W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters 125, 250 Watt AC-DC (DC-DC) Converters Convert Select Features * RoHS lead-free-solder and lead-solder-exempted products are available * Rugged 35 mm DIN-rail snap-fit design * Class I equipment * Universal AC-input or DC-input (66 - 150 or 90 - 350 VDC) with single stage conversion * Power factor correction, harmonics IEC/EN 61000-3-2 * Virtually no inrush current * Immunity to IEC/EN 61000-4-2, -3, -4, -5, -6, -8, -11 * Emissions according to EN 55011/022 * Very high efficiency; up to 89% * Short-term output peak power capability, rectangular current limiting characteristic * Single or two independently regulated outputs with 12, 24, 36, or 48 V * Outputs no-load, overload, and short-circuit proof * PCBs coated by protective lacquer * Very high reliability Safety-approved to IEC/EN 60950-1 and UL/CSA 60950-1 2nd Ed., UL 508 listed components 138 5.43" 1 103 4.05" 114 4.49" 1 Description The Convert Select front end series represents a family of DIN-rail mountable DC-DC and AC-DC converters with power factor correction. The converters have been designed according to the latest industry requirements and standards. The converters are ideal for use in outdoor and other demanding applications to power building control systems, factory automation, industrial controls, instrumentation, electromagnetic drives, fans, and other DC loads. Different models are available with a single output or two independently regulated, electrically isolated outputs with 12, 24, 36, or 48 V. Special models for battery charging are available. The EW Table of Contents not EW models are particularly suitable for 110 V railway applications; they have been designed in accordance with the railway standards EN 50155 and EN 50121. Key features of the Convert Select line include power factor correction with low harmonic distortion, negligibly low inrush current, high immunity to transients and surges, and low electromagnetic emissions. Internal protection circuits such as input over- and undervoltage lockout, thermal protection, as well as output overvoltage protection by a second control loop ensure safe operation of the final system. The outputs deliver an electrically-isolated Safety Extra Low Voltage (SELV) and low output noise. They are no-load, Page Page Description .......................................................................... 1 Model Selection .................................................................. 2 Functional Description ........................................................ 4 Electrical Input Data ............................................................ 6 Electrical Output Data ......................................................... 8 Electromagnetic Compatibility (EMC) ............................... 13 Immunity to Environmental Conditions ................................. 16 Mechanical Data ................................................................... 17 Safety and Installation Instruction ......................................... 18 Description of Options .......................................................... 21 Accessories ........................................................................... 24 Copyright (c) 2018, Bel Power Solutions Inc. All rights reserved. BCD20020-G Rev AE, 25-APR-2018 MELCHER The Power Partners. Page 1 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters overload, and short-circuit proof. The electronically controlled short-term peak power capability of up to 150% of the rated output power enables the front end converters to deliver additional power to start-up motors or to safely operate subsequent circuit breakers. Built-in large sized output capacitors absorb possible reverse energy, which may be caused by quick deceleration of electromagnetic drives connected directly to the output. A green LED at the front cover displays the status of the output(s). The Convert Select Series was designed according to all relevant international safety standards. The converters are approved by TUV and UL, and are UL 508 listed. Adequate clearances and creepage distances allow operation in pollution degree 3 environment (with AC input). All board assemblies are coated with a protective lacquer. The thermal concept allows operation at full load up to an ambient temperature of 60 C (LW models) or 70 C (EW models) in free air without forced cooling. A rugged DIN snap-fit device allows easy and reliable fixing onto the various 35 mm DIN rail models. The converters are fitted with cage clamp terminals which are easily accessible from the front. System connectors with screw terminals for use with pre-assembled harnesses, external adjustment of the output voltage as well as various auxiliary functions are available as options. The letter E stands for improved EMC performance of LW models. Models without E are obsolete. Model Selection Table 1: Standard models Output 1 Vo1 nom1 I o1 nom [VDC] [A] Output 2 Vo2 nom1 I o2 nom [VDC] [A] Output Power Po nom [W] Operating Input Voltage Vi min - Vi max Type Designation 6 Effic. min 8 [%] Options 3, 5 85 2 - 264 VAC, 47 - 63 Hz 4, 90 2 - 350 VDC 7 LWR1301-6E 3 83* LWN1301-6E 3 83* LWR1601-6E 87 LWN1601-6E 87 R D1, D2, D5 M1, M2 F K2, G 12.35 7.5* - - 93* 12.35 14* - - 173* 24.7 5 - - 124 24.7 10 - - 247 37 3.3 - - 122 LWR1701-6E 3 LWN1701-6E 3 88 37 6.6 - - 244 49.4 2.5 - - 124 LWR1801-6E 88 49.4 5 - - 247 LWN1801-6E 88 83* 12.35 7* 12.35 7* 173* 24.7 5 24.7 5 247 LWN2660-6E 87 37 3.3 37 3.3 244 LWN2770-6E 3 89 49.4 2.5 49.4 2.5 247 LWN2880-6E 89 EWR1601-0 9 87 EWN2660-0 9 87 24.7 5 - - 120 24.7 5 24.7 5 240 LWN2320-6E 3 88 66 - 150 VDC R, M1, M2 Q, K2, G * Version 106 or higher 1 R-input not connected. 