impedance or other circuits connected to the same source. E/LM and LMZ modules have a built-in series diode. In A/B/C/D/FM and C/DMZ modules, no series diode is built-in, since it would generate up to 10 W of additional power loss inside the converter. Consequently the maximum operational ambient temperature would have to be reduced accordingly. max Unit 0.8 V DC 50 -100 A -220 The behavior of the outputs is similar with either the input voltage applied or the inhibit switched low. An output voltage overshoot will not occur when the module is turned on or off. th [ms] 1000.00 LM/LMZ Output EM 100.00 Uo nom 0.95Uo nom tr tf t 10.00 th Ui 7.1 0.1 0 C/DM, C/DMZ A/B/FM 1 t 0 1.00 Inhibit 1 t 0 U i DC _____ 0.10 1 Fig. 8 Output response as a function of input voltage (on/off switching) or inhibit control 2 3 4 5 6 Ui min DC Fig. 9 Typical hold-up time th versus relative input voltage at Io nom Table 10: Output response time t r, values not applicable for modules equipped with option E t r at Po =0 and t f at Po = Po nom t r and t f at Po = 3 / 4 Po nom typ max typ max Type of Converter A...LM 1001-7R and A...LM 1301-7R and A...LM 1501-7R and A...LM 1601-7R and A...LM 1901-7R and C/D/LMZ 1001-7R C/D/LMZ 1301-7R C/D/LMZ 1501-7R C/D/LMZ 1601-7R C/D/LMZ 1901-7R t r at Po = Po nom typ max 5 10 5 15 65 10 20 10 30 130 5 15 10 25 100 10 30 20 50 200 10 20 30 40 165 20 40 60 80 330 A...LM 2320-7 and C/D/LMZ 2320-7 A...LM 2540-7 and C/D/LMZ 2540-7 20 15 40 30 30 20 60 40 50 35 100 70 A...LM 3020-7 and C/D/LMZ 3020-7 A...LM 3040-7 and C/D/LMZ 3040-7 55 40 110 80 85 60 170 120 145 100 290 200 Unit ms Conditions: R input not used. For multiple output modules the figures indicated in the table above relate to the output which reacts slowest. All outputs are resistively loaded. Variation of the input voltage within Ui min...Ui max does not influence the values. Edition 2/96 - (c) Melcher AG MELCHER The Power Partners. 7 - 11 M-Family DC-DC Converters <100 W Programmable Voltage (R Input) As a standard feature single output modules offer an adjustable output voltage identified by letter R in the type designation. The control input R (pin 14) 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. The control input is protected against external overvoltage up to 8 V max. a) Adjustment by means of an external control voltage Uext between pin 14 (R) and pin 17 (G): The control voltage range is 0...2.75 V and allows an adjustment in the range of approximately Uo = 0...110% Uo nom. Uo Uext ------ * 2.5 V Uo nom b) Adjustment by means of an external resistor: Depending upon the value of the required output voltage, the resistor shall be connected either: Between pin 14 and pin 17 (Uo < Uo nom) to achieve an output voltage adjustment range of approx. Uo = 0...100% Uo nom Uo R ext 4 k * --------- Uo nom - U o 7.1 or: Between pin 14 and pin 20 (Uo > Uo nom) to achieve an output voltage adjustment range of approximately Uo = 100...110 % of Uo nom. (U o - 2.5 V) R' ext 4 k * ------------------ 2.5 V * (U o / Uo nom - 1) For output voltages Uo > Uo nom, the minimum input voltage according to "Electrical Input Data" increases proportionally to Uo /Uo nom. Rugged Environment The value of R'ext should never be less than 47 k to avoid damage to the unit! R inputs may be parallel connected, but 1/Rtot = 1/R1 + 1/R2 +.... should be considered. Remark The R-feature excludes option P (output voltage adjustment by potentiometer). Vo1+ Vi+ 29 20 2.5 V 4 k 14 R + control circuit Uext 17 Vi- Vi+ 32 AM...LM 1000 C/D/LMZ 1000 23 G - Vo1- Vo1+ 29 20 R'ext 2.5 V 4 k 14 R control circuit Rext 17 Vi- AM...LM 1000 C/D/LMZ 1000 32 23 G Vo1- Fig. 10 Output voltage control by means of the R input Warning Table 11a: Rext for Uo < Uo nom (conditions: Ui nom, Io nom, rounded up to resistor values E 96, Rext' = ) 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 0.432 0.976 1.65 2.61 3.83 5.76 8.66 14.7 30.1 200.0 Uo nom = 12 V Uo [V] Rext [k] Uo nom = 15 V Uo [V] Rext [k] Uo nom = 24 V Uo [V] Rext [k] Uo nom = 48 V Uo [V] Rext [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 11b: R'ext for Uo > Uo nom (conditions: Ui nom, Io nom, rounded up to resistor values E 96, Rext = ) Uo nom = 5.1 V Uo [V] R'ext [k] 5.15 5.20 5.25 5.30 5.35 5.40 5.45 5.50 7 - 12 464 215 147 110 90.9 78.7 68.1 61.9 Uo nom = 12 V Uo [V] R'ext [k] 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 13.0 13.2 1780 909 619 464 383 316 274 249 200 169 