Cassette Style DC-DC Converters 50 Watt DC-DC (AC-DC) Converters M Series M Series Wide input voltage from 8...373 V DC 1, 2 or 3 isolated outputs up to 48 V DC 4 kV AC I/O electric strength test voltage * Extremely wide input voltage range suitable for battery (and AC) operation * Efficient input filter and built-in surge and transient suppression circuitry * Outputs individually isolated and controlled * Outputs fully protected against overload Safety according to IEC/EN 60950 LGA 111 4.37" 3U Summary The M series 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. The converter inputs are protected against surges and transients occuring at the source lines. An input over- and undervoltage lock-out circuitry disables the outputs if the input voltage is outside the specified range. Certain types include an inrush current limitation preventing circuit breakers and fuses from being damaged at switch-on. All outputs are open- and short-circuit proof and are protected against overvoltages by means of built-in suppressor diodes. The outputs can be inhibited by a logic signal applied to the connector pin 2 (i). If the inhibit function is not used pin 2 should be connected to pin 23 to enable the outputs. LED indicators display the status of the converter and allow visual monitoring of the system at any time. Full input to output, input to case, output to case and output to output isolation is provided. The modules are designed and built according to the international safety standard IEC/EN 60950 and have been approved by the safety Table of Contents 39 1.54" 8 TE 168 6.6" agencies LGA (Germany) and UL (USA). The UL Mark for Cana-da has been officially recognized be regulatory authorities in provinces across Canada. The case design allows operation at nominal load up to 71C in a free air ambient temperature. If forced cooling is provided, the ambient temperature may exceed 71C but the case temperature 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. Page Page Summary .......................................................................... 1 Type Survey and Key Data .............................................. 2 Type Key .......................................................................... 3 Functional Description ...................................................... 4 Electrical Input Data ......................................................... 5 Electrical Output Data ...................................................... 7 Auxiliary Functions ......................................................... 10 Electromagnetic Compatibility (EMC) ............................ 13 Immunity to Environmental Conditions ........................... 15 Mechanical Data ............................................................ 16 Safety and Installation Instructions ................................ 17 Description of Options .................................................... 19 Accessories .................................................................... 25 Edition 01/01.2001 1/25 Cassette Style DC-DC Converters M Series Type Survey and Key Data Non standard input/output configurations or special custom adaptions are available on request. See also: Commercial Information: Inquiry Form for Customized Power Supply. The type survey tables provide an overview of the basic input and output configurations. More than 1000 different types have been manufactured providing different output configurations and customized specialities. Please consult PowerOne'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 Io nom [V DC] [A] Uo nom Io nom [V DC] [A] Uo nom Io nom [V DC] [A] Input voltage range and efficiency 1 Ui min...Ui max 8...35 V DC h min [%] Ui min...Ui max 14...70 V DC h min [%] Ui min...Ui max 20...100 V DC Options h min [%] 5.1 12.0 15.0 24.0 48.0 8.0 4.0 3.4 2.0 1.0 - - - - 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 12.0 15.0 2.0 1.7 12.0 15.0 2.0 1.7 - - 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 5.1 5.1 5.0 5.0 12.0 15.0 0.7 0.6 12.0 15.0 0.7 0.6 AM 3020-7 AM 3040-7 75 75 BM 3020-7 BM 3040-7 76 76 FM 3020-7 FM 3040-7 76 76 Table 1b: Class I equipment Output 1 Output 2 Output 3 Uo nom Io nom [V DC] [A] Uo nom Io nom [V DC] [A] Uo nom Io nom [V DC] [A] Input voltage range and efficiency 1 Ui min...Ui max 28...140 V DC h min [%] Ui min...Ui max 44...220 V DC h min [%] Ui min...Ui max 88...372 V DC (85...264 V AC) Options h min [%] 5.1 12.0 15.0 24.0 48.0 8.0 4.0 3.4 2.0 1.0 - - - - 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 12.0 15.0 2.0 1.7 12.0 15.0 2.0 1.7 - - 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 5.1 5.1 5.0 5.0 12.0 15.0 0.7 0.6 12.0 15.0 0.7 0.6 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 Table 1c: Class II equipment (double insulation) 1 Output 1 Output 2 Output 3 Uo nom Io nom [V DC] [A] Uo nom Io nom [V DC] [A] Uo nom Io nom [V DC] [A] Input voltage range and efficiency 1 Ui min...Ui max 28...140 V DC h min [%] Ui min...Ui max 44...220 V DC h min [%] Ui min...Ui max 88...372 V DC (85...264 V AC) Options h min [%] 5.1 12.0 15.0 24.0 48.0 8.0 4.0 3.4 2.0 1.0 - - - - 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 12.0 15.0 2.0 1.7 12.0 15.0 2.0 1.7 - - CMZ 2320-7 CMZ 2540-7 79 80 DMZ 2320-7 DMZ 2540-7 80 80 LMZ 2320-7 LMZ 2540-7 77 78 5.1 5.1 5.0 5.0 12.0 15.0 0.7 0.6 12.0 15.0 0.7 0.6 CMZ 3020-7 CMZ 3040-7 76 76 DMZ 3020-7 DMZ 3040-7 77 76 LMZ 3020-7 LMZ 3040-7 73 71 -9 E P D0...D9 V0,V2,V3 A H F Efficiency at Ui nom and Io nom. Notes: EM types with an input voltage range of 67...385 V DC are available upon request. 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. See: AC-DC converters 100 W: M-Series. Edition 01/01.2001 2/25 Cassette Style DC-DC Converters M Series Type Key Type Key C M Z 2 5 40 -7 E R P D V A H F 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 Series .............................................................................. M Class II Equipment ........................................................... Z 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 Ambient temperature range TA: -25...71C .............. -7 -40...71C .............. -9 customer specific ........ -0...