The Power of Melcher. Power [W] Output [V DC] 3 5 15 24 36 48 No. of outputs DC-DC Converters Input [V DC] 3 10 20 60 Series 80 180 Print Mountable 1 1...12 2.4 3 3...15 4 6 6...20 6...30 7 7 10 10...30 15 15 25 25/40 1, 2 1, 2, 3 1 1,2 1, 2, 3 1, 2 1, 2 1, 2 1, 2, 3 1, 2 1, 2 1, 2 1, 2, 3 1, 2 1, 2 1, 2 1, 2, 3 DSP IMP CHS IXP IMR IMX 4 IMO DFA DFC IMS 7 IMX 7 IML DGP IMS 15 IMX 15, IMY 15 OBS, OBD IMR 25, IMR 40 Cassette Style 20 50 50 100...150 100 150 1 1, 2, 3 1, 2, 3 1, 2 1, 2 1, 2 SR H M Q S K Open Frame 150 3, 4 MDU Bricks 15...60 25...150 33...100 38...66 38...150 50...60 100...190 100...300 100...300 113...225 1 1 1 1 1 1 1 1 1 1 HAS HES HBS QES QBS QAS XWS FES VWS TES Comprehensive data sheets are available from either source: - Internet: www.melcher.ch - Melcher CD-ROM - Melcher Databook - Nearest sales office by fax or mail. MELCHER The Power Partners. Edition 6/3.99 DC-DC Converters >100 Watt 120/180 Watt DC-DC Converters P Series P Series Input to output isolation Single output: 3.3, 5.1 V DC Double output: 3.3/5.1, 2 x 5.1, 2 x 12, 2 x 15, 2 x 24 V Triple output: 5.1/ 2 x 12, 5.1/ 2 x 15 V DC Quadruple output: 5.1/3.3 with 2 x 12, 2 x 24 with 2 x 24 V DC * Extremely high efficiency * Flex power: Flexible load distribution * Excellent surge and transient protection * 4242 V DC input to output electric strength test * Redundant operation (n+1), current sharing option * Extremely low inrush current, hot plug-in * Externally adjustable output voltage * Inhibit primary or secondary referenced 111 4.4" 3U * Very compact and fully functional unit (20 mm wide) * Telecoms compatible input voltage range of DP units according to prETS 300132-2 (40...101 V DC) 20 0.8" 4 TE 164 6.5" Safety according to IEC/EN 60950, UL 1950 LGA C Safety approvals in progress Summary These extremely compact DC-DC converters incorporate all necessary input and output filtering, signalling and protection features which according to the latest industry standards are required in the majority of applications. The converters provide important advantages such as flexible output power through primary current limitation, extremely high efficiency, excellent reliability, very low ripple and RFI noise levels, full input to output isolation, negligible inrush current, soft start, overtemperature protection and input over-/undervoltage lock-out. The converter inputs are protected against surges and transients occurring on the source lines, covering a total input voltage range from 16 V DC up to 150 V DC with five different types. The outputs are continuously open- and short-circuit proof. LEDs at the front panel and an isolated output power good option indicate the status of the power supply modules. Voltage suppressor diodes protect the outputs against an internally generated overvoltage. Full system flexibility and n +1 redundant operating mode are possible due to virtually unrestricted series or parallel connection capabilities of all outputs. In parallel connection Table of Contents of several units, current sharing option is provided by a single wire interconnection. As a modular power supply or as part of a distributed power supply system, the low profile design significantly reduces the necessary power supply volume without sacrificing high reliability. The units are designed as forward converters using planar magnetics and control circuits in hybrid technology. The switching frequency is fix at 307 kHz under normal operating conditions. Triple and quadruple output modules have their voltage regulation of output 3 and 4 relying on the close magnetic coupling of transformer and output conductor together with the circuit symmetry of their main outputs 2, respectively 1. Outputs with an equal output voltage can either be series or parallel connected. The fully enclosed, black coated aluminium case acts as heat sink and RFI shield. It is particularly suitable for 19" rack systems occupying 3U/4TE only, but can also be chassis-mounted by means of four M3 screws. Connector type is H15 and for single output modules H15 S2. Page Page Summary .......................................................................... 