Melcher.
The Power
of
Comprehensive data sheets are available from either source:
– Internet: www.melcher.ch
– Melcher CD-ROM
– Melcher Databook
– Nearest sales office by fax or mail.
Edition 6/3.99
MELCHER
The Power Partners.
Power Output [V DC] No. of Input [V DC] Series
[W] 3 5 15 24 36 48 outputs 3 10 20 60 80 180
Print Mountable
1❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1, 2 ❚❚❚ DSP
1...12 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1, 2, 3 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ IMP
2.4 ❚❚❚❚ 1❚❚❚❚❚❚ CHS
3❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1,2 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ IXP
3...15 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1, 2, 3 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ IMR
4❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1, 2 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ IMX 4
6❚❚❚❚❚❚❚❚❚❚❚ 1, 2 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ IMO
6...20 ❚❚❚❚❚❚❚❚❚❚❚ 1, 2 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ DFA
6...30 ❚❚❚❚❚❚❚❚❚❚❚ 1, 2, 3 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ DFC
7❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1, 2 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ IMS 7
7❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1, 2 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ IMX 7
10 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1, 2 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ IML
10...30 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1, 2, 3 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ DGP
15 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1, 2 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ IMS 15
15 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1, 2 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ IMX 15, IMY 15
25 ❚❚❚❚❚❚❚❚ 1, 2 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ OBS, OBD
25/40 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1, 2, 3 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ IMR 25, IMR 40
Cassette Style
20 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ SR
50 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1, 2, 3 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ H
50 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1, 2, 3 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ M
100...150 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1, 2 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ Q
100 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1, 2 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ S
150 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1, 2 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ K
Open Frame
150 ❚❚❚❚❚❚❚❚❚❚❚ 3, 4 ❚❚❚❚❚❚❚❚❚❚❚ MDU
Bricks
15...60 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ HAS
25...150 ❚❚❚❚❚❚❚❚ 1❚❚❚❚❚❚❚❚❚❚❚ HES
33...100 ❚❚❚❚❚❚❚❚❚❚❚❚❚ 1❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ HBS
38...66 ❚❚❚ 1❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ QES
38...150 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ QBS
50...60 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1❚❚❚❚❚❚❚❚❚❚❚ QAS
100...190 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ XWS
100...300 ❚❚❚❚❚❚❚❚ 1❚❚❚❚❚❚❚❚❚❚❚❚ FES
100...300 ❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ 1❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ VWS
113...225 ❚❚❚❚❚❚❚❚ 1❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚❚ TES
DC-DC
Converters
Industrial Environment DC-DC Converters >100 Watt P Series
Edition 4/6.99
1/8
MELCHER
The Power Partners.
Preliminary
120/180 Watt DC-DC Converters P Series
Input to output isolation
Single output: 3.3, 5.1 V DC
Double output: 3.3/5.1, 2 × 5.1, 2 × 12, 2 × 15, 2 × 24 V
Triple output: 5.1/ 2 × 12, 5.1/ 2 × 15 V DC
Quadruple output: 5.1/3.3 with 2 × 12,
2 × 24 with 2 × 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
•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)
Safety according to IEC/EN 60950, UL 1950
LGA
C
Summary
These extremely compact DC-DC converters incorporate
all necessary input and output filtering, signalling and pro-
tection 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 pro-
tected 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
of several units, current sharing option is provided by a sin-
gle 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 operat-
ing 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 conduc-
tor 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.
164
6.5"
20
0.8"
4 TE
111
4.4"
3 U
Table of Contents Page
Summary .......................................................................... 1
Type Survey and Key Data .............................................. 2
Type Key and Product Marking ........................................ 4
Page
Mechanical Data .............................................................. 5
Safety and Installation Instructions .................................. 6
Safety approvals in progress
P Series DC-DC Converters >100 Watt Industrial Environment
Edition 4/6.99
2/8
MELCHER
The Power Partners.
Preliminary
Type Survey and Key Data
Table 1a: Type survey BP, CP
Output 1, 4 3 Output 2, 3 3 Input voltage range and efficiency 2 Options
U
o nom
T
A = 50°C
T
A = 71°C
U
o nom
T
A = 50°C
T
A = 71°Chmin
U
i min...
U
i max 4 hmin
U
i min...