-8 Auxiliary functions and options: Inrush current limitation (C/E/LM and C/LMZ) ................. E Output voltage control input (single output modules) ...... R 2 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 1 2 3 EM types available upon request Feature R excludes option P and vice versa Option D excludes option V and vice versa 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. Note: All units feature input and output filters and the auxiliary function inhibit which are not shown in the type designation. Edition 01/01.2001 3/25 Cassette Style DC-DC Converters M Series Functional Description 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- mary switching transistor. This signal is fed back via a coupling transformer. 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 main control circuit. P 03009 4 Main control circuit 2 i 5 D/V 14 R 17 G 4 CY 29 Vi- Input filter Fuse 1 2 3 Forward converter approx. 70 kHz Vi+ 20 Output 1 filter 23 CMKT Control circuit 14 Output 2 filter 17 CMKT 32 8 Output 3 filter Control circuit 11 26 CY Fig. 1a Block diagram, class I equipment P CY 03010 CY 4 Main control circuit 2 i 5 D/V 14 R 17 G 4 29 Vi- Input filter Fuse 1 2 3 Forward converter approx. 70 kHz Vi+ Output 1 filter 32 20 23 CMKT Control circuit Output 2 filter 14 17 CMKT Control circuit Output 3 filter 8 11 Fig. 1b Block diagram, class II equipment (double insulation) 1 Transient suppressor diode in AM, BM, CM, FM and CMZ types. Bridge rectifier in LM and LMZ, series diode in EM types. 3 Inrush current limiter (NTC) in CM, DM, EM, LM and CMZ, DMZ, LMZ types (option E: refer to the description of option E). 4 Single output modules AM...LM 1000 and CMZ...LMZ 1000 with feature R. For output configuration please refer to table: Pin allocation. 2 Edition 01/01.2001 4/25 Cassette Style DC-DC Converters M Series 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 2a: Input data Input AM Characteristics Ui Conditions Ui nom Operating input voltage Io = 0...Io nom TC min...TC max Nominal input voltage Ii Input current Ui 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 tinr h Time to half-value Ri Input resistance Ci Input capacitance min typ 8 min 35 14 typ U i abs Input voltage limits without any damage min 70 20 typ CM/CMZ max min 100 28 typ 15 30 50 60 2.0 1.2 1.0 1.5 9 9 1 7 6 1.5 9 9 1 7 6 1.5 9 9 1 7 6 max Unit 140 V DC A 1.5 9 9 2 2 2 2 400 500 400 170 4 60 50 170 TC = 25C FM max 4.0 1 7 6 Ui = Ui max RS = 0 3 TC = 25C BM max 40 100 87.5 A s 60 60 140 W 280 824 4 250 m 2600 4000 670 1100 370 600 370 600 F 0 40 0 80 0 120 0 160 V DC Table 2b: Input data Input DM/DMZ Characteristics Ui Conditions Operating input voltage Io = 0...Io nom TC min...TC max 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 inhibit mode Iinr p 6 Peak inrush current Ui = Ui max RS = 0 3 TC = 25C t inr r Rise time t inr h Time to half-value Ri Input resistance Ci Input capacitance Ui abs Input voltage limits without any damage 1 2 3 4 5 6 TC = 25C max min 44 Ui nom Nominal input voltage Ii typ EM typ LM/LMZ max 220 67 min typ 85 385 88 110 220 310 0.55 0.275 0.20 1 7 6 1.5 9 9 1 7 6 1.5 9 9 1 7 6 max Unit 264 V AC 1 372 V DC A 1.5 9 9 2 2 2 110 4 160 4 60 4 40 40 300 250 240 900 2000 4 2400 4 W A s 6200 4 m 140 270 140 270 140 270 F 0 400 5 -400 400 -400 400 V DC - - - - 0 284 V AC In AC powered mode: LM types: 47...440 Hz; LMZ types: 47...65 Hz. See: AC-DC Converters 100 W: M-Series. With multiple output modules, the same condition for each output applies. RS = source resistance. Value for initial switch-on cycle. 1 s max., duty cycle 1% max. Iinr p = Ui/(Rs + Ri). See also: Inrush Current. Edition 01/01.2001 5/25 Cassette Style DC-DC Converters M Series 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 Lock-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). Between Ui min and the undervoltage lock-out level the output voltage may be below the value defined in table: Output data (see: Technical Information: Measuring and Testing). Table 3: 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 FM 1000...3000 SPT 5 A 250 V 0001.2511 CM/CMZ 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 Reverse Polarity Reverse polarity at the input of AM, BM, CM, DM, FM and CMZ, DMZ types will cause the fuse to blow. In EM, LM and LMZ types a series diode will protect the module. A series diode is not incorporated in AM, BM, CM, DM, FM and CMZ, DMZ types to avoid unwanted power loss. Inrush Current I i [A] The CM, DM, EM, LM and CMZ, DMZ, LMZ (excluding FM) modules incorporate an 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. 04014 10.00 AM BM 1.00 04015 I i [A] A...EM LM 400 BM FM 350 CM/CMZ EM LM/LMZ AM 300 DM/DMZ 50; 250 FM 40; 200 0.10 1 2 3 4 5 6 U i DC ________ U i min DC Fig. 2 Typical input current versus relative input voltage at nominal output load LM/LMZ EM 30; 150 DM/DMZ 20; 100 10; CM/CMZ 50 t [ms] 0 0 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 4.0 LM Fig. 3 Typical inrush current at initial switch-on cycle and at Ui max [DC] versus time Edition 01/01.2001 6/25 Cassette Style DC-DC Converters M Series Electrical Output Data General conditions - TA = 25C, unless TC is specified. - Connector pins 2 and 23 interconnected, Uo = Uo nom (option P), R input not connected. Table 4: Output data Uo nom Output Characteristics Uo Output voltage Uo p Output overvoltage protection 6 Io nom Output current Conditions U i nom, I o nom 1 uo Output Switch. freq. Ui nom, Io nom 1 voltage IEC/EN 61204 5 Total noise BW = 20 MHz DUo U Static line regulation U i min...U i nom U i nom...U i max I o nom 1 3 4 5 6 48 V min typ max 5.07 5.13 11.93 Static load regulation U i nom I o nom...0 2 U i nom I o nom...0 3 12.07 14.91 21 15.09 23.86 25 24.14 47.72 41 48.28 Unit V 85 see Type Survey and Key Data see Fig. Typical output voltage Uo1 versus output currents Io 15 30 25 50 35 70 40 80 60 120 40 80 40 80 40 80 10 30 12 50 15 60 15 60 15 60 60 150 6 25 13 50 17 60 30 80 0 15 0 20 0 30 0 40 50 100 mVpp mV - 220 110 150 130 150 0.6 0.6 0.5 1 2 ms u o d c Dynamic Voltage U i nom cross load deviation Io nom 1/3 Io nom 3 regulation IEC/EN 61204 td c Recovery 4 time +10 -100 +10 -75 +10 -140 +20 -200 - mV 0.05 0.5 0.2 0.3 0.5 0.7 1 2 - ms a Uo 0.02 0.02 0.02 0.02 0.02 %/K 1.0 2.4 3.0 4.8 9.6 mV/K td 1 24 V min typ max Dynamic Voltage Ui nom load deviation