1 Type Survey and Key Data .............................................. 2 Type Key and Product Marking ........................................ 4 Mechanical Data .............................................................. 5 Safety and Installation Instructions .................................. 6 MELCHER The Power Partners. Edition 4/6.99 1/8 Preliminary Industrial Environment Preliminary P Series DC-DC Converters >100 Watt Industrial Environment Type Survey and Key Data Table 1a: Type survey BP, CP Output 1, 4 3 Uo nom [V DC] Output 2, 3 3 TA = 50C TA = 71C Po max [W] Po nom [W] Uo nom [V DC] Input voltage range and efficiency 2 TA = 50C TA = 71C Po max [W] Po nom [W] hmin [%] 4 Ui min...Ui max 16...36 V DC hmin [%] Options 4 Ui min...Ui max 33.6...75 V DC 3.3 5.1 125 152 106 122 - - - BP 1101-7R BP 1001-7R CP 1101-7R CP 1001-7R 3.3 5.1 12 15 24 62 76 90 82 84 53 61 72 60 60 5.1 5.1 12 15 24 76 76 90 82 84 61 61 72 60 60 BP 2101-7R BP 2001-7R BP 2320-7R BP 2540-7R BP 2660-7R CP 2101-7R CP 2001-7R CP 2320-7R CP 2540-7R CP 2660-7R 5.1 5.1 76 76 61 61 12, 12 15, 15 72 1 75 1 60 1 60 1 BP 3020-7R BP 3040-7R CP 3020-7R CP 3040-7R 5.1, 3.3 5 24, 24 50 1 84 1 40 1 60 1 12, 12 24, 24 72 1 84 1 60 1 60 1 BP 4720-7R BP 4660-7R CP 4720-7R CP 4660-7R -9 D V6 G T6 i W Table 1b: Type survey DP, EP Output 1, 4 3 Uo nom [V DC] Output 2, 3 3 TA = 50C TA = 71C Po max [W] Po nom [W] Uo nom [V DC] Input voltage range and efficiency 2 TA = 50C TA = 71C Po max [W] Po nom [W] hmin [%] Ui min...Ui max 4 40...101 V DC hmin [%] Options Ui min...Ui max 4 66...150 V DC 3.3 5.1 125 152 106 122 - - - DP 1101-7R DP 1001-7R EP 1101-7R EP 1001-7R 3.3 5.1 12 15 24 62 76 90 82 84 53 61 72 60 60 5.1 5.1 12 15 24 76 76 90 82 84 61 61 72 60 60 DP 2101-7R DP 2001-7R DP 2320-7R DP 2540-7R DP 2660-7R EP 2101-7R EP 2001-7R EP 2320-7R EP 2540-7R EP 2660-7R 5.1 5.1 76 76 61 61 12, 12 15, 15 72 1 75 1 60 1 60 1 DP 3020-7R DP 3040-7R EP 3020-7R EP 3040-7R 5.1, 3.3 5 24, 24 50 1 84 1 40 1 60 1 12, 12 24, 24 72 1 84 1 60 1 60 1 DP 4720-7R DP 4660-7R EP 4720-7R EP 4660-7R -9 D V6 G T6 i W Table 1c: Type survey GP Output 1, 4 3 Uo nom [V DC] 1 2 3 4 5 6 Output 2, 3 3 TA = 50C TA = 71C Po max [W] Po nom [W] Uo nom [V DC] Input voltage range and efficiency 2 TA = 50C TA = 71C Po max [W] Po nom [W] hmin [%] Options Ui min...Ui max 19.2...57.6 V DC 3.3 5.1 100 120 80 92 - - - GP 1101-7R GP 1001-7R 3.3 5.1 12 15 24 50 60 72 68 70 40 46 54 50 48 5.1 5.1 12 15 24 60 60 72 68 70 46 46 54 50 48 GP 2101-7R GP 2001-7R GP 2320-7R GP 2540-7R GP 2660-7R 5.1 5.1 60 60 46 46 12, 12 15, 15 66 1 68 1 48 1 50 1 GP 3020-7R GP 3040-7R 5.1, 3.3 5 24, 24 40 1 70 1 30 1 48 1 12, 12 24, 24 66 1 70 1 48 1 48 1 GP 4720-7R GP 4660-7R -9 D V6 G T6 i W The cumulated power of both outputs may not exceed the total power for the specified ambient temperature. Minimum efficiency at Ui nom, Po nom and TA = 25C Output configuration with second output semi-regulated (5% Uo nom if each output is loaded with 5% Po nom). Parallel or series configuration possible. Short deviations of Ui min/Ui max according to EN 50155 possible. Internal common ground. Not available for all types. MELCHER The Power Partners. Edition 4/6.99 2/8 DC-DC Converters >100 Watt P Series 01009 Output Configuration The P unit