2 For derating at low input voltage see section Output Power Derating. 3 For minimum quantity and lead times contact the Company. 4 The converters have been tested up to 440 Hz; operation at 16 2/ Hz is also possible, but the output ripple is slightly higher. For questions 3 when operating at frequencies <47 Hz or >63 Hz, consult the Company. 5 On double-output models the options R, M2, D1, D2, D5 are related to the second output only. 6 Improved EMC performance for LWN/LWR models. Former models without E are still available on request. 7 V 250 VDC for models with option F i 8 Min. efficiency at V i nom, Io nom, and TA = 25 C. Typical values are approx. 2% better. 9 EWN and EWR models are designed for railway applications according to EN 50155 and EN 50121. NFND: Not for new designs. BCD20020-G Rev AE, 25-APR-2018 Preferred for new designs MELCHER The Power Partners. Page 2 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters Table 2: Battery charger models (M1 included) VBat [VDC] Output Voltage Vo safe1 Vo max [VDC] [VDC] 12.841 12 25.681 24 38.521 36 51.361 48 14.65 29.3 43.95 58.6 Nominal Output ValuesOperating InputType Designation 6Effic. Vo nom 5 Io nom 5 Po nom 5 Voltage [VDC] [A] [W] Vi min - Vi max 13.8 27.3 40.88 54.5 7.5 * 104* 85 2 - 264 VAC, 47 - 63 Hz 4, 90 2 - 350 VDC 7 Options 3 min 8 [%] LWR1140-6EM1 3 83* LWN1140-6EM1 3 85* 14* 194* 4.2 115 LWR1240-6EM1 86 8.4 230 LWN1240-6EM1 85 2.8 115 LWR1840-6EM1 3 86 5.6 230 LWN1840-6EM1 3 86 2.1 115 LWR1740-6EM1 86 4.2 230 LWN1740-6EM1 87 F K2, G * Version 106 or higher Setting voltage (typ.) with open R-input 2 For derating at low input voltage, see section Output Power Derating. 3 For minimum quantity and lead times, contact the Company. 4 The converters have been tested up to 440 Hz; for operating frequency <47 Hz or >63 Hz consult the Company. 5 Nominal output figures, calculated with a cell voltage of 2.27 V at 20 C. 6 Improved EMC performance. Former models without E are still available on request. 7 V 250 VDC for models with option F. i 8 Min. efficiency at V i nom, Vo nom, Io nom, and TA = 25 C. Typical values are approx. 2% better. 1 Part Number Description L W N 2 6 60 -6 E D2 F K2 G Input voltage range .......................................................... E, L Series .................................................................................. W Nominal output power 125 W .............................................................. R 250 W .............................................................. N Number of outputs ............................................................ 1, 2 Type specification .................................................. 000 - 999 Operational ambient temperature range TA -40 to 60 C ................................................... -6 EW or customer-specific ........................... -0, -5 Improved EMC performance ................................................ E Output voltage control input 1 ....................................... R Save data signal 1 .......................................... D1, D2, D5 Multiple functions via D-SUB connector 1 .. M1, M2 Options Built-in second fuse, input diode ................. F, Q System connector .......................................... K2 RoHS compliant for all six substances ............ G 1 Only one of these options is possible. Note: The sequence of options must follow the order above. NFND: Not for new designs Example: Preferred for new designs. LWN2660-6ED2FK2G: Power factor corrected AC-DC converter, operating input voltage range 85 - 264 VAC, 2 electrically isolated and individually regulated outputs, each providing 24.7 V, 5 A, improved EMC performance, options D2, F, K2, and RoHS-compatible for all 6 substances. BCD20020-G Rev AE, 25-APR-2018 MELCHER The Power Partners. Page 3 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters Product Marking Basic type designation, applicable safety approval and recognition marks, CE mark, warnings, pin designation, company logo. Functional Description The W Series converters are primary controlled AC-DC or DCDC flyback converters with a constant switching frequency of 130 kHz. The power-factor-corrected single-step conversion of the input voltage to a low output voltage results in extremely high efficiency. Depending upon the output power, the converters are fitted with one (125 W) or two (250 W) powertrains. Models with two powertrains have one or two outputs. Double-output models exhibit individually regulated powertrains. The input voltage is fed via fuse, filter, and rectifier to the main transformer, designed in planar technique. The input filter with very small input capacitance generates virtually no inrush current. An input transient suppressor protects the converter against high voltage peaks and surges. Input over- and undervoltage lockout as well as input current limitation protect the converter from operation outside of its specification. The input voltage waveform is sensed by the primary control logic to allow active power factor correction, forcing the input current to follow the input voltage waveform. Specific type designation, input voltage range, nominal output voltages and currents, degree of protection, batch no., serial no., and data code including production site, version, and date of production. The secondary side of the main transformer supplies via the rectifier diode a large electrolytic