Io nom 1/3 Io nom 2 regulation IEC/EN 61204 Recovery time uo d 2 15 V min typ max U i min...U i max TC min...TC max Output current limitation response DUo I c Static cross load regulation 4 12 V min typ max 7.5 Io L DUo I 5.1 V min typ max Temperature coefficient DUo/DTC U i min...U i max 0...I o nom 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 nom. See fig.: Dynamic load regulation. Condition for non-specified output, individually tested, other output(s) loaded with constant current Io nom. See fig.: Dynamic load regulation. Multiple output modules. See: Technical Information: Measuring and Testing. By suppressor diode. Edition 01/01.2001 7/25 Cassette Style DC-DC Converters Uo1 Uo1 nom M Series 05022 Io nom IoL1 IoL2,IoL3 1.0 .95 Uo 05010 uod DU o I Io1 Io2,Io3 0.5 td DU o I uod td t I o/I o nom 1 0 0.5 1.0 1.2 Io Io nom 0 10 s t 10 s Fig. 4 Typical output voltage Uo1 versus output currents Io. Fig. 5 Dynamic load regulation uo d versus load change. Thermal Considerations Thermal Protection If a converter is located in free, quasi-stationary air (convection cooling) at the indicated maximum ambient temperature TA max (see table: Temperature specifications) and is operated at its nominal input voltage and output power, the temperature measured at the: Measuring point of case temperature TC (see: Mechanical Data) will approach the indicated value TC max after the warm-up phase. However, the relationship between TA and TC depends heavily on the conditions of operation and integration into a system. The thermal conditions are influenced by input voltage, output current, airflow and temperature of surrounding components and surfaces. TA max is therefore, contrary to TC max, an indicative value only. A temperature sensor generates an internal inhibit signal which disables the outputs if the case temperature exceeds TC max. The outputs are automatically re-enabled if the temperature drops below this limit. 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 71C (e.g. 85C) if TC max is not exceeded. For -7 or -9 units at an ambient temperature TA of 85C with only convection cooling, the maximum permissible current for each output is approx. 50% of its nominal value as per figure. Io /Io nom 05031 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 Convection cooling TC max TA min 50 60 70 80 90 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 limitation which will cause an increase in case temperature. Consequently, a reduction of the max. ambient temperature by 10 K is recommended. Main or auxiliary outputs can be connected in series with any other output of the same or another module. In series connection, the maximum output current is limited by the lowest current limit. Output ripple and regulation values are added. Connection wiring should be kept as short as possible. Forced cooling 1.0 Output Protection 100 TA [C] 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! Fig. 6 Output current derating versus temperature for -7 and -9 units. Edition 01/01.2001 8/25 Cassette Style DC-DC Converters M Series Output Current Allocation for Special Types Output currents differing from those given for standard types (as per: Type Survey and Key Data) can be provided. A maximum output power of 50 W should be considered, if an ambient temperature range of -25...71C 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 Power-One's sales engineers for a proposal appropriate to your specific needs. See also: Commercial Information: Inquiry Form for Customized Power Supply. Table 5: Current allocation with special types 2 1 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 Special high current components required. 2 Temperature U i min has to be increased. 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 (see fig.: Output response as a function of input voltage or inhibit control) before the output voltage falls below 0.95 Uo nom. To achieve the hold-up times indicated in fig.: Typical hold-up time th versus relative input voltage at Io nom, AM, BM, CM, DM, FM and CMZ, 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. EM, LM and LMZ modules have a built-in series diode. In AM, BM, CM, DM, FM and CMZ, 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. Output Uo nom 0.95Uo nom Note: For additional hold-up time see also Description of Options: V ACFAIL Signal (VME). 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] 05024 1000.00 LM/LMZ EM 100.00 CM/DM CMZ/DMZ AM/BM/FM 05025 10.00 0.1 0 Ui tr tf t th 1 0 1.00 t Inhibit 1 0 Fig. 7 Output response as a function of input voltage (on/off switching) or inhibit control Edition 01/01.2001 t 0.10 1 2 3 4 5 6 Ui DC ______ Ui min DC Fig. 8 Typical hold-up time th versus relative input voltage at Io nom 9/25 Cassette Style DC-DC Converters M Series Table 6: Output response time t r and t f. 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 t r at Po = Po nom typ max A...LM 1001-7R and C/D/LMZ 1001-7R A...LM 1301-7R and C/D/LMZ 1301-7R A...LM 1501-7R and C/D/LMZ 1501-7R A...LM 1601-7R and C/D/LMZ 1601-7R A...LM 1901-7R and C/D/LMZ 1901-7R 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 considerably. Auxiliary Functions i Inhibit for Remote On and Off Iinh [mA] The outputs of the module may be enabled or disabled by means of a logic signal (TTL, CMOS, etc.) applied between the inhibit input i and the negative pin of output 1 (Vo1-). In systems with several units, this feature can be used, for example, to control the activation sequence of the converters. If the inhibit function is not required, connect the inhibit pin 2 to pin 23 to enable the outputs (active low logic, fail safe). For output response refer to: Hold-up Time and Output Response. 