Rugged Environment Class l:-Equipment Single: output:::series: AM: EM:1000 Double: output: series AM: .-EM 2000 Triple-outout::series: AM: EM: 3000 Class ll Equipment (double insulation): [5] Single output: series CMZ,;DMZ, LMZ:1000 Double:output::series:CMZ;; DMZ."EMZ:2000 Triple output: series: CMZ;; DMZ: EMZ 3000 + Extremely wide: input voltage range suitable for battery (and: AC): operation Efficient:input filter and: built-in: surge:and: transient suppression circuitry * 5600: V DC input to:output electric strength test * Outputs individually isolated: and controlled + Outputs Tully protected: against overload Safety according to: |EC/EN: 60950 LGA Awwaw CE Summary The M-family of DC-DC (AC-DC) converters represents a broad and flexible range of power supplies for use in ad- vanced 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 tran- sients occuring at the source lines. An input over- and undervoltage lock-out circuitry disables the outputs if the in- put voltage is outside the specified range. Certain types in- clude an inrush current limitation preventing circuit break- ers and fuses from being damaged at switch-on. All outputs are open- and short-circuit proof and are pro- tected against overvoltages by means of built-in suppressor diodes. The outputs can be inhibited by a logic signal ap- plied to the connector pin 2 (i). If the inhibit function is not used pin 2 should be connected to pin 23 to enable the out- puts. LED indicators display the status of the converter and allow visual monitoring of the system at any time. Table of Contents SUMIMALY oo. e eee ceeeeeeeeeeeeeeee erent eeeaaeeeeeeaeeenaeeeeenaeeesaaes Type Survey and Key Data Type Key and Product Marking ...........:::eseeeeeeseeeee 7-23 Functional Description Electrical Input Data ............. Electrical Output Data Auxiliary FUNCTIONS 0.0.0. eee eset eneeeeeenneeeeeeeeetneeeeees DC-DC Converters <100 W 50 W DC-DC (AC-DC) Converters M-Family M-Family 40 168 157 6.6 Full input to output, input to case, output to case and output to output isolation is provided. The modules are designed and built according to the international safety standard IEC/EN 60950 and have been approved by the safety agen- cies 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 7c 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 in- dividual applications. The modules may either be plugged into 19 inch rack sys- tems according to DIN 41494, or be chassis mounted. Electromagnetic Compatibility (EMC) 0.0... eee Immunity to Environmental Conditions Mechanical Datta ....... eee eesseeseeeeeeseeeeeenaeeeeeees Safety and Installation Instructions ............... Description of Options 0... eceeeeeeeeeseeeeeeeees ACCOSSOLSIOS 0... eeeceeeeneeeeenneeeeeeeeeeeneeeeeeaeeeseneeeetnaeeeeas Edition 3/12.97/CD 1.98 - Melcher AG? M-Family DC-DC Converters <100 W Rugged Environment Type Survey and Key Data Non standard input/output configurations or special custom adaptions are available on request. See also Commercial In- formation: 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 Melcher's field sales engineers for specific requirements. The best technical solution will carefully be considered and a detailed pro- posal submitted. Table 1a: Class | equipment Output:1 Output 2 Output 3 Input voltage: range:and efficiency ' Options O nom I nom Us nom. Ig nom: Us nom I nom U, mins Ur, max Trin Ui imine Oj max. Tmnin o mine Of max Termin VDE} TAR PIM DCE TAR oP IM DC} Al 8.35 VDC | [%]- |} 14.70 VDC | [96] | 20,100 VDC | [2%] 5.1 80 AM 1001-7R 72 | BM 1001-7R 74 | FM 1001-7R 74 -9 12.0 4.0 AM 1301-7R 79 | BM 1301-7R 80 | FM 1301-7R 80 P 150 34 AM 1501-7R 79 | BM 1501-7R 81 | FM 1501-7R 81 DO...D9 240 2.0 AM 1601-7R 81 | BM 1601-7R 83 | FM 1601-7R 82 | V0,V2,V3 48.0 1.0 AM 1901-7R 81 | BM 1901-7R 83 | FM 1901-7R 83 A 12.0 2.0 12.0 2.0 AM 2320-7 77 | BM 2320-7 79 | FM 2320-7 80 H 15.0 1.7 15.0 1.7 AM 2540-7 78 | BM 2540-7 80 | FM 2540-7 79 F 5.1 50 12.0 07 12.0 0.7 AM 3020-7 75 | BM 3020-7 76 | FM 3020-7 76 5.1 50 150 06 150 06 AM 3040-7 75 | BM 3040-7 76 | FM 3040-7 76 Table 1b: Class | equipment Output:1 Output: 2 Output 3 Input voltage range and efficiency Options O nom I nom Us nom. Ig nom: Us nom I nom U, mins Ur, max Trin Ui imine Oj max. Tmnin o mine Of max Termin [VDE} TAR PIM DCE PAR oP MDC} TAR | 28.440 VDC: | [94] |) 44...220 V DG | [96] | 88.872 VDE | [%] (85..,264 VAC) 5.1 80 CM 1001-7R 74 | DM 1001-7R 74 | LM 1001-7R 73 -9 12.0 4.0 CM 1301-7R 80 | DM 1301-7R 81 | LM 1301-7R 79 E 150 34 CM 1501-7R 82 | DM 1501-7R 82 | LM 1501-7R 78 P 240 2.0 CM 1601-7R 82 | DM 1601-7R 83 | LM 1601-7R 81 DO...D9 48.0 1.0 CM 1901-7R 82 | DM 1901-7R 83 | LM 1901-7R 81 | VO,V2,V3 12.0 2.0 12.0 2.0 CM 2320-7 79 | DM 2320-7 80 | LM 2320-7 77 A 15.0 1.7 15.0 1.7 CM 2540-7 80 | DM 2540-7 80 | LM 2540-7 78 H 5.1 50 12.0 07 12.0 0.7 CM 3020-7 76 | DM 3020-7 77 | LM 3020-7 73 F 5.1 50 150 06 150 06 CM 3040-7 76 | DM 3040-7 76 | LM 3040-7 71 Table 1c: Class Il equipment (double insulation) [Oo] Output Output 2 Output 3 Input: voltage range and efficiency ' Options Us nom: to nem Os nom te:nor Upon to nom OF nines: Oh max Tmniin Oh imines Olina Tein Ohinine Umax Tcin [V:DG}::[A] [VDC] :[A] IV: DG]: fA} 28...140: VDC) [9%]: 4a 220 VDC [Mh 8B 372. VDE [9%] (85::264:V:AC) 5.1 80 CMZ 1001-7R 74 | DMZ 1001-7R 74 | LMZ 1001-7R 73 -9 12.0 40 CMZ 1301-7R 80 | DMZ 1301-7R 81 | LMZ 1301-7R 79 E 15.0 34 CMZ 1501-7R 82 | DMZ 1501-7R 82 | LMZ 1501-7R 78 P 240 2.0 CMZ 1601-7R 82 | DMZ 1601-7R 83 | LMZ 1601-7R 81 DO...D9 48.0 1.0 CMZ 1901-7R 82 | DMZ 1901-7R 83 | LMZ 1901-7R 81 | V0,V2,V3 120 20 12.0 20 CMZ 2320-7 79 | DMZ 2320-7 80 | LMZ 2320-7 77 A 15.0 1.7 15.0 1.7 CMZ 2540-7 80 | DMZ 2540-7 80 | LMZ 2540-7 78 0 5.1 50 12.0 07 120 07 CMZ 3020-7 76 | DMZ 3020-7 77 | LMZ 3020-7 73 5.1 50 15.0 06 150 06 CMZ 3040-7 76 | DMZ 3040-7 76 | LMZ 3040-7 71 1 Efficiency at Uj nom and fo 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-Family. Edition 3/12.97/CD 1.98 - Melcher AGRugged Environment DC-DC Converters <100 W M-Family Type Key and Product Marking Type Key CMZ 2540-7ERPDVAHF Input voltage range U:: 8...35 VDC oe A 14..70V DC we B 20...100 VDC we F 28...140 VDC we. Cc 44...220V DC woe D 67...385 V DC wee E1 85...264 V AC, 88...372 V DC oe L FAUMILY oe eee ee eee ee centre eeeeeeeeneeeeeaaeesaeeeeeaeeeseaaeeseeeeeeneeeenes M Class I] EQuipMent 0.000... eeceeesneeeeenneeeeeeeeeeneeeennaeeeennes Z Number Of OUtQUtS 2000... eeeeececeeeeeeeeeeeeseeeeeeetsaeeneeeeaes 1...3 Output 1, Uo4 pom! 5.1 V 0...2 12V wie 3 IBV oe 4...5 24 wees 6 other voltages .......... 7...8 ABV wees 9 other specs for single output modules ...... 01...99 Output 2 and 3, Usa nom U3 nom' 5.1V .... 01...19 12V 0... 20...39 15V ow... 40...59 24V .... 60...69 other voltages for multiple output modules ...... 