K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Features * RoHS lead-free-solder and lead-solder-exempted products available. * 5 year warranty for RoHS compliant products with an extended temperature range * Compliant with EN 50155, EN 50121-3-2 * Fire & smoke according to EN 45545 and NF-F-16 (vers. V108 or later; not models with H15-S4 connector) * Class I equipment * Extremly wide input voltage ranges from 8 to 385 VDC, and 85 to 264 VAC, 47 to 440 Hz * Input over- and undervoltage lockout * Adjustable output voltage with remote on/off * 1 or 2 outputs: SELV, no load, overload, and shortcircuit proof * Rectangular current limiting characteristic * PCBs protected by lacquer * Very high reliability Safety-approved to the latest edition of IEC/EN 60950-1 and UL/CSA 60950-1 111 4.4" 3U 80 3.2" 16 TE 168 6.6" Description The K Series of DC-DC and AC-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. LK models can be powered by DC or AC with a wide-input frequency range (without PFC). The converter inputs are protected against surges and transients. An input over- and undervoltage lockout circuitry disables the outputs, if the input voltage is outside of the specified range. Certain types include an inrush current limiter preventing circuit breakers and fuses from tripping at switchon. All outputs are open- and short-circuit proof, and are protected against overvoltages by means of built-in suppressor diodes. The output can be inhibited by a logic signal applied to pin 18 (i). 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 for visual monitoring of the system at any time. Table of Contents Full input-to-output, input-to-case, output-to-case, and output to output isolation is provided. The converters are designed, built, and safety-approved to the international safety standards IEC/EN 60950-1. They are particulary suitable for railway applications and comply with EN 50155 and EN 50121-3-2. The case design allows operation at nominal load up to 71 C with natural cooling. If forced cooling is provided, the ambient temperature may exceed 71 C, but the case temperature must remain below 95 C. A temperature sensor generates an inhibit signal, which disables the outputs when the case temperature TC exceeds the limit. The outputs are automatically re-enabled, when the temperature drops below the limit. Various options are available to adapt the converters to individual applications. The converters may either be plugged into a 19 " DIN-rack system according to IEC 60297-3, or be chassis mounted. Important: For applications requiring compliance with IEC/EN 61000-3-2 (harmonic distortion), please use our LK4000 or LK5000 Series with incorporated power factor correction (PFC). Page Description .......................................................................... 1 Model Selection .................................................................. 2 Functional Description ........................................................ 4 Electrical Input Data ............................................................ 5 Electrical Output Data ......................................................... 8 Auxiliary Functions ............................................................ 12 Page Electromagnetic Compatibility (EMC) ............................... Immunity to Environmental Conditions ............................. Mechanical Data ............................................................... Safety and Installation Instructions ................................... Description of Options ...................................................... Accessories ....................................................................... 15 17 18 20 23 30 Copyright (c) 2018, Bel Power Solutions Inc. All rights reserved. BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. Page 1 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Model Selection Non-standard input/output configurations or special customer adaptations are available on request. Table 1a: Models AK Output 1 Vo nom Io nom [VDC] [A] Output 2 Vo nom Io nom [VDC] [A] Efficiency 1 min [%] Input Voltage Vi min - Vi max 8 - 35 VDC Options 5.1 12 15 24 20 10 8 5 - - - - - - - - AK1001-9RG AK1301-9RG AK1501-9RG AK1601-9RG 79 81 83 84.5 -74, P, D, V 2, T, B, B1, non-G 12 15 24 5 4 2.5 12 3 15 3 24 3 5 4 2.5 AK2320-9RG AK2540-9RG AK2660-9RG 79 80.5 80.5 -74, P, D, T, B, B1, non-G Table 1b: Models BK, FK, CK Output 1 Vo nom Io nom [VDC] [A] Output 2 Vo nom Io nom [VDC] [A] Input Voltage Vi min - Vi max 14 - 70 VDC Effic.1 Input Voltage min Vi min - Vi max [%] 20 - 100 VDC Effic.1 min [%] Input Voltage Vi min - Vi max 28 - 140 VDC Effic.1 min [%] Options 5.1 12 15 24 25 12 10 6 - - - - - - - - BK1001-9RG BK1301-9RG BK1501-9RG BK1601-9RG 80.5 83 84 85 FK1001-9RG FK1301-9RG FK1501-9RG FK1601-9RG 80 82 85 86 CK1001-9ERG CK1301-9ERG CK1501-9ERG CK1601-9ERG 80 82 85 86 -74, P, D, V 2, T, B, B1, non-G 12 15 24 6 5 3 12 3 15 3 24 3 6 5 3 BK2320-9RG BK2540-9RG BK2660-9RG 80 82 82 FK2320-9RG FK2540-9RG FK2660-9RG 81 83 84 CK2320-9ERG CK2540-9ERG CK2660-9ERG 81 84 84 -74, P, D, T, B, B1, non-G Table 1c: Models DK, EK, LK Output 1 Vo nom Io nom [VDC] [A] 5.1 12 12.84 5 15 24 25 12 10 10 6 12 15 24 25.68 6 6 5 3 2.5 1 2 3 4 5 6 7 Output 2 Vo nom Io nom [VDC] [A] - - - - - 12 3 15 3 24 3 25.68 3 6 Input Voltage Vi min - Vi max 44 - 220 VDC Effic.1 Input Voltage min Vi min - Vi max [%] 67 - 385 VDC Effic.1 min [%] Input Voltage Effic.1 min Vi min - Vi max 88 - 372 VDC [%] 100 - 240 VAC Options - - - - - DK1001-9ERG DK1301-9ERG DK1740-9ERG 5 DK1501-9ERG DK1601-9ERG 80 83 83 85 86 --EK1301-9ERG --EK1501-9ERG EK1601-9ERG -83 -84 86 LK1001-9ERG LK1301-9ERG LK1740-9ERG 5 LK1501-9ERG LK1601-9ERG 79 83 83 84 85 -74, P, D, V 2, T, K7, B, B1, non-G 6 5 3 2.5 DK2320-9ERG DK2540-9ERG DK2660-9ERG DK2740-9ERG 6 81 83 84 84 EK2320-9ERG EK2540-9ERG EK2660-9ERG --- 82 83 84 -- LK2320-9ERG LK2540-9ERG LK2660-9ERG LK2740-9ERG 6 81 83 82 83 -74, P, D, T B, B1, non-G Min. efficiency at Vi nom, Io nom and TA = 25 C. Typical values are approximately 2% better. Option V for models with 5.1 V outputs; excludes option D Second output semi-regulated AK, BK, FK models are available as -7 or -9, but without opt. E. The other models CK, DK, EK, LK are available as -7 or -9E (but not -7E). Battery loader for 12 V batteries. Vo is controlled by the battery temperature sensor (see Accessories) within 12.62 - 14.12 V. Options P and D are not available. Battery loader for 24 V (and 48 V batteries with series-connected outputs). Vo is controlled by the battery temperature sensor (see Accessories) within 25.25 - 28.25 V (50.5 - 56.5 V for 48 V batteries). Options P and D are not available. Option K is available only for LK with 5.1 V output in order to avoid the H15S4 connector. Efficiency is approx. 1.5% worse. NFND: Not for new designs BCD20002-G Rev AF1, 17-Apr-2018 Preferred for new designs MELCHER The Power Partners. Page 2 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Part Number Description Operating input voltage Vi: 8 - 35 VDC ................................................................ AK 14 - 70 VDC .............................................................. BK 20 - 100 VDC ............................................................ FK 28 - 140 VDC ........................................................... CK 44 - 220 VDC .......................................................... DK 67 - 385 VDC ........................................................... EK 100 - 240 VAC (rated voltage) or 88 - 372 VDC ...... LK CK 2 5 40 -9 E R D3 T B1 G Number of outputs .......................................................... 1, 2 Nominal voltage of output 1 (main output) Vo1 nom 5.1 V ............................................................................ 0 12 V ............................................................................ 3 15 V ............................................................................ 5 24 V ............................................................................ 6 Other voltages 1 ....................................................... 7, 8 Nominal voltage of output 2 Vo2 nom None (single-output models) ..................................... 12 V, 12 V .................................................................. 15 V, 15 V .................................................................. 24 V, 24 V .................................................................. Other specifications or additional features 1 ...... 21 - 01 20 40 60 99 Operational ambient temperature range TA: -25 to 71 C ............................................................... -7 - 40 to 71 C ............................................................... -9 Other 1 ............................................................... -0, -5, -6 Auxiliary functions and options: Inrush current limitation ............................................. E 2 Output voltage control input ....................................... R 3 Potentiometer (output voltage adjustment) ................ P 3 Vi / Vo monitor (D0 - DD, to be specified 1) ................ D 4 ACFAIL signal ........................................................... V 4 Current share control ................................................... T H15 standard connector for 5.1 V output models ...... K 5 Cooling plate standard case .............................. B or B1 Cooling plate for long case 220 mm 1 ...................... B2 1 RoHS-compliant for all 6 substances 6 .................................. G 1 2 3 4 5 Customer-specific models Option E is mandatory for all -9 models, except AK, BK, FK. Feature R excludes option P and vice versa. Option P is not available for battery charger models. Option D excludes option V and vice versa; option V is available for single-output models with 5.1 V only. Option K is available for single-output models with 5.1 V output to avoid the expensive H15-S4 connector. Note: The sequence of options must follow the order above. This part number description is descriptive only; it is not intended for creating part numbers. Example: CK2540-9ERD3T B1G: DC-DC converter, operating input voltage range 28 - 140 VDC, 2 electrically isolated outputs, each providing 15 V, 5 A, input current limiter E, control input R to adjust the output voltages, undervoltage monitor D3, current share feature T, cooling plate B1, and RoHS-compliant for all six substances. Product Marking Basic type designation, applicable approval marks, CE mark, warnings, pin designation, patents and company logo, identification of LEDs, test sockets, and potentiometer. BCD20002-G Rev AF1, 17-Apr-2018 Specific type designation, input voltage range, nominal output voltages and currents, degree of protection, batch no., serial no., and data code including production site, modification status (version), and date of production. MELCHER The Power Partners. Page 3 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Functional Description The input voltage is fed via an input fuse, an input filter, a bridge rectifier (LK models only), and an inrush current limiter to the input capacitor. This capacitor sources a single-transistor forward converter with a special clamping circuit and provides also the power during the hold-up time. Each output is powered by a separate secondary winding of the main transformer. The resultant voltages are rectified and their ripple smoothed by a power choke and an output filter. The control logic senses the main output voltage Vo1 and generates, with respect to the maximum admissible output currents, the control signal for the switching transistor of the forward converter. The second output of double-output models is tracking the main output, but has its own current limiting circuit. If the main output voltage drops due to current limitation, the second output voltage will fall as well and vice versa. Standard models with a single 5.1 V output have a synchronous rectifier to provide good efficiency. 03057b 26 Vi+ 28 18 i 20 D/V 4 Ci + 4 CY 22 T 12 S+ 4 Vo- 10 30 Vi- 32 14 S- CY Fig. 1 Block diagram of single-output converters 2 3 4 8 CY 3 24 1 Vo+ 6 Output filter Forward converter (approx. 120 kHz) Fuse 1 Bridge rectifier 4 Input filter 2 L 16 R CY Control circuit 4 N Opt. P - + Transient suppressor (VDR) Suppressor diode (AK, BK, FK models) Inrush current limiter (NTC, only for models with TA min = -25 C ) or option E (for CK, DK, EK, LK models only) LK models only 03058b Opt. P Vi+ 28 18 i 4 20 D 4 Vi- Forward converter (approx. 120 kHz) 22 T CY CY 12 Vo1+ 14 Vo1- CY 4 3 6 Output 2 filter L Ci + Bridge rectifier 4 Fuse 1 Input filter 2 Output 1 filter 4 16 R CY Control circuit N 26 30 32 CY 8 CY 10 24 Fig. 2 Block diagram of double-output models 1 2 3 4 Vo2+ - Vo2- + Transient suppressor (VDR) Suppressor diode (AK, BK, FK models) Inrush current limiter (NTC, only for models with TA min = -25 C ) or option E (for CK, DK, EK, LK models only) LK models only BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. Page 4 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Electrical Input Data General Conditions - TA = 25C, unless TC is specified. - Pin 18 connected to pin 14, Vo adjusted to Vo nom (if option P); R input not connected. - Sense line pins S+ and S- connected to Vo+ and Vo- respectively. Table 2a: Input data Input AK Characteristics Conditions min typ min 35 14 Vi Operating input voltage V i nom Nominal input voltage Io = 0 - Io nom TC min -TC max Ii Input current Vi nom, Io nom 1 Pi 0 No-load input power Vi min - Vi max 2.5 P i inh Idle input power unit inhibited 1.5 TC = 25 C Ri Input resistance R NTC NTC resistance 2 Ci Input capacitance V i RFI Conducted input RFI 15 9.0 832 min 70 20 300 VDC 2.5 2.5 W 1.5 1.5 3.75 A 70 m no NTC 370 1200 1500 A A F B A 40 Unit max 100 no NTC 1040 0 typ 50 100 A Input voltage limits without damage max 6.0 65 EN 55022 V i nom, I o nom FK typ 30 no NTC Radiated input RFI V i abs 8 BK max A 0 84 0 100 VDC Table 2b: Input data Input CK Characteristics Vi Conditions Operating input voltage Io = 0 - Io nom TC min - TC max min typ 28 DK max min 140 44 EK typ max min 220 67 typ LK max 385 min Unit typ max 88 372 VDC 85 4 (230) 264 4 VAC 4 V i nom Nominal input voltage Ii Input current Vi nom, Io nom 1 Pi 0 No-load input power Vi min - Vi max 2.5 2.5 2.5 2.5 P i inh Idle input power unit inhibited 1.5 1.5 1.5 4.5 Ri Input resistance TC = 25 C R NTC NTC resistance 2 Ci Input capacitance V i RFI Conducted input RFI Radiated input RFI V i abs 1 2 3 4 60 110 220 310 3.0 1.6 0.8 0.57 150 170 1000 960 EN 55022 V i nom, I o nom Input voltage limits without damage 0 180 2000 1200 264 216 m 270 216 270 B B B B A A A 0 400 3 0 W 4000 A 154 A 480 4000 330 VDC 400 -400 F 400 VDC Both outputs of double-output models are loaded with Io nom. Valid for -7 versions without option E (-9 versions exclude NTC). This is the nominal value at 25 C and applies to cold converters at initial switch-on cycle. Subsequent switch-on/off cycles increase the inrush current peak value. For 1 s max. Rated input voltage range is 100 - 240 VAC (nominal 230 VAC). Nominal frequency range is 50 - 60 Hz; operating frequency range is 47 - 440 Hz (440 Hz for 115 V mains). For frequencies 63 Hz, refer to Installation Instructions. BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. Page 5 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Input Transient Protection Inrush Current Limitation 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. The CK, DK, EK, and LK models 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, such protecting 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 Option E. Standard nominal battery voltages are: 12, 24, 36, 48, 60, 72, 110, and 220 V. Railway batteries are specified with a tolerance of -30% to +25%, with short excursions up to 40%. In certain applications, additional surges according to RIA 12 are specified. The power supply must not switch off during these surges, and since their energy can practically not be absorbed, an extremely wide input range is required. The EK input range for 110 V batteries has been designed and tested to meet this requirement. Input Fuse 05109a Rs ext + A fuse mounted inside the converter protects against severe defects. This fuse may not fully protect the converter, when the input voltage exceeds 200 VDC. In applications, where the converters operate at source voltages above 200 VDC, an external fuse or a circuit breaker at system level should be installed. Table 3: Fuse Specification Fuse type Reference AK BK FK CK DK EK, LK fast-blow 1 fast-blow 1 slow-blow 2 slow-blow 2 slow-blow 2 slow-blow 2 Littlefuse 314 Littlefuse 314 Schurter SPT Schurter SPT Schurter SPT Schurter SPT Fuse size 6.3 x 32 mm Iinr p RNTC Ri Ci int Vi source Fig. 4 Equivalent input ciruit Static Input Current Characteristic Model 1 The inrush current peak value (initial switch-on cycle) can be determined by following calculation; see also fig. 3: Vi source Iinr p = ---------------- (Rs ext + Ri + RNTC) 2 Rating 30 A, 125 V 25 A, 125 V 16 A, 250 V 12.5 A, 250 V 8 A, 250 V 4 A, 250 V Ii [A] 20 04044a 10 Fuse size 5 x 20 mm 5 Ii inr [A] AK 05108a 150 BK 2 FK CK 1 100 DK CK EK, LK DK 0.5 1 50 EK LK (DC input) 2 3 4 5 Vi ____ Vi min Fig. 5 Typical input current versus relative input voltage Reverse Polarity 0 0.1 1 2 3 t [ms] Fig. 3 Typical inrush current versus time at Vi max, Rext = 0 . For AK, BK, FK, and for application-related values, use the formula in this section to get realistic results. BCD20002-G Rev AF1, 17-Apr-2018 The converters (except LK models) are not protected against reverse polarity at the input to avoid unwanted power losses. In general, only the input fuse will trip. LK models are fully protected by the built-in bridge rectifier. MELCHER The Power Partners. Page 6 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Input Under-/Overvoltage Lockout If the input voltage remains below approx. 0.8 Vi min or exceeds approx. 