Uo nom = 15 V Uo [V] R'ext [k] 15.2 15.4 15.6 15.8 16.0 16.2 16.4 16.5 1470 750 511 383 332 274 237 226 MELCHER The Power Partners. Uo nom = 24 V Uo [V] R'ext [k] 24.25 24.50 24.75 25.00 25.25 25.50 25.75 26.00 26.25 26.40 3160 1620 1100 825 715 590 511 453 402 383 Uo nom = 48 V Uo [V] R'ext [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 Edition 2/96 - (c) Melcher AG Rugged Environment DC-DC Converters <100 W M-Family EMC and Immunity to Input Transients 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 M-family has been successfully tested to the following specifications: Electromagnetic Immunity Test procedure Performance Source impedance In operation Waveform III i/o, i/c, o/c +i/-i, +o/-o 5000 Vp 1.2/50 s 500 3 pos. and 3 neg. impulses per coupling mode no High frequency disturbance IEC 255-4 App. E5 6 (1976) III i/o, i/c, o/o, o/c 2500 Vp 200 1 1000 Vp 2 s per coupling mode yes +i/-i, +o/-o 400 damped 1 MHz waves/s Voltage surge IEC 571-1 3 i/c, +i/-i 800 Vp 100 s 100 yes 1 1500 Vp 50 s 3000 Vp 5 s 1 pos. and 1 neg. voltage surge per coupling mode 4000 Vp 1 s 7000 Vp 100 ns 3.5 * Ubatt 20 ms 0.2 1 positive surge yes 1 10 positive and 10 negative discharges yes 1 26...1000 MHz yes 2 1 min positive 1 min negative bursts per coupling mode yes 1 (1990-07) Supply related surge RIA 12 (1984) Direct transient A 5 +i/-i B 1.5 * Ubatt C 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 G Indirect coupled transient H i/c 1s 8400 Vp 0.05/0.1 s 1800 Vp 5/50 s J 3600 Vp 0.5/5 s K 4800 Vp 0.1/1 s L 8400 Vp 0.05/0.1 s 8000 Vp 1/50 ns Electrostatic discharge IEC 801-2 (1991-04) 4 contact discharge to case, Electric field IEC 801-3 (1984) 3 antenna in 1 m distance Fast transient/ burst IEC 801-4 (1988) 3 i/c, +i/-i 5 100 330 air dischg. to case 15000 Vp 10 V/m 4 Transient Conducted disturbance IEC 801-5 (Draft 1993-01) 4 IEC 801-6 (Draft 1992-12) 3 1 i/c 4000 Vp +i/-i 2000 Vp i, o, signal wires 140 dBV (10 Vrms) Normal operation, no deviation from specifications Normal operation, temporary deviation from specs possible 3 Will be replaced by EN 50155 4 i = input, o = output, c = case 5 Only met with extended input voltage range of BM (24 V battery), CM (48 V battery) and EM (110 V battery) types. These 2 Edition 2/96 - (c) Melcher AG AM modulated 80 %, 1 kHz 2000 Vp bursts of 5/50 ns 5 kHz rep. rate transients with 15 ms burst duration and a 4000 Vp 300 ms period 1.2/50 s 50 2 12 2 AM modulated 80 %, 1 kHz 5 pos. and 5 neg. impulses 7.1 Coupling mode 4 IEC 255-4 App. E4 6 (1976) Level Impulse voltage Standard Value applied Phenomenon Table 12: Immunity type tests 150 5 pos. and 5 neg. impulses per coupling mode yes 1 0.15...80 MHz yes 2 units are available on customer's request. Standard DM units (110 V battery) will not be damaged, but overvoltage lock-out will occur during the surge 6 In correspondence with DIN 57435 part 303 and VDE 0435 part 303 (1984-09) MELCHER The Power Partners. 7 - 13 M-Family DC-DC Converters <100 W Rugged Environment Electromagnetic Emissions Table 13: Emissions at Ui nom and Io nom (LM/LMZ at 230 V AC) Types Level: B B B B B A N N N K K K B B B B B A B B B B B A BM 1000 BM 2000 BM 3000 B B B B B A N N N K K K B B B B B A B B B B B A CM 1000 CM 2000 CM 3000 B B B B B A N N N K K K B B B B B A B B B B B A DM 1000 DM 2000 DM 3000 B B B B B A N N N K K K B B B B B A B B B B B A EM 1000 EM 2000 EM 3000 B B B B B A N N N K K K B B B B B A B B B B B A FM 1000 FM 2000 FM 3000 A A A B B A N N N K K K B B B B B A A A A B B A LM 1000 LM 2000 LM 3000 B B B B B A N N N K K K B B B B B A B B B B B A CMZ 1000 CMZ 2000 CMZ 3000 B >A A >A N G K G B A A >A B A A >A DMZ 1000 DMZ 2000 DMZ 3000 - - - - - - - - LMZ 1000 LMZ 2000 LMZ 3000 >A A >A >A G N K N A B >A >A >A A >A >A Identical with CISPR 11 (1990-09) and VDE 0875 part 11 (1992-07) Identical with CISPR 22 (1985) and VDE 0878 part 3 (1989-11) [dBV/m] [dBV] 100 100 90 90 80 80 A 70 70 60 0 B Frequency [MHz] Frequency [MHz] Fig. 11a Conducted RFI at input according to EN 55011 (quasi peak) 7 - 14 A 1000 0 20 30 10 10 10 5 20 2 20 1 30 0.5 30 0.1 0.2 40 0.05 40 0.02 50 0.01 50 500 B 200 60 100 2 FCC: 47 CFR 15.xxx 15.107 15.103 30 MHz 30 MHz AM 1000 AM 2000 AM 3000 50 1 EN 55011, 1991 1 EN 55022, 1987 2 30 MHz 30 MHz VDE 0875 part 3 12.88 30 MHz 30 MHz 30 7.1 VDE 0871 6.78 30 MHz 30 MHz Fig. 11b Radiated RFI according to EN 55011 (Distance 10 m) MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Rugged