70...99 Ambient temperature range T,: 25...71O Leen -7 40...71C eee -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? Potentiometers for fine adjustment of output voltages ..... P2 Save data signal (DO...D9, to be specified) ee Ds ACFAIL signal (VO, V2, V3, to be specified) ....... ee vs Output voltage test SOCKEIS 0... eesseeeseeeeesteeeeenateeeenees A Increased electric strength test voltage (O/C) 0... ee H Input fuse built-in (not accessible) .........eeeeeeeseeeeeeeeeees F 1 EM types available upon request 2 Feature R excludes option P and vice versa 3 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. Product Marking (refer also to Mechanical Data) Main face: Basic type designation, applicable safety approval and recognition marks, CE mark, warnings, pin allocation, Melcher patent nos. and company logo. Front plate: Identification of LEDs, optional test sockets and potentiometers. Back plate: Specific tyoe designation, input voltage range, nominal output voltage(s) and current(s), pin allocation of op- tions and auxiliary functions, fuse specification and degree of protection. Rear face: Label with batch no., serial no. and data code comprising production site, modification status and date of pro- duction. Confirmation of successfully passed final test. Edition 3/12.97/CD 1.98 - Melcher AG? M-Family Functional Description The input voltage is fed via an input fuse, an input filter, a rectifier and an inrush current limiter 4 to the input capaci- tor. This capacitor sources a single transistor forward con- verter. 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 U,, and generates, with respect to the maximum admissible output currents, the control signal for the pri- DC-DC Converters <100 W Rugged Environment mary switching transistor. This signal is fed back via a cou- pling transformer. The auxiliary outputs Ue and Ups are individually regulated by means of secondary switching transistors. Each aux- iliary output's current is sensed using a current transformer. If one of the outputs is driven into current limit, the other out- puts will reduce their output voltages as well because all output currents are controlled by the same main control cir- cuit. bo ee ee ee eee eee 93009 _D pe | I nnn enn e eee Div | Maincontrolcircuit [ss sstssssSCSS<~S~S 5 GR 5 ees (ttttti<(;RN)TS****d;:CC Ree eee e ee @MGa | || || ' Bt _ 20, or a 7 a Output 1 zx i filter 7) fl glee Cr : ra ' >< 5 SI =| | 8 R Control | Output 2 te 5 px circuit filter a eg} | a go = ' =a : h o% Cukt =F 4 _ 8 T Control x Output 3 +O circuit filter a 5 \ Y == == == ! Fig. la Block diagram, class | equipment we eee Dooce cece ee cee eee ceeeeeeeeeeeeeeceeeeeceee.Q8010 | Il Il i ' ' I i TS ' cyHl cya rE | 2) j nnn nee nee ene ef ene pv | Main control circuit [se el an) GR : 5A ee farm gene ees @a I ' by = ~ ! | a Output 1 ae Vi + . filter 8) | 1 2 3 o N C => 1 oF Pi K 5x MKT =F ' to ra ' > x _ a ' Bh 4 =]: ! gk m Control | 5 Output 2 te : 5 px circuit filter A 1 2 1 4 ox =]: =o ' ! Hh os Cut ! ; = 8 Control IK Output 3 +O | circuit filter f Fig. 16 Block diagram, class |! equipment (double insulation) 1 Transient suppressor (VDR) in CM, DM, EM, FM, LM and CMZ, DMZ, LMZ. 2 Transient suppressor diode in AM, BM, CM, FM and CMZ types. 3 Bridge rectifier in LM and LMZ, series diode in EM types. 4 Inrush current limiter (NTC) in CM, DM, EM, LM and CMZ, DMZ, LMZ types (option E: refer to the description of option E). 5 Single output modules AM...LM 1000 and CMZ...LMZ 1000 with feature R. For output configuration please refer to table Pin allocation. Edition 3/12.97/CD 1.98 - Melcher AGRugged Environment DC-DC Converters <100 W M-Family Electrical Input Data General conditions: Ta = 25C, unless Tc is specified. Connector pins 2 and 23 interconnected, with option P: Up = Us nom, R input not connected. Table 2a: Input data Input AM BM FM CM/CMZ Characteristics Conditions Min Ay OM ae RAIN ype MX ENE YS TE ATI type ma eS UATE U; Operating input voltage | /, = 0... fo nom 8 35 14 70 20 100 28 140 | VDC U nom | Nominal input voltage | min--- 1c max 15 30 50 60 j Input current Uinom, fo nom? 4.0 2.0 1.2 1.0 A P No-load input power: Uji nom Single output fo1239=0 1 1.5 1 1.5 1 1.5 1 1.5 Ww Double output 7 9 7 9 7 9 7 9 Triple output 6 9 6 9 6 9 6 9 Piinn | Idle input power inhibit mode 2 2 2 2 line p | Peak inrush current U; = Ui max 400 500 400 1704 A tir: | Rise time Rs = 0 28 60 50 40 60 us To = 25C torn | Time to half-value 170 100 60 280 RB; Input resistance Te = 25C 87.5 140 250 8244 mQ Ci Input capacitance 2600 4000 | 670 1100 | 370 600 | 370 600 uF U jabs | Input voltage limits 0 40 0 80 0 120 0 160 | VDC without any damage Table 2b: input data Input DM/DMZ EM LM/EMZ Gharacteristics Gonditions min typ Max: }ocmin typ max min typ. max Unit U Operating input voltage | 4, = 0...fo nom - - 85 264 VAC! Te min--- Te max 44 220 | 67 385 | 88 372 | VDC U; om| Nominal input voltage 110 220 310 I Input current U om: to nom 0.55 0.275 0.20 A P. No-load input power: U nom Single output hio3=0 1 1.5 1 1.5 1 1.5 Ww Double output 7 9 7 9 7 9 Triple output 6 9 6 9 6 9 P ign | Idle input power inhibit mode 2 2 2 linrp | Peak inrush current U =U nox 1104 1604 604 A a Rg =0 Q8 tin, | Rise time Tr _ 25C 40 40 300 us tinrh | Time to half-value 250 240 900 R_ | Input resistance To = 25C 2000 4 2400+ 62004 mQ C, Input capacitance 140 270 140 270 140 270 pF U. aps | Input voltage limits 0 4005 | -400 400 | 400 400 VDC without any damage _ _ _ _ 0 284 VAC 1 In AC powered mode: LM types: 47...440 Hz; LMZ types: 47...65 Hz. See AC-DC Converters <100 W: M-Family. 2 With multiple output modules, the same condition for each output applies. 3 Rs = source resistance. 4 Value for initial switch-on cycle. 5 1s max., duty cycle 1% max. Intp = U/(As + Ai). See also Inrush Current. Edition 3/12.97/CD 1.98 - Melcher AGM-Family 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 U, min or exceeds 1.1U; max (approx. values), an internally generated inhibit signal disables the output(s). When checking this function the absolute maximum input voltage rating U; abs must be carefully considered (see table: Input data). ATA 04014 10.00 AM BM 1.00 FM CM/CMZ DM/DMZ EM LM/LMZ Vide 0.10 1 2 3 4 5 6 Yimin de Fig. 2 Typical input current versus relative input voliage at nominal output load DC-DC Converters <100 W Rugged Environment Table 3: Fuse types (slow-blow) Series Schurter:type Partnumber. AM 1000...3000 | SPT10A 250V 0001.2514 BM 1000..3000 |SPT8A 250V 0001.2513 FM 1000..3000 | SPT5A 250V 0001.2511 CM/CMZ 1000...3000 | SPT3.15A 250 V 0001.2509 DM/DMZ 1000..3000 | SPT25A 250V 0001.2508 EM 1000...3000 LM/LMZ 1000...3000 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 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 in- rush current to avoid damage to connectors and switching devices. Subsequent switch-on cycles within a short inter- val will cause an increase of the peak inrush current due to the warming up of the NTC resistor. Refer also to Option E description. KA] 04015 A...EM LM 400 - BM 350 4 AM 300 50; 250 40; 20044 LM/LMZ 30; 150-4 EM DM/DMZ 20; 100 + CM/CMZ 10; 50 it [ms ee ee ee 0 02 04 06 08 1.0 1.2 1.4 1.6 A...EM 05 10 15 20 25 30 35 40 LM Fig. 3 Typical inrush current at initial switch-on cycle and at Ui max [DC] versus time Edition 3/12.97/CD 1.98 - Melcher AGRugged Environment DC-DC Converters <100 W M-Family Electrical Output Data General conditions Ta = 25C, unless Tc is specified. Connector pins 2 and 23 interconnected, Up = Us nom (option P), R input not connected. Table 4: Output data Output Us nom BAN 12-V 15:V, 24a-V. 48:V: Characteristics Conditions min typ max AA typ max in typed | min typ ra omnia typo make fo Unit Up Output voltage Uinom: fo nom 5.07 5.13 | 11.93 12.07|14.91 15.09/23.86 24.14/47.72 48.28) V U,, | Output overvoltage 75 21 25 4 85 protection Ignom | Output current Ui min--- Ui max see Type Survey and Key Data fo Output current Te min... Tc max see Fig. Typical output voltage U,, versus output currents |, limitation response Uo Output | Switch. freq.