2.0 1.2 0.8 0.4 Vi- Uo = off -0.4 -0.8 -50 I inh U inh Uo = on 0 Vo+ i Uinh = 2.4 V 1.6 06031 Vi+ Uinh = 0.8 V 06032 Note: With open i input: Output is disabled (Uo = off). -30 -10 0 10 30 50 Uinh [V] Fig. 10 Typical inhibit current I inh versus inhibit voltage U inh Vo- Fig. 9 Definition of Uinh and Iinh. Table 7: Inhibit data Characteristics U inh Inhibit input voltage to keep output voltage I inh Inhibit current Edition 01/01.2001 Uo = on Uo = off Conditions min U i min...U i max TC min...TC max -50 Uinh = 0 -60 typ 2.4 max Unit 0.8 V DC 50 -100 -220 A 10/25 Cassette Style DC-DC Converters M Series R-Control for Output Voltage Adjustment Notes: With open R input, Uo Uo nom. R excludes option P. Vo1+ As a standard feature, single output modules offer an adjustable output voltage identified by letter R in the type designation. R2 The output voltage Uo1 can either be adjusted with an external voltage (Uext) or with an external resistor (R1 or R2). The adjustment range is approximative 0...110% of Uo nom. For output voltages Uo > Uo nom, the minimum input voltage according to: Electrical Input Data increases proportionally to Uo/Uo nom. R1 Vo1+ 06087 Uref 4000 R Uext 4000 + - R G Fig. 12 Voltage adjustment with external resistor R1 or R2 b) Uo 0...100% Uo G (17): nom, using R1 between R (14) and 4000 * Uo R1 ---------- Uo nom - Uo R1 Uo Uo nom * ----------- R1 + 4000 + - + 06088 Uref c) Uo Uo G nom...Uo max, using R2 between R (14) and Vo1+ (20): Uo max = Uo nom + 10% Fig. 11 Voltage adjustment with external voltage Uext a) Uo 0...110% Uo nom, using Uext between R (14) and G (17): Uo Uext Uext 2.5 V * ----- Uo Uo nom * ----- Uo nom 2.5 V Caution: To prevent damage, Uext should not exceed 8 V, nor be negative. 4000 * Uo * (Uo nom - 2.5 V) R2 ------------------------ 2.5 V * (Uo - Uo nom) Uo nom * 2.5 V * R2 Uo -------------------------------- 2.5 V * (R2 + 4000 ) - Uo nom * 4000 Caution: To prevent damage, R2 should never be less than 47 k. Note: R inputs of n units with paralleled outputs may be paralleled, too, but if only one external resistor is to be used, its value should be R1/n, or R2/n respectively. Table 8a: R1 for Uo < Uo nom (conditions: Ui nom, Io nom, rounded up to resistor values E 96, R2 = ) Uo nom = 5.1 V Uo [V] R1 [k] 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 0.432 0.976 1.65 2.61 3.83 5.76 8.66 14.7 30.1 200.0 Uo nom = 12 V Uo [V] R1 [k] Uo nom = 15 V Uo [V] R1 [k] Uo nom = 24 V Uo [V] R1 [k] Uo nom = 48 V Uo [V] R1 [k] 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 2.0 4.0 6.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 4.0 6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0 22.0 8.0 12.0 16.0 20.0 24.0 28.0 32.0 36.0 40.0 44.0 0.806 1.33 2.0 2.87 4.02 5.62 8.06 12.1 20.0 44.2 0.619 1.47 2.67 4.53 6.04 8.06 11.0 16.2 26.1 56.2 0.806 1.33 2.0 2.87 4.02 5.62 8.06 12.1 20.0 44.2 0.806 1.33 2.0 2.87 4.02 5.62 8.06 12.1 20.0 44.2 Table 8b: R2 for Uo > Uo nom (conditions: Ui nom, Io nom, rounded up to resistor values E 96, R1 = ) Uo nom = 5.1 V Uo [V] R2 [k] 5.15 5.20 5.25 5.30 5.35 5.40 5.45 5.50 464 215 147 110 90.9 78.7 68.1 61.9 Edition 01/01.2001 Uo nom = 12 V Uo [V] R2 [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] R2 [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 Uo nom = 24 V Uo [V] R2 [k] 24.25 24.50 24.75 25.00 25.25 25.50 25.75 26.00 26.25 26.40 3160 1620 1100 825 715 590 511 453 402 383 Uo nom = 48 V Uo [V] R2 [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 11/25 Cassette Style DC-DC Converters M Series Display Status of LEDs 06002 Uo1 > 0.95...0.98Uo1 adj OK i Io L Ui Ui uv Ui min Ui max Ui ov Uo1 > 0.95...0.98Uo1 adj Fig. 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 abs Uo1 < 0.95...0.98Uo1 adj OK Io L Io Io nom IoL i TC max LED "OK" and "Io L"status versus output current Conditions: U i min...U i max, TC TC max, U inh 0.8 V TC LED "i"versus case temperature Conditions: U i min...U i max, I o I o nom, U inh 0.8 V Ui inh LED "i"versus U inh Conditions: U i min...U i max, I o I o nom, TC TC max TPTC threshold Uinh threshold i -50 V LED off Edition 01/01.2001 +0.8 V +2.4 V LED Status undefined +50 V LED on 12/25 Cassette Style DC-DC Converters M Series Electromagnetic Compatibility (EMC) A suppressor diode or a metal oxide VDR (depending upon the type) together with an input fuse and an input filter form an effective protection against high input transient voltages which typically occur in most installations, but especially in battery driven mobile applications. The M series has been successfully tested to the following specifications: Electromagnetic Immunity Table 9: Immunity type tests Phenomenon Standard 1 Level Coupling mode 2 Value applied Waveform Source imped. Test procedure 1 MHz burst disturbance IEC 60255-22-1 III i/o, i/c, o/o, o/c 2500 Vp 2 s per coupling mode yes A 1000 Vp 400 damped 1 MHz waves/s 200 +i/-i, +o/-o Voltage surge IEC 60571-1 100 1 pos. and 1 neg. voltage surge per coupling mode yes A 0.2 1 positive surge yes A 5 pos. and 5 neg. impulses yes A Supply related surge RIA 12 Direct transient RIA 12 EN 50155 (for EN 50155 levels D, G, H and L only) -i/c, +i/-i A4 +i/-i B Electrostatic discharge (to case) 100 s 50 s 3000 Vp 5 s 4000 Vp 1 s 7000 Vp 100 ns 3.5 * Ubatt 2/20/2 ms 1.5 * Ubatt 0.1/1/0.1 s 1 1.4 * Ubatt EN 50155 Indirect coupled transient 800 Vp 1500 Vp C -i/c, +i/-i 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 8400 Vp 0.05/0.1 s 1800 Vp 5/50 s H -o/c, +o/-o, -o/-i 5 100 J 3600 Vp 0.5/5 s K 4800 Vp 0.1/1 s L 8400 Vp 0.05/0.1 s contact discharge 8000 Vp 1/50 ns 330 yes A6 air discharge 15000 Vp 10 positive and 10 negative discharges antenna 20 V/m AM 80% 1 kHz n.a. 26...1000 MHz yes A5 30 V/m 50% duty cycle, 200 Hz repetition frequency 900 5 MHz yes A 2000 Vp 50 1 min positive 1 min negative transients per coupling mode yes A5 4000 Vp bursts of 5/50 ns 2.5/5 kHz over 15 ms; burst period: 300 ms 1.2/50 s 12 5 pos. and 5 neg. surges per coupling mode yes A 0.15...80 MHz yes B A5 IEC/EN 61000-4-2 4 Electromagnetic IEC/EN field 61000-4-3 x Electromagnetic ENV 50204 field, pulse modulated 4 Electrical fast transient/burst IEC/EN 61000-4-4 3 Surge IEC/EN 61000-4-5 4 i/c 4000 Vp 3 +i/-i 2000 Vp x i/c, +i/-i 2500 Vp 10/700 s 40 3 i, o, signal wires 10 Vrms (140 dBV) AM 80% 1 kHz 150 Conducted disturbances IEC/EN 61000-4-6 In Peroper. form. 3 direct, i/c, +i/-i 4 2 B 1 Related and previous standards are referenced in: Technical Information: Standards. i = input, o = output, c = case. 3 A = Normal operation, no deviation from specifications, B = Temporary deviation from specs possible. 4 Only met with extended input voltage range of BM (24 V battery), CM (48 V battery) and EM (110 V battery) types. These 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. 