Environment DC-DC Converters <100 W M-Family Supplementary Data Important Advice Isolation Input to output electric strength tests, in accordance with the safety standards IEC 950, EN 60950, VDE 0805 and EN 41003 are performed as factory tests and should not be repeated in the field. Testing by applying AC voltages will result in high and dangerous leakage currents through the Y-capacitors (see fig. 1). Melcher will not honour any guarantee/warranty claims resulting from high voltage field tests. Reference is also made to chapter: Safety and Installation Instructions. Table 14: Electric strength test voltage, insulation resistance, clearance and creepage distances Input/Output a) b) a) b) Electric strength test voltage DC: 1 s 4243 1 56001 2122 2800 4243 5600 707 1414 - 300 AC: 50 Hz, 1 min 3000 1 4000 1 1500 2000 3000 4000 500 1000 - 200 Insulation resistance at 500 V DC - 300 - 300 - 300 - 100 - - M Clearance and Creepage distances AM/BM 4.0 5.0 2.0 4.0 4.0 5.0 1.0 2.0 - 0.9 mm C...LM and C/D/LMZ 4.0 8.0 2.0 4.0 4.0 5.0 1.0 2.0 - 0.9 a) Input/Case Class I a) b) b) Input/Case Class II a) b) Output/Case Output/Output Unit V Only subassemblies performance in accordance with IEC 950 Leakage Currents in AC-DC operation Leakage currents will flow due to internal leakage capacitances and RFI suppression Y-capacitors. The current values are proportional to the mains voltage and nearly proportional to the mains frequency and are specified at an input condition of 264 V/50 Hz where phase, neutral and protective earth are correctly connected as required for class I equipment. Under test conditions the leakage currents flow through a measurement circuit, consisting of a 1500 resistance with a 150 nF capacitor connected in parallel. The voltage drop across this element is measured and the current value calculated from the measured voltage divided by 1500 . If inputs of M-units are connected in parallel, their individual leakage currents are added. + + LMZ 1000...LMZ 3000 LM 1000...LM 3000 - - connection to case MD for earth leakage current MD for enclosure leakage current MD for output leakage current MD for output leakage current MD 1500 150 nF Fig. 12 Definition of leakage currents and measurement procedure by means of the measuring device MD V Table 15: Leakage currents Characteristic a) permissible according to IEC 950 b) value at 264 V, 50 Hz a) max b) max a) max b) max Earth leakage current 3.5 1.4 - - - - 0.25 0.03 0.25 0.005 0.25 0.15 Enclosure leakage current Output leakage current Edition 2/96 - (c) Melcher AG Class I (LM) Class II (LMZ) MELCHER The Power Partners. Unit mA 7 - 15 7.1 1 Characteristic a) values according to IEC 950, b) Product's performance M-Family DC-DC Converters <100 W Rugged Environment Display Status of LEDs Uo1 > 0.95...0.98Uo1 adj OK i Fig. 13 LEDs "OK" and "i" status versus input voltage Conditions: Io Io nom, TC TC max , Uinh 0.8 V Ui uv = undervoltage lock-out, Ui ov = overvoltage lock-out Ui Ui uv Ui min Ui max Uo1 > 0.95...0.98Uo1 adj Ui ov Ui abs Uo1 < 0.95...0.98Uo1 adj OK Io L LED "OK" and "I o L" status versus output current Conditions: U i min...U i max, TC TC max, U inh 0.8 V Io Io nom IoL LED "i"versus case temperature i TC max TC Conditions: U i min...U i max, I o I o nom, U inh 0.8 V Ui inh LED "i"versus U inh Conditions: U i min...U i max, I o I o nom, TC TC max TPTC threshold Uinh threshold i +0.8 V -50 V LED off +2.4 V +50 V LED Status undefined LED on Description of Options Table 16: Survey of options 7.1 Option 1 3 Function of Option Characteristic -9 Extended operational ambient temperature range TA = -40...71C E Electronic inrush current limitation circuitry Extended inrush current limitation for C/E/LM, C/LMZ P1 Potentiometer for fine adjustment of output voltage Adjustment range 5% of Uo nom, excludes R input D2 Input and/or output undervoltage monitoring circuitry Safe data signal output (D0...D9) V23 Input and/or output undervoltage monitoring circuitry ACFAIL signal according to VME specifications (V0, V2, V3) A Test sockets at front panel for check of output voltage U o internally measured at the connector terminals H Enhanced output to case electric strength test voltage 2000 V AC (standard: 1000 V AC) F Input fuse built-in inside case Fuse not externally accessible U UL recognized full ambient temperature range Full temperature range according to temperature suffix 2 Function R excludes option P and vice versa Only available