1.1 Vi max, an internally generated inhibit signal disables the output(s). When checking this function, the absolute maximum input voltage V i abs should be observed. Between Vi min and the undervoltage lock-out level the output voltage may be below the value defined in table Electrical Output data. Hold-Up Time th [ms] 04045a EK 100 CK/FK DK 10 AK BK 1 0.1 1 2 3 4 5 6 Vi ____ Vi min Fig. 6a Typical hold-up time t h versus relative DC input voltage. Vi/Vi min. DC-DC converters require an external series diode in the input path, if other loads are connected to the same input supply lines. th [ms] 04049a 100 10 V i _______ 2 1 2 3 4 Vi min Fig. 6b Typical hold-up time t h versus relative AC input voltage (LK models) BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. Page 7 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Electrical Output Data General Conditions: - TA = 25 C, unless TC is specified. - Pin 18 (i) connected to pin 14 (S- or Vo1-), R input not connected, Vo adjusted to Vo nom (option P), - Sense line pins 12 (S+) and 14 (S-) connected to pins 4 (Vo1+) and 8 (Vo1-), respectively. Table 5: Output data of single-output models Model Nom. output voltage AK - LK1001 5.1 V Characteristics Vo Conditions Output voltage min Vi nom, Io nom Vo BR Overvoltage protection (suppressor diode) 7 Io nom Output current nom. 1 Vi min - Vi max TC min - TC max IoL Output current limit Vi min - Vi max vo Output noise 3 typ 5.07 max min 5.13 11.93 5 Switching frequ. typ 206/25 min 12.07 5 14.91 5 Total incl. spikes max AK - LK1601 24 V min typ 15.09 23.86 Unit max 24.14 V 28.5 86/10 10.25 6/12.2 Vi nom, I o nom BW = 20 MHz typ 19.6 105 6/12 216/26 AK - LK1501 15 V max 15.2/17.55 6.0 Low frequency 8 AK - LK1301 / 1740 5 12 V / 12.84 V 5 56/6 8.2 6/10.2 5 A 5.2 6/6.2 5 10 5 5 5 80 50 70 100 5 mVpp mV Vo u Static line regulation with respect to Vi nom Vi min - Vi max Io nom 15 20 25 30 Vo I Static load regulation 2 Vi nom (0.1 - 1) Io nom -20 2 -30 -40 - 50 vo d Dynamic Voltage Vi nom load deviation 9 Io nom 1/2 Io nom regulat.9 9 Recovery time 150 130 130 150 0.3 0.4 0.4 0.3 ms Temperature coefficient of output voltage 4 0.02 0.02 0.02 0.02 %/K td Vo 1 2 3 4 5 6 7 8 9 TC min - TCmax Io nom If the output voltages are increased above Vo nom through 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 fig. 7 below ! Measured according to IEC/EN 61204 with a probe according to annex A For battery charger applications, a defined negative temperature coefficient can be provided by using a temperature sensor (see Accessories), but we recommend choosing the special battery charger models. Especially designed for battery charging using the temperature sensor (see Accessories). Vo is set to 12.84 V 1% (R-input open) Values for AK models Breakdown voltage of the incorporated suppressor diode (1 mA; 10 mA for 5 V output). Exceeding Vo BR is dangerous for the suppressor diode. LK models only (twice the input frequency) See Dynamic load regulation VoR Vo [V] Models with diodes 5.1 Models with synchr. rectifier 0.15 JM049 1.0 Io/Io nom Fig. 7 Output voltage regulation for models with synchronous rectifier and with diode rectifier BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. Page 8 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Table 6a: Output data of double-output models. General conditions as per table 5. Model Nom. output voltage AK - LK2320 2 x 12 V Output 1 Vo Vi nom, Io1 nom, Io2 nom 11.93 12.07 11.82 12.18 14.91 15.2 15.2 19.6 Vo BR Overvoltage protection (suppressor diode) Io nom Output current nom. 2 Vi min - Vi max TC min - TC max IoL Output current limit 10 Vi min - Vi max vo Output noise 3 Low frequency9 min 5 1/6 typ max 15.09 14.78 5 50 50 -40 5 vo d Dynamic Voltage load deviation 4 regulat. Recovery time 4 Vi nom, Io1 nom 1/2 Io1 nom Temperature coefficient of output voltage 6 TC min - TC max Io nom 100 150 100 23.86 7 Vo BR 8 nom.2 %/K 1 2 typ Unit Output 2 max min typ 24.14 7 23.64 7 max 24.36 7 V Output current IoL Output current limit 10 Vi min - Vi max vo Output Low frequency9 noise 3 Switching freq. Vi nom, I o nom Vi min - Vi max TC min - TC max BW = 20 MHz Total incl. spikes 2.51 7/3 2.51 7/3 A 2.71 7/3.2 5 5 5 5 80 80 mVpp Static line regulation with respect to Vi nom Vi min - Vi max Io nom 30 5 Vo I Static load regulation Vi nom (0.1 - 1) Io nom -60 5 vo d Dynamic Voltage Vi nom Io1 nom 1/2 Io1 nom load deviation 4 1 regulat. 4 /2 Io2 nom Recovery time 100 0.2 ms Temperature coefficient TC min - TC max of output voltage 6 Io nom 0.02 %/K BCD20002-G Rev AF1, 17-Apr-2018 5 6 2.71 7/3.2 Vo u v o 3 28.5/347 4 Io nom td 150 0.02 28.5/347 Overvoltage protection (suppressor diode) 5 0.02 Output 1 min -50 mV ms AK - LK2660 / 2740 7 2 x 24 V / 2 x 25.68 V 7 Conditions 5 0.2 Model Nom. output voltage Vi nom, Io1 nom, Io2 nom 25 mVpp 0.2 Table 6b: Output data of double-output models. General conditions as per table 5. Output voltage A 5 40 Vi nom (0.1 - 1) Io nom V 4.2 1/5.2 40 Static load regulation Vo 4 1/5 5 Vo I Characteristics 15.22 5 20 max 19.6 5 Vi min - Vi max I o nom Vo typ 5 Static line regulation with respect to Vi nom /2 Io2 nom min 5 Vo u 1 Unit Output 2 max 4.2 1/5.2 5 td typ 41/5 5.2 1/6.2 5 Total incl. spikes min 5 1/6 5.2 1/6.2 Vi nom, Io nom BW = 20 MHz Switching freq. max Output 1 Conditions Output voltage typ Output 2 Characteristics 8 min AK - LK2540 2 x 15 V mV 150 7 8 9 MELCHER The Power Partners. Values for AK models If the output voltages are increased above Vo nom via Rinput control, option P setting, remote sensing, or option T, the output currents should be reduced accordingly, so that Po nom is not exceeded. Measured according to IEC/EN 61204 with a probe annex A See Dynamic Load Regulation See Output Voltage Regulation of Double-Output Models For battery charger applications, a defined negative temperature coefficient can be provided by using a temperature sensor; see Accessories. Especially designed for battery charging using the battery temperature sensor; see Accessories. Vo1 is set to 25.68 V 1% (Rinput open-circuit). Breakdown voltage of the incorporated suppressor diodes (1 m A). Exceeding Vo BR is dangerous for the suppressor diodes. LK models only (twice the input frequency) Page 9 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Thermal Considerations 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 upon 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. Caution: The installer must ensure that under all operating conditions TC remains within the limits stated in the table Temperature specifications. Notes: Sufficient forced cooling or an additional heat sink allows TA to be higher than 71 C (e.g., 85 C), as long as TC max is not exceeded. Details are specified in fig. 8. applied overvoltages. Overload at any of the outputs will cause a shut-down of all outputs. A red LED indicates the overload condition. Note: Vo BR is specified in Electrical Output Data. If this voltage is exceeded, the suppressor diode generates losses and may become a short circuit. Parallel and Series Connection Single- or double-output models with equal output voltage can be connected in parallel using option T (current sharing). If the T pins are interconnected, all converters share the output current equally. Single-output models and/or main and second outputs of double-output models can be connected in series with any other (similar) output. Notes: - Parallel connection of double-output models should always include both, main and second output to maintain good regulation. - Not more than 5 converters should be connected in parallel. - Series connection of second outputs without involving their main outputs should be avoided, as regulation may be poor. 1.0 - The maximum output current is limited by the output with the lowest current limitation when several outputs are connected in series. 05089a Io /Io nom 0.8 Forced cooling Convection cooling 0.6 TC max Vo/Vo nom 0.4 0.98 0.2 0 TA min 50 60 70 80 90 100 TA [C] 0.5 Io1 IoL Fig. 8 Output current derating versus temperature for -7 and -9 models. Thermal Protection 05098a 0 A temperature sensor generates an internal inhibit signal, which disables the outputs, when the case temperature exceeds TC max. The outputs automatically recover, when the temperature drops below this limit. Continuous operation under simultaneous extreme worst-case conditions of the following three parameters should be avoided: Minimum input voltage, maximum output power, and maximum temperature. 0.5 1.0 Io/Io nom Fig. 9 Output characteristic Vo versus Io (single-output models or double-output models with parallel-connected outputs). 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 BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. Page 10 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Vo Vo2 [V] Vod Vo 1 % Vo 1 % 05106a 15.75 Vod Io1 = 5.0 A Io1 = 3.75 A Io1 = 2.5 A Io1 = 1.25 A Io1 = 0.5 A 15.5 td td 15.25 t Io /Io nom 15.0 1 14.75 0.5 10 s 10 s 0 05102c 14.5 t Fig. 10 Typical dynamic load regulation of Vo. 14.25 14.0 0 1 2 3 4 5 6 Output Voltage Regulation figure 10 applies to single-output or double-output models with parallel-connected outputs. For independent configuration, output 1 is under normal conditions regulated to Vo nom, irrespective of the output currents. Vo2 depends upon the load distribution. If both outputs are loaded with more than 10% of Io nom, the deviation of Vo2 remains within 5% of Vo1. Fig. 11 to 13 show the regulation depending on load distribution. Two outputs of a double-output model connected in parallel behave like the output of a single-output model. Note: If output 2 is not used, connect it in parallel with output 1! This ensures good regulation and efficiency. Io2 [A] Fig. 12 Models with 2 outputs 15 V: Vo2 versus Io2 with various Io1 (typ) Vo2 [V] 05107a 26 Io1 = 3 A Io1 = 2 A Io1 = 1 A Io1 = 0.5 A Io1 = 0.3 A 25.5 25 24.5 24 23.5 Vo2 [V] 05105a 12.6 23 Io1 = 6.0 A Io1 = 4.5 A Io1 = 3.0 A Io1 = 1.5 A Io1 = 0.6 A 12.4 12.2 0 0.5 1 1.5 2 2.5 3 3.5 Io2 [A] Fig. 13 Models with 2 outputs 24 V: Vo2 versus Io2 with various Io1 (typ) 12.0 11.8 11.6 11.4 11.2 0 1 2 3 4 5 6 7 Io2 [A] Fig. 11 Models with 2 outputs 12 V: Vo2 versus Io2 with various Io1 (typ) BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. Page 11 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Sense Lines (Single-Output Models) Auxiliary Functions Inhibit for Remote On/Off The outputs may be enabled or disabled by means of a logic signal (TTL, CMOS, etc.) applied between the inhibit input i (pin 18) and pin 14 (S- or Vo1-). In systems with several converters, this feature can be used to control the activation sequence of the converters. If the inhibit function is not required, connect the inhibit pin 18 with pin 14! Note: If pin 18 is not connected, the output is disabled. 