5 For converters with 3 output voltages, temporary deviation from specs possible. 6 With class II equipment (CMZ, DMZ, LMZ) only met if case is earthed. 2 Edition 01/01.2001 13/25 Cassette Style DC-DC Converters M Series Electromagnetic Emissions [dBV] 90 Table 10: Emissions at Ui nom and Io nom (LM/LMZ at 230 V AC) Level 80 A CISPR14/ EN 55014 30 MHz 70 50 B 60 AM 1000 AM 2000 AM 3000 B B B B B B <limit <limit <limit BM 1000 BM 2000 BM 3000 B B B A B A <limit <limit <limit CM 1000 CM 2000 CM 3000 B B B B B A <limit <limit <limit DM 1000 DM 2000 DM 3000 B B B B B A <limit <limit <limit EM 1000 EM 2000 EM 3000 B B B B B A <limit - FM 1000 FM 2000 FM 3000 B B B A A A <limit >limit - [dBV/m] 50 LM 1000 LM 2000 LM 3000 B B B B B A <limit <limit <limit 40 CMZ 1000 CMZ 2000 CMZ 3000 B A A >A <limit >limit DMZ 1000 DMZ 2000 DMZ 3000 A A >limit LMZ 1000 LMZ 2000 LMZ 3000 B A A A <limit >limit 40 30 20 10 0 20 30 10 5 2 1 0.5 0.1 0.02 0.01 MHz 0.05 Fig. 14 Typical disturbance voltage (quasi-peak) at the input according to CISPR 11/22 and EN 55011/22, measured at Ui nom and Io nom. 07036 A B 30 20 10 500 200 30 1000 [MHz] 0 100 CISPR11/EN 55011 CISPR22/EN 55022 30 MHz 30 MHz 50 Types 07007 Fig. 15 Typical radiated electromagnetic field strength (quasipeak) according to CISPR 11/22 and EN 55011/22, normalized to a distance of 10 m, measured at Ui nom and Io nom. Edition 01/01.2001 14/25 Cassette Style DC-DC Converters M Series Immunity to Environmental Conditions Table 11: Mechanical stress Test method Standard Test conditions Status Damp heat steady state IEC/DIN IEC 60068-2-3 MIL-STD-810D section 507.2 Temperature: Relative humidity: Duration: 40 2 C Ea Shock (half-sinusoidal) IEC/EN/DIN EN 60068-2-27 MIL-STD-810D section 516.3 Acceleration amplitude: Bump duration: Number of bumps: 100 gn = 981 m/s2 6 ms 18 (3 each direction) Unit operating Eb Bump (half-sinusoidal) IEC/EN/DIN EN 60068-2-29 MIL-STD-810D section 516.3 Acceleration amplitude: Bump duration: Number of bumps: 40 gn = 392 m/s2 6 ms 6000 (1000 each direction) Unit operating Fc Vibration (sinusoidal) IEC/EN/DIN EN 60068-2-6 MIL-STD-810D section 514.3 Acceleration amplitude: Unit operating Frequency (1 Oct/min): Test duration: 0.35 mm (10...60 Hz) 5 gn = 49 m/s2 (60...2000 Hz) 10...2000 Hz 7.5 h (2.5 h each axis) Ca Unit not operating 93 +2/-3 % 56 days Fda Random vibration wide band Reproducibility high IEC 60068-2-35 DIN 40046 part 23 Acceleration spectral density: Frequency band: Acceleration magnitude: Test duration: 0.05 g n2 /Hz 20...500 Hz 4.9 gn rms 3 h (1 h each axis) Unit operating Kb Salt mist, cyclic (sodium chloride NaCl solution) IEC/EN/DIN IEC 60068-2-52 Concentration: Duration: Storage: Storage duration: Number of cycles: 5% (30C) 2 h per cycle 40C, 93% rel. humidity 22 h per cycle 3 Unit not operating Table 12: Temperature specifications, valid for an air pressure of 800...1200 hPa (800...1200 mbar) Temperature Standard -7 Characteristics TA 1 2 3 Ambient temperature 1 min max min max Unit Operational 2 -25 71 -40 71 C -25 95 -40 95 -40 100 -55 100 3 TC Case temperature TS Storage temperature 1 Option -9 Conditions Non operational MIL-STD-810D section 501.2 and 502.2. See: Thermal Considerations. Overtemperature lock-out at TC >95C (PTC). Table 13: MTBF Values at specified case temperature 1 2 Module types MTBF 1 A...LM 1000 and C...LMZ 1000 A...LM 2000 and C...LMZ 2000 A...LM 3000 and C...LMZ 3000 Device hours 2 A...LM 1000 and C...LMZ 1000 A...LM 2000 and C...LMZ 2000 A...LM 3000 and C...LMZ 3000 Ground benign 40C 320'000 255'000 225'000 Ground fixed 40C 70C 130'000 105'000 80'000 40'000 32'000 28'000 Ground mobile 50C Unit 35'000 28'000 25'000 h 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 01/01.2001 15/25 Cassette Style DC-DC Converters M Series Mechanical Data European Projection 32 6TE 12.1 09012 28.6 26 29 23 20 17 14 11 8 2 5 Dimensions in mm. Tolerances 0.3 mm unless otherwise indicated. 20.5 34 100 0.6 Male connector H11 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) 173.7 0.5 127 159.4 22 Rear face Measuring point for case temperatureTC 68 168.5 0.5 Main face 4 Mounting plane of connector H11 (11.6) 88 111.2 0.8 (3U) 38.7 Back plate o 4.0 o 3.5 31.5 0.1 22.30 17.25 12.17 7.09 30.48 25.40 20.32 15.24 10.16 5.08 0 94.5 0.1 95 0.5 0 OK (LED green) Inhibit i (LED red) Potentiometer (option D) or potentiometer (option V) IoL (LED red) Test sockets (option A) Potentiometer(s) (option P) Fig. 16 DC-DC converter in case M02, weight 770 g (approx.). Case aluminium, black finish and self cooling. Edition 01/01.2001 Note: Long case, elongated by 60 mm for 220 mm rack depth, is available on request. 16/25 Cassette Style DC-DC Converters M Series Safety and Installation Instructions 10015 Connector Pin Allocation The connector pin allocation table defines the electrical potentials and the physical pin positions on the H11 connector. Pin no. 26, the protective earth pin present on all AM...LM (class I equipment) DC-DC converters is leading, ensuring that it makes contact with the female connector first. 32 29 26 23 20 17 14 11 8 5 2 Fig. 17 View of male H11 connector. Table 14: Pin allocation Electrical determination A...LM 1000 Pin Ident C...LMZ 1000 Pin Ident A...LM 2000 Pin Ident C...LMZ 2000 Pin Ident A...LM 3000 Pin Ident C...LMZ 3000 Pin Ident Inhibit control input Safe Data or ACFAIL 2 5 i D or V 2 5 i D or V 2 5 2 5 2 5 i D or V 2 5 i D or V Output voltage (positive) Output voltage (negative) 8 11 Vo1+ Vo1- 8 11 Vo1+ Vo1- 8 11 8 11 Vo3+ Vo3- 8 11 Vo3+ Vo3- Control input + 1 Control input - 14 17 R G 14 17 R G Output voltage (positive) Output voltage (negative) 1 2 Output voltage (positive) Output voltage (negative) 20 23 Protective earthing 2 26 DC input voltage 3 DC input voltage AC input voltage 4 AC input voltage i D or V i D or V 8 11 14 17 Vo2+ Vo2- 14 17 Vo2+ Vo2- 14 17 Vo2+ Vo2- 14 17 Vo2+ Vo2- Vo1+ Vo1- 20 23 Vo1+ Vo1- 20 23 Vo1+ Vo1- 20 23 Vo1+ Vo1- Vo1+ Vo1- 20 23 Vo1+ Vo1- 20 23 29 32 Vi+ Vi- 29 32 Vi+ Vi- 29 32 Vi+ Vi- 29 32 Vi+ Vi- 29 32 Vi+ Vi- 29 32 Vi+ Vi- 29 32 N P 29 32 N P 29 32 N P 29 32 N P 29 32 N P 29 32 N P 26 This function is not simultaneously available with option P Leading pin (pregrounding) 3 4 26 AM, BM, CM, DM, EM, FM and CMZ, DMZ types LM and LMZ types Installation Instructions The