} Usnom, fonom | 15 30 25 50 35 70 40 80 50 100 | MVop voltage IEC/EN 612045 Total 60 120 40 80 40 80 40 80 - noise | BW = 20 MHz AU, y | Static line regulation | Uj min---Ui nom +10 +30 +12 +50 +15 +60 +15 +60 +15 +60 | mV Ui nom:-- Uj max I, nom 1 AU,| | Static load regulation] Uj nom 6 25 13 50 17 60 30 80 60 150 Io nom.--0 2 AU, | -| Static cross load Ui nom QO +15 QO +20 0 +30 0 +40 - regulation 4 Io nom.--03 Ua |Dynamic | Voltage Ui nom +220 +110 +150 +130 +150 load deviation | fy nom 1/3 lo nom2 ty regulation Recovery IEC/EN 61204 0.6 0.6 0.5 1 2 ms time Uode |Dynamic | Voltage Ui nom +10 +10 +10 +20 - mV cross load} deviation | fo nom 1/3 bo nom? -100 -75 -140 200 - tdc regulation Recovery IEC/EN 61204 0.05 0.2 0.5 1 - ms time 0.5 0.3 0.7 2 - Quo | Temperature Ui min--- Ui max +0.02 +0.02 +0.02 +0.02 +0.02 ol K coefficient 0..-fonom +1.0 42.4 +3.0 +4.8 +9.6 mv/K AUSATe 1 With multiple output modules, the same condition for each output applies. 2 Condition for specified output. With multiple output modules, other output(s) loaded with constant current / nom. See fig. Dynamic load regulation. 3 Condition for non-specified output, individually tested, other output(s) loaded with constant current fy nom. See fig. Dynamic load regu- lation. 4 Multiple output modules. 5 See Technical Information: Measuring and Testing. 8 By suppressor diode. Edition 3/12.97/CD 1.98 - Melcher AGM-Family | | | | | | hol. o5+ 1 027/03 i; od i Wea | | 1 il 1 tp 7 if |! i tp ik gy 0 iH 1h 9 05 1.0 12 ono Fig. 4 Typical output voltage U,, versus output currents |b. Thermal Considerations If a converter is located in free, quasi-stationary air (con- vection cooling) at the indicated maximum ambient tem- perature 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 in- dicated value Tc max after the warm-up phase. However, the relationship between Ta and Tc depends heavily on the con- ditions of operation and integration into a system. The ther- mal conditions are influenced by input voltage, output cur- rent, airflow and temperature of surrounding components and surfaces. Ta max is therefore, contrary to 7c max, an in- dicative value only. Caution: Fhe:installer must ensure that: under all operat- Ing: conditions: :7e 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 To max is not exceeded. For -7 or -9 units at an ambient temperature 7, of 85C with only convection cooling, the maximum permissible current for each output is approx. 50% of its nominal value as per figure. fall nom A Forced cooling \ 1.0-+* 0.9 + 0.8 + 0.7 4 0.6 + 0.5 + --------------4----- 0.4 4 0.3 4 0.2 4 0.1 4 0 Z ! ! ! ! ! Lm FT 1C Tham 50. 60 70 80 90 100 tC Fig. 6 Ouiput current derating versus temperature for -7 and -9 units. -e0s0 Te max DC-DC Converters <100 W Rugged Environment U, 7 05010 You] | AU, | AU, | x | [ | | t | lollo nom 1 | | | | | 0 t ol! >10 us _ 1/210 ps Fig. 5 Dynamic load regulation u, 4 versus load change. Thermal Protection A temperature sensor generates an internal inhibit signal which disables the outputs if the case temperature exceeds Tc max. The outputs are automatically re-enabled if the tem- perature drops below this limit. Output Protection Each output is protected against overvoltages which could occur due to a failure of the internal control circuit. Voltage suppressor diodes (which under worst case condition may become a short circuit) provide the required protection. The suppressor diodes are not designed to withstand externally applied overvoltages. Overload at any of the outputs will cause a shut-down of all outputs. A red LED indicates the overload condition of the respective output. Parallel and Series Connection Main outputs of equal nominal voltage can be connected in parallel. It is important to assure that the main output of a multiple output module is forced to supply a minimum cur- rent of 0.1 Ato 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 possi- ble. If output terminals are connected together in order to estab- lish 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 exces- sive output ripple voltages. Auxiliary outputs should never be connected in parallel! Edition 3/12.97/CD 1.98 - Melcher AGRugged Environment 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 volta- ges are different from standard values, the relevant output currents have to be adapted accordingly. Table 5: Current allocation with special types DC-DC Converters <100 W M-Family With reduced maximum ambient temperature or with forced cooling, the total output power may exceed 50 W. Custom- ized configurations always need to be checked by a feasibil- ity study first. Please ask Melcher's sales engineers for a proposal appropriate to your specific needs. See also Com- mercial Information: Inquiry Form for Customized Power Supply. Output voltage Output 1 Output 2 Output 2 Output 3 Temperature alktypes alltypes A..: EM: 2000 A:.:.LM:3000 A,;.LEM:3000 Ue4/3/3 nom EV] Foy max: [A} fea max. [A] Toa max [A] 163 max: [A] Tp PC] Te [C] 5.1 8.0 4.0 1.8 (2.51) 1.5 -25...71 -25...95 12 4.0 2.0 1.5 1.2 15 3.4 1.7 1.2 1.0 24 2.0 1.0 0.7 0.5 2 5.1 10.0 45 2.1 (2.8 1) 1.8 -25...60 -25...90 12 5.0 2.5 1.7 1.5 15 4.0 2.0 1.5 1.3 24 2.5 1.3 0.9 0.7 5.1 11.0 5.0 2.4 (3.01) 2.0 -25...50 -25...85 12 6.0 3.0 2.0 1.7 15 46 2.3 1.7 1.5 24 3.0 1.5 1.0 0.8 1 Special high current components required. ? Uj 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 # (see fig. Output response as a function of input voliage or inhibit control) be- fore the output voltage falls below 0.95 Up nom. To achieve the hold-up times indicated in fig. Typical hold-up time t, versus relative input voltage at ly 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 opera- tional ambient temperature would have to be reduced ac- cordingly. Output 05025 Up nom 0.95U, nom Inhibit 1 0 Fig. 7 Ouiput response as a function of input voltage (on/off switching) or inhibit control Note: For additional hold-up time see also Description of Options: V AVFAIL 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. t, [ms] 05024 1000.00 LM/LMZ EM CM/DM CMZ/DMZ AM/BM/FM 100.00 10.00 1.00 