design allows high flexibility in output configuration to cover almost every individual requirement, by simply wiring the separated outputs in parallel, series or independent configurations as per following figures. Parallel and series operation of several modules with equal output voltage is possible also. Triple output Vo1+ 4 S1+ 12 S1- 14 28 i 01006 30 Vi+ Vo1- 8 32 Vi- Vo2+ 6 Vo3+ 18 Vo2- 10 Vo3- 20 Double output Vo2+ 6 S2+ 18 Vo1+ 4 28 i S1+ 12 30 Vi+ S1- 14 32 Vi- Vo1- 8 Load 1 Load 2 Fig. 4 Parallel configurration of output 2 and 3 Load 1 01010 S2- 20 Vo2- 10 Triple output Vo1+ Fig. 1 Parallel output configuration 28 i 01007 28 i 30 Vi+ 32 Vi- 6 S2+ 18 S2- 20 Vo2- 10 Vo1+ 4 S1+ 12 S1- 14 Load 1 30 Vi+ Vo1- 8 32 Vi- Vo2+ 6 Double output Vo2+ 4 Vo2- 10 Vo3+ 18 Vo3- 20 Load 2 Fig. 5 Series configurration of output 2 and 3 Load 1 01011 S1+ 12 S1- 14 Vo1- Quadruple output Vo1+ 8 Fig. 2 Series output configuration 28 i 01008 Triple output Vo1+ 4 S1+ 12 28 i S1- 14 30 Vi+ Vo1- 8 32 Vi- Vo2+ 6 Vo2- 10 Load 1 4 Vo1- 8 Load 1 Vo4- 14 Load 4 12 30 Vi+ Vo4+ 32 Vi- Vo2+ 6 Vo2- 10 Vo3+ 18 Vo3- 20 Load 2 Load 3 Fig. 6 Common ground configuration of output 1 with 4 and independent configuration of output 2 and 3 Load 2 Vo3+ 18 Vo3- 20 01012 Quadruple output Vo1+ Load 3 Fig. 3 Independent output configuration (all outputs) 28 i 4 Vo4+ 12 Vo4- 14 Load 1 30 Vi+ Vo1- 8 32 Vi- Vo2+ 6 Vo2- 10 Vo3+ 18 Vo3- 20 Load 2 Fig. 7 Parallel configuration of output 1 with 4 and series configuration of output 2 with 3 MELCHER The Power Partners. Edition 4/6.99 3/8 Preliminary Industrial Environment Preliminary P Series DC-DC Converters >100 Watt Industrial Environment Type Key and Product Marking Type Key C P 2 5 40 -7 R D V G T i W Input voltage range Ui: 16...36 V DC ................................................. B 33.6...75 V DC .............................................. C 40...101 V DC ............................................... D 66...150 V DC ................................................ E 19.2...57.6 V DC .......................................... G Series ............................................................................... P Number of outputs: Single output ................................................. 1 Double output ................................................ 2 Triple output .................................................. 3 Quadruple output ........................................... 4 Nominal voltage output 1/output 4, Uo1/4 nom: 5.1 V .............................................................. 0 3.3 V .............................................................. 1 12 V ............................................................... 3 15 V ........................................................... 4, 5 24 V ............................................................... 6 5.1/3.3 V ........................................................ 7 other voltages ............................................ 2, 8 Other specifications for main output ........................ 01...99 Nominal voltage output 2/output 3, Uo2/3 nom 5.1 V ............................................................ 01 12 V ............................................................. 20 15 V ............................................................. 40 24 V ............................................................. 60 other voltages ....................................... 70...99 Operational ambient temperature range TA: -25...71C ................................................... -7 -40...71C (option) ....................................... -9 customer specific .................................... -0...