M series DC-DC converters are components, intended exclusively for inclusion within other equipment by an industrial assembly operation or by professional installers. Installation must strictly follow the national safety regulations in compliance with the enclosure, mounting, creepage, clearance, casualty, markings and segregation requirements of the end-use application. See also: Technical Information: Installation and Application. Connection to the system shall be made via the female connector H11 (see Accessories). Other installation methods may not meet the safety requirements. AM...LM DC-DC converters (class I equipment) are provided with pin no. 26 ( ), which is reliably connected with their case. For safety reasons it is essential to connect this pin with the protective earth of the supply system if required in: Safety of operator accessible output circuit . An input fuse is built-in in the connection from pin no. 32 (Vi- or P ) of the unit. Since this fuse is designed to protect the unit in case of an overcurrent and does not necessarily cover all customer needs, an external fuse suitable for the application and in compliance with the local requirements might be necessary in the wiring to one or both input pins (no. 29 and/or no. 32). Make sure that there is sufficient air flow possible for convection cooling. This should be verified by measuring the case temperature when the unit is installed and operated in the end-use application. The maximum specified case temperature TC max shall not be exceeded. See also: Thermal Considerations. If the end-product is to be UL certified, the temperature of the main isolation transformer should be evaluated as part of the end-product investigation. Protection Degree Condition: Female connector fitted to the unit. IP 40: All units, except those with options P, A or K, and except those with option D or V with potentiometer. IP 30: All units fitted with options A or K, except those with option P, and except those with option D or V with potentiometer. IP 20: All units fitted with option P, or with option D or V with potentiometer. Cleaning Agents In order to avoid possible damage, any penetration of liquids (e.g. cleaning fluids) is to be prevented, since the power supplies are not hermetically sealed. Important: Whenever the inhibit function is not in use, pin 2 (i) should be connected to pin 23 (Vo1-) to enable the output(s). Do not open the modules, or guarantee will be invalidated. Edition 01/01.2001 17/25 Cassette Style DC-DC Converters M Series Isolation The electric strength test is performed as a factory test in accordance with IEC/EN 60950 and UL 1950 and should not be repeated in the field. Power-One will not honour any guarantee/warranty claims resulting from electric strength field tests. Table 15: Isolation Characteristic Electric strength test voltage Input to case class I Input to case class II Input to output class I Input to output class II Required according to IEC/EN 60950 1.5 3.0 3.0 1 3.0 2.1 4.2 4.2 1 4.2 0.7 Actual factory test 1 s 2.8 5.6 5.6 1 5.6 1.4 AC test voltage equivalent to actual factory test 2.0 4.0 4.0 1 4.0 1.0 2.0 0.2 kVrms >300 >300 >300 >300 >300 >300 >100 2 M Insulation resistance at 500 V DC 1 2 Output to Output to Output to case case output option H 0.5 0.5 Unit - kVrms 0.7 - kV DC 2.8 0.3 In accordance with IEC/EN 60950 only subassemblies are tested in factory with this voltage. Tested at 300 V DC. For creepage distances and clearances refer to: Technical Information: Safety. Safety of Operator Accessible Output Circuit If the output circuit of a DC-DC converter is operator accessible, it shall be an SELV circuit according to the IEC/EN 60950 related safety standards. DC-DC converter to be an SELV circuit. Only voltage adaption and rectification to the specified input voltage range of the DC-DC converter is needed. Since the M series DC-DC converters provide double or reinforced insulation between input and output, based on a rated primary input voltage of 250 V AC and 400 V DC (for class II units 250 V AC and DC), only operational insulation is needed between the AC mains and the input of the DCDC converter. This means that there is no need for an electrical isolation between the AC mains circuit and the DC-DC converter input circuit to cause the output of an M series The following table shows a possible installation configuration, compliance with which causes the output circuit of the DC-DC converter to be an SELV circuit according to IEC/ EN 60950 up to a configured output voltage (sum of nominal voltages if in series or +/- configuration) of 36 V. However, it is the sole responsibility of the installer to assure the compliance with the relevant and applicable safety regulations. More information is given in: Technical Information: Safety. Table 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 Mains Operational (i.e. there is 250 V AC no need for electrical isolation between the mains supply voltage and theDC-DC converter input voltage) 1 2 Maximum rated DC output voltage from the front end Minimum required safety status of the front end output circuit DC-DC converter Result Equipment Safety status of the DC-DC converter output circuit Measures to achieve the specified safety status of the output circuit 400 V 1 (The Primary circuit rated voltage between any input pin and earth can be up to 250 V AC or 400 V DC) Class I Double or reinforced (A...LM) insulation, based on 250 V AC and 400 V DC (provided by the DC-DC converter) and earthed case 2 250 V 1 (The rated voltage between any input pin and earth can be up to 250 V AC or DC) Class II (CMZ, DMZ, LMZ) SELV circuit Double or reinforced insulation, based on 250 V AC or DC (provided by the DC-DC converter) The front end output voltage should match the specified operating input voltage range of the DC-DC converter. The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC/EN 60950. Edition 01/01.2001 18/25 Cassette Style DC-DC Converters Standards and Approvals Max. 250 V AC or 400 (250) V DC ~ AM...LM DC-DC converters correspond to class I equipment, while CMZ, DMZ, LMZ types correspond to class II equipment. All types are UL recognized according to UL 1950, UL recognized for Canada to CAN/CSA C22.2 No. 950-95 and LGA approved to IEC/EN 60950 standards. 