06031a Vo+ Vi+ Iinh i 18 S-/Vo1- 14 Fig. 14 Definition of Vinh and Iinh. Table 7: Inhibit characteristics Characteristic Conditions min max Unit Vinh - 50 0.8 V 2.4 50 Inhibit Vo = on voltage Vo = off Vi min - Vi max I inh Inhibit current Vinh = 0 tr Rise time tf Fall time Iinh [mA] typ To ensure correct operation, both sense lines (S+, S-) should be connected to their respective power outputs (Vo+ and Vo-), and the voltage difference between any sense line and its respective power output (as measured on the connector) should not exceed the following values: 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, 24 V <1.0 V <0.25 V Programmable Output Voltage (R-Function) depending on Io As a standard feature, the converters offer an adjustable output voltage, identified by letter R in the type designation. The control input R (pin 16) accepts either a control voltage Vext or a resistor Rext to adjust the desired output voltage. When input R is not connected, the output voltage is set to Vo nom. Vinh = 2.4 V a) Adjustment by means of an external control voltage Vext between pin 16 (R) and pin 14 (S-): - 400 30 Vinh = 0.8 V This feature allows for compensation of voltage drops across the connector contacts and if necessary, across the load lines. We recommend connecting the sense lines directly at the female connector. Table 7: Maximum voltage compensation allowed using sense lines Vinh Vi- Important: Sense lines must always be connected! Incorrectly connected sense lines may activate the overvoltage protection resulting in a permanent short-circuit of the output. A ms 2.0 06032a The control voltage range is 0 - 2.75 VDC and allows for an adjustment in the range of approximately 0 - 110% of Vo nom. Vo Vext ------ * 2.5 V Vo nom 1.6 1.2 0.8 Vo = on 0.4 05074a Vo = off Vi+ 0 16 -0.4 14 -0.8 -40 -20 0 20 40 Vinh [V] + S-/Vo1- - Vext Vi- Fig. 15 Typical inhibit current I inh versus inhibit voltage Vinh 06001 Vo /Vo nom 1 0.1 0 R Vi+ 12 t tr tf 16 14 Inhibit 1 0 Fig. 16 Output response as a function of inhibit control BCD20002-G Rev AF1, 17-Apr-2018 S+/Vo1+ R'ext R S-/Vo1- Rext Vi- t Fig. 17 Output voltage control for single-output models MELCHER The Power Partners. Page 12 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters 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 16 and pin 14 to achieve an output voltage adjustment range of approximately 0 - 100% of Vo nom. or: Between pin 16 and pin 12 to achieve an output voltage adjustment range of 100 - 110% of Vo nom. Warnings: Vo2+ 4 Vo2+ 6 Vo2- 8 Vo2- 10 Vo1+ 12 Vo1- 14 R 16 - Vext shall never exceed 2.75 VDC. - The value of R'ext shall never be less than the lowest value as indicated in table R'ext (for V0 > V0 nom) to avoid damage to the converter! - The R-Function excludes option P (output voltage adjustment by potentiometer). If the output voltages are increased above Vo nom via R-input control, option P setting, remote sensing, or option T, the output currents should be reduced, so that Po nom is not exceeded. - In case of parallel connection the output voltages should be individually set within a tolerance of 1 - 2%. + 24 V Vo1 30 V 48 V Co - R'ext Rext Fig. 18 Double-output models: Wiring of the R-input for output voltages 24 V, 30 V, or 48 V with both outputs in series. A ceramic capacitor (Co ) across the load reduces ripple and spikes. Notes: - With double-output models, the second output follows the voltage of the controlled main output. 06004a The positive test socket is protected by a series resistor (see: Functional Description, block diagrams). The voltage measured at the test sockets is slightly lower than the value at the output terminals. Test Sockets Test sockets (pin diameter 2 mm) for measuring the main output voltage Vo or Vo1 are located at the front of the converter. Table 8a: Rext for Vo < Vo nom; approximate values (Vi nom, Io nom, series E 96 resistors); R'ext = not fitted Vo nom = 5.1 V Vo [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 Vo nom = 12 V 2 3 4 5 6 7 8 9 10 11 Vo nom = 15 V ] Rext [k Vo [V] 1 4 6 8 10 12 14 16 18 20 22 0.806 1.33 2 2.87 4.02 5.62 8.06 12.1 20 42.2 Vo nom = 24 V ] Rext [k Vo [V] 1 2 4 6 8 9 10 11 12 13 14 4 8 12 16 18 20 22 24 26 28 0.619 1.47 2.67 4.53 6.04 8.06 11 16.2 26.1 56.2 ] Rext [k Vo [V] 1 4 6 8 10 12 14 16 18 20 22 8 12 16 20 24 28 32 36 40 44 0.81 1.33 2.0 2.87 4.02 5.62 8.06 12.1 20 44.2 Table 8b: R'ext for Vo > Vo nom; approximate values (Vi nom, Io nom, series E 96 resistors); Rext = not fitted Vo nom = 5.1 V 1 Vo [V] ] R'ext [k 5.15 5.2 5.25 5.3 5.35 5.4 5.45 5.5 432 215 147 110 88.7 75 64.9 57.6 Vo nom = 12 V Vo 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 13.0 13.2 Vo nom = 15 V ] R'ext [k [V] 1 24.2 24.4 24.6 24.8 25.0 25.2 25.4 25.6 26.0 26.4 1820 931 619 475 383 316 274 243 196 169 Vo [V] 15.2 15.4 15.6 15.8 16.0 16.2 16.4 16.5 1 30.4 30.8 31.2 31.6 32.0 32.4 32.8 33.0 Vo nom = 24 V ] R'ext [k 1500 768 523 392 316 267 232 221 Vo [V] 1 24.25 24.5 24.75 25.0 25.25 25.5 25.75 26.0 26.25 26.4 48.5 49.0 49.5 50.0 50.5 51.0 51.5 52.0 52.5 52.8 ] R'ext [k 3320 1690 1130 845 698 590 511 442 402 383 First column: Vo or Vo1; second column: double-output models with series-connected outputs BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. Page 13 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Display Status of LEDs Vo1 > 0.95 to 0.98 Vo1 adj 06002a OK i Io L LEDs "OK ", "i " and "Io L" status versus input voltage Conditions: Io Io nom, TC TC max, Vinh 0.8 V Vi uv = undervoltage lock-out, Vi ov = overvoltage lock-out Vi Vi uv Vi min Vi max Vi ov Vo1 > 0.95 to 0.98 Vo1 adj Vi abs Vo1 < 0.95 to 0.98 Vo1 adj OK Io L Io nom Io LEDs "OK" and "Io L" status versus output current Conditions: Vi min - Vi max, TC TC max, Vinh 0.8 V TC LED "i " versus case temperature Conditions: Vi min - Vi max , Io Io nom, Vinh 0.8 V Vi inh LED "i " versus Vinh Conditions: Vi min - Vi max , Io Io nom, TC TC max IoL i TC max TPTC threshold Vinh threshold i -50 V LED off +0.8 V +2.4 V LED Status undefined +50 V LED on Fig. 19 LED indicators Cell voltage [V] 2.45 Battery Charging / Temperature Sensor All converters with an R-input are suitable for battery charger applications, but we recommend choosing the models especially designed for this application DK/LK1740 or DK/ LK2740; see Model Selection. 2.40 2.35 For optimal battery charging and life expectancy of the battery an external temperature sensor can be connected to the Rinput. The sensor is mounted as close as possible to the battery and adjusts the output voltage according to the battery temperature. 2.30 Depending upon cell voltage and the temperature coefficient of the battery, different sensor types are available, see Accessories. 2.15 Vo safe 2.25 2.20 2.10 -20 Input Power supply Load R -10 0 10 VC = 2.27 V, -3 mV/K VC = 2.23 V, -3 mV/K 03099d Vo+ Vo- 06139b 20 30 40 50 C VC = 2.27 V, -3.5 mV/K VC = 2.23 V, -3.5 mV/K Fig. 21 Trickle charge voltage versus temperature for defined temperature coefficient. Vo nom is the output voltage with open R-input. + - Temperature sensor + Battery Fig. 20 Connection of a temperature sensor BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. Page 14 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Electromagnetic Compatibility (EMC) A metal oxide VDR together with the input fuse and an input filter form an effective protection against high input transient voltages, which typically occur in most installations. The converters have been successfully tested to the following specifications: Electromagnetic Immunity Table 9: Electromagnetic immunity (type tests) Phenomenon Standard Level Coupling mode 1 Value applied Waveform Source imped. Test procedure In oper. Perf. crit.2 Supply related surge RIA 12 3 A4 +i/- i 3.5 VBat 2/20/2 ms 0.2 1 positive surge yes A 1.5 VBat 0.1/1/0.1 s 960 V p 10/100 s 5 5 pos and 5 neg. yes B B Direct transients C +i/- i, - i/c D3 1800 V p 5/50 s E 3600 V p 0.5/5 s F 4800 V p 0.1/1 s G3 8400 V p 0.05/0.1 s Indirect couples transients H 1800 V p 5/50 s J +o/c, - o/c 3600 V p 0.5/5 s K 4800 V p 0.1/1 s L 100 8400 V p 0.05/0.1 s contact discharge 8000 Vp 1/50 ns A 15000 Vp 10 positive and 10 negative discharges yes air discharge 330 , 150 pF x6 antenna 20 V/m AM 80% /1 kHz n.a. 80 - 1000 MHz yes A 7 antenna 20 V/m AM 80% /1 kHz n.a. 800 - 1000 MHz yes A Electrostatic discharge (to case) IEC / EN 61000-4-2 45 Electromagnetic field IEC / EN 61000-4-3 10 V/m 1400 - 2100 MHz 5 V/m 2100 - 2500 MHz 3 antenna 10 V/m 50% duty cycle, 200 Hz rep. rate n.a. 900 5 MHz yes A Electrical fast transients/burst IEC / EN 61000-4-4 38 capacitive, o/c 2000 Vp A 4000 Vp 60 s positive 60 s negative transients per coupling mode yes i/c, +i/-i direct bursts of 5/50 ns 2.5/5 kHz over 15 ms; burst period: 300 ms 50 4 Surges IEC / EN 61000-4-5 39 1.2/50 s 12 5 pos. and 5 neg. surges per coupling mode yes A 2 Conducted disturbances IEC / EN 61000-4-6 150 0.15 - 80 MHz yes A Power frequency magnetic field IEC / EN 61000-4-8 60 s in all 3 axis yes A 1 2 3 4 5 6 7 8 9 10 11 i/c 2000 Vp +i/- i 1000 Vp 3 10 i, o, signal wires 10 VAC (140 dBV) 3 11 -- 300 A/m AM 80% 1 kHz i = input, o = output, c = case A = normal operation, no deviation from specs.; B = temporary loss of function or deviation from specs possible RIA 12 covers or exceeds IEC 60571-1 and EN 50155:1995. Surge