-6 Output voltage control input (auxiliary function) .............. R Options: Out OK output .............................................. D VME compatible monitoring circuit ................ V Second control loop (OVP) ........................... G Current sharing .............................................. T Isolated inhibit on secondary side .................. i Synchronisation of switching frequency ....... W Example: CP 2540-7R: DC-DC converter, input voltage range 33.6...75 V, each providing 15 V, equipped with R-control for output 1 and operating ambient temperature of -25...71C. Note: All units feature the following auxiliary functions which are not shown in the type designation: input and output filter, inhibit (primary referenced), sense lines (single, double and triple output modules only) and LED indicators. Product Marking Basic type designation, applicable safety approval and recognition marks, CE mark, warnings, pin allocation of input, output and auxiliary functions, Melcher patents and company logo. Label with specific type designation, input voltage range, nominal output voltage and output current, degree of protection, batch no., serial no. and data code including production site, modification status and date of production. Confirmation of success fully passed final test. Identification of LED's. MELCHER The Power Partners. Edition 4/6.99 4/8 DC-DC Converters >100 Watt P Series Mechanical Data Dimensions in mm. Tolerances 0.3 mm unless otherwise indicated. European Projection 5.5 09099 104 0.15 20 Front plate Rear face 171.93 (DIN 41494) 127 0.15 Measuring point of case temperature TC Main face 8 0.5 164 0.5 100 M3; through 70 Back plate 111 100 19.8 13.43 20.32 (4 TE) 95 LED "Out OK" green LED "In OK" green Fig. 8 Case P01, weight 480 g Aluminium, fully enclosed, black finish and self cooling MELCHER The Power Partners. Note: Long Cases, elogated by 60 mm for 220 mm rack depth is available on request. Edition 4/6.99 5/8 Preliminary Industrial Environment Preliminary P Series DC-DC Converters >100 Watt Industrial Environment Safety and Installation Instructions Connector Pin Allocation The connector pin allocation table defines the electrical potentials and the physical pin positions on the H15 connector. Pin no. 26, the protective earth pin present on all BP...GP DC-DC converters is leading, ensuring that it makes contact with the female connector first. 30 32 26 28 22 24 18 20 14 16 10 12 6 8 30 10025 32 4 Fig. 9 View of male H15 connector 26 28 24 22 18 20 14 16 8/10 10051 12 4/6 Fig. 10 View of male H15 S2 connector for P 1000 Table 2: Pin allocation of the H15 S2 and H 15 connector Pin 4 P 1000 Vo1+ 1 Output 1 6 8 Vo1- 1 Output 1 10 12 S+ 2 Output 1 Vo1+ Output 1 Vo1+ Output 1 Vo2+ Output 2 Vo2+ Output 2 Vo2+ Output 2 Vo1- Output 1 Vo1- Output 1 Vo1- Output 1 Vo2- Output 2 Vo2- Output 2 Vo2- Output 2 Sense 1 Vo4+ Output 4 Sense S1+ 2 Sense 1 S1+ 2 14 S- Sense Sense 1 Sense 1 Vo4- Output 4 R Control of Uo R1 Control of Uo1 R1 Control of Uo1 R1/4 Control of Uo1/4 T1 Current sharing T1 Current sharing 18 3 T Current sharing T1 Current sharing Vo3+ Output 3 Vo3+ Output 3 S2+ Sense 2 20 3 n.c. Not connected S2- Sense 2 Vo3- Output 3 Vo3- Output 3 Pd in Power down Pd in Power down Out OK+ Output good Out OK+ Output good Out OK+ Output good Out OK+ Output good i+ Inhibit secondary i+ Inhibit secondary i+ Inhibit secondary D Save data D Save data Out OK- Output good Out OK- Output good Output good Out OK- Output good i- Inhibit secondary i- Inhibit secondary i- Inhibit secondary i- Inhibit secondary Rst Reset Reset 28 3 3 Vo1+ 16 3 26 2 2 P 4000 S1- 2 24 3 1 P 3000 S1- 2 22 3 2 P 2000 Rst Prot. ground Inhibit secondary i+ Out OK- Prot. ground Prot. ground Prot. ground i Inhibit i Inhibit i Inhibit i Inhibit W Synchronisat. W Synchronisat. W Synchronisat. W Synchronisat. 