10018 + Mains ~ AC-DC front end Battery Fuse Fuse Max. 250 V AC or 400 (250) V DC M Series DC-DC converter SELV - The units have been evaluated for: * Building in * Basic insulation between input and case and double or reinforced insulation between input and output, based on 250 V AC and 400 V DC (class I equipment) * Double or reinforced insulation between input and case and between input and output, based on 250 V AC and DC (class II equipment) * Operational insulation between output(s) and case * Operational insulation between the outputs * The use in a pollution degree 2 environment * Connecting the input to a primary or secondary circuit with a maximum transient rating of 2500 V Earth connection (class I) Fig. 18 Schematic safety concept. Use earth connection as per table: Safety concept leading to an SELV output circuit. Use fuse if required by the application. See also: Installation Instructions. The DC-DC converters are subject to manufacturing surveillance in accordance with the above mentioned UL, CSA, EN and with ISO 9001 standards. Description of Options Table 17: Survey of options Option Function of option Characteristic -9 Extended operational ambient temperature range TA = -40...71C A Test sockets at front panel for check of output voltage U o internally measured at the connector terminals E Electronic inrush current limitation circuitry Active inrush current limitation for CM, EM, LM, CMZ, LMZ P1 Potentiometer for fine adjustment of output voltage Adjustment range 5% of U o nom, excludes R input Input fuse built-in inside case Fuse not externally accessible F H 1 2 3 Enhanced output to case electric strength test voltage 2000 V AC (standard: 1000 V AC) 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) Function R excludes option P and vice versa Option D excludes option V and vice versa Only available if main output voltage Uo1 = 5.1 V -9 Extended Temperature Range P Potentiometer 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. 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. 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. Note: Potentiometers are not recommended for mobile applications. Table 18: 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. Edition 01/01.2001 19/25 Cassette Style DC-DC Converters M Series E Electronic Inrush Current Limitation F Fuse Not Accessible Available for CM, EM, LM and CMZ, LMZ types. 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 standard version of the modules CM, DM, EM, LM as well as CMZ, DMZ, LMZ include a passive inrush current limitation in the form of a NTC resistor. For applications which require an improved inrush current limitation, an active electronic circuit as shown in fig. 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 ETS 300132-2 if fitted with option E combined with option D6 (input voltage 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 ETS 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. 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 AM, BM, CM, FM or CMZ type or if a power component inside fails (switching transistor, freewheeling diode, etc). In such cases the defective unit has to be returned to Power-One for repair. H Enhanced Electric Strenght Test Electric strength test voltage output to case 2800 V DC (2000 V AC) instead of 1400 V DC (1000 V AC). Table 19: Inrush current characteristics with option E Characteristic CM, CMZ at Ui = 110 V DC typ max EM, LM, LMZ at Ui = 110 V DC typ max EM, LM, LMZ at Ui = 372 V DC typ max Iinr p Peak inrush current 6.5 8 2.2 4 7.3 10 A tinr Inrush current duration 22 30 10 20 20 40 ms 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 CM, EM, LM and CMZ, LMZ modules with a nominal output power of 51 W maximum. Converter Input Filter 11018 Control FET Rectifier (LM/LMZ types) RS RI Unit Ii [A] 11019 12 10 8 CM, CMZ at 110 V DC EM, LM, LMZ at 372 V DC 6 EM, LM, LMZ at 110 V DC 4 t inr t inr Ii = Po /(Ui * ) Normal operation (FET fully conducting) 2 t [ms] 0 0 10 20 30 40 Fig. 20 Typical inrush current waveforms of CM, CMZ, EM, LM and LMZ DC-DC converter with option E Ci Fig. 19 Option E block diagram Edition 01/01.2001 20/25 Cassette Style DC-DC Converters M Series D Undervoltage Monitor The input and/or output undervoltage monitoring circuit operates independently of the built-in input undervoltage lockout circuit. A logic "low" (JFET output) or "high" signal (NPN output) is generated at pin 5 as soon as one of the monitored voltages drops below the preselected threshold level Ut. The return for this signal is Vo1- (pin 23). The D output recovers when the monitored voltage(s) exceed(s) U t + U h. The threshold level 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 20: Undervoltage monitor functions Output type JFET NPN D1 1 2 3 4 D5 Monitoring Ui U o1 no Minimum adjustment range of threshold level Ut U ti U to yes - Typical hysteresis Uh [% of U t ] for U t min...U t max U hi U ho 3.5 V...48 V 1 - - 1 2.3...1 D2 D6 yes no U i min...U i max 3.0...0.5 - D3 D7 yes yes U i min...U i max 1 0.95...0.98 U o1 2 3.0...0.5 "0" D4 D8 no yes - 0.95...0.98 U o1 2 - "0" D0 D9 no yes - 3.5 V...48 V 3 - 1.8...1 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" Threshold level adjustable by potentiometer (not recommended for mobile applications) Fixed value between 95% and 98% of Uo1 (tracking) Fixed value, resistor-adjusted according to customer's specifications 2% at 25C; individual type number is determined by PowerOne Adjusted at Io nom 11006 Vo1+ JFET output (D0...D4): U i , U o1 status D output, U D U i or U o1 < U t low, L, U D 0.4 V at I D = 2.5 mA U i and U o1 > U t + U h high, H, I D 25 A at U D = 5.25 V Rp ID Input Connector pin D is internally connected via the drainsource path of a JFET (self-conducting type) to the negative potential of output 1. UD 0.4 V (logic low) corresponds to a monitored voltage level (Ui and/or Uo1) <Ut. The current ID through the JFET should not exceed 2.5 mA. The JFET is protected by a 0.5 W Zener diode of 8.2 V against external overvoltages. D UD Vo1- Fig. 21 Options D0...D4, JFET output 11007 Vo1+ NPN output (D5...D9): U i , U o1 status D output, U D U i or U o1 < U t high, H, I D 25 A at U D = 40 V U i and U o1 > U t + U h