output storage capacitor providing for the hold-up time. Double-output models exhibit an individual control logic each. The output voltage and the output current are measured and fed back to the primary control logic via an optocoupler. A second control loop monitors the output voltage. It disables the output in the case of a failure in the control logic and limits the output voltage. Built-in temperature sensors monitor the internal temperature of each powertrain. If the temperature exceeds the limit, the converter reduces the output power continuously to keep the temperature below its limit. A green LED on the front cover confirms the presence of the output voltage(s). The R input (option R, M1, or M2) allows for external adjustment of the output voltage by means of a resistor or an external voltage source. An external sensor can be connected to the R input and allows for temperature-controlled battery charging (see Accessories). 03103b Cy 2 2nd fuse (option F) 1 1 EW models have a link or a decoupling diode (opt. Q) in the Vi+ line. Rectifier1 Input filter N Vi- 2 Vo+ + Shunt Shunt Output filter 3 Vi+ Input filter L Fuse 3 6 CY 4 Vo- Cy Cy 7 5 8 Control circuit including PFC and input OVP/UVP Vo/Io control CY 9 1 2nd control loop (SELV) 11 10 AUX Fig. 1 Single-output converters (125 W). BCD20020-G Rev AE, 25-APR-2018 MELCHER The Power Partners. Page 4 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters 03104b 2nd fuse (option F) 1 EW models have a link or a decoupling diode (opt. Q) in the Vi+ line. Input filter Control circuit including PFC and input OVP/UVP 2 3 Vo1+ 4 Vo1- 5 Vo/Io control 2nd control loop + Shunt Shunt Cy Control circuit including PFC and input OVP/UVP Cy Cy Cy Cy 1 Shunt Shunt Output filter Input filter + Vo/Io control 2nd control loop Output filter 2 Cy Rectifier1 N Vi- 3 Input filter L Vi+ Fuse Cy 6 Cy 8 7 9 Vo2+ Vo2- 1 11 10 AUX Fig. 2 250 W converters. The figure shows a double-output model. For the pinout of 250 W single-output models, see fig. 1 or table 13. BCD20020-G Rev AE, 25-APR-2018 MELCHER The Power Partners. Page 5 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters Electrical Input Data General conditions: TA = 25 C, unless TC is specified. Table 4a: Input data of LW models Input LWR AC-Input Characteristic Vi Operating input voltage range V i nom Rated input volt. range fi Rated input frequency1 Ii Input current Conditions min Io = 0 - Io nom Tc - Tc max 85 2 264 typ max 350 4 V 220 100 (230) 240 220 50 - 60 -- 50 - 60 -- Hz A 1.25 1.3 1.67 3.5 3.3 1.2 0.9 1.3 1 W 3 3 5 5 A 6 F Ci Input capacitance PF Power factor V i nom = 230 V, Io nom Vi RFI Conducted input RFI EN 55011/55022 V i nom, Io nom 5 90 2 0.65 V i max , t > 0.1 ms 4 typ max min 85 2 1.75 V i min - V i max 3 min 4 0.63 Inrush current 2 (230) 240 max 350 Unit DC-Input I o nom, V i = V i nom No-load input power 1 typ 90 2 AC-Input I o nom, V i = V i min I inrush fswitch max min 264 100 Pi0 Radiated input RFI typ LWN DC-Input 5 Switching frequency 5 0.86 5 6 0.86 5 -- -- A, B3 A, B3 A, B 3 A, B 3 B3 B3 B3 B3 130 130 130 130 kHz For operating frequencies <47 Hz and >63 Hz consult the Company. The converters have been tested up to 440 Hz. Output power derating at low input voltage and/or high case temperature TC (see Output power derating). Models with feature E (type test with LWN1801-6E) Vi 250 VDC for models with option F. Models with 12 V output: 0.70 for LWR, 0.75 for LWN Table 4b: Input data of EW models Input Characteristic Conditions min Vi Operating input voltage range Io = 0 - Io nom Tc to Tc max 66 V i nom Nominal input voltage V UVT Undervoltage trigger Ii Input current Radiated input RFI 1 min 66 typ max 150 1 V 110 60 54 60 I o nom, V i = 66 V 2.2 4.4 0.8 1.3 W 6 12 A 2.5 4.5 F A A V i max , t > 0.1 ms Switching frequency max 150 1 2.5 V i min - V i max fswitch typ 1.25 Inrush current Conducted input RFI DC-Input 54 No-load input power Input capacitance DC-Input Unit I o nom, V i = V i nom Pi0 Ci EWN 110 I inrush Vi RFI EW R EN 55011/55022 V i nom, Io nom -- -- 130 130 A kHz Vi 168 VDC for 3 s. Overvoltage trigger adjusted to 170 - 182 V. BCD20020-G Rev AE, 25-APR-2018 MELCHER The Power Partners. Page 6 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters Output Power Derating The output power of LW models must be decreased at low input voltage and/or powertrain temperature above 125 C. The powertrain temperature depends on the output power, the input voltage, and the cooling method. At low input voltage the losses increase. At the maximum specified environment temperature TA free air convection cooling might be insufficient approaching maximum ambient conditions. As a result, the output power has to be reduced according to the tables below. Note: The measurements have been made by the approval boards with free air convection cooling according to UL 60950 specified ambient temperature TA and with the converter built in a cardboard box according to UL 508 and a specified temperature outside the box Tout. The tables give a correlation between TA or Tout and the case temperature TC (measuring point TC see Mechanical Data). For models not specified, please contact the Company. EW models need no derating. Table 5a: Po derating according to UL 60950 at TA = 60 C, or according to UL 508 at Tout = 50 C Model Po nom TC max [W] [C] Vi [VAC] Vi [VDC] [W/V] 124 80 108 98 -0.67 LWR1601-6E Derate below derate by LWN1601/2660-6E 247 89 125 115 -1.25 LWR1701-6E 122 80 125 115 -1.25 LWN1701-6E 244 90 125 115 -1.25 LWR1801-6E 124 80 98 93 - 0.67 LWN1801/2880-6E 247 89 125 115 -1.25 Table 5b: Po derating according to UL 60950 at TA = 50 C, or according to UL 508 at Tout = 40 C Model Po nom TC max [W] [C] Derate below derate by Vi [VAC] Vi [VDC] [W/V] LWR1601-6E 124 76 98 no derating -0.67 LWN1601/2660-6E 247 86 115 105 -1.25 LWR1801-6E 124 76 93 no derating -0.67 LWN1801/2880-6E 247 86 105 95 -1.25 Input Fuse and Protection Efficiency A fast-blow fuse ( Schurter F 6.3 A, 5 x 20 mm), protected by a sleeve, is connected to the input L or Vi+. EW models have a smaller fuse (250 V, 4 x 9 mm, SOC NT3 6.3A V009, ULrecognized E-39265). For DC input voltages above 250 V consult the Installation Instructions. 