30 Vi+ Input Vi+ Input Vi+ Input Vi+ Input 32 Vi- Input Vi- Input Vi- Input Vi- Input H15 S2 connector with two high current contacts. Leading pin (pre-connecting). One function/option per pin possible only. MELCHER The Power Partners. Edition 4/6.99 6/8 DC-DC Converters >100 Watt P Series Installation Instruction The P 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. Cleaning Agents Connection to the system shall be made via the female connector H15 or H15 S2 (see: Accessories) according to Connector pin allocation. Other installation methods may not meet the safety requirements. They are pending to be 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 and have been designed in accordance with these standards for: * Building in * Basic insulation between input and case, based on 250 V AC or 240 V DC * Double or reinforced insulation between input and output, based on 250 V AC or 240 V DC * Operational insulation between output(s) and case * Operational insulation between the outputs * Operational insulation between option D or i and output(s) * Operational insulation between option D or i and case * The use in a pollution degree 2 environment * Connecting the input to a primary circuit with a maximum transient rating of 2500 V (overvoltage class III based on a 110 V primary circuit, overvoltage class II based on a 230 V primary circuit). Check for hazardous voltages before altering any connections. The DC-DC converters are provided with pin no. 26 ( ), which is reliably connected to the case. For safety reasons it is essential to connect these pins to the protective earth of the supply system if required in: Safety of operator accessible output circuit. The Vi input (pin no. 32) is internally fused. This fuse is designed to protect the unit in case of overcurrent and may not be able to satisfy all customer requirements. External fuses in the wiring to one or both input pins (no. 30 and/or no. 32) may therefore be necessary to ensure compliance with local requirements. Important: Whenever the inhibit function is not in use, pin 28 (i) should be connected to pin 32 (Vi-) to enable the output(s). Do not open the modules, or guarantee will be invalidated. Make sure that there is sufficient air flow available 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 must not be overridden. In order to avoid possible damage, any penetration of cleaning fluids is to be prevented, since the power supplies are not hermetically sealed. Standards and approvals All P series DC-DC converters correspond to class I equipment. After approvals, the AC-DC converters are subject to manufacturing surveillance in accordance with the above mentioned UL, CSA, EN and with ISO 9001 standards. Protection Degree Condition: Female connector fitted to the unit. The protection degree of the DC-DC converters is IP 40. Ensure that a unit failure (e.g. by an internal short-circuit) does not result in a hazardous condition. See also: Safety of operator accessible output circuit. Isolation The electric strength test is performed as factory test in accordance with IEC/EN 60950 and UL 1950 and should not be repeated in the field. Melcher will not honour any guarantee claims resulting from electric strength field tests. Table 3: Isolation Characteristic Electric Required according to strength IEC/EN 60950 test voltage Actual factory test 1 s AC test voltage equivalent to actual factory test Insulation resistance at 500 V DC 1 2 Input to case Input to Output to Output to Auxiliary 1 Auxiliary 1 Auxiliary 1 output(s) case output(s) to input to case to output 1.5 3.0 2 0.5 - 3.0 2 0.5 0.5 