low, L, U D 0.4 V at I D = 20 mA Edition 01/01.2001 Rp Input Connector pin D is internally connected via the collectoremitter path of a NPN transistor to the negative potential of output 1. UD 0.4 V (logic low) corresponds to a monitored voltage level (Ui and/or Uo1) > Ut + Uh. The current ID through the open collector should not exceed 20 mA. The NPN output is not protected against external overvoltages. UD should not exceed 40 V. ID D UD Vo1- Fig. 22 Options D5...D9, NPN output 21/25 DC-DC Converters UD Threshold tolerances and hysteresis: DUti Uhi 11021 Po = 0 Po = Po nom UD high Po = 0 If Ui is monitored, the internal input voltage after the input filter and rectifier (EM, LM and LMZ types) is measured. Consequently this voltage differs from the voltage at the connector pins by the voltage drop DUti 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 DUti 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 Series Po = Po nom Cassette Style UD low Ui Uti Fig. 23 Definition of Uti, DUti and Uhi (JFET output) Input voltage monitoring NPN UD UD high 11008 3 3 3 3 UD low t 0 ID ID high ID low 0 t JFET UD UD high UD low 0 t tlow min4 th1 tlow min4 Uo1 Uo1 nom 1 0.95 tlow min4 thigh min th1 t 0 Ui [V DC] Uti +Uhi Uti t 0 Input voltage failure Input voltage sag Switch-on cycle Output voltage monitoring NPN UD UD high Switch-on cycle and subsequent input voltage failure 2 3 3 UD low t 0 ID ID high ID low 0 t JFET UD UD high UD low 0 t tlow min4 1 Uo1 2 Uo1 nom Uto +Uho Uto 3 t 0 4 See: Electrical 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 Output voltage failure Fig. 24 Relationship between Ui, Uo1, UD, ID and Uo1/Uo nom versus time. Edition 01/01.2001 22/25 Cassette Style DC-DC Converters 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 ti should be adequately above the minimum input voltage Ui min of the converter so that enough energy is remaining in the input capacitance. If the input voltage is below the required level, an external hold-up capacitor (Ci ext) should be added. Formula for threshold level for desired value of t h: U ti = M Series Formula for additional external input capacitor 2 * Po * (t h + 0.3 ms) * 100 C i ext = --------------------- - C i min * (U ti 2 - U i 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 Uti 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 AM, BM, CM, DM and 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 * Table 21: Available internal input capacitance and factory potentiometer setting of Ut i with resulting hold-up time Types AM BM CM/CMZ DM/DMZ EM FM LM/LMZ Ci min 2.6 0.67 0.37 0.14 0.14 0.37 0.14 mF Ut i 9.5 19.5 39 61 104 39 120 V DC th 0.34 0.69 1.92 1.73 6.69 2.92 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 Unit 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 22: Undervoltage monitor functions V output (VME compatible) V2 Monitoring Ui U o1 yes no U i min...U i max 1 1 V3 yes yes U i min...U i max V0 yes no U i min...U i max 3 4 yes yes Typical hysteresis U h [% of U t ] for U t min...U t max U hi U ho Minimum adjustment range of threshold level U t U ti U to U i min...U i max 34 - 0.95...0.98 U o1 2 0.95...0.98 U o1 2 3.0...0.5 - 3.0...0.5 "0" 2.2...0.4 - 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 25C) acc. to customer's specifications; individual type number is determined by Power-One. 11009 V output (V0, V2, V3): Vo1+ Ui, Uo1 status V output, UV U i or U o1 < U t low, L, U V 0.6 V at I V = 50 mA U i and U o1 > U t + U h high, H, I V 25 A at U V = 5.1 V Edition 01/01.2001 Rp Input Connector pin V is internally connected to the open collector of a NPN transistor. The emitter is connected to the negative potential of output 1. U V 0.6 V (logic low) corresponds to a monitored voltage level (U i and/or Uo1) < U t. The current I V through the open collector should not exceed 50 mA. The NPN output is not protected against external overvoltages. U V should not exceed 80 V. IV V UV Vo1- Fig. 25 Output configuration of options V0, V2 and V3 23/25 DC-DC Converters Threshold tolerances and hysteresis: M Series UV If Ui is monitored, the internal input voltage is measured after the input filter and rectifier (EM, 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 = 25C. The value of U t i depends upon the input voltage range (AM, BM, ...), threshold level U t i, temperature and input current. The input current is a function of input voltage and output power. DUti Uhi 11023 Po = 0 Po = 0 Po = Po nom UV high Po = Po nom Cassette Style UV low Ui Uti Fig. 26 Definition of Uti, Uti and Uhi Input voltage monitoring V2 UV UV high t low min 2 t low min 2 t low min 2 3 3 3 11010 4 4 2 2 UV low t 0 t low min V3 UV UV high 3 t low min 3 3 UV low t 0 th 1 th 1 Uo1 5.1 V 4.875 V 2.0 V 0 t Ui [V DC] Uti + Uhi Uti t 0 Input voltage failure Input voltage sag Switch-on cycle Switch-on cycle and subsequent input voltage failure Output voltage monitoring V2 UV UV high 4 UV low 4 t 0 V3 UV UV high t low min 2 3 3 4 UV low 0 t Uo1 5.1 V 4.875 V 2.0 V 0 t 1 2 Ui 3 Uti + Uhi Uti 4 VME request: minimum 4 ms t low min = 40...200 ms, typically 80 ms UV level not defined at Uo1 < 2.0 V The V signal drops simultaneously with the output voltage, if the pull-up resistor RP is connected to Vo1+. The V signal remains high if RP is connected to an external source. t 0 Output voltage failure Fig. 27 Relationship between U i, Uo1, U V, I V and Uo1 /Uo nom versus time. Edition 01/01.2001 24/25 Cassette Style DC-DC Converters M Series Accessories A variety of electrical and mechanical accessories are available including: - Front panels for 19" rack mounting, Schroff and Intermas systems. - Mating H11 connectors with screw, solder, fast-on or press-fit terminals. - Connector retention facilities. - Code key system for connector coding. - Flexible H11 PCB for mounting of the unit onto a PCB. - Chassis mounting plates for mounting the 19" cassette to a chassis/wall where only frontal access is given. - Universal mounting bracket for DIN-rail or chassis mounting. For more detailed information please refer to: Accessory Products. H11 female connector, Code key system Front panels Flexible H11 PCB Universal mounting bracket for DIN-rail mounting. Mounting plate, Connector retention clips Edition 01/01.2001 25/25