04071 90 80 Converters with option F have 2 small fuses, one in each input line. Converters with option EF (E and F) have 2 large fuses ( F6.3 A, 5 x 20 mm). The DC input voltage for converters with option F is limited to 250 V. 70 60 50 A VDR and a symmetrical input filter form an effective protection against input transients. 40 30 An under- and an overvoltage lockout protect the converter, which is disabled below Vi min and above Vi max by an internally generated inhibit signal. 20 10 0 The built-in bridge rectifier (LW models) provides reverse polarity protection at the input if operated from DC. EW models are protected by the (blowing) input fuse in connection with the body diode of the main transistor. Option Q offers a serial diode, but this reduces the efficiency by approx. 1%. BCD20020-G Rev AE, 25-APR-2018 0 0.2 0.4 Vi = 125 VAC 0.6 Io Io nom 0.8 1 Vi = 230 VAC Fig. 3 Efficiency versus load (LWN2660-6) MELCHER The Power Partners. Page 7 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters PF 1 Power Factor, Harmonics All converters feature active power factor correction. LWN1701-6E mA/W 4 04069a 0.9 04070b 0.8 0.7 0.6 Limit class D according to IEC/EN 61000-3-2 3 0.5 0.4 2 0.3 0.2 1 0.1 0 0 3 5 7 9 13 Harm. 11 Fig. 4 Harmonic currents at input current, measured at Vi = 230 VAC, Io = Io nom (LWN1701-6E). 0 0.2 0.4 0.6 0.8 1 Io Io nom Vi = 125 VAC Vi = 230 VAC Fig. 5 Power factor versus load (LWN2660-6) Electrical Output Data Table 6a: Output data of 125 Watt standard models. General conditions: TA = 25 C, unless TA is specified; R input open-circuit Model LWR1301 Characteristic V o nom Conditions Output voltage nominal 1 min V i nom, Io nom Vo L Overvoltage protection Po nom Nominal output power Io nom Output current nominal 3 Io L Output current limit Iop Output current boost 4 vo Ripple and noise V i min - V i max typ. 1 s LWR1801 typ max min 24.25 24.7 25.2 36.4 37 37.8 48.5 49.36 50.4 12.35 12.5 24.55 24.7 24.85 36.8 37 37.2 49.06 49.36 49.66 13.0 24.0 25.8 36.0 15 * 28.5 30 typ 38.7 48.0 42.7 45 max V 51.6 57 60 105 * 124 122 124 W 7.5 * 5.0 3.3 2.5 A 7.6 8.5 5.1 11.3 5.7 7.5 3.4 3.8 2.53 5.0 2.9 3.75 - 500 - - V i = 230 VAC, fi = 50 Hz, Io nom 100 100 100 100 1100 2 1100 2 1200 2 1200 2 V o u Static line regulation 100 V - V i max, I o nom 0.08 0.1 0.15 0.15 V o l Static load regulation (droop) V i nom, I o = (0.1 - 1) Io nom - 0.2 - 0.4 - 0.6 - 0.8 vod V i nom, I o = (0.5 1) Io nom 1 1.2 1.5 1.8 vo Dynamic load regulation Voltage deviation Recovery time Temperature coefficient tor Start-up time Vi = 0 Vi nom, Io nom t oh min Hold-up time I o nom, Vo nom 0.8 Vo nom TC min - TC max Unit max min 14 * V i = 100 V - V i max LWR1701 typ V i min - V i max, 11.9 Io = (0.1 - 1) Io nom EWR V i = 110 VDC, I o nom LWR EWR/LWR1601 max min 12.0 * 12.2 V o worst Output voltage range of tolerance typ mVpp V 40 40 80 80 ms 0.02 0.02 0.02 0.02 %/K 700 700 700 700 ms 10 6/15 20 25 * Converters with feature E and version 106 1 Setting voltage with open R-input 2 Superimposed low frequency ripple at 2 * f i 3 Rectangular current limit characteristic (continuous operation) 4 Short-term peak power capability 150% of P o nom for approx. 1 s BCD20020-G Rev AE, 25-APR-2018 MELCHER The Power Partners. Page 8 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters Table 6b: Output data of 250 Watt single-output standard models. General conditions as in table 6a Model LWN1301 Characteristic V o nom Conditions Output voltage nominal 1 min V i nom, Io nom Vo L Overvoltage protection Po nom Nominal output power Io nom Output current nominal 3 LWN1601 max min -* 12.2 V o worst Output voltage range of tolerance typ typ LWN1801 max min typ Unit max 24.25 24.7 25.2 36.4 37 37.8 48.5 49.36 50.4 37 37.2 49.06 49.36 49.66 13.0 24.0 14 * V i min - V i max LWN1701 max min 12.35 12.5 24.55 24.7 24.85 36.8 V i min - V i max, 11.9 Io = (0.1 - 1) Io nom V i = 100 V - V i max typ 25.8 36.0 15 * 28.5 30 38.7 48.0 42.7 45 V 51.6 57 60 173 * 247 244 247 W 14 * 10 6.6 5.0 A Io L Output current limit Iop Output current boost 4 typ. 1 s 14.1 * 16* 10.2 vo Ripple and noise V i = 230 VAC, f i = 50 Hz, Io nom 100 100 100 100 1100 2 1100 2 1200 2 1200 2 21 11.4 6.7 15 7.6 5.1 10 5.6 7.5 V o u Static line regulation 100 V - V i max, I o nom 0.08 0.1 0.15 0.15 V o l Static load regul. (droop) V i nom, (0.1 - 1) Io nom - 0.2 - 0.4 - 0.6 - 0.8 vod V i nom, I o = (0.5 1) Io nom 1 1.2 1.5 1.8 vo Dynamic load regulation Voltage deviation Recovery time Temperature coefficient tor Start-up time t oh min Hold-up time mVpp V 40 40 80 80 ms 0.02 0.02 0.02 0.02 %/K Vi = 0 Vi nom, Io nom 700 700 700 700 ms I o nom, Vo nom 0.8 Vo nom 10 15 20 25 TC min - TC max Table 6c: Output data of 250 Watt double-output standard models. General conditions as in table 6a Model LWN2320 Characteristic Conditions V o1 nom Output voltage nominal 1 V o2 nom V i nom, Io nom V o worst Output voltage range of tolerance