kVrms 2.1 4.2 2 0.7 - 4.2 2 0.7 0.7 kV DC 2.1 4.2 2 1.5 0.5 4.2 2 1.5 0.5 1.5 3.0 2 1.1 0.35 3.0 2 1.1 0.35 kVrms >300 >300 >300 >100 >300 >100 >100 M Insulated auxiliary circuits, e.g. Out OK output circuit (option D), inhibit on output side (option i). In accordance with IEC/EN 60950 only subassemblies are tested in factory with this voltage. MELCHER The Power Partners. Unit Edition 4/6.99 7/8 Preliminary Industrial Environment Preliminary P Series DC-DC Converters >100 Watt Industrial Environment Safety of operator accessible output circuit If the output circuit of an DC-DC converter is operator accessible, it shall be an SELV circuit according to IEC/EN 60950 related safety standards The following table shows some possible installation configurations, compliance with which causes the output circuit of the DC-DC converter to be an SELV circuit according to IEC/EN 60950 up to a configured output voltage (sum of nominal voltages if in series or +/- configuration) of 35 V. However, it is the sole responsibility of the installer to assure the compliance with the relevant and applicable safety regulations. More information about this subject and about output circuits at hazardous voltages are given in: Technical Information: Safety. Table 4: Safety concept leading to an SELV output circuit Conditions Front end Nominal supply voltage DC-DC converter Minimum required grade of insolation, 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 circuit and the DC-DC converter input circuit) Result Maximum DC output voltage from the front end 1 Minimum required safety Measures to achieve the status of the front end output specified safety status of the circuit output circuit Safety status of the DC-DC converter output circuit 168 V Primary circuit (The nominal voltage between any input pin and earth can be up to 250 V AC or 240 V DC.) Double or reinforced insulation, based on 250 V AC and 240 V DC (provided by the DC-DC converter) and earthed case 3 SELV circuit Earth related hazardous voltage secondary circuit 2 (The nominal voltage between any input pin and earth can be up to 250 V AC or 240 V DC.) Double or reinforced insulation, based on the maximum nominal output voltage from the front end (both provided by the DC-DC converter) and earthed 2 case Basic Unearded hazardous voltage Supplementary insulation, secondary circuit based on 250 V AC and DC and double or reinforced insulation, based on the maximum nominal output voltage from the front end (both providedby the DC-DC converter) andearthed 3 case Supplementary 1 2 3 Unearded hazardous voltage Basic insulation, based on secondary circuit 3 250 V AC and DC (provided by theDC-DC converter) The front end output voltage should match the specified input voltage range of the DC-DC converter. The maximum rated input voltage of the EQ units according to IEC/EN 60950/UL 1950 is 150 V. Has to be insulated from earth by at least supplementary insulation (by the installer) according to the relevant safety standards, e.g. IEC/EN 60950, based on the maximum nominal output voltage from the front end. If the converter case is accessible, it has to be earthed or the front end output circuit has to be insulated from the converter case by at least basic insulation, based on the maximum nominal mains supply voltage. Max. 250 V AC or 240 V DC ~ Mains ~ The Power Partners. 10052 + AC-DC front end Battery Fuse DC-DC converter Max. 250 V AC or 240 V DC Fig. 11 Schematic safety concept Use fuse, suppressor diode and earth connections as per table: Safety concept leading to an SELV output circuit. Use fuse(s) also if required by the application. See: Installation Instructions. MELCHER Fuse Edition 4/6.99 8/8 Earth connection SELV -