Uioc 0.10 Ui minde 1 2 3 4 5 6 Fig. 8 Typical hold-up time t, versus relative input voltage at Ip nom Edition 3/12.97/CD 1.98 - Melcher AGM-Family DC-DC Converters <100 W Rugged Environment Table 6: Output response time t, and t;. Values not applicable for modules equipped with option E. Type of converter. ty at Ps= O:and i at Po= Po nom t and i at Pyaty Py hom: t at Py= P, nom Unit typ max typ max typ max A...LM 1001-7R and C/D/LMZ 1001-7R 5 10 5 10 10 20 ms A...LM 1301-7R and C/D/LMZ 1301-7R 10 20 15 30 20 40 A...LM 1501-7R and C/D/LMZ 1501-7R 5 10 10 20 30 60 A...LM 1601-7R and C/D/LMZ 1601-7R 15 30 25 50 40 80 A...LM 1901-7R and C/D/LMZ 1901-7R 65 130 100 200 165 330 A...LM 2320-7 and C/D/LMZ 2320-7 20 40 30 60 50 100 A...LM 2540-7 and C/D/LMZ 2540-7 15 30 20 40 35 70 A...LM 3020-7 and C/D/LMZ 3020-7 55 110 85 170 145 290 A...LM 3040-7 and C/D/LMZ 3040-7 40 80 60 120 100 200 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 Uj min...Uj max does not influence the values considerably. Auxiliary Functions i Inhibit for Remote On and Off : Wi i input: is di = fn [MA Note: With open i input: Output is disabled (U, off. inn [MA] Un, = 0.8V Unp =2.4V The outputs of the module may be enabled or disabled by 20 o means of a logic signal (TTL, CMOS, etc.) applied between 8 7 the inhibit input i and the negative pin of output 1 (Vot1). In 1.6 systems with several units, this feature can be used, for ex- 4.2 ample, to control the activation sequence of the converters. If the inhibit function is not required, connect the inhibit pin 0.8 2 to pin 23 to enable the outputs (active low logic, fail safe). 0.4 For output response refer to Hold-up Time and Output Re- sponse. 0 rrr rrr I 06031 0.4 O Vi+ Vo+ OO, ' ie finn ( L 08 Unn [VI I i -50 -30 -10 0 10 30 50 I . i ; Uinn Fig. 10 ! 1 Typical inhibit current lin, versus inhibit voltage Uinn O vi- Vo QO L----~--------4 Fig. 9 Definition of Vinh and Inn. Table 7: Inhibit data Characteristics Conditions min typ max Unit Uinn | Inhibit input voltage to keep U, =on Ui min--- Ui max -50 0.8 vbc output voltage U, = off To min. TC max 2.4 50 Tinh Inhibit current Unn =O -60 -100 220 yA Edition 3/12.97/CD 1.98 - Melcher AGRugged Environment R-Control for Output Voltage Adjustment Notes: With open R input, U, = Up nom. R excludes option P. As a standard feature, single output modules offer an adjustable output voltage identified by letter R in the type designation. The output voltage U,; can either be adjusted with an exter- nal voltage (Uex:) or with an external resistor (Ay or Ae). The adjustment range is approximative 0...110% of Us nom. For output voltages Up > Us nom, the minimum input voltage ac- cording to Electrical Inout Data increases proportionally to U/ Up nom: Fig. 117 Voltage adjusiment with external voltage Usxt a) Up = 0...110% Ub nom, Using Us; between R (14) and G (17): Uext = 2.5 V Uo _ Vext Up nom * 25V Caution: To: prevent: damage; Us: should: not exceed 8; -norbe negative. DC-DC Converters <100 W M-Family Fig. 12 Voltage adjustment with external resistor Ry or Ro b) Uy = 0...100% Up nom, using A; between R (14) and G (17): R, 4000 2+ Uy R, + 4000 Py = U, = Us nom * U. ~U, ionom 0 C) Us = Us nom---Uo max, USINg Ao between R (14) and Vo1+ (20): Us max = Uonom+ 10% Ro = 4000 2 Uy * (Up nom 2-5 V) 2.5 V * (Uo Us nom) _ Up nom * 2.5 V * Ro ~ 2.5 V+ (Re + 4000 Q) Upnom* 4000 O Ug Caution: To prevent: damage; As should: never be:less than: 47 kQ. 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 R;/n, or Re/n respectively. Table 8a: R; for Uy < Uy nom (conditions: Uinom; ' nom, founded up to resistor values E 96, Ro = -) Os pom = B1-N. UOsnom:e12.V. Us inom = 15:V. Usinom = 24V: Us nom = 48.V. Us [VJ Ay [KO] Us [VJ Ry [ko] U, {V] Ay [kQ] U, [VJ Ay [kQ] Up [V] Ay [KO] 0.5 0.432 2.0 0.806 2.0 0.619 4.0 0.806 8.0 0.806 1.0 0.976 3.0 1.33 4.0 1.47 6.0 1.33 12.0 1.33 1.5 1.65 4.0 2.0 6.0 2.67 8.0 2.0 16.0 2.0 2.0 2.61 5.0 2.87 8.0 4.53 10.0 2.87 20.0 2.87 2.5 3.83 6.0 4.02 9.0 6.04 12.0 4.02 24.0 4.02 3.0 5.76 7.0 5.62 10.0 8.06 14.0 5.62 28.0 5.62 3.5 8.66 8.0 8.06 11.0 11.0 16.0 8.06 32.0 8.06 4.0 14.7 9.0 12.1 12.0 16.2 18.0 12.1 36.0 12.1 4.5 30.1 10.0 20.0 13.0 26.1 20.0 20.0 40.0 20.0 5.0 200.0 11.0 44.2 14.0 56.2 22.0 44.2 44.0 44.2 Table 8b: Ro for Uy > Us nom (conditions: Ui nom, 'b nom, founded up to resistor values E 96, Ry = -) Us nom = DEV. Us som = 12-V. Us nom: = 1B:N. Us nom = 24NV. Us nom = 48:V. Uc TV] Fis [kQ] UG TV] Fie [ko] USN] Po TkQ] UgIV] Fo [ko] Us [VI Fe [kQ] 5.15 464 12.1 1780 15.2 1470 24.25 3160 48.5 6810 5.20 215 12.2 909 15.4 750 24.50 1620 49.0 3480 5.25 147 12.3 619 15.6 511 24.75 1100 49.5 2370 5.30 110 12.4 464 15.8 383 25.00 825 50.0 1780 5.35 90.9 12.5 383 16.0 332 25.25 715 50.5 1470 5.40 78.7 12.6 316 16.2 274 25.50 590 51.0 1270 5.45 68.1 12.7 274 16.4 237 25.75 511 51.5 1100 5.50 61.9 12.8 249 16.5 226 26.00 453 52.0 953 13.0 200 26.25 402 52.5 845 13.2 169 26.40 383 52.8 806 Edition 3/12.97/CD 1.98 - Melcher AGM-Family Display Status of LEDs U, > 0.95. ..0.98 Uo) agj 06002 Uj | | | Uj uv Uj min Uj max Uj ov Uj abs U5, > 0.95...0.98U,, adj U5, < 0.95...0.98U,, adj DC-DC Converters <100 W Rugged Environment Fig. 13 LEDs OK" and "i" status versus input voltage Conditions: Ip S$ lonom, ToS Tomax, Uinn S 0.8 V Ui w = undervoliage lock-out, Uj oy = overvoltage lock-out OK LED "OK" and "|, ."status versus output current bx ee. Conditions: Uj min-.-Ui max Te S Te maxy Uinn $ 0.8 V | | l nom fot es LED i"versus case temperature To Conditions: U; min--Ui max lo S lo noms Uinn $ 0.8 V To max Tet threshold Binh threshold i a | LED "i"versus Vinh inn Conditions: Uj min.--Ui max: fo S lo nom: To S Te max -50 V +0.8V +2.4V +50 V [_] LED off = LED Status undefined ME LED on 7-32 Edition 3/12.97/CD 1.98 - Melcher AGDC-DC Converters <100 W Rugged Environment M-Family Electromagnetic Compatibility (EMC) Asuppressor diode or a metal oxide VDR (depending upon the type) together with an input fuse and an input filter form which typically occur in most installations, but especially in battery driven mobile applications. The M-family has been an effective protection against high input transient voltages Electromagnetic Immunity Table 9: Immunity type tesis successfully tested to the following specifications: Phenomenon | Standard": Level Coupling Value Waveform): Source Test In Per- mode 2 applied imped; procedure oper. |form.? 1 MHz burst IEC Ul i/o, i/c, o/o, o/c | 2500 Vp 400 damped 200 2s per yes A disturbance 60255-22-1 +i/, +0/-0 1000 V, 1 MHz waves/s coupling mode Voltage surge IEC 60571-1 -i/c, +i/-i 800 V, 100 us 100 2 | 1 pos. andineg. | yes A 1500 V> 50 us voltage surge per coupling mode 3000 V, 5 us 4000 V, ius 7000 Vp 100 ns Supply related RIA 12 A4 +i/-i 3.5 Ubatt 2/20/2 ms 0.22 1 positive yes A surge B 1.5 Ubar | 0.1/1/0.1s surge EN 50155 1.4 Upatt 12 Direct transient | RIA 12 Cc -i/c, +i/-i 960 V, 10/100 us 5Q 5 pos. and5neg. | yes A EN 50155 impulses D 1800 V, 5/50 (for EN 5015 p HS levels D, G, E 