V i min - V i max, 11.9 Io = (0.1 - 1) Io nom 13.0 24.0 14 * 15 * 28.5 Overvoltage protection Po nom Nominal output power Io nom Output current nominal Io L Output current limit Iop Output current boost 4 typ. 1 s vo Ripple and noise V i = 230 VAC, fi = 50 Hz, Io nom typ max min -* Vo L 3 min EWN/LWN2660 12.2 V i = 100 V - V i max max min 24.25 24.7 25.2 12.35 12.5 24.55 24.7 24.85 36.8 173* 7.1 * 30 5.1 LWN2880 max min max 48.5 49.36 50.4 37 37.2 49.06 49.36 49.66 38.7 48.0 45 60 247 2 x 3.3 3.4 V 51.6 57 244 5.7 typ Unit 37 42.7 2x 5 7.8* typ 25.8 36.0 247 2x 7 * V i min - V i max typ LWN2770 W 2 x 2.5 A 3.8 2.53 2.9 2 x 10.5* 2 x 7.5 2 x 5.0 100 100 5 100 2 x 3.75 100 1100 2 1100 2 1200 2 1200 2 mVpp V o u Static line regulation 100 V - V i max, I o nom 0.08 0.1 0.15 0.15 V o l Static load regul. (droop) V i nom, (0.1 - 1) Io nom - 0.2 - 0.4 - 0.6 - 0.8 vod V i nom, I o = (0.5 1) Io nom 1 1.2 1.5 1.8 40 40 80 80 ms vo Dynamic load regulation Voltage deviation Recovery time Temperature coefficient 0.02 0.02 0.02 0.02 %/K tor Start-up time Vi = 0 Vi nom, Io nom 700 700 700 700 ms t oh min Hold-up time I o nom, Vo nom 0.8 Vo nom 10 6 /15 20 25 TC min - TC max * Converters with feature E and version 106 1 Setting voltage with open R-input 2 Superimposed low frequency ripple at 2 * f i BCD20020-G Rev AE, 25-APR-2018 3 4 5 V Rectangular current limit characteristic (continuous operation) Short-term peak power capability 150% of Po nom for approx. 1 s EWN2660: 500 mV @ Vi = 110 VDC MELCHER The Power Partners. Page 9 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters Table 7a: Output data of 125 Watt battery charger models. General conditions: TA = 25 C, unless TA is specified; R input left open-circuit, unless otherwise specified Model LWR1140-6EM1 V o safe Output setting voltage 1 V i nom, Io nom 12.25 12.84 13.15 24.5 25.68 26.3 36.75 38.52 39.5 49 Vo L Overvoltage protection Po nom Nominal output power Io nom V i min - V i max, I o = (0.1 - 1) Io nom 14.65 15.4* V i = 100 V - V i max Output current nominal limit 3 typ max min 29.3 16.3* 30.9 typ LWR1740-6EM1 min Output voltage (max.) controlled by R input max min LWR1840-6EM1 Conditions V Bat typ LWR1240-6EM1 Characteristic max min 43.95 32.5 46 typ max 51.36 52.6 48.8 61.8 65 104 * 115 115 115 W 7.5 * 4.2 2.8 2.1 A Output current Iop Output current boost 4 typ. 1 s 11.2 * vo Ripple and noise V i = 230 VAC, fi = 50 Hz, Io nom 100 100 100 100 1100 2 1100 2 1200 2 1200 2 7.6* 8.4 * 4.3 4.8 3.2 3.7 6.3 2.2 4.2 2.5 3.2 mVpp V o u Static line regulation 100 V - V i max, I o nom 0.08 0.1 0.15 0.15 V o l Static load regulation (droop) V i nom, I o = (0.1 - 1) Io nom - 0.2 - 0.4 - 0.6 - 0.8 vod 1.2 1.2 1.6 1.9 vo Dynamic load regulation V i nom, Voltage deviation I o = (0.5 1) Io nom Recovery time Temperature coefficient TC min - TC max tor Start-up time Vi = 0 Vi nom, Io nom V 58.6 Io L V i min - V i max Unit V 40 40 80 80 ms 0.02 0.02 0.02 0.02 %/K 700 700 700 700 ms Table 7b: Output data of 250 Watt battery charger models. General conditions as in table 7a Model LWN1140-6EM1 max min LWN1740-6EM1 min V o safe Output setting voltage 1 V i nom, Io nom 12.25 12.84 13.15 24.5 25.68 26.3 36.75 38.52 39.5 V Bat Output voltage (max.) controlled by R input V i min - V i max, I o = (0.1 - 1) Io nom Vo L Overvoltage protection 15.4* V i = 100 V - V i max max LWN1840-6EM1 min 14.65 typ min Conditions Po nom Nominal output power typ LWN1240-6EM1 Characteristic 29.3 16.3* 30.9 194* max 49 43.95 32.5 46 230 51.36 52.6 48.8 61.8 230 Output current nominal Output current limit Iop Output current boost 4 typ. 1 s 21 * 12.6 8.4 6.3 vo Ripple and noise V i = 230 VAC, fi = 50 Hz, Io nom 100 100 100 100 1100 2 1100 2 1200 2 1200 2 14.2 * 15.6 * 8.6 5.6 9.6 6.4 V 65 Io L V i min - V i max Unit max 58.6 230 8.4 typ Io nom 3 14 * typ W 4.2 7.4 A 4.4 5.0 mVpp V o u Static line regulation 100 V - V i max, I o nom 0.08 0.1 0.15 0.15 V o l Static load regulation (droop) V i nom, I o = (0.1 - 1) Io nom - 0.2 - 0.4 - 0.6 - 0.8 vod 1.2 1.2 1.6 1.9 40 40 80 80 ms vo Dynamic load regulation V i nom, Voltage deviation I o = (0.5 1) Io nom Recovery time Temperature coefficient TC min - TC max 0.02 0.02 0.02 0.02 %/K tor Start-up time 700 700 700 700 ms Vi = 0 Vi nom, Io nom V * Converters with feature E and version 106 1 Setting voltage with open R-input = V o safe 2 Superimposed low frequency ripple at 2 * f i 3 Rectangular current limit characteristic (continuous operation) 4 Short-term peak power capability 150% of P o nom for approx. 1 s BCD20020-G Rev AE, 25-APR-2018 MELCHER The Power Partners. Page 10 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters Parallel Operation Double-output models exhibit an independent control logic each. Both outputs can be connected in parallel, provided that options S (included in M1) and R are not used, since they influence only the 2 nd output. The two power trains share the current due to their output voltage droop characteristic. 