if main output voltage Uo1 = 5.1 V Option -9 Extended temperature range 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 A Test sockets Test sockets (pin O = 2 mm, distance d = 5.08 mm) are located at the front of the module. The output voltage is sensed at the connector pins inside the module. Option D excludes option V and vice versa Option P Potentiometer Optionally built-in multi-turn potentiometers provide an output voltage adjustment range of minimum 5 % of Uo nom and are accessible through holes in the front cover. Compensation of voltage drop across connector and wiring becomes easily achievable. For output voltages Uo > Uo nom, the minimum input voltage according to "Electrical Input Data" increases proportionally to Uo /Uo nom. Note: Potentiometers are not recommended for mobile applications Table 17: Configuration of option A and option P Type of option 1 AM...LM/CMZ...LMZ 1000 Output 1 AM...LM/CMZ...LMZ 2000 Output 1 Output 2 AM...LM/CMZ...LMZ 3000 Output 1 Output 2 Output 3 Potentiometer 1 yes yes yes yes no no Test sockets yes yes yes yes no no AM...LM 1000 types equipped with option P do not provide the R input simultaneously, pins 14 and 17 are not connected. 7 - 16 MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Rugged Environment DC-DC Converters <100 W Option E Extended inrush current limitation Available for C/E/LM and C/LMZ types. The standard version of the modules C/D/E/LM as well as C/D/LMZ include a passive inrush current limitation in the form of a NTC resistor. For applications which require an extended inrush current limitation, an active electronic circuit as shown in "Option E block diagram" has been developed. Typical inrush current waveforms of units equipped with this option are shown below. CM and CMZ units meet the CEPT/ETSI standards for 48 V DC supply voltage according to prETS 300132-2 if fitted with option E combined with option D6 (input voltage M-Family monitoring). Option D6, externally adjustable via potentiometer, is necessary to disable the converter at input voltages below the actual service ranges, avoiding an excessive input current when the input voltage is raised slowly according to prETS 300132-2. Option D6 threshold level Ut i + Uh i (refer to description of option D) should be adjusted to 36.0...40.5 V for 48 V DC nominal supply voltage (for 60 V DC systems, threshold should be set to 44.0...50.0 V DC). The D output (pin 5) should be connected to the inhibit (pin 2). For applications where potentiometers are not allowed refer to option D9. Table 18: Inrush current characteristics with option E Characteristic CM/CMZ/EM at Ui = 110 V DC LM/LMZ at Ui = 230 VAC CM/CMZ typ Iinr p Peak inrush current tinr Inrush current duration EM LM/LMZ max 6.5 8 2.2 4 6 10 A 22 30 19 30 35 50 ms Control FET Rectifier (LM/LMZ types) RS 7.1 typ Converter typ Input Filter max Precautions: In order to avoid overload of the series resistor RI the on/off switching cycle should be limited to 12 s if switched on/off continuously. There should not be more than 10 start-up cycles within 20 s at a case temperature of 25C. If CM and CMZ types are driven by input voltages below 35 V DC or LM and LMZ types below 100 V AC, the maximum case temperature should be derated by 10 K or the total output power should be derated by 20%. EM, LM and LMZ units driven by DC input voltages do not need to be derated within the full specified input voltage range. Availability: Option E is available for C/E/LM and CMZ/LMZ modules with a nominal output power of 51 W maximum. max Unit Ci RI Fig. 14 Option E block diagram Ii [A] Ii [A] LM type Ui = 230 V AC Po = Po nom 12 Iinr p = Ui / (RS+RI) 6 10 CM type Ui = 110 V DC Po = Po nom 8 6 EM type Ui = 110 V DC Po = Po nom 4 4 Capacitor Ci fully charged 2 Normal operation (FET fully conducting) 0 Capacitor Ci fully charged -2 Normal operation (FET fully conducting) -4 2 Ii = Po /Ui * -6 t [ms] t [ms] 0 0 10 20 t inr 30 0 40 Fig. 15 Typical inrush current waveforms of a CM and an EM type Edition 2/96 - (c) Melcher AG 20 tinr 40 60 80 Fig. 16 Typical inrush current waveform of a LM type MELCHER The Power Partners. 