3600 V, 0.5/5 us 100 2 HandLonly)) 4800 Vp 0.1/1 us G 8400 V, 0.05/0.1 us Indirect coupled H o/c, +0/-0, -o/-i| 1800 V, 5/50 us transient J 3600 V> 0.5/5 us K 4800 V, 0.1/1 us L 8400 V, 0.05/0.1 us A Electrostatic IEC/EN 4 | contact discharge} 8000 V, 1/50 ns 330 10 positive and yes A discharge 61000-4-2 air discharge | 15000 V> 10 negative (to case) discharges Electromagnetic | IEC/EN x antenna 20 V/m AM 80% na. 26...1000 MHz yes A field 61000-4-3 1 kHz Electromagnetic | ENV 50204 4 30 V/m_ | 50% duty cycle, 900 +5 MHz yes A field, 200 Hz repetition pulse modulated frequency Electrical fast IEC/EN direct, i/c, +i/-i | 2000 V, | bursts of 5/50 ns} 509 1 min positive yes A transient/burst | 61000-4-4 4 4000 V> 2.5/5 kHz over 1 min negative B 15 ms; burst transients per period: 300 ms coupling mode Surge IEC/EN 4 ic 4000 V, 1.2/50 us 12Q | 5pos.and5neg. | yes A 61000-4-5 3 +i/-i 2000 Vp 20 surges per coupling mode Xx ic, +i/-i 2500 Vp 10/700 us 409 Conducted IEC/EN 3 i, 0, signal wires 10 Vims AM 80% 15092 0.15...80 MHz yes B disturbances 61000-4-6 (140 dBuVv) 1 kHz 1 Related and previous standards are referenced in Technical Information: Standards. 2 | = 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. 8 With class II equipment (CMZ, DMZ, LMZ) only met if case is earthed. Edition 3/12.97/CD 1.98 - Melcher AGM-Family DC-DC Converters <100 W Rugged Environment Electromagnetic Emissions Table 10: Emissions at U nom and Ip nom [dBuv] (LM/LMZ at 230 V AC) 90 ee Types Level 80 CISPRIT/EN: 55011 CISPR14/ 70 GISPR22/EN:55022 EN:55014 <30:MHz 230: MHz 230: MHz 60 AM 1000 B B <limit 50 AM 2000 B B <limit AM 3000 B B <limit 40 BM 1000 B A <limit 30 BM 2000 B B <limit BM 3000 B A <limit 20 CM 1000 B B <limit 40 CM 2000 B B <limit CM 3000 B A <limit 0 MHz DM 1000 B B <limit es os 8 S&B DM 2000 B B <limit oo DM 3000 B A <limit Fig. 14 EM 1000 B B limit Typical disturbance voliage (quasi-peak) at the input accora- EM 2000 B B . ing to CISPR 11/22 and EN 55011/22, measured at U nom EM 3000 B A - ANd Ip nom- FM 1000 B A <limit [dBuv/m] FM 2000 B A >limit 50 07036 FM 3000 B A - A LM 1000 B B <limit LM 2000 B B <limit 40 B LM 3000 B A <limit CMZ 1000 B A <limit 30 WAM CMZ 2000 - - - N\ IMM] CMZ 3000 A >A >limit VA / ad Ns ww DMZ 1000 - - - 20 Ww DMZ 2000 - - - \ DMZ 3000 A A limit 10 LMZ 1000 B A <limit LMZ 2000 - - - LMZ 3000 A A limit 0 [MHz] So oS So So So So oO Ww oO Oo Oo So - N Ww oO Fig. 15 Typical radiated electromagnetic field strength (quasi- peak) according to CISPR 11/22 and EN 5501 1/22, nor- malized to a distance of 10 m, measured at U; nom and I nom- 7 - 34 Edition 3/12.97/CD 1.98 - Melcher AGRugged Environment DC-DC Converters <100 W M-Family Immunity to Environmental Conditions Table 11: Mechanical stress Test:method Standard Test conditions Status Ca Damp heat IEC/DIN IEC 60068-2-3 Temperature: 40 22C Unit not steady state MIL-STD-810D section 507.2 | Relative humidity: 93 +2/-3.% operating Duration: 56 days Ea Shock IEC/EN/DIN EN 60068-2-27 | Acceleration amplitude: 100 g, = 981 m/s? Unit (half-sinusoidal) MIL-STD-810D section 516.3 | Bump duration: 6 ms operating Number of bumps: 18 (3 each direction) Eb Bump IEC/EN/DIN EN 60068-2-29 Acceleration amplitude: 40 gp = 392 m/s? Unit (half-sinusoidal) MIL-STD-810D section 516.3 | Bump duration: 6 ms operating Number of bumps: 6000 (1000 each direction) Fe Vibration IEC/EN/DIN EN 60068-2-6 Acceleration amplitude: 0.35 mm (10...60 Hz) Unit (sinusoidal) MIL-STD-810D section 514.3 5 gn = 49 m/s? (60...2000 Hz) | operating Frequency (1 Oct/min): 10...2000 Hz Test duration: 7.5 h (2.5 h each axis) Fda | Random vibration | IEC 60068-2-35 Acceleration spectral density: 0.05 g,2/Hz Unit wide band DIN 40046 part 23 Frequency band: 20...500 Hz operating Reproducibility Acceleration magnitude: 4.9 Qnims high Test duration: 3h (1h each axis) Kb Salt mist, cyclic IEC/EN/DIN IEC 60068-2-52 | Concentration: 5% (30C) Unit not (sodium chloride Duration: 2h per cycle operating NaCl solution) Storage: 40C, 93% rel. humidity Storage duration: 22 h per cycle Number of cycles: 3 Table 12: Temperature specifications, valid for an air pressure of 800...1200 hPa (800...1200 mbar) Temperature Standard:-7 Option:-9 Characteristics Cotiditions min max min max Unit Ta | Ambient temperature ! Operational 2 -25 71 40 71 C To | Case temperature ? 25 95 40 95 Ts | Storage temperature ' Non operational -40 100 55 100 1 MIL-STD-810D section 501.2 and 502.2. 2 See Thermal Considerations. 3 Overtemperature lock-out at Te >95C (PTC). Table 13: MTBF Values at specified Module:types Ground:benign Ground fixed Ground mobile Unit case temperature 40C 40C 70C 50C MTBF 1 A...LM 1000 and C...LMZ 1000 320'000 130'000 | 40'000 35'000 h A...LM 2000 and C...LMZ 2000 255'000 105'000 | 32'000 28'000 A...LM 3000 and C...LMZ 3000 225'000 80'000 | 28'000 25'000 Device hours 2 A...LM 1000 and C...LMZ 1000 880'000 A...LM 2000 and C...LMZ 2000 720'000 A...LM 3000 and C...LMZ 3000 740'000 1 Calculated in accordance with MIL-HDBK-217E (calculation according to edition F would show even better results) 2 Statistical values, based on an average of 4300 working hours per year and in general field use, over 3 years Edition 3/12.97/CD 1.98 - Melcher AGM-Family DC-DC Converters <100 W Rugged Environment Mechanical Data Dimensions in mm. Tolerances +0.3 mm unless otherwise indicated. European Projection 09012 ol 7 wo) x uu Ny {5 Mounting holes for retaining clips V WwW | So | LN Male connector H11 according to DIN 41 612 ty | c. = (Gold plated contacts on customer's request) a | 400 10.6 |__34 _ _ Front plate T 103 | o a | 4. Pe Lee. _ _ O | Oro | oy 3; depth = 4mm i | i (chassis mount) ! ! ! : | Main Rear | face, face | | | : | i i i wo o/s]. | 1}3 wo} Ql a | ; lL] . . wo} 2) = i | i oS Measuring point for | | 22 iy case temperature 7, | | ! | p | | | | | | : | | | @ : | | | | | Li oy pee Hee fe 4 . Mounting plane of | connector H11 a... 4 oR See eee |-.---- ra EH Pe : | Elks | benpees ~{ tT [pen] (11.6) 88 ' 38.7 111.2 40.8 (3U) | 94.5101 Back plate 95 10.5 ; 22.30 gs) 2 e 17.25 - 10 a 8 12.17 o | | 7.09 -9-9-- OK (LED green) Io. (LED red) Inhibit i (LED red) Test sockets (option A) Potentiometer (option D) Potentiometer(s) (option P) or potentiometer (option V) Fig. 16 Note: Long case, elongated by 60 mm for 220 mm rack DC-DC converter in case M02, weight 770 g (approx.). depth, is available on request. Case aluminium, black finish and self cooling. Edition 3/12.97/CD 1.98 - Melcher AGRugged Environment DC-DC Converters <100 W M-Family 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 con- nector. Pin no. 26, the protective earth pin present on all AM...LM (class | equipment) DC-DC converters is leading, ensuring that it makes contact with the female connector first. Offi ttt rrr yo 32 29 26 2320171411 8 5 2 ) Fig. 17 View of male H11 connector. Table 14: Pin allocation Electrical determination Ay. LME1000 C..LMZ:1000 (A... EM:2000 C..:LMZ 2000 (A:.