11054b AUX 10 Vi Vo+ 6 Vo- 5 Vo- 4 Vo+ 3 Up to 3 converters with the same output voltage may be operated in parallel. It is possible to parallel W Series with X Series converters. Reasonable current sharing is achieved by the droop characteristic. Correct mode of operation is highly dependent upon the wiring of the converters and the impedance of these wires. Use wires with equal length and equal cross sections of min. 1.5 mm 2. The best results for parallel operation can be achieved with the wiring shown in fig. 6. Vo+ 2 AUX 10 Vo- 9 Vo- 8 Vo+ 7 Vi Vo+ 6 Vo- 5 Parallel operation of single-output models using the option R (output voltage adjust) is possible, but not recommended. Refer to fig. 6; the connections between the pins 8 and 9 (both Vo-) should be as short as possible. + Load _ Vo- 4 Vo+ 3 Vo+ 2 Note: Parallel operation is not possible, if a temperature sensor is connected, as the sensor eliminates the output voltage droop. Note: For ORing diodes, we recommend to use Schottky diodes, mounted on a common heatsink to avoid thermal run away (or the use of double diodes). VR Vo- 9 Vo- 8 Vo+ 7 AUX 10 Vo- 9 Vo- 8 Vo+ 7 Vi Vo+ 6 Series Connection Vo- 5 Series connection of several outputs up to 150 V is possible. Exceeding an output voltage of 60 V, the output is not SELV. Vo- 4 Vo+ 3 Vo+ 2 Additional wiring for output currents Io 10 A Additional wiring, if using the R-input Output Characteristic and Protection The output characteristic, individual for each powertrain, is rectangular with a droop to ease parallel operation; see fig. 7. Fig. 6 Wiring for single-output converters connected in parallel. Additional wiring for higher output currents and with the use of option R is shown. However, a 50% higher output current is possible for a short time, such allowing startup of loads or charging of capacitors; see fig. 8. Vo /Vo nom Each output is independently protected against internal overvoltage by means of a second control loop. When the output voltage exceeds Vo L, the respective output is disabled. 1.0 0.8 0.6 0.4 Overtemperature Protection A built-in temperature sensor protects each powertrain is independently protected against overtemperature. When a BCD20020-G Rev AE, 25-APR-2018 05181a 0.2 0 Fig. 0.6 0 7 0.2 0.4 0.8 1.0 1.2 Vo versus Io (single-output model, typical values). MELCHER The Power Partners. Io /Io nom Page 11 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters Io / Io nom 1.6 allows for connecting a battery-specific temperature sensor, which provides temperature controlled adjust of the trickle charge voltage. This optimizes charging as well as battery life time. Depending upon the cell voltage and the temperature coefficient of the battery, different sensor types are available; see Accessories. 05194b 1.4 1.2 1.0 Note: Parallel operation is not possible, if the temperature sensor is connected to the paralleled outputs Vo+, as the sensor eliminates the output voltage droop. 0.8 0.6 - 0.5 0 1 0.5 1.5 2 2.5 s Fig. 8 Short term peak power characteristic: overcurrent versus time (typical values). However, it is possible to insert bleeding resistors in the Vo+ output lines of each converter in order to create a droop of approx. 0.6 V @ Io nom for 24 V outputs (1.2 V @ Io nom for 48V outputs), but this creates considerable power losses. certain temperature is reached, the concerned powertrain reduces its output power continuously. 03099d Input Thermal Considerations Power supply The thermal conditions are influenced by input voltage, output current, airflow, and temperature of surrounding components. TA max is therefore, contrary to TC max, an indicative value only. Vo+ Vo- Load R + - Caution: The installer must ensure that under all operating conditions TC remains within the limits stated in the table Temperature specifications. Note: Sufficient forced cooling allows TA to be higher than TA max provided that TC max is not exceeded. It is recommended that continuous operation under worst case conditions of the following 3 parameters be avoided: Minimum input voltage, maximum output power, and maximum temperature. Temperature sensor + Battery Fig. 10 Schematic circuit diagram of a system with battery backup and temperature-controlled charging. Battery Charging and Temperature Sensor The battery charger models exhibit the option M1 and have been designed to charge lead-acid batteries. The R-input Cell voltage [V] 2.45 06139b 2.40 2.35 2.30 2.25 2.20 2.15 Vo safe 2.10 -20 -10 0 10 VC = 2.27 V, -3 mV/K VC = 2.23 V, -3 mV/K 20 30 40 50 C VC = 2.27 V, -3.5 mV/K VC = 2.23 V, -3.5 mV/K Fig. 9 Trickle charge voltage versus temperature for different temperature coefficients (Vo safe with disconnected sensor) BCD20020-G Rev AE, 25-APR-2018 MELCHER The Power Partners. Page 12 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters Electromagnetic Compatibility (EMC) Electromagnetic Immunity The W Series has been successfully tested to the following specifications: Table 8: Electromagnetic immunity (type tests) Phenomenon Standard Level Coupling mode 1 Value applied Waveform Source imped. Test procedure Electrostatic discharge (to case) IEC/EN 61000-4-2 43 Electromagnetic field RF IEC/EN 61000-4-3 contact discharge 8000 Vp 1/50 ns 330 A 15000 Vp 10 positive and 10 negative discharges yes air discharge 34 antenna 10 V/m 4 AM 80%, 1 kH z sinusoidal n.a. 80 - 1000 MHz yes A ENV 50204 3 antenna 10 V/m 50% duty cycle, 200 Hz repet. frequ. n.a. 900 5 MHz yes A IEC/EN 61000-4-3 (EW models) 5 antenna 20 V/m 80% AM, 1 kHz sinusoidal n.a. 800 - 1000 MHz yes A 10 Vm In Perf. oper. criter. 