7 - 17 M-Family DC-DC Converters <100 W Option D Undervoltage monitor The input and/or output undervoltage monitoring circuit operates independently of the built-in input undervoltage lockout circuit. A logic "low" (JFET output) or "high" signal (NPN output) is generated at pin 5 as soon as one of the monitored voltages drops below the preselected threshold level Ut. The return for this signal is Vo1- (pin 23). The D output recovers when the monitored voltage(s) exceed(s) Ut+Uh. Rugged Environment The threshold level Ut is either adjustable by a potentiometer, accessible through a hole in the front cover, or is factory adjusted to a fixed value specified by the customer. Option D exists in various versions D0...D9 as shown in the following table. Table 19: Undervoltage monitor functions Output type JFET NPN Monitoring Ui Uo1 Typical hysteresis Uh [ % of U t] for U t min... Ut max U hi U ho Minimum adjustment range of threshold level U t Uti Uto D1 D5 no yes - 3.5 V...48 V 1 - 2.3...1 D2 D6 yes no Ui min... Ui max 1 - 3.0...0.5 - yes 1 0.95...0.98 Uo1 2 3.0...0.5 "0" 2 D3 D7 yes Ui min... Ui max D4 D8 no yes - 0.95...0.98 Uo1 - "0" D0 D9 no yes - 3.5 V...48 V 3 - 1.8...1 yes no Ui min...Ui max 3 4 - 2.2...0.4 - yes yes Ui min...Ui max 3 4 0.95...0.98 Uo1 2 2.2...0.4 "0" 1 Threshold level adjustable by potentiometer (not recommended for mobile applications) Fixed value between 95% and 98% of Uo1 (tracking) 3 Fixed value, resistor-adjusted according to customer's specifications 2% at 25C; individual type number is determined by Melcher 4 Adjusted at I o nom 7.1 2 JFET output (D0...D4): 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. Ui , U o1 status D output, U D Ui or U o1 < Ut 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 Vi+ 20 Vo1+ ID Rp 5 D UD 6 V Vi- 32 23 Vo1- Fig. 17 Options D0...D4, JFET output NPN output (D5...D9): Vi+ 29 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. Ui , Uo1 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, UD 0.4 V at I D = 20 mA 7 - 18 29 20 Vo1+ Rp ID 5 D UD Vi- 32 23 Vo1- Fig. 18 Options D5...D9, NPN output MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG DC-DC Converters <100 W Uti UD Uhi Po = 0 Po = Po nom UD high Po = Po nom Threshold tolerances and hysteresis: If Ui is monitored, the internal input voltage after the input filter and rectifier (E/LM and LMZ types) is measured. Consequently this voltage differs from the voltage at the connector pins by the voltage drop Uti across input filter and rectifier. The threshold level of the D0 and D9 options is factory adjusted at nominal output current Io nom and at TA = 25C. The value of Uti depends upon the input voltage range (AM, BM, ...), threshold level Ut, temperature and input current. The input current is a function of the input voltage and the output power. M-Family Po = 0 Rugged Environment UD low Ui Uti Fig. 19 Definition of Uti, Uti and Uhi (JFET output) Input voltage monitoring NPN UD UD high 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 7.1 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 UD low t 0 ID ID high ID low 0 t JFET UD UD high UD low 0 t 1 tlow min4 2 Uo1 3 Uo1 nom Uto +Uho Uto 4 See "El. output data", for hold-up time. With output voltage monitoring the hold-up time t h = 0 The D signal remains high if the D output is connected to an external source. t low min = 40...200 ms, typically 80 ms t 0 Output voltage failure Fig. 20 Relationship between Ui, Uo1, UD, ID and Uo1/Uo nom versus time. Edition 2/96 - (c) Melcher AG MELCHER The Power Partners. 7 - 19 M-Family DC-DC Converters <100 W Option V ACFAIL signal (VME) Available for units with Uo1 = 5.1 V. This option defines an undervoltage monitoring circuit for the input or the input and main output voltage equivalent to option D and generates the ACFAIL signal (V signal) which conforms to the VME standard. The low state level of the ACFAIL signal is specified at a sink current of IV = 48 mA to UV 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 is provided by the internal input capacitance. Consequently the working input voltage and the threshold level U t i should be adequately above the minimum input voltage Ui min of the converter so that enough energy is remaining in the input capacitance. If the input voltage is below the required level, an external holdup capacitor (Ci ext) should be added. Formula for threshold level for desired value of t h : Rugged Environment Formula for additional external input capacitor 2 * Po * (t h + 0.3 ms) * 100 C i ext = --------------------- - C i min * (U ti 2 - Ui min2) where as: C i min = minimum internal input capacitance [mF], according to the table below C i ext = external input capacitance [mF] Po = output power [W] = efficiency [%] th = hold-up time [ms] U i min = minimum input voltage [V] U ti = threshold level [V] Remarks: The threshold level Ut i of option V2 and V3 is adjusted during manufacture to a value according to the table below. A decoupling diode should be connected in series with the input of A...D/FM converters to avoid the input capacitance discharging through other loads connected to the same source voltage. If LM or LMZ units are AC powered, an external input capacitor cannot be applied unless an additional rectifier is provided. 