-EM 3000 C...LMZ:3000 Pin Ident Pin Ident Pine cldent Pinesscldent Pinesscldent Pinessldent Inhibit control input 2 i 2 i 2 i 2 i 2 i 2 i Safe Data or ACFAIL 5 DorV | 5 DorV | 5 DorV | 5 DorV | 5 DorV | 5 DorvV Output voltage (positive) 8 Vol+ 8 Vol+ 8 8 8 Vo3+ 8 Vo3+ Output voltage (negative) 11 Vol- 11 Vol- 11 11 11 Vo3- 11 Vo3- Control input +1 14 R 14 R Control input 17 G 17 G Output voltage (positive) 14 Vo2+ 14 Vo2+ 14 Vo2+ 14 Vo2+ Output voltage (negative) 17 Vo2 17 Vo2 17 Vo2- 17 Vo2- Output voltage (positive) 20 Vol+ 20 Vol+ 20 Voi+ 20 Voi+ 20 Voi+ 20 Vol+ Output voltage (negative) 23 Vol- 23 Vol- 23 Vo1- 23 Vo1- 23 Vo1- 23 Vol- Protective earthing 2 26 26 26 DC input voltage 3 29 Vi+ 29 Vi+ 29 Vi+ 29 Vi+ 29 Vi+ 29 Vi+ DC input voltage 32 Vi- 32 Vi- 32 Vi- 32 Vi- 32 Vi- 32 Vi- AC input voltage + 29 x 29 x 29 x 29 x 29 x 29 x AC input voltage 32 x 32 x 32 x 32 x 32 x 32 x 1 This function is not simultaneously available with option P 2 Leading pin (pregrounding) Installation Instructions The M-family DC-DC converters are components, intended exclusively for inclusion within other equipment by an in- dustrial assembly operation or by professional installers. In- stallation must strictly follow the national safety regulations in compliance with the enclosure, mounting, creepage, clearance, casualty, markings and segregation require- ments of the end-use application. See also Technical Infor- mation: Installation and Application. Connection to the system shall be made via the female con- nector H11 (see Accessories). Other installation methods may not meet the safety requirements. AM...LM DC-DC converters (class | equipment) are pro- vided 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 Px) 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). Important: Whenever: the:inhibit functions: not-in-use; pin:2:() should: be connected to:pin:23:(Vo1) to-enable the output(s). Do: not open: the modules; or guarantee willbe invali- dated. 3 AM, BM, CM, DM, EM, FM and CMZ, DMZ types 4LM and LMZ types Make sure that there is sufficient air flow possible for con- vection 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 tem- perature 7c max shall not be exceeded. See also Thermal Considerations. Standards and Approvals AM...LM DC-DC converters correspond to class | equip- ment, 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. 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 | 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 The DC-DC converters are subject to manufacturing sur- veillance in accordance with the above mentioned UL, CSA, EN and with ISO 9001 standards. Edition 3/12.97/CD 1.98 - Melcher AGM-Family Cleaning Agents In order to avoid possible damage, any penetration of liq- uids (e.g. cleaning fluids) is to be prevented, since the power supplies are not hermetically sealed. Isolation The electric strength test is performed as a factory test in DC-DC Converters <100 W Rugged Environment 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. All units fitted with options A or K, except those with option P, and except those with option D or V with IP 30: accordance with IEC/EN 60950 and UL 1950 and should potentiometer, a . not be repeated in the field. Melcher will not honour any IP 20: All units fitted with option P, or with option D or V with guarantee/warranty claims resulting from electric strength potentiometer. field tests. Table 15: Isolation Characteristic Input:to:: Input te::):Inputto:/Input:to::|: Output: to:|:Outputto) Output to.) Unit case case output output case case output class:l class:Il class! class ll option 'H Electric Required according to 1.5 3.0 3.01 3.0 0.5 0.5 - kV ims strength _| IEC/EN 60950 24 4.2 4.21 4.2 0.7 0.7 - |kvpc test voltage Actual factory test 1s 2.8 5.6 5.61 5.6 1.4 2.8 0.3 AC test voltage equivalent 2.0 4.0 4.01 4.0 1.0 2.0 0.2 kV ims to actual factory test Insulation resistance at 500 V DC >300 >300 >300 >300 >300 >300 >1002 MQ 1 In accordance with IEC/EN 60950 only subassemblies are tested in factory with this voltage. 2 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 acces- sible, it shall be an SELV circuit according to the IEC/EN 60950 related safety standards. Since the M-family DC-DC converters provide double or re- inforced 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 DC- DC converter. This means that there is no need for an elec- trical isolation between the AC mains circuit and the DC-DC converter input circuit to cause the output of an M-family DC-DC converter to be an SELV circuit. Only voltage Table 16: Safety concept leading to an SELV output circuit adaption and rectification to the specified input voltage range of the DC-DC converter is needed. The following table shows a possible installation configura- tion, 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 nomi- nal voltages if in series or +/- configuration) of 36 V. However, it is the sole responsibility of the installer to as- sure the compliance with the relevant and applicable safety regulations. More information is given in Technical Informa- tion: Safety. Conditions: |::Front:end DC-DC: converter Result Nominal Minimum required :grade:::|: Maximum :rated Minimum: required: Equip-:::Measures to: achieve the:: |: Satety:status supply. of insulation: tobe: pro- DC: output-voltage'|: safety status: of the:|::ment specified safety: status: of::|-of the: DC-DC. voltage vided by: the AC-DC front:)from:the front-end: |front:end output the: output:circult converter end: ineluding: mains Circuit output: cireult supplied: battery:charger Mains Operational (i.e. there is | <400 V (The Primary circuit Class | | Double or reinforced SELV circuit <250 V AC | no need for electrical rated voltage (A...LM) | insulation, based on isolation between the between any input 250 V AC and 400 V DC mains supply voltage and | pin and earth can (provided by the DC-DC theDC-DC converter be up to 250 V AC converter) and earthed input voltage) or 400 V DC) case 2 <250 V1 (The Class II | Double or reinforced rated voltage (CMZ, insulation, based on between any input DMZ, 250 V AC or DC (provided pin and earth can LMZ) by the DC-DC converter) be up to 250 V AC or DC) 1 The front end output voltage should match the specified operating input voltage range of the DC-DC converter. 2 The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC/EN 60950. 7 - 38 Edition 3/12.97/CD 1.98 - Melcher AGRugged Environment 400 (250) V DC iP 250 V AC or ~ + Fuse !DC-DC; Mains = Battery : con- | SELV . 6 verter _ | Max. 250 V AC or tT Earth connection 1,400 (250) v Dc (class 1) Fig. 18 Schematic safety concept. Description of Options Table 17: Survey of options DC-DC Converters <100 W M-Family Use earth connection as per table Safety concept leading to an SELV output circuit. Use fuse if required by the applica- tion. See also Installation Instructions. 