2 1400 - 2100 MHz 5 V/m 2100 - 2500 MHz 3 capacitive, o/c A 2000 Vp 6 60 s positive + 60 s negative transients per coupling mode yes i/c, +i/- i direct coupling 2000 Vp bursts of 5/50 ns, 5 kHz over 15 ms, burst period: 300 ms 50 36 IEC /EN 61000-4-5 37 +i/c, -i/c 2000 Vp 1.2/50 s 12 yes B +i/-i 1000 Vp 1.2/50 s 2 5 pos. and 5 neg. surges per coupling mode Conducted disturbances IEC /EN 61000-4-6 38 i, o, signal wires 10 VAC (140 dBV) AM 80% 1 kHz 150 0.15 - 80 MHz yes A Power frequency magnetic field IEC /EN 61000-4-8 -- -- 100 A/m 50 and 60 Hz -- x, y, and z axis yes A Surges (EW models) IEC/EN wave 50155:2001 A9 +i/c, -i/c 1800 Vp 5/50 s 5 5 pos. and 5 neg. pulses yes B Electrical fast transients/burst IEC/EN 61000-4-4 Surges 1 2 3 4 5 6 7 8 9 i = input, o = output, c = case. A = Normal operation, no deviation from specifications, B = Normal operation, temporary loss of function or deviation from specs. possible. Exceeds EN 50121-3-2:2006 table 9.3 and EN 50121-4:2006 table 1.4. EW models: 20 V/m, which corresponds to EN 50121-3-2:2006 table 9.1 and exceeds EN 50121-4:2006 table 1.1. EW models only. Corresponds to EN 50121-3-2:2006 table 9.2 and EN 50121-4:2006 table 1.2 (compliance with digital mobile phones). Corresponds to EN 50121-3-2:2006 table 7.2 and EN 50121-4:2006 table 2.2. Complies with EN 50121-3-2:2006 table 7.3 and EN 50121-4:2006 table 2.3. Corresponds to EN 50121-3-2:2006 table 8.1 and EN 50121-4:2006 table 3.1 (radio frequency common mode). Corresponds to EN 50121-3-2:2000. Covers EN 50155:1995, RIA12, direct transients, waveform D (EW models only). BCD20020-G Rev AE, 25-APR-2018 MELCHER The Power Partners. Page 13 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters Emissions Table 9: Electromagnetic emissions for LW models with feature E: (type tests with LWN1801-6E) Phenomenon Standards Conditions Results Harmonics EN 61000-3-2:2006 Vi = 230 V, Vo nom, Io nom Class A, D Voltage fluctuation and flicker EN 61000-3-3 + A2:2005 Vi = 230 V, Vo nom, Io nom Complied Note: An external toroid ferrite core across the input lines reduces the emissions considerably. dBpW 07119a 80 dBV 07118b 80 60 EN 55022 A 70 EN 55022 B 60 40 50 20 40 30 0 20 50 100 150 200 250 300 MHz 10 0 0.03 0.1 0.3 1 3 10 30 MHz Fig. 11a Conducted emissions for LW models without feature E: Typical disturbances (quasi-peak) at the input according to EN 55022, measured at Vi nom and Io nom. Fig. 12a Conducted emissions of LW models with feature E: Disturbances (quasi-peak) at the phase input according to EN 55022, measured at Vi nom and Io nom. (LWN1801-6E) BCD20020-G Rev AE, 25-APR-2018 Fig. 11b Radiated emissions for LW models without feature E: Typical electromagnetic field strength (quasi-peak) according to EN 55014, measured at Vi nom and Io nom. Fig. 12b Radiated emissions measured according to EN 55022:2001 for LW models with feature E (LWN1801-6E, antenna 3 m distance, horizontal polarized) MELCHER The Power Partners. Page 14 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters PMM 8000 PLUS dBV PMM 8000 PLUS Limit: 61204bqp Detector: Peak, conducted Vi+, 6.6.06 EWN2660-0 Ui=110VDC, Io=10A, outputs in parallel configuration dBV EN 55011 B 60 Limit: 61204aqp Detector: Average Phase line Filter3 01.09.06 LWN1701-6E Ui=230VAC, Ponom, Schurter-Filter 4A + Drossel 11H/4A 60 40 40 20 20 0 0 0.2 0.5 1 2 5 10 20 MHz Fig. 13a Conducted emissions of EW models: Disturbances (peak) at the phase input according to EN 55011, measured at Vi nom and Io nom. (EWN2660- 0) dBV/m 50 TUV-Divina, ESVS 30:R&S, BBA 9106/UHALP 9107:Schwarzb., QP, 2006-05-29 Testdistance 10 m, EWN2660-0 Ui=110 V, Uo=24 V Io= 2 x 5 A EN 55011 A 40 JM038a 30 0.2 0.5 1 2 5 10 JM006 JM008 EN 55022 B 20 MHz Fig. 14b Conducted disturbances (average) of LW models (feature E) with external filter at phase input according to EN 55011/ 55022, at Vi = 230 VAC, Io nom (LWN1701-6E). Fig. 14a and 14b show the conducted emissions smoothed by an external filter. The standards EN 55011 and 55022 define limits for conducted (quasi)peak and conducted average emissions. In general the limits for average emissions are more difficult to meet. The figure below shows the used external filter configuration consisting of the inlet filter KMF1.1241.11 (4 A, Schurter www.schurter.com) and the decoupling choke EPCOS B82111B0000C018, 11 H, 4 A, 6 x 20 mm. <25 dbV/m 20 10 Note: This filter allows for connection of an IEC inlet and is available with 1 or 2 incorporated fuses. 50 100 200 500 1000 MHz Fig. 13b Radiated emissions of EW models, measured at Vi nom, Io nom, accord. to EN 55011, antenna 3 m distance, (EWN2660-0) A similar filter with AMP terminals (6.3 x 20 mm) is also available (Schurter FMLB 5500.2028). JM007 L' External EMC Filter for Models with Feature E An external EMC filter can be connected to the inputs lines of the converter. However, a small choke has to be included in the phase line to avoid interferences between the internal and external filter, which would cause dramatically increased low harmonics. PMM 8000 PLUS dBV Limit: 61204bqp Detector: Peak Phase Line Filter3 01.09.06 LWN1701-6E Ui=230VAC, Ponom, Schurter-Filter 4A + Drossel 11H/4A EN 55022 B 60 PE Choke L PE' PE N' N Converter 0 30 JM005 Fig. 15a External filter to reduce conducted emissions of LW models with feature E (L1 = L2 = 1.6 mH, Cx = 47 nF, Cy = 2.2 nF) 40 20 0 0.2 0.5 1 2 5 10 20 MHz Fig. 14a Conducted disturbances (peak) of LW models (feature E) with external filter at phase input according to EN 55011/ 55022, at Vi = 230 VAC, Io nom (LWN1701-6E). BCD20020-G Rev AE, 25-APR-2018 Fig. 15b External inlet filter MELCHER The Power Partners. Page 15 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters Immunity to Environmental Conditions Table 10: Mechanical stress and climatic Test method Standard Test conditions Cab Damp heat steady state IEC/EN 60068-2-78 MIL-STD-810D sect. 507.2 Temperature: Relative humidity: Duration: 40 2 C 93 +2/-3 % 56 days Converter not operating Kb Salt mist, cyclic (sodium chloride NaCl solution) IEC/EN 60068-2-52 Concentration: Duration: Conditions: Storage duration: 5% (30 C) 2 h per cycle 40 C, 93% rel. humidity 3 