D corresponds to EN 50155:2001, waveform A; surge G corresponds to EN 50155:2001, waveform B Only met with extended input voltage range of CS (for 48 V battery) and ES (for 110 V battery) model types. Such CS models are available on customer's request. Standard DS models types (on 110 V battery) will shut down during the surge and recover automatically. Exceeds EN 50121-3-2:2015 table 6.3 and EN 50121-4:2016 table 2.4. Corresponds to EN 50121-3-2:2015 table 6.1 and exceeds EN 50121-4:2016 table 2.1. Corresponds to EN 50121-3-2:2015 table 6.2 and EN 50121-4:2016 table 2.2 (compliance with digital communication devices). Corresponds or exceeds EN 50121-3-2:2015 table 4.2 and EN 50121-4:2016 table 4.2. Covers or exceeds EN 50121-3-2:2015 table 4.3 and EN 50121-4:2016 table 4.3. Corresponds to EN 50121-3-2:2015 table 4.1 and EN 50121-4:2016 table 4.1 (radio frequency common mode). Corresponds to EN 50121-4:2016 table 2.3. BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. Page 15 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Electromagnetic Emissions dBV PMM 8000 PLUS: Peak, conducted Vi+, QP + AV, 2009-11-20, 12:35 h BK1601-9R, Ui=30 V, Uo=24 V Io= 6 A dBV/m JM052a TUV-Divina, ESVS 30:R&S, BBA 9106/UHALP 9107:Schwarzb., QP, 2009-11-20 Testdistance 10 m, BK1601-9R, Ui=24 V, Uo=24 V Io= 6 A 50 80 EN 55011 A EN 55022 A (qp) 40 JM050 EN 55022 A (av) 60 30 <25 dbV/m 40 20 20 0 10 0.2 0.5 1 2 5 10 0 30 20 MHz Fig. 22a Conducted emissions (peak/quasipeak and average) at the phase input according to EN 55011/32, measured at Vi nom and Io nom (BK1601-9R). The neutral line performs quite similar. PMM 8000 PLUS: Peak, conducted Vi+, QP + AV, 2009-11-20, 13:00 h DK1601-9ERB1, Ui=110 V, Uo=24 V Io= 6 A dBV JM053 50 100 200 500 1000 MHz Fig. 23a Typical radiated emissions according to EN 55011/32, antenna 10 m distance, measured at Vi nom and Io nom (BK1601-9R) dBV/m TUV-Divina, ESVS 30:R&S, BBA 9106/UHALP 9107:Schwarzb., QP, 2009-11-20 Testdistance 10 m, DK1601-9ERB1, Ui=110 V, Uo=24 V Io= 6 A 50 EN 55011 A 80 40 JM051 60 EN 55022 B (qp) 30 EN 55022 B (av) <25 dbV/m 40 20 20 0 10 0.2 0.5 1 2 5 10 20 MHz Fig. 22b Conducted emissions (peak/quasipeak and average) at the phase input according to EN 55011/32, measured at Vi nom and Io nom (DK1601-9ERB1). The neutral line performs quite similar. BCD20002-G Rev AF1, 17-Apr-2018 0 30 50 100 200 500 1000 MHz Fig. 23b Typical radiated emissions according to EN 55011/32, antenna 10 m distance, measured at Vi nom and Io nom (DK1601-9ERB1) MELCHER The Power Partners. Page 16 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Immunity to Environmental Conditions Table 10: Mechanical and climatic stress Test Method Standard Test Conditions Cab Damp heat steady state IEC/EN 60068-2-78 MIL-STD-810D sect. 507.2 Temperature: Relative humidity: Duration: 40 2 C 93 +2/-3 % 56 days Converter not operating Status Kb Salt mist, cyclic (sodium chloride NaCl solution) IEC/EN 60068-2-52 Concentration: Storage: Duration: 5% (30 C) for 2 h 40 C, 93% rel. humidity 3 cycles of 22 h Converter not operating Fc Vibration (sinusoidal) IEC/EN 60068-2-6 MIL-STD-810D sect. 514.3 Acceleration amplitude: Converter 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) Fh Random vibration broad band (digital control) IEC/EN 60068-2-64 Acceleration spectral density: Frequency band: Acceleration magnitude: Test duration: 0.05 gn2 /Hz 8 - 500 Hz 4.9 gn rms 1.5 h (0.5 h each axis) Converter operating Ea Shock (half-sinusoidal) IEC/EN 60068-2-27 MIL-STD-810D sect. 516.3 Acceleration amplitude: Bump duration: Number of bumps: 50 g n = 490 m/s2 11 ms 18 (3 each direction) Converter operating -- Shock EN 50155:2007 sect. 12.2.11, EN 61373 sect. 10, class B, body mounted 1 Acceleration amplitude: Bump duration: Number of bumps: 5.1 gn 30 ms 18 (3 in each direction) Converter operating -- Simulated long life EN 50155:2007 sect. 12.2.11, testing at EN 61373 sect. 8 and 9, increased random class B, body mounted 1 vibration levels Acceleration spectral density: Frequency band: Acceleration magnitude: Test duration: 0.02 g n2 /Hz 5 - 150 Hz 0.8 gn rm s 15 h (5 h in each axis) Converter operating 1 Body mounted = chassis of a railway coach Temperatures Table 11: Temperature specifications, values below are for an air pressure of 800 - 1200 hPa (800 - 1200 mbar) -5 2 Temperature Characteristics Conditions TA Ambient temperature TC Case temperature TS Storage temperature 1 2 1 Converter operating Not operating min -6 2 max min -7 (option) max min max -9 min Unit max -25 50 -25 60 -25 71 -40 71 -25 85 1 -25 90 1 -25 95 1 -40 95 1 -40 85 -40 85 -40 85 -55 85 C Overtemperature lockout at TC > 95 C Customer-specific models Reliability and Device Hours Table 12: MTBF calculated according to MIL-HDBK 217F Values at specified case temperature Model MTBF 1 LK2660-7 Device hours 2 AK - LK 1 2 Ground benign 40 C 514 000 Ground fixed 40 C 70 C 88 000 38 000 Ground mobile 50 C Unit 35 000 h 500 000 Calculated according to MIL-HDBK-217F-N2 Statistic values, based on an average of 4300 working hours per year, over 3 years in general field use. BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. Page 17 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Mechanical Data Dimensions in mm. The converters are designed to be inserted into a 19" rack, 160 mm long, according to IEC 60297-3. European Projection 7 TE 30.3 4.5 20.3 159 7.04 10.3 12.1 9 TE 3.27 Gravitational axis 4.5 9.5 29.9 19.7 Test sockets (+/-) Option P (Vo) Option D (Vto) d Option D (Vti) LED i (red) 51.5 Measuring point of case temperature TC 6.5 89 111 (3U) 09002e 50 LED OK (green) LED IoL (red) 42 27.38 (171.0 .... 171.9) 80 168.5 Back plate 5 x 90 2.8 = O 4.1 = O 3.5 0.2 Main face 11.8 Front plate 25.9 Screw holes of the frontplate 4 Notes: - free air location: the converter should be mounted with fins in a vertical position to achieve maximum airflow through the heat sink. Mounting slots for chassis or wall mounting Fig. 24 Aluminum case K02 with heat sink; black finish (EP powder coated); weight approx. 1.6 kg BCD20002-G Rev AF1, 17-Apr-2018 - d 15 mm, recommended minimum distance to next part in order to ensure proper air circulation at full output power. MELCHER The Power Partners. Page 18 of 31 47.2 6.5 6.5 5 38.5 11.2 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters 11027 European Projection 13 140 127 11.8 133.4 0.2 17.3 30 168 Fig. 25 Option B: Aluminum case K02 with large cooling plate; black finish (EP powder coated). Suitable for front mounting. Total weight approx. 1.3 kg 7 TE 50 38.5 5 11.8 5 158 4 TE 3.27 09003b 101 111 (3U) M4 Measuring point of case temperature TC 17.3 133.4 47.2 5 168 (171.0 ... 171.9) Fig. 26 Option B1: Aluminum case K02 with small cooling plate; black finish (EP powder coated). Suitable for mounting with access from the backside. Total weight approx. 1.2 kg. Note: Long case with option B2, elongated by 60 mm for 220 mm rack depth, is available on request (no LEDs, no test sockets). BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. Page 19 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters connector. The protective earth is connected by a leading pin (no. 24), ensuring that it makes contact with the female connector first. Safety and Installation Instructions Connector Pin Allocation The connector pin allocation table defines the electrical potentials and the physical pin positions on the H15 or H15-S4 Installation Instructions Note: These converters have no power factor correction (PFC). The LK4000/5000 models are intended to replace the LK1000 and LK2000 converters in order to comply with IEC/EN 61000-3-2. LK1000 is replaced by LK4003 with option K. 10010b Fixtures for connector retention clips HZZ01209G (see Accessories) 32 The 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. 4 Connector type H15 Connection to the system shall be made via the female connector H15 (standard) or H15S4; see Accessories. Other installation methods may not meet the safety requirements. Fixtures for connector retention clips HZZ01209G (see Accessories) 30/32 Pin no. 24 ( ) is connected with the case. For safety reasons it is essential to connect this pin reliably to protective earth. The input pins 30/32 (Vi- or L ) are connected via a built-in fuse, which is designed to protect in the case of a converter failure. An additional external fuse, suitable for the application, might be necessary in the wiring to the other input 26 /28 (Vi+ or N ) or even to pins 30/32, particularly if: 4/6 Connector type H15S4 Fig. 27 View of module's male connectors * Local requirements demand an individual fuse in each source line Table 13: H15 and H15-S4 connector pin allocation Pin No. Connector type H15-S4 AK1000 (all), BK - LK1001 except opt. K Connector type H15 AK2000 BK - LK1301/1501/1601 BK - LK1001 with opt. K 4 Vo+ BK - LK2000 Vo2+ Vo+ Pos. output 1 Vo2+ Pos. output 2 Vo- Neg. output 1 Vo2- Neg. output 2 12 S+ Pos. sense Vo1+ Pos. output 1 S+ Pos. sense Vo1+ Pos output 1 14 S- Neg. sense Vo1- Neg. output 1 S- Neg. sense Vo1- Neg. output 1 16 R1 Control of V o R1 Control of V o1 R1 Control of V o R1 Control of V o1 18 i Inhibit i Inhibit i Inhibit i Inhibit D3 Save data V3 ACFAIL D3 Safe data D3 Save data D3 Save data T5 Current sharing T5 Current sharing T5 Current sharing T5 Current sharing 6 8 10 20 22 Protective earth 26 Pos. input Vi+ N 4 Vi- L 4 30 32 1 2 3 4 5 Vo+ Vo- 24 2 28 Pos. output 1 Neutral line 4 Pos. input Vi- Neg. input Neg. input Phase line 4 Vo2- Neg. output 1 Vo- Protective