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, internally measured at the connector terminals E Electronic inrush current limitation circuitry Active inrush current limitation for CM, EM, LM, CMZ, LMZ Pp! Potentiometer for fine adjustment of output voltage Adjustment range +5% of Us nom, excludes R input F Input fuse built-in inside case Fuse not externally accessible H 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 (DO...D9) ves Input and/or output undervoltage monitoring circuitry | ACFAIL signal according to VME specifications (VO, V2, V3) 1 Function R excludes option P and vice versa 2 Option D excludes option V and vice versa 3 Only available if main output voltage Up, = 5.1 V -9 Extended Temperature Range Option -9 extends the operational ambient temperature range from 25...71C (standard) to 40...71C. The power supplies provide full nominal output power with convection cooling. A Test Sockets Test sockets (pin = 2 mm, distance d = 5.08 mm) are lo- cated at the front of the module. The output voltage is sensed at the connector pins inside the module. Table 18: Configuration of option A and option P P Potentiometer Optionally built-in multi-turn potentiometers provide an out- put voltage adjustment range of minimum +5% of Uo nom and are accessible through holes in the front cover. Com- pensation of voltage drop across connector and wiring be- comes easily achievable. For output voltages Up > Ub nom, the minimum input voltage according to Electrical Input Data increases proportionally to Up/Ub nom- Note: Potentiometers are not recommended for mobile ap- plications. Type of option AN...LM/GMZ...LMZ:1000 ANL..LM/CMZ.;.LMZ:2000 AN...EM/CMZ,..;LMZ:3000 Output: Output:4 Output:2 Output:1 Output:2 Output'3 Potentiometer 1 yes yes yes yes no no Test sockets yes yes yes yes no no 1 AM...LM 1000 types equipped with option P do not provide the R input simultaneously, pins 14 and 17 are not connected. F Fuse Not Accessible The standard M units have a fuseholder containing a 5 x 20 mm fuse which is externally accessible and to be found in the back plate near the connector. Some applications re- quire an inaccessible fuse. Option F provides a fuse moun- ted directly onto the main PCB inside the case. The full self-protecting functions of the module do normally not lead to broken fuses, except as a result of inverse polar- ity at the input of an AM, BM, CM, FM or CMZ type or if a power component inside fails (switching transistor, free- wheeling diode, etc). In such cases the defective unit has to be returned to Melcher 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). Edition 3/12.97/CD 1.98 - Melcher AGM-Family E Electronic Inrush Current Limitation Available for CM, EM, LM and CMZ, LMZ types. 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 moni- Table 19: Inrush current characteristics with option E DC-DC Converters <100 W Rugged Environment toring). Option D6, externally adjustable via potentiometer, is necessary to disable the converter at input voltages be- low 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 U4; + U,; (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 appli- cations where potentiometers are not allowed refer to op- tion D9. Characteristic CM; CMZ EM, EM, LMZ EM, LM, LMZ Unit atUp=110:V:DG at Us T10-V:DC. at U= 372 VDC. typ max typ max typ max horp 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: i [A] 11019 In order to avoid overload of the series resistor R, the on/off A switching cycle should be limited to 12 s if switched on/off 142 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 10> 35 V DC or LM and LMZ types below 100 V AC, the maxi- mum case temperature should be derated by 10 K or the to- 8s CM. CMZat 110 VDC tal output power should be derated by 20%. EM, LM and EM, LM, LMZ at 372 V DC LMZ units driven by DC input voltages do not need to be 7 derated within the full specified input voltage range. 6 ae EM, LM, LMZ at 110 V DC Availability: Option E is available for CM, EM, LM and CMZ, LMZ mod- 4 tin ules with a nominal output power of 51 W maximum. eae h= Pol(U en) ne ats, Normal operation i (FET fully conducting) 0 i SUT T arses I a fal ] t : we ~/ms 11 5 5 | | | | | | Control 2 0 10 20 30 40 tie ph =) ; 13 [FET 5 Fig. 20 i; = | | oO Typical inrush current waveforms of CM, CMZ, EM, LM 1 Rectifier = and LMZ DC-DC converter with option E I (LM/LMZ types) Rs RA, C; Fig. 19 Option E block diagram Edition 3/12.97/CD 1.98 - Melcher AGRugged Environment D Undervoltage Monitor The input and/or output undervoltage monitoring circuit op- erates independently of the built-in input undervoltage lock- out circuit. A logic "low" (JFET output) or "high" signal (NPN output) is generated at pin 5 as soon as one of the moni- tored voltages drops below the preselected threshold level U,. The return for this signal is Vo1 (pin 23). The D output recovers when the monitored voltage(s) exceed(s) U+ Ub. Table 20: Undervoltage monitor functions DC-DC Converters <100 W M-Family The threshold level U4 is either adjustable by a potentio- meter, accessible through a hole in the front cover, or is fac- tory adjusted to a fixed value specified by the customer. Option D exists in various versions DO...D9 as shown in the following table. Output:-type Monitoring Minimum:-adjustment range Typical hysteresis Uj, :[%: of: U;] JFET NPN UY; Uy of threshold: level: U; for: Ge mines Gemax Cy the Ohi Ohis D1 D5 no yes - 3.5 V...48 V1 - 2.3...1 D2 D6 yes no Ui min. Ui max" - 3.0...0.5 - D3 D7 yes yes Ui min--- Ui max | 0.95...0.98 Up; 2 3.0...0.5 "0" D4 D8 no yes - 0.95...0.98 Up, 2 - "oO" DO D9 no yes - 3.5 V...48 V3 - 1.8...4 yes no Ui min. Ui max 34 - 2.2...0.4 - yes yes Ui min. Ui max 34 0.95...0.98 Up, 2 2.2...0.4 "oO" 1 Threshold level adjustable by potentiometer (not recommended for mobile applications) 2 Fixed value between 95% and 98% of Up; (tracking) 3 Fixed value, resistor-adjusted according to customer's specifications +2% at 25C; individual type number is determined by Melcher 4 Adjusted at fy nom JFET output (DO...D4): Connector pin D is internally connected via the drain- source path of a JFET (self-conducting type) to the nega- tive potential of output 1. Up < 0.4 V (logic low) corresponds to a monitored voltage level (U, and/or U1) <U;,. The current Ip 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. Ue Uy status Uj or Uo < U, Uj and Uo4 > Ur+ Ur D: output; Up low, L, Up <0.4V at /p=2.5 mA high, H, /p < 25 pA at Up = 5.25 V NPN output (D5...D9): Connector pin D is internally connected via the collector- emitter path of a NPN transistor to the negative potential of output 1. Up < 0.4 V (logic low) corresponds to a monitored voltage level (U; and/or U41) > U + Up. The current /p through the open collector should not exceed 20 mA. The NPN output is not protected against external overvoltages. Up should not exceed 40 V. GiUo4 status Uj or Uo < U, Uj and Uo4 > U, + Ur D:output;:Up5 high, H, /p < 25 pA at Up = 40 V low, L, Up < 0.4 V at Ip = 20 mA Input Fig. 21 Input Fig. 22 Options D5...D9, NPN output Edition 3/12.97/CD 1.98 - Melcher AGM-Family DC-DC Converters <100 