2 * Po * (t h + 0.3 ms) * 100 --------------------- + U i min2 C i min * U ti = Table 20: Available internal input capacitance and factory potentiometer setting of Ut i with resulting hold-up time AM BM FM CM/CMZ DM/DMZ EM LM/LMZ Unit Ci min 2.6 0.67 0.37 0.37 0.14 0.14 0.14 mF 7.1 Types Ut i 9.5 19.5 39 39 61 104 120 V DC th 0.34 0.69 2.92 1.92 1.73 6.69 8.18 ms Option V operates independently of the built-in input undervoltage lock-out circuit. A logic "low" signal is generated at pin 5 as soon as one of the monitored voltages drops below the preselected threshold level Ut. The return for this signal is Vo1- (pin 23). The V output recovers when the monitored voltage(s) exceed(s) Ut + Uh. The threshold level Ut is either adjustable by a potentiometer, accessible through a hole in the front cover, or is factory adjusted to a determined customer specified value. Versions V0, V2 and V3 are available as shown below. Table 21: Undervoltage monitor functions V output (VME compatible) Monitoring Typical hysteresis U h [% of Ut ] for U t min... Ut max U hi Uh o Minimum adjustment range of threshold level U t U ti U to Ui U o1 V2 yes no U i min...U i max 1 - 3.0...0.5 - V3 yes yes U i min...U i max 1 0.95...0.98 U o1 2 3.0...0.5 "0" V0 yes no U i min...U i max 3 4 - 2.2...0.4 - yes yes U i min...U i max 3 4 0.95...0.98 U o1 2 2.2...0.4 "0" 1 Threshold level adjustable by potentiometer (not recommended for mobile applications). 2 Fixed value between 95 % and 98% of Uo1 (tracking), output undervoltage monitoring is not a requirement of VME standard. 3 Adjusted at Io nom. 4 Fixed value, resistor-adjusted (2% at 25 C) acc. to customer's specifications; individual type number is determined by Melcher. V output (V0, V2, V3): Connector pin V is internally connected to the open collector of a NPN transistor. The emitter is connected to the negative potential of output 1. U V 0.6 V (logic low) corresponds to a monitored voltage level (U i and/or Uo1) < U t. The current I V through the open collector should not exceed 50 mA. The NPN output is not protected against external overvoltages. U V should not exceed 80 V. Ui , Uo1 status U i or U o1 < U t U i and U o1 > U t + U h 7 - 20 Vi+ 20 Vo1+ Rp IV 5 V UV V output, UV Vi- low, L, U V 0.6 V at I V = 50 mA high, H, I V 25 A at U V = 5.1 V 29 32 23 Vo1- Fig. 21 Output configuration of options V0, V2 and V3 MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Rugged Environment DC-DC Converters <100 W M-Family Threshold tolerances and hysteresis: UV If Ui is monitored, the internal input voltage is measured after the input filter and rectifier (E/LM and LMZ types). Consequently this voltage differs from the voltage at the connector pins by the voltage drop U t i across input filter and rectifier. The threshold level of option V0 is factory adjusted at Io nom and TA = 25 C. The value of U t i depends upon the input voltage range (AM, BM, ...), threshold level U ti , temperature and input current. The input current is a function of input voltage and output power. Uti Uhi Input voltage monitoring Ui Uti t low min 2 t low min 2 t low min 2 3 Po = Po nom U V low Fig. 22 Definition of Uti, Ut i and Uhi V2 UV UV high Po = 0 Po = 0 Po = Po nom U V high 3 3 4 4 t low min 2 t low min 2 UV low t 0 V3 UV UV high 3 3 3 UV low t 0 th 2.0 V 0 t Ui [V DC] Uti + Uhi Uti t 0 Input voltage failure Input voltage sag Switch-on cycle Switch-on cycle and subsequent input voltage failure Output voltage monitoring V2 UV UV high 4 UV low 4 0 V3 UV UV high t low min 2 3 3 4 UV low 0 Uo1 5.1 V 4.875 V 2.0 V 0 1 VME request: minimum 4 ms t low min = 40...200 ms, typically 80 ms 3 U level not defined at U V o1 < 2.0 V 4 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. 2 Ui Uti + Uhi Uti 0 Output voltage failure Fig. 23 Relationship between U i, Uo1, U V , I V and Uo1 / Uo nom versus time. Edition 2/96 - (c) Melcher AG MELCHER The Power Partners. 