U
i max 4
[V DC]
P
o max [W]
P
o nom [W] [V DC]
P
o max [W]
P
o nom [W] [%] 16...36 V DC [%] 33.6...75 V DC
3.3 125 106 - - - BP 1101-7R CP 1101-7R -9
5.1 152 122 - - - BP 1001-7R CP 1001-7R D
3.3 62 53 5.1 76 61 BP 2101-7R CP 2101-7R V 6
5.1 76 61 5.1 76 61 BP 2001-7R CP 2001-7R G
12 90 72 12 90 72 BP 2320-7R CP 2320-7R T 6
15 82 60 15 82 60 BP 2540-7R CP 2540-7R i
24 84 60 24 84 60 BP 2660-7R CP 2660-7R W
5.1 76 61 12, 12 72 1 60 1 BP 3020-7R CP 3020-7R
5.1 76 61 15, 15 75 1 60 1 BP 3040-7R CP 3040-7R
5.1, 3.3 5 50 1 40 1 12, 12 72 1 60 1 BP 4720-7R CP 4720-7R
24, 24 84 1 60 1 24, 24 84 1 60 1 BP 4660-7R CP 4660-7R
Table 1b: Type survey DP, EP
Output 1, 4 3 Output 2, 3 3 Input voltage range and efficiency 2 Options
U
o nom
T
A = 50°C
T
A = 71°C
U
o nom
T
A = 50°C
T
A = 71°Chmin
U
i min...
U
i max 4 hmin
U
i min...
U
i max 4
[V DC]
P
o max [W]
P
o nom [W] [V DC]
P
o max [W]
P
o nom [W] [%] 40...101 V DC [%] 66...150 V DC
3.3 125 106 - - - DP 1101-7R EP 1101-7R -9
5.1 152 122 - - - DP 1001-7R EP 1001-7R D
3.3 62 53 5.1 76 61 DP 2101-7R EP 2101-7R V 6
5.1 76 61 5.1 76 61 DP 2001-7R EP 2001-7R G
12 90 72 12 90 72 DP 2320-7R EP 2320-7R T 6
15 82 60 15 82 60 DP 2540-7R EP 2540-7R i
24 84 60 24 84 60 DP 2660-7R EP 2660-7R W
5.1 76 61 12, 12 72 1 60 1 DP 3020-7R EP 3020-7R
5.1 76 61 15, 15 75 1 60 1 DP 3040-7R EP 3040-7R
5.1, 3.3 5 50 1 40 1 12, 12 72 1 60 1 DP 4720-7R EP 4720-7R
24, 24 84 1 60 1 24, 24 84 1 60 1 DP 4660-7R EP 4660-7R
Table 1c: Type survey GP
Output 1, 4 3 Output 2, 3 3 Input voltage range and efficiency 2 Options
U
o nom
T
A = 50°C
T
A = 71°C
U
o nom
T
A = 50°C
T
A = 71°Chmin
U
i min...
U
i max
[V DC]
P
o max [W]
P
o nom [W] [V DC]
P
o max [W]
P
o nom [W] [%] 19.2...57.6 V DC
3.3 100 80 - - - GP 1101-7R -9
5.1 120 92 - - - GP 1001-7R D
3.3 50 40 5.1 60 46 GP 2101-7R V 6
5.1 60 46 5.1 60 46 GP 2001-7R G
12 72 54 12 72 54 GP 2320-7R T 6
15 68 50 15 68 50 GP 2540-7R i
24 70 48 24 70 48 GP 2660-7R W
5.1 60 46 12, 12 66 1 48 1 GP 3020-7R
5.1 60 46 15, 15 68 1 50 1 GP 3040-7R
5.1, 3.3 5 40 1 30 1 12, 12 66 1 48 1 GP 4720-7R
24, 24 70 1 48 1 24, 24 70 1 48 1 GP 4660-7R
1The cumulated power of both outputs may not exceed the total power for the specified ambient temperature.
2Minimum efficiency at
U
i nom,
P
o nom and
T
A = 25°C
3Output configuration with second output semi-regulated (±5%
U
o nom if each output is loaded with ≥5%
P
o nom). Parallel or series con-
figuration possible.
4Short deviations of
U
i min/
U
i max according to EN 50155 possible.
5Internal common ground.
6Not available for all types.
Industrial Environment DC-DC Converters >100 Watt P Series
Edition 4/6.99
3/8
MELCHER
The Power Partners.
Preliminary
Output Configuration
The P unit design allows high flexibility in output configura-
tion to cover almost every individual requirement, by simply
wiring the separated outputs in parallel, series or independ-
ent configurations as per following figures. Parallel and se-
ries operation of several modules with equal output voltage
is possible also.