W Rugged Environment Threshold tolerances and hysteresis: Up ee oe Oni _ moet If U; is monitored, the internal input voltage after the input A filter and rectifier (EM, LM and LMZ types) is measured. Up high Consequently this voltage differs from the voltage at the 5 5 connector pins by the voltage drop AU across input filter e e and rectifier. The threshold level of the DO and D9 options is iy Yo mA 4 : . as Wl as ll factory adjusted at nominal output current fy nom and at Ta = n ae 25C. The value of AU; depends upon the input voltage range (AM, BM, ...), threshold level U,, temperature and in- UD low put current. The input current is a function of the input volt- U mu; age and the output power. Fig. 23 ti Definition of Uj, AU; and U,; (JFET output) Input voltage monitoring NPN U, Up tigh == - === epee So a 11008 (UX Up low 7 i ee OL COL fd PF 0 t h : ! i lp high TT Poe [| pots lp VOW fm mo i te TD - - 0 r ~t JFET Up Up high -->>_-- 4 -------- ------------------ pe ] ------------ [ Sialatateiatatatetetaieieatatel l Posen snen ? Up lw ------------__-- eet rr - - t 4 _4 t _4 _ 4 low min low min low min ! Input voltage failure Switch-on cycle Input voltage sag Switch-on cycle and subsequent a input voltage failure Output voltage monitoring NPN UU Up hign {------------ Up low 0 lp high lp low =}------------' I 0 D high JFET Up Up low =} ------------ 7 0 tow min* 1 See: Electrical Output Data, for hold-up time. : 2 With output voltage monitoring the hold-up time #, = 0 3 The D signal remains high if the D output is connected to an external source. ; 4 tlow min = 40...200 ms, typically 80 ms U o1 o1 nom] Up +Une7] Output voltage failure Fig. 24 Relationship between U,, Us1, Ub, lp and Uo1/Uo nom versus time. Edition 3/12.97/CD 1.98 - Melcher AGRugged Environment V ACFAIL Signal (VME) Available for units with U4; = 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 speci- fied at a sink current of 4y = 48 mAto Ly < 0.6 V (open-col- lector output of a NPN transistor). The pull-up resistor feed- ing 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 , 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 7, is provided by the internal input capacitance. Consequently the working input voltage and the threshold level U;; should be adequately above the mini- mum input voltage U; 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 ca- pacitor (Cj ext) should be added. Formula for threshold level for desired value of ty: Uy = 2+ Po (tn +0.3 ms) +100 | " Cimin 7) i min DC-DC Converters <100 W M-Family Formula for additional external input capacitor 2 Po* (tf, + 0.3 ms) * 100 Ciot = 1+ (Uri? U; min?) Cimin where as: Ci min = Minimum internal input capacitance [mF], accord- ing to the table below Ciext = external input capacitance [mF] P, = output power [W] 7 = efficiency [%] t, = hold-up time [ms] Ui min = Minimum input voltage [V] Ui; = threshold level [V] Remarks: The threshold level U,; of option V2 and V3 is ad- justed 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. Table 21: Available internal inout capacitance and factory potentiometer setting of U,| with resulting hold-up time Types AM BM CM/CMZ DM/DMZ EM FM EM/LMZ Unit Ci min 2.6 0.67 0.37 0.14 0.14 0.37 0.14 mF Ui 9.5 19.5 39 61 104 39 120 VDC 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 under- voltage 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 U;. The return for this signal is Vo1 (pin 23). The V output recovers when the monitored Table 22: Undervoltage monitor functions voltage(s) exceed(s) U, + Up. The threshold level U; is either adjustable by a potentiometer, accessible through a hole in the front cover, or is factory adjusted to a determined cus- tomer specified value. Versions VO, V2 and V3 are available as shown below. V-output Monitoring Minimum-adjustment range Typical:-hysteresis: Uj [%:of Uj] (VME:compatible) of threshold: level::U; for: Uy nin Ui max Oj Uo Uy Us Ohi Oks V2 yes no Ui min---Uii max | - 3.0...0.5 - v3 yes yes Ui min.-- Ui max | 0.95...0.98 Ug? 3.0...0.5 "o" vo yes no Ui min... Uj max 34 - 2.2...0.4 - yes yes Ui min... Uj max 34 0.95...0.98 Ug, 2 2.2...0.4 "oO" 1 Threshold level adjustable by potentiometer (not recommended for mobile applications). 2 Fixed value between 95% and 98% of Us; (tracking), output undervoltage monitoring is not a requirement of VME standard. ? Adjusted at Io nom- 4 Fixed value, resistor-adjusted (+2% at 25C) acc. to customer's specifications; individual type number is determined by Melcher. V output (VO, V2, V3): Connector pin V is internally connected to the open collec- tor of a NPN transistor. The emitter is connected to the negative potential of output 1. Uy < 0.6 V (logic low) corre- sponds to a monitored voltage level (U; and/or Ui) < U;. The current /y through the open collector should not exceed 50 mA. The NPN output is not protected against external overvoltages. Uy should not exceed 80 V. Ui O54 status Uj or Uo < U, Uj and Uo4 > U, + Ur Veoutput; Oy low, L, Uy <0.6 V at yy =50 mA high, H, 4ys25 pA at Uy=5.1V Input Fig. 25 Edition 3/12.97/CD 1.98 - Melcher AGM-Family DC-DC Converters <100 W Rugged Environment Threshold tolerances and hysteresis: Uy AU, _ Ubi 11023 If U; is monitored, the internal input voltage is measured af- A ter the input filter and rectifier (EM, LM and LMZ types). Uy high _ Consequently this voltage differs from the voltage at the 5 connector pins by the voltage drop AU;; across input filter 2 and rectifier. The threshold level of option VO is factory ad- Vy ya ", justed at fo nom and Ta = 25C. The value of AU;; depends a upon the input voltage range (AM, BM, ...), threshold level U;i, temperature and input current. The input current is a OV low > function of input voltage and output power. mu A = Fig. 26 Definition of U,,, AU, and Up; Input voltage monitoring v2 U tow min 2 tow min 2 tow min 2 U v 3 3 _a * V high -fppp - -_ - - = 5 se ae 5 AA Uy low TJ) 2-2 ee AZ AA | ---------- 0 | 1 14 V3 Uy, | ! 3 3 | ! tow min - Oy righ -----4 AA Ba 1 AAAA | Input voltage failure Switch-on cycle Input voltage sag Switch-on cycle and subsequent input voltage failure Output voltage monitoring 1 VME request: minimum 4 ms 2 tow min = 40...200 ms, typically 80 ms i 3 W level not defined at Up; < 2.0 V [_---------------------- Lee eee eee ee eee 4 The V signal drops simultaneously with the output voltage, if the a eee pull-up resistor Ap is connected to Vo1+. The V signal remains high if Ap is connected to an external source. Fig. 27 Output voltage failure Relationship between Uj, Uo1, Uy, ly and Up1/Up nom versus time. Edition 3/12.97/CD 1.98 - Melcher AGRugged Environment DC-DC Converters <100 W M-Family 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 moun- ting. For more detailed information please refer to Accessory Products. Front panels H11 female connector, Flexible H11 PCB Code key system Universal mounting bracket for DIN-rail mounting. Mounting plate, Connector retention clips Edition 3/12.97/CD 1.98 - Melcher AG