earth Vi+ Pos. output 2 Vo2+ Neg. output 2 Vo2- Protective earth Vi+ N 4 Vi+ N 4 Neutral Vi- L 4 Neg. input Vi- L 4 Pos. input Phase line 4 line 4 Protective earth Vi+ N 4 Pos. input Vi+ N 4 Neutral line 4 Vi- L 4 Neg. input 4 Vi- L 4 Phase line 4 Not connected, if option P is fitted. Leading pin (pre-connecting) Option D excludes option V and vice versa. Pin 20 is not connected, unless option D or V is fitted. LK models Only connected, if option T is fitted. BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. Page 20 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters * Phase and neutral of the AC mains are not defined or cannot be assigned to the corresponding terminals. * Neutral and earth impedance is high or undefined Notes: The converters are subject to manufacturing surveillance in accordance with the above mentioned standards and ISO 9001:2000. A CB-scheme is available. Railway Applications and Fire Protection - If the inhibit function is not used, pin no. 18 (i) should be connected with pin no. 14 to enable the output(s). - Do not open the converters, or warranty will be invalidated. The converters have been designed by observing the railway standards EN 50155, EN 50121-3-2, and EN 50121-4. All boards are coated with a protective lacquer. - Due to high current values, the converters provide two internally parallel contacts for certain paths (pins 4/6, 8/10, 26/28 and 30/ 32). It is recommended to connect both female connector pins of each path in order to keep the voltage drop low and avoid excessive connector currents. The converters with version V108 (or later, but not models with H15S4 connector: 5 V output without option K) comply with NF-F16 (I2/F1). They also comply with EN 45545-1, EN 45545-2 (2013), if installed in a technical compartment or cabinet. - If the second output of double-output models is not used, connect it parallel with the main output. Protection Degree and Cleaning Liquids Make sure that there is sufficient airflow available for convection cooling and verify it by measuring the case temperature TC, when the converter is installed and operated in the end-use application; see Thermal Considerations. Ensure that a converter failure (e.g, an internal short-circuit) does not result in a hazardous condition. Standards and Approvals The converters are safety-approved according to the latest edition of IEC/EN 60950-1 and UL/CSA 60950-1. The converters correspond to Class I equipment and have been evaluated for: * Building-in * Basic insulation between input and case based on 250 VAC, and double or reinforced insulation between input and output(s) * Functional insulation between outputs Condition: Female connector fitted to the converter. * IP 30: All models except those with option P, and except those with option D or V including a potentiometer. * IP 20: All models fitted with option P, or with option D or V with potentiometer. In order to avoid damage, any penetration of cleaning fluids has to be prevented, since the power supplies are not hermetically sealed. Isolation and Protective Earth The electric strength test is performed in the factory as routine test in accordance with EN 50514 and IEC/EN 60950. The company will not honor any warranty claims resulting from incorrectly executed electric strength field tests. The resistance between earth connection and case (<0.1 ) is tested as well. Leakage Currents * Pollution degree 2 environment Leakage currents flow due to internal leakage capacitances and Y-capacitors. The current values are proportional to the supply voltage and are specified in the table below. * Max. altitude: 2000 m LK Models Operated at Greater than 63 Hz * The converters fulfill the requirements of a fire enclosure. Above 63 Hz, the earth leakage current may exceed 3.5 mA, the maximum value allowed in IEC 60950. Frequencies 350 Hz only permitted with Vi 200 VAC. * Overvoltage category II Table 14: Earth leakage currents for LK models Characteristic Class I Unit Max. leakage Permissible accord. to IEC/EN 60950 current Typ. value at 264 V, 50 Hz 3.5 mA The built-in Y-caps are approved for 100 Hz. Safety approvals and CB scheme cover only 50 - 60 Hz. 1.43 Table 15: Isolation Characteristic Electric strength test Input to case and output(s) Output(s) to case Output 1 to output 2 Unit Factory test >1 s 2.8 1 1.4 0.15 kVDC AC test voltage equivalent to factory test 2.0 1 1.0 0.1 kVAC >300 >100 2 M -- -- mm Insulation resistance at 500 VDC >300 Creepage distances 3.2 1 2 3 3 According to EN 50514 and IEC/EN 60950, subassemblies connecting input to output are pre-tested with 5.6 kVDC or 4 kVAC. Tested at 150 VDC Input to outputs: 6.4 mm BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. Page 21 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Safety of Operator-Accessible Output Circuits If the output circuit of a DC-DC converter is operatoraccessible, it shall be an SELV circuit according to the standard IEC 60950-1. The following table shows some possible installation configurations, compliance with which causes the output circuit of the converter to be an SELV circuit according to IEC 609501 up to a configured output voltage (sum of nominal voltages if in series or +/- configuration) of 36 V. However, it is the sole responsibility of the installer to assure the compliance with the rapplicable safety regulations. 150 VAC or VDC for AK, BK 250 VAC or VDC for CK, DK, EK, FK, LK Mains AC-DC front end + 10044a Fuse Battery Fuse DC-DC converter + SELV - 150 VAC or VDC for AK, BK 250 VAC or VDC for CK, DK, EK, FK, LK Fig. 28 Schematic safety concept. Use earth connections as per the table below. Earth connection Table 16: Safety concept leading to an SELV output circuit Conditions Front end Nominal supply voltage Minimum required grade of insulation, to be provided by the AC-DC front end, including mains supplied battery charger Nominal DC output voltage from the front end Mains 150 V AC Functional (i.e. there is no need for electrical insulation between the mains supply voltage and the DC-DC converter input voltage) 100 V (The nominal voltage between any input pin and earth can be up to 150 V AC or DC) Basic Double or reinforced 2 3 4 Result Minimum required safety status of the front end output circuit Types Measures to achieve the specified safety status of the output circuit Safety status of the DC-DC converter output circuit Primary circuit AK BK Double or reinforced insulation, based on the mains voltage and 2 (provided by the DC-DC converter) and earthed case 3 SELV circuit 400 V (The nominal voltage between any input pin and earth can be up to 250 V AC or 400 V DC) Mains 250 V AC 1 DC-DC converter 400 V CK DK EK FK Unearthed hazardous voltage secondary circuit AK BK CK DK EK FK 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 Functional 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 60950-1. Earthing of the case is recommended, but not mandatory. BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. Page 22 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters If the output circuit of an AC-DC converter is operatoraccessible, it shall be an SELV circuit according to standard IEC 60950-1. The following table shows some possible installation configurations, compliance with which causes the output circuit of LK models to be SELV according to IEC 60950-1 up to a configured output voltage (sum of nominal voltages if in series or +/- configuration) of 36 V. 10021a Mains ~ ~ Fuse Fuse + AC-DC converter If the LK converter is used as DC-DC converter, refer to the previous section. SELV - Earth connection Fig. 29 Schematic safety concept. Use earth connection as per table 17. Use fuses if required by the application; see also Installation Instructions. Table 17: Safety concept leading to an SELV output circuit Conditions AC-DC converter Installation Result Nominal voltage Grade of insulation between input and output provided by the AC-DC converter Measures to achieve the resulting safety status of the output circuit Safety status of the AC-DC converter output circuit Mains 250 VAC Double or reinforced Earthed case1 and installation according to the applicable standards SELV circuit 1 The earth connection has to be provided by the installer according to the relevant safety standards, e.g. IEC/EN 60950. Description of Options Table 18: Survey of options Option Function of option Characteristic -7 Extended operational ambient temperature range TA = - 25 to 71 C E Electronic inrush current limitation circuitry Active inrush current limitation Potentiometer for fine adjustment of output voltage Adjustment range +10/ - 60% of Vo nom, excludes R-input P 2 D1 Input and/or output undervoltage monitoring circuitry Safe data signal output (D0 - DD) V1 Input and/or output undervoltage monitoring circuitry ACFAIL signal according to VME specifications (V0, V2, V3) T Current sharing Interconnect T-pins for parallel connection (max 5 converters) K Standard H15 Connector H15 standard connector instead H15-S4 for models with Vo = 5.1 V) Cooling plate (160 or 220 mm long) Replaces the standard heat sink, allowing direct chassis-mounting RoHS-compliant for 5 substances Tin-lead solder B, B1, B2 non-G 1 2 Option D excludes option V and vice versa; option V only for 5.1 V outputs. Option P is not available for battery charger models. -7 Temperature Range E Inrush Current Limitation Option -7 designates converters with an operational ambient temperature range of - 25 to 71 C. Not for new designs. CK/DK/EK/LK models may be supplemented