Load 1
Vo2+
Vo1–
Vo3+
S1–
S1+
Vo1+
Triple output
Vi–
Vi+
i
28
30
32
4
12
14
8
6
18
01009
Load 2
Vo2–
Vo3–
10
20
Fig. 4
Parallel configurration of output 2 and 3
Fig. 2
Series output configuration
S1–
S1+
Vo1–
Vo1+
Vo2–
Vo2+
Double output
Vi–
Vi+
iLoad 1
28
30
32
6
10
4
12
14
8
01007
18
20
S2+
S2–
Fig. 6
Common ground configuration of output 1 with 4 and in-
dependent configuration of output 2 and 3
Load 1
Load 2
Vo2+
Vo4+
Vo2–
Vo4–
Vo1–
Vo1+
Quadruple output
Vi–
Vi+
i
28
30
32
4
8
14
12
6
10
01011
Load 3
Vo3+
Vo3–
18
20
Load 4
Load 1
Vo2+
Vo1–
Vo2–
S1–
S1+
Vo1+
Triple output
Vi–
Vi+
i
28
30
32
4
12
14
8
6
10
01010
Load 2
Vo3+
Vo3–
18
20
Fig. 5
Series configurration of output 2 and 3
Fig. 1
Parallel output configuration
Load 1
Vo2–
Vo1–
S1–
Vo1+
Vo2+
S1+
Double output
Vi–
Vi+
i
28
30
32
6
4
12
14
8
10
01006
18
20
S2–
S2+
Load 1
Load 2
Vo2+
Vo1–
Vo2–
S1–
S1+
Vo1+
Triple output
Vi–
Vi+
i
28
30
32
4
12
14
8
6
10
01008
Load 3
Vo3+
Vo3–
18
20
Fig. 3
Independent output configuration (all outputs)
Load 2
Load 1
Vo2+
Vo1–
Vo2–
Vo4–
Vo4+
Vo1+
Quadruple output
Vi–
Vi+
i
28
30
32
4
12
14
8
6
10
01012
Vo3+
Vo3–
18
20
Fig. 7
Parallel configuration of output 1 with 4 and series con-
figuration of output 2 with 3
P Series DC-DC Converters >100 Watt Industrial Environment
Edition 4/6.99
4/8
MELCHER
The Power Partners.
Preliminary
Type Key and Product Marking
Type Key C P 2 5 40 -7 R D V G T i W
Input voltage range
U
i:
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
, U
o1/4 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,
U
o2/3 nom
5.1 V ............................................................ 01
12 V ............................................................. 20
15 V ............................................................. 40
24 V ............................................................. 60
other voltages ....................................... 70...99
Operational ambient temperature range
T
A:
–25…71°C ................................................... -7
–40...71°C (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...71°C.
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, out-
put 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.
Industrial Environment DC-DC Converters >100 Watt P Series
Edition 4/6.99
5/8
MELCHER
The Power Partners.
Preliminary
Mechanical Data
Dimensions in mm. Tolerances ±0.3 mm unless otherwise indicated. European
Projection
Note: Long Cases, elogated by 60 mm for 220 mm rack
depth is available on request.
104
±0.15
70
111
20
100
127
±0.15
164
±0.5
8
±0.5
19.8
M3; through
Measuring point of
case temperature T
C
20.32 (4 TE)
13.43
100
95
5.5
LED "Out OK" green
LED "In OK" green
171.93 (DIN 41494)
09099
Front plate
Main
face
Rear
face
Back plate
Fig. 8
Case P01, weight 480 g
Aluminium, fully enclosed,
black finish and self cooling
P Series DC-DC Converters >100 Watt Industrial Environment
Edition 4/6.99
6/8
MELCHER
The Power Partners.
Preliminary
Fig. 9
View of male H15 connector
32 28 24 20 16 12 8 4
30 26 22 18 14 10 6
10025
Fig. 10
View of male H15 S2 connector for P 1000
32 28 24 20 16 12 4/6
30 26 22 18 14 8/10
10051
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.
Table 2: Pin allocation of the H15 S2 and H 15 connector
Pin P 1000 P 2000 P 3000 P 4000
4 Vo1+ 1 Output 1 Vo1+ Output 1 Vo1+ Output 1 Vo1+ Output 1
6 Vo2+ Output 2 Vo2+ Output 2 Vo2+ Output 2
8Vo1– 1 Output 1 Vo1–Output 1 Vo1–Output 1 Vo1–Output 1
10 Vo2–Output 2 Vo2–Output 2 Vo2–Output 2
12 S+ 2 Sense S1+ 2 Sense 1 S1+ 2 Sense 1 Vo4+ Output 4
14 S– 2 Sense S1– 2 Sense 1 S1– 2 Sense 1 Vo4–Output 4
16 3 R Control of
U
oR1 Control of
U
o1 R1 Control of
U
o1 R1/4 Control of
U
o1/4
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
22 3 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 i+ Inhibit secondary
D Save data D Save data
24 3 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 i–Inhibit secondary
Rst Reset Rst Reset
26 2 Prot. ground Prot. ground Prot. ground Prot. ground
28 3 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
1H15 S2 connector with two high current contacts.