7 - 21 7.1 th 1 Uo1 5.1 V 4.875 V 1 M-Family DC-DC Converters <100 W Option F Fuse not accessible The standard M units have a fuseholder containing a 5 x 20 mm fuse which is externally accessible and to be found in the back plate near the connector. Some applications require an inaccessible fuse. Option F provides a fuse mounted directly onto the main PCB inside the case. The full self-protecting functions of the module do normally not lead to broken fuses, except as a result of inverse polarity at the input of an A/B/C/D/FM or C/DMZ type or if a power component inside fails (switching transistor, freewheeling diode, etc). In such cases the defective unit has to be returned to Melcher for repair. Rugged Environment Option U UL Version Underwriters Laboratories (UL) have approved the M series converters as recognized components up to an ambient temperature of TA max - 15 K given by the upper temperature limit of the standard PCB material. If the full maximum ambient temperature TA max is required with UL approval, option U should be requested. It consists of an alternative PCB material with a higher maximum temperature specification. The European approval boards have in contrast accepted the converters with the standard PCB material to be operated up to TA max without any further precautions. Immunity to Environmental Conditions Table 22: Mechanical stress Standard Test Conditions Ca Damp heat steady state DIN 40046 part IEC 68-2-3 MIL-STD-810D section 507.2 Temperature: Relative humidity: Duration: 40 2 C 93 +2/-3 % 56 days Unit not operating Ea Shock (half-sinusoidal) DIN 40046 part 7 IEC 68-2-27 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 Continuous shock (half-sinusoidal) DIN 40046 part 26 IEC 68-2-29 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) DIN 40046 part 8 IEC 68-2-6 MIL-STD-810D section 514.3 Frequency (1 Oct/min): Maximum vibration amplitude: Acceleration amplitude: Test duration: 10...2000 Hz 0.35 mm (10...60 Hz) 5 gn = 49 m/s 2 7.5 h (2.5 h each axis) Unit operating Fda Random vibration wide band reproducibility high DIN 40046 part 23 IEC 68-2-35 Acceleration spectral density: Frequency band: Acceleration magnitude: Test duration: 0.05 g2 /Hz 20...500 Hz 4.9 grms 3 h (1 h each axis) Unit not operating Kb Salt mist cyclic (sodium chloride NaCl solution) DIN 40046 part 105 IEC 68-2-52 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 7.1 Test Method 7 - 22 MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Rugged Environment DC-DC Converters <100 W M-Family Thermal considerations Table 23: Temperature specifications, values given are for an air pressure of 800...1200 hPa (800...1200 mbar) Characteristic min max Unit TA Standard operational ambient temperature range -7, (MIL-STD-810D sections 501.2 and 502.2) -25 71 C TA Extended operational ambient temperature range -9, (MIL-STD-810D sections 501.2 and 502.2) -40 71 TC Standard operational case temperature range -7, overtemp. lock-out (PTC) at TC > 95C -25 95 TC Extended operational case temperature range -9, overtemp. lock-out (PTC) at TC > 95C -40 95 TS Storage temperature range -7, (MIL-STD-810D sections 501.2 and 502.2) -40 100 TS Extended storage temperature range -9, (MIL-STD-810D sections 501.2 and 502.2) -55 100 In general: For an ambient temperature of 85 C with only convection cooling, the maximum permissible current for each output is approx. 50% of it's nominal value for -7 or -9 units as per figure. Io nom [%] 110 Io nom (forced cooling) 100 90 Io nom each output (convection cooling) 80 70 60 TC max 50 40 30 20 10 0 TA min 50 60 70 80 90 100 TA [C] Fig. 24 Output derating versus ambient temperature under convection and forced cooling conditions Table 24: MTBF Values at specified Case Temperature 1 2 Module Types Ground Benign 40C Ground Fixed 40C 70C Ground Mobile 50C Unit MTBF 1 A...LM 1000 and C/D/LMZ 1000 A...LM 2000 and C/D/LMZ 2000 A...LM 3000 and C/D/LMZ 3000 320'000 255'000 225'000 130'000 40'000 105'000 32'000 80'000 28'000 35'000 28'000 25'000 h Device hours 2 A...LM 1000 and C/D/LMZ 1000 A...LM 2000 and C/D/LMZ 2000 A...LM 3000 and C/D/LMZ 3000 880'000 720'000 740'000 Calculated in accordance with MIL-HDBK-217E (calculation according to edition F would show even better results) Statistical values, based on an average of 4300 working hours per year and in general field use, over 3 years Edition 2/96 - (c) Melcher AG MELCHER The Power Partners. 