by an electronic circuit (option E, replacing the standard built-in NTC resistor) BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. Page 23 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters to achieve an enhanced inrush current limiting function (not available with AK/BK/FK types). Option E is mandatory for all CK/DK/EK/LK models with option -9. Option D6 should be adjusted with the potentiometer to a threshold of 36 - 40.5 V for 48 V batteries and to 44 - 50 V for 60 V batteries. Refer also to the description of option D. 10017b Ci FET Rs Note: Subsequent switch-on cycles at start-up are limited to max. 10 cycles during the first 20 seconds (cold converter) and then to max. 1 cycle every 8 s. Converter Input Filter LK models Control monitor) meet the standard ETS 300132-2 for 48 VDC supplies. Option D6 is necessary to disable the converter at low input voltage, such avoiding an excessive input current. Connect output D (pin 20) with inhibit (pin 18). LK models powered by 230 VAC/ 50 Hz exhibit an inrush current as per the fig. below, when switched on at the peak of Vi. In this case, the inrush current I inr p is 21.7 A and its duration tinr is 5 ms. This is the worst case. RSt If the LK converter is switched on in a different moment, Iinr p is much lower, but t inr rises up to 10 ms. Fig. 30 Block diagram of option E Current limiting resistance Rv = Rs + RSt = 15 The figure below shows two consecutive peaks of the inrush current, the first one is caused by Vi /Rv and the second one by the rising current across the FET. The shape of the curve depends on model, but the tables below show the higher of both peaks. CK models fitted with option E and option D6 (input voltage Ii [A] 20 15 Capacitor Ci fully charged 10 Table 19 a: Inrush current at Vi nom (DC supply) and I o nom Normal operation (FET fully conducting) 5 Characteristics CK DK EK LK Unit Vi nom Input voltage 60 110 220 310 V I inr p Peak inrush current 6.5 7.4 14.6 21 A t inr Inrush current duration 25 14 16 12 ms 0 -5 -10 tinr Table 19 b: Inrush current at Vi max (DC supply) and I o nom Characteristics CK DK EK LK Unit Vi nom Input voltage 140 220 385 372 V 14.5 25.7 24.8 A I inr p Peak inrush current 9 t inr Inrush current duration 30 Iinr [A] Capacitor Ci fully charged V i / Rv 14 12 Normal operation (FET fully conducting) 11039a 0 ms 0 20 40 60 t [ms] 80 Fig. 32 Inrush current for LK models with option E (AC supply) Vi = 230 VAC, f i = 50 Hz, Po = Po nom P Potentiometer Ii = Pi / Vi 0 12 10065a -15 tinr t [ms] A potentiometer provides an output voltage adjustment range of +10/- 60% of Vo nom. It is accessible through a hole in the front cover. Option P is not available for battery charger models and is not recommended for converters connected in parallel. Option P excludes the R-function. With double-output models, both outputs are influenced by the potentiometer setting (doubling the voltage, if the outputs are in series). Note: If the output voltages are increased above Vo nom via R input control, option P setting, remote sensing, or option T, the output current(s) should be reduced, so that Po nom is not exceeded. Fig. 30 Inrush current with option E (DC supply) 2 different wafe shapes depending on model BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. Page 24 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters T Current Sharing 11037b This option ensures that the output currents are approximately shared between all parallel-connected converters, hence increasing system reliability. To use this facility, simply interconnect the T pins of all converters and make sure that the reference for the T signal, pin 14 (S- or Vo1-), are also connected together. The load lines should have equal length and cross section to ensure equal voltage drops. Power bus + - Vo2+ Vo2- Converter T Vo1+ Vo1- Load Not more than 5 converters should be connected in parallel. The R pins should be left open-circuit. If not, the output voltages must be individually adjusted prior to paralleling within 1 to 2% or the R pins should be connected together. Vo2+ Vo2- Converter Note: Parallel connection of converters with option P is not recommended. T Vo1+ Vo1- Vo+ 11003a Load Max. 5 converters in parallel connection Vo- Fig. 35 Parallel connection of double-output models with the outputs connected in series, using option T. The signal at the T pins is referenced to Vo1-. Vo+ Vo- Vo+ Vo- D Undervoltage Monitor Fig.33 Example of poor wiring for parallel connection (unequal length of load lines) 11036b Vo+ 2 1 S+ Converter T 1 S- The input and/or output undervoltage monitor operates independently of the built-in input undervoltage lockout circuit. A logic "low" signal (output with self-conducting JFET) or "high" signal (NPN open-collector output) is generated at the D output (pin 20), when one of the monitored voltages drops below the preselected threshold level V t. This signal is referenced to S- / Vo1-. The D output recovers, when the monitored voltages exceed Vt + Vh. The threshold levels Vti and Vto are either adjusted by a potentiometer, accessible through a hole in the front cover, or adjusted in the factory to a fixed value specified by the customer. Option D exists in various versions D0 - DD, as shown in table 21. D0 and D9 are adjusted according to customer's request and receive a customer-specific model number. Vo- Load Vo+ JFET output (D0 - D4): 2 Pin D is internally connected via the drain-source path of a JFET (self-conducting type) to the negative potential of output S+ T Converter 1 S- Vo- 11006a Vo+/Vo1+ 1 Input 1 Lead lines should have equal length and cross section, and should run in the same cable loom. 2 Diodes recommended in redundant operation only Fig. 34 Parallel connection of single-output models using option T with the sense lines connected at the load BCD20002-G Rev AF1, 17-Apr-2018 Rp ID Max. 5 converters in parallel connection Self-conducting junction FET 20 D VD 14 S-/Vo1- Fig. 36 Option D0 - D4: JFET output, I D 2.5 mA MELCHER The Power Partners. Page 25 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Table 20: Undervoltage monitoring functions Output type JFET NPN 2 3 4 5 Minimum adjustment range Typ. hysteresis Vho [% of Vt ] of threshold level Vtfor Vt min - Vt max potentioVt o Vh i Vh o Vt i 1 D1 D5 no yes -- 3.5 V - Vo BR D2 D6 yes no Vi min - Vi max 1 -- D3 D7 yes yes Vi min - Vi max 1 (0.95 - 0.985 Vo) 2 Number of meters -- 2.5 - 0.6 V 1 3.4 - 0.4 V -- 1 3.4 - 0.4 V "0" 1 2 D4 D8 no yes -- (0.95 - 0.985 Vo) -- "0" -- D0 5 D9 5 no yes -- 3.5 V - Vo BR V 3 -- 2.5 - 0.6 V -- yes no Vi min - Vi max 3 4 -- -1 Monitoring Vi Vo or Vo1 DD 34 3.5 V - Vo BR 3.4 - 0.4 V -- V3 4 3.4 - 0.4 V 2.5 - 0.6 V yes yes Vi min - Vi max yes yes Vi min - Vi max 3 4 (0.95 - 0.985 Vo) 2 3.4 - 0.4 V "0" yes yes Vi min - Vi max 1 3.5 V - Vo BR V 1 3.4 - 0.4 V 2.5 - 0.6 V 2 Threshold level adjustable by potentiometer; see Electrical Output Data for Vo BR. Fixed value. Tracking if Vo/Vo1 is adjusted via R-input, option P, or sense lines. The threshold level permanently adjusted according to customer specification 2% at 25 C. Any value within the specified range is basically possible, but causes a special type designation in addition to the standard option designations (D0/D9). See Electrical Output Data for Vo BR. Adjustment at Io nom. Customer-specific part number NPN transistor to the negative potential of output 1. VD < 0.4 V (logic low) corresponds to a monitored voltage level (Vi and/or Vo1) > Vt + Vh. The current ID through the open collector should not exceed 20 mA. The NPN output is not protected against external overvoltages. VD should not exceed 40 V. Table 21: JFET output (D0 -- D4) Vb, Vo1 status D output, VD Vb or Vo1 < Vt low, L, VD 0.4 V at I D = 2.5 mA Vb and Vo1 > Vt + Vh high, H, I D 25 A at VD = 5.25 V Threshold tolerances and hysteresis: 1. VD 0.4 V (logic low) corresponds to a monitored voltage level (Vi and/or Vo1) <Vt. The current I D 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. NPN output (D5 - DD): Pin D is internally connected via the collector-emitter path of a If Vi is monitored, the internal input voltage after the input filter is measured. Consequently this voltage differs from the voltage at the connector pins by the voltage drop V ti across the input filter. The threshold levels of the D0 and D9 options are factory adjusted at nominal output current Io nom and TA = 25 C. The value of V ti depends upon input voltage range (CK, DK, ..), threshold level Vt, temperature, and input current. The input current is a function of the input voltage and the output power. 