2Leading pin (pre-connecting).
3One function/option per pin possible only.
Industrial Environment DC-DC Converters >100 Watt P Series
Edition 4/6.99
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MELCHER
The Power Partners.
Preliminary
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 Input to Input to Output to Output to Auxiliary 1 Auxiliary 1 Auxiliary 1 Unit
case output(s) case output(s) to input to case to output
Electric Required according to 1.5 3.0 2 0.5 - 3.0 2 0.5 0.5 kVrms
strength IEC/EN 60950 2.1 4.2 2 0.7 - 4.2 2 0.7 0.7 kV DC
test voltage Actual factory test 1 s 2.1 4.2 2 1.5 0.5 4.2 2 1.5 0.5
AC test voltage equivalent 1.5 3.0 2 1.1 0.35 3.0 2 1.1 0.35 kVrms
to actual factory test
Insulation resistance at 500 V DC >300 >300 >300 >100 >300 >100 >100 MΩ
1Insulated auxiliary circuits, e.g. Out OK output circuit (option D), inhibit on output side (option i).
2In accordance with IEC/EN 60950 only subassemblies are tested in factory with this voltage.
Installation Instruction
The P series DC-DC converters are components, intended
exclusively for inclusion within other equipment by an in-
dustrial assembly operation or by professional installers.
Installation must strictly follow the national safety regula-
tions in compliance with the enclosure, mounting, creep-
age, clearance, casualty, markings and segregation re-
quirements of the end-use application. See also:
Technical
Information: Installation and Application
.
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.
Check for hazardous voltages before altering any connec-
tions.
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 accessi-
ble output circuit
.
The Vi input (pin no. 32) is internally fused. This fuse is de-
signed 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 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
T
C max must not be overridden.
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
.
Cleaning Agents
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 equip-
ment.
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 out-
put, 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 out-
put(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).
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.
P Series DC-DC Converters >100 Watt Industrial Environment
Edition 4/6.99
8/8
MELCHER
The Power Partners.
Preliminary
Table 4: Safety concept leading to an SELV output circuit
Conditions Front end DC-DC converter Result
Nominal Minimum required grade Maximum DC Minimum required safety Measures to achieve the Safety status
supply of insolation, to be pro- output voltage status of the front end output specified safety status of the of the DC-DC
voltage vided by the AC-DC front from the front circuit output circuit converter
end, including mains end 1 output circuit
supplied battery charger
Mains Operational (i.e. there is ≤168 V Primary circuit (The nominal Double or reinforced insula- SELV circuit
≤250 V AC no need for electrical iso- voltage between any input tion, based on 250 V AC and
lation between the mains pin and earth can be up to 240 V DC (provided by the
supply circuit and the 250 V AC or 240 V DC.) DC-DC converter) and
DC-DC converter input earthed case 3
circuit)
Basic Earth related hazardous Double or reinforced insula-
voltage secondary circuit 2 tion, based on the maximum
(The nominal voltage nominal output voltage from
between any input pin and the front end (both provided
earth can be up to 250 V AC by the DC-DC converter) and
or 240 V DC.) earthed 2 case
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 Unearded hazardous voltage Basic insulation, based on
secondary circuit 3250 V AC and DC (provided
by theDC-DC converter)
1The front end output voltage should match the specified input voltage range of the DC-DC converter.
2The maximum rated input voltage of the EQ units according to IEC/EN 60950/UL 1950 is 150 V.
3Has 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.
Safety of operator accessible output circuit
If the output circuit of an DC-DC converter is operator ac-
cessible, it shall be an SELV circuit according to IEC/EN
60950 related safety standards
The following table shows some possible installation con-
figurations, 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 as-
sure the compliance with the relevant and applicable safety
regulations. More information about this subject and about
output circuits at hazardous voltages are given in:
Techni-
cal Information: Safety
.
AC-DC
front
end
DC-DC
con-
verter
Mains SELV
Earth
connection
+
–
~
~
10052
Battery
Max. 250 V AC or 240 V DC
Max. 250 V AC or 240 V DC
Fuse
Fuse
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:
Instal-
lation Instructions
.