7 - 23 7.1 Basically the available output power is limited by thermal characteristics. Customer specific applications requiring slightly higher output power, i.e. increased voltages or currents, are available on request. Usually the maximum ambient and case temperatures are reduced compared with standard types. Operation at higher temperatures with nominal output currents is also possible if forced cooling can be provided (heat sink, fan, etc.). Example: Sufficient forced cooling allowsTA max = 85C. A simple check of the case temperature TC ( TC 95C) at full load ensures correct operation of the system (temperature measurement point on the case see "Mechanical Data"). M-Family DC-DC Converters <100 W Rugged Environment Mechanical Data European Projection 12.1 6TE 28.6 32 29 26 23 20 17 14 8 11 5 2 Dimensions in mm. Tolerances 0.3 mm unless otherwise indicated. 20.5 34 100 0.6 Male connector H 11 according to DIN 41 612 (Gold plated contacts on customer's request) 1.6 2TE 15 3.27 Mounting holes for retaining clips V Front plate 20 103 M 3; depth = 4 mm (chassis mount) 171.93 (DIN 41494) 127 159.4 22 Rear face Measurement point for case temperatureTC 68 168.5 0.5 Mounting plane of connector H11 (11.6) 4 88 111.2 0.8 o 4.0 o 3.5 31.5 0.1 22.30 17.25 12.17 7.09 38.7 Back plate 94.5 0.1 95 0.5 30.48 25.40 20.32 15.24 10.16 5.08 0 7.1 Main face 0 OK (LED green) Inhibit i (LED red) Potentiometer (option D) or potentiometer (option V) Fig. 25 Case M02, weight 770 g (approx.) 7 - 24 IoL (LED red) Test sockets (option A) Potentiometer(s) (option P) Note: Long case, elongated by 60 mm for 220 mm rack depth, is available on request. MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Rugged Environment DC-DC Converters <100 W M-Family Type Key and Product Marking Type Key C M Z 2 5 40 -7 E R P D V A H F U 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 85...264 V AC, 88...372 V DC ............... A ............... B ............... F .............. C .............. D ............... E 1 .............. L Family .............. M Class II Equipment ............... Z Blank ................. Number of outputs .......... 1...3 Output 1, Uo1 nom: 5.1 V 12 V 15 V 24 V other voltages 48 V .......... 0...2 ............... 3 .......... 4...5 ............... 6 .......... 7...8 ............... 9 other specs for single output modules Output 2 and 3, Uo2 nom, Uo3 nom: 5.1 V 12 V 15 V 24 V other voltages for multiple output modules ...... 01...99 ...... 01...19 ...... 20...39 ...... 40...59 ...... 60...69 ...... 70...99 7.1 Ambient temperature range TA: -25...71C .............. -7 (operational) -40...71C .............. -9 customer specific ........ -0...-6 Output voltage control input (single output modules only) R 2 Options: Inrush current limitation (C/E/LM and C/LMZ only) ......... E Potentiometers for fine adjustment of output voltages ..... P 2 Save data signal (D0...D9, to be specified) ..................... D 3 ACFAIL signal (V0, V2, V3, to be specified) .................... V 3 Output voltage test sockets .............................................. A Increased electric strength test voltage (O/C) ................. H Input fuse built-in (not accessible) ................................... F UL recognized component for TA max ............................... U 1 EM types upon custom specifications available Feature R excludes option P and vice versa 3 Option D excludes option V and vice versa 2 Example: CM 2540-7PD3A: DC-DC converter, input voltage range 28...140 V, providing output 1 with 15 V/1.7 A and output 2 with 15 V/1.7 A; equipped with potentiometers, undervoltage monitor and test sockets. Accessories: Front panels, female connectors, mounting facilities, etc. please refer to section "Accessories". Product Marking (refer also to "Mechanical Data") Main face: Basic type designation, applicable safety approval and recognition marks, warnings, pin allocation, Melcher patents and company logo. Front plate: Back plate: Identification of LEDs, optional test sockets and potentiometers. Specific type designation, input voltage range, nominal output voltage(s) and current(s), pin allocation of options and auxiliary functions, fuse specification and degree of protection. Rear face: Label with batch no., serial no. and data code comprising production site, modification status of the main PCB, date of production. Confirmation of successfully passed final test. Edition 2/96 - (c) Melcher AG MELCHER The Power Partners. 7 - 25