11007a Vo+/Vo1+ Vti Vhi 11021a Po = 0 VD 14 S-/Vo1- Po = Po nom D Po = 0 VD high 20 NPN open collector VD Rp Po = Po nom Input ID VD low Fig. 37 Option D5 - DD: NPN output, Vo 40, ID 2.5 mA Table 22: NPN output (D5 - DD) Vb, Vo1 status D output, VD Vb or Vo1 < Vt high, H, I D 25 A at VD = 40 V Vb and Vo1 > Vt + Vh low, L, VD 0.4 V at I D = 20 mA BCD20002-G Rev AF1, 17-Apr-2018 Vti Vi Fig. 38 Definition of Vti, Vt i and Vhi (JFET output) MELCHER The Power Partners. Page 26 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Table 23: D-output logic signals Vi < Vt or Vo < Vt Vi > Vt + Vh or Vo > Vt Configuration D1, D2, D3, D4, D0 Version of D low high JFET D5, D6, D7, D8, D9, DD high low NPN Input voltage monitoring NPN VD VD high 11008a 3 VD low 3 3 3 t 0 ID ID high ID low 0 t JFET VD VD high VD low 0 t th1 Vo1 Vo1 nom 1 0.95 tlow min4 tlow min4 tlow min4 thigh min th1 t 0 Vi [VDC] Vti+Vhi Vti t 0 Input voltage failure Input voltage sag Switch-on cycle Switch-on cycle and subsequent input voltage failure Output voltage monitoring NPN VD VD high 2 3 3 VD low t 0 ID 1 Hold-up time see Electrical Input Data 2 With output voltage monitoring, hold-up time t = 0 h ID high 3 The signal remains high, if the D output is connected ID low 0 t to an external source 4 t l ow min = 100 - 170 ms, typ. 130 ms JFET VD VD high VD low 0 t tlow min4 Vo1 Vo1 nom Vto+Vho Vto t 0 Output voltage failure Fig. 39 Relationship between Vi, Vo, V D, Vo /Vo nom versus time BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. Page 27 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Table 24: Option V: Factory potentiometer setting of Vti with resulting hold-up time Model AK BK FK CK Vt i 9.5 19.5 39 39 th 0.1 0.1 3.4 1.1 V ACFAIL signal (VME) Available for units with Vo nom = 5.1 V only. This option defines an undervoltage monitoring circuit for the input or for the input and main output voltage ( 5.1 V) similar to option D and generates an ACFAIL signal (V signal), which conforms to the VME standard. The low state level of the ACFAIL signal is specified at a sink current of I V 48 mA to V V 0.6 V (open-collector output of an 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 V ti should be adequately above Vi min of the converter, so that enough energy is remaining in the input capacitance. If V i is below the required level, an external hold-up capacitor (C i ext) should be added; refer to the formulas below: Vt i = 1 EK LK Unit 61 97 120 VDC 1.1 2.7 4.2 ms Note: Option V2 and V3 can be adjusted by the potentiometer to a threshold level between Vi min and Vi 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. Option V operates independently of the built-in input undervoltage lockout circuit. A logic "low" signal is generated at pin 20, as soon as one of the monitored voltages drops below the preselected threshold level V t. The return for this signal is S-. The V output recovers, when the monitored voltages exceed V t + V h. The threshold level V t i is either adjustable by a potentiometer, accessible through a hole in the front cover, or adjusted in the factory to a determined customer-specific value. Refer to table 26. V output (V0, V2, V3): Pin V is internally connected to the open collector of an NPN transistor. The emitter is connected to S-. V V 0.6 V (logic low) corresponds to a monitored voltage level (V i and/or Vo) <V t. I V should not exceed 50 mA. The V output is not protected against external overvoltages: V V should not exceed 60 V. Threshold tolerances and hysteresis: 2 * Po * (t h + 0.3 ms) * 100 ------------------------ + Vi min2 Ci min * If Vi is monitored, the internal input voltage is measured after the input filter. Consequently this voltage differs from the 2 * Po * (t h + 0.3 ms) * 100 C i ext = ---------------------- - Ci min * (Vti 2 - Vi min2 ) where as: C i min = C i ext = Po = = th = V i min = V ti = DK Table 26: NPN-output (V0, V2, V3) Vi, Vo status internal input capacitance [mF]; see table 2 external input capacitance [mF] output power [W] efficiency [%] hold-up time [ms] minimum input voltage [V] 1 threshold level [V] V output, VV V i or V o1 < V t low, L, V V 0.6 V at I V = 50 mA V i and V o1 > V t + V h high, H, I V 25 A at V V = 5.1 V voltage at the connector pins by the voltage drop V ti across the input filter. The threshold level of option V0 is adjusted in the factury at Io nom and TA = 25 C. The value of V ti depends upon the input voltage range (AK, BK, etc.), threshold level V t, temperature, and input current. The input current is a function of input voltage and output power. V i min see Electrical Input Data. For output voltages Vo > Vo nom, V i min increases proportionally to Vo /Vo nom. Table 25: Undervoltage monitor functions Option V2 Monitoring Vi V o1 yes no 4 V i min - V i max 1 1 V3 yes yes V i min - V i max V0 yes no V i min - V i max 3 4 yes 1 Minimum adjustment range of threshold level V t V ti V to yes V i min - V i max 34 Typical hysteresis Vh [% of V t] for V t min - V t max V hi V ho -0.95 - 0.985 V o1 2 -0.95 - 0.985 V o1 2 2 3.4 - 0.4 -- 3.4 - 0.4 "0" 3.4 - 0.4 -- 3.4 - 0.4 "0" 3 Threshold level adjustable by potentiometer. Fixed value between 95% and 98.5% of Vo1 (tracking). Adjusted at Io nom. Fixed value, resistor-adjusted (2% at 25C) accord. to customer's specification; individual type number is determined by the company. BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. Page 28 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters Vhi VV high 11023a Po = 0 V VV VV low S- Fig. 40 Output configuration of options V0, V2 and V3 Input voltage monitoring Fig. 41 Definition of Vti, Vti and Vhi VV high 3 Vi Vti tlow min 2 tlow min 2 tlow min 2 VV Po = Po nom 20 NPN open collector 14 V2 Vti Po = Po nom Rp IV Input VV 11009a Po = 0 Vo+ 3 3 11010a 4 4 VV low t 0 V3 tlow min tlow min 2 VV VV high 3 2 3 3 VV low t 0 th 1 th 1 Vo 5.1 V 4.875 V 2.0 V 0 t Vi [VDC] Vti + Vhi Vti t 0 Input voltage failure Input voltage sag Switch-on cycle Switch-on cycle and subsequent input voltage failure Output voltage monitoring V2 VV VV high 4 VV low 4 t 0 V3 tlow min 2 VV VV high 3 3 1 4 2 3 VV low 0 t 4 Vo 5.1 V 4.875 V 2.0 V 0 VME request: minimum 4 ms t low min = 40 - 200 ms, typ 80 ms VV level not defined at Vo < 2.0 V The V signal drops simultaneously with Vo, if the pull-up resistor R P is connected to Vo+; the V signal remains high if R P is connected to an external source. t Vi Vti + Vhi Vti t 0 Fig. 42 Relationship between Vb, Vo, VD, Vo /Vo nom versus time Output voltage failure BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. Page 29 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters K Standard H15 Connector calculated by ( see Model Selection): Option K is available only for 5.1 V output models in order to avoid the connector with high current contacts. Efficiency is approx. 1.5% worse. B, B1, B2 Cooling Plate Where a cooling surface is available, we recommend the use of a cooling plate instead of the standard heat sink. The mounting system should ensure that the maximum case temperature TC max is not exceeded. The cooling capacity is (100% - ) PLoss = ---------- * Vo * Io For the dimensions of the cooling plates, see Mechanical Data. Option B2 is for customer-specific models with elongated case (for 220 mm DIN-rack depth). G RoHS RoHS-compliant for all six substances. Accessories A variety of electrical and mechanical accessories are available including: - Front panels for 19" DIN-rack: Schroff or Intermas, 12 TE / 3U; see fig. 43. Fig. 45 Connector retention clips to fasten the H15 connector to the rear plate; see fig. 24. HZZ01209-G consists of 2 clips. - Mating H15 connectors with screw, solder, faston, or pressfit terminals, code key system and coding wedges HZZ00202-G; see fig. 44. - Pair of connector retention clips HZZ01209-G; see fig. 45 - Connector retention brackets HZZ01216-G; see fig. 46 - Cage clamp adapter HZZ00144-G; see fig. 47 20 to 30 Ncm Fig. 46 Connector retention brackets HZZ01216-G (CRB-HKMS) Fig. 43 Different front panels Fig. 44 Different mating connectors BCD20002-G Rev AF1, 17-Apr-2018 Fig. 47 Cage clamp adapter HZZ00144-G MELCHER The Power Partners. Page 30 of 31 K Series Data Sheet 150 Watt DC-DC and AC-DC Converters - Different cable hoods for H15 connectors (fig. 48): - HZZ00141-G, screw version - HZZ00142-G, use with retention brackets HZZ01218-G - HZZ00143-G, metallic version providing fire protection - Chassis or wall-mounting plate K02 (HZZ01213-G) for models with option B1. Mating connector (HZZ00107-G) with screw terminals; see fig. 49 - DIN-rail mounting assembly HZZ0615-G (DMB-K/S); see fig. 50 - Additional external input and output filters - Different battery sensors S-KSMH... for using the converter as a battery charger. Different cell characteristics can be selected; see fig. 51, table 27, and Battery Charging / Temperature Sensors. Fig. 50 DIN-rail mounting assembly HZZ00615-G (DMB-K/S) For additional accessory product information, see the accessory data sheets listed with each product series or individual model at our web site. European Projection 9.8 (0.4") 26 (1.02") 09125a L 56 (2.2") adhesive tape L = 2 m (standard length) other cable lengths on request Fig. 51 Battery temperature sensor Table 27: Battery temperature sensors Fig. 48 Different cable hoods Fig. 49 Chassis- or wall-mounting plate HZZ01213-G (Mounting plate K02) Battery voltage nom.[V] Sensor type Cell voltage [V] Cell temp. Cable coefficient length [mV/K] [m] 12 S-KSMH12-2.27-30-2 2.27 - 3.0 2 12 S-KSMH12-2.27-35-2 2.27 - 3.5 2 24 S-KSMH24-2.27-30-2 2.27 - 3.0 2 24 S-KSMH24-2.27-35-2 2.27 - 3.5 2 24 S-KSMH24-2.31-35-0 2.31 - 3.5 4.5 24 S-KSMH24-2.31-35-2 2.31 - 3.5 2 24 S-KSMH24-2.35-35-2 2.35 - 3.5 2 48 S-KSMH48-2.27-30-2 2.27 - 3.0 2 48 S-KSMH48-2-27-35-2 2.27 - 3.5 2 Note: Other temperature coefficients and cable lengths are available on request. NUCLEAR AND MEDICAL APPLICATIONS - These products are not designed or intended for use as critical components in life support systems, equipment used in hazardous environments, or nuclear control systems. TECHNICAL REVISIONS - The appearance of products, including safety agency certifications pictured on labels, may change depending on the date manufactured. Specifications are subject to change without notice. Copyright (c) 2018, Bel Power Solutions Inc. All rights reserved. BCD20002-G Rev AF1, 17-Apr-2018 MELCHER The Power Partners. belfuse.com/power-solutions Page 31 of 31