cycles of 22 h Converter not operating Eb Bump (half-sinusoidal) IEC/EN 60068-2-29 MIL-STD-810D sect. 516.3 Acceleration amplitude: Bump duration: 6000 bumps: 25 g n = 245 m/s2 11 ms 1000 in each direction Converter not operating , wall-mounted1 Acceleration amplitude: Bump duration: 6000 bumps: 10 g n = 98.1 m/s2 11 ms 1000 in each direction Converter not operating , on DIN-rail 2 Acceleration amplitude and frequency (1 Octave/min): Test duration: 0.35 mm (10 - 60 Hz) 5 g n = 49 m/s2 (60 - 2000 Hz) 7.5 h (2.5 h each axis) Converter operating, wall-mounted1 Acceleration amplitude and frequency (1 Octave/min): Test duration: 0.25 mm (10 - 60 Hz) 2 g n = 19 m/s2 (60 - 2000 Hz) 7.5 h (2.5 h each axis) Converter operating, on DIN-rail 2 Fc Vibration (sinusoidal) IEC/EN 60068-2-6 MIL-STD-810D sect. 514.3 Status Ea Shock (half-sinusoidal) IEC /EN 60068-2-27 MIL-STD-810D sect. 516.3 Acceleration amplitude: Bump duration: Number of bumps: 50 g n = 490 m/s2 11 ms 18 (3 in each direction) Converter not operating , wall-mounted1 -- Shock EN 50155/EN 61373 3 sect. 10, class A and B body mounted 4 Acceleration amplitude: Bump duration: Number of bumps: 5.1 g n 30 ms 18 (3 in each direction) Converter operating, on DIN-rail 2 Fh Random vibration broad band, digital control and guidance IEC/EN 60068-2-64 Acceleration spectral density: Frequency band: Acceleration magnitude: Test duration: 0.05 gn2 /Hz 8 - 500 Hz 4.9 g n rms 3 h (1 h each axis) Converter operating, wall-mounted1 Fda Random vibration wide band, high reproducibility IEC/EN 60068-2-35 Acceleration spectral density: Frequency band: Acceleration magnitude: Test duration: 0.01 g n2 /Hz 20 - 500 Hz 2.2 g n rms 1.5 h (0.5 h each axis) Converter operating, mounted on a DIN-rail 2 -- EN 50155 /EN 61373 3 sect. 8 and 9, class B body mounted 3 Acceleration spectral density: Frequency band: Acceleration magnitude: Test duration: 0.01 gn2 /Hz 5 - 150 Hz 0.8 g n rms 1.5 h (0.5 h each axis) Converter operating, mounted on a DIN-rail 2 1 2 3 4 Simulated long life time testing at increased random vibration levels Wall-mounted with brackets UMB-W [HZZ00618]; see Accessories Fastened on a DIN-rail with 2 additional DIN-rail fixing brackets DMB-EWG, see Accessories. This covers also wall-mounting with brackets, because wall mounting performs better in vibration test. EW models (railway standards) Body mounted = chassis of a railway coach Temperatures Table 11: Temperature specifications, valid for an air pressure of 800 - 1200 hPa (800 - 1200 mbar) Model LW models -6 EW models -0 Characteristics Conditions min max min max TA -40 60 -40 70 3 -40 90 2 -40 903 -40 100 -40 100 TC Case temperature Converter operating 1 TS Storage temperature Not operating 1 2 3 Ambient temperature Unit C See Thermal Considerations See table 5 Po derating Mounted in vertical position BCD20020-G Rev AE, 25-APR-2018 MELCHER The Power Partners. Page 16 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters Failure Rates Table 12: MTBF Values at specified case temperature MTBF 1 1 Module types Ground benign 40 C LWR1601 LWN1601 LWN2660 892 000 644 000 522 000 Ground fixed 40 C 70 C 180 000 131 000 101 000 Ground mobile 50 C Unit 68 000 51 000 38 000 h 197 000 72 000 55 000 Calculated in accordance with MIL-HDBK-217E, notice 2. Mechanical Data Dimensions in mm. 40 (1.6") 106.6 (4.2") 122.8 (4.84") 15 (0.59") 113.6 (4.47") European Projection 108 (4.25") 103 (4.05") 29.4 (1.16") 09107c x axis z axis (vertical) 43 (1.69") D-SUB Male connector Option M (female connector) 49 (1.93") 33 (1.3") Wall mounting brackets (accessories) 13 (0.51") 138 (5.43") TC Option M (female connector) 31 (1.22") LED Measuring point for case temperature TC Fig. 16 Case W01 EWN/LWN: weight approx. 1400 g EWR/LWR: weight approx. 1200 g Case designed by ATP, Munich. BCD20020-G Rev AE, 25-APR-2018 MELCHER The Power Partners. Page 17 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters Safety and Installation Instructions Terminal Allocation The terminal allocation tables define the electrical potential of the converters. 10066 1 2 3 10067 1 2 3 4 5 6 7 8 9 10 11 Fig. 17b View of the output terminals (cage clamp style) Table 13a: Input terminals of LW models Pin designation 1 The converters of the W Series are components, intended exclusively for inclusion within other equipment 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. DIN-rail mounting is possible with the built-in snap-fit device on a DIN-rail. This fulfills the mechanical transport requirements as per ETSI 300019-1-2, class 2 (vertical). Fig. 17a View of the input terminals (cage clamp style) Pin no. Installation Instructions Electrical determination Protective earth PE 2 N Input neutral, DC negative 3 L Input phase, DC positive To fulfill the requirements of IEC 721-3-2, class 2.1 (vertical), 2 additional fixing brackets HZZ00624-G (see Accessories) must be fitted on the bottom side of the DIN-rail. For heavy duty railway applications, we recommend installing all 4 fixing brackets HZZ00624-G. Chassis or wall mounting is possible using the universal chassis-mounting brackets HZZ00618-G (see Accessories). Such installation complies with IEC 721-3-2, class 2.2 (vertical and horizontal). Caution: Install the converters vertically, and make sure that there is sufficient airflow available for convection cooling. The minimum space to the next device should be: top/bottom: 30 mm, left/right: 20 mm. The converters of the W Series are class I equipment: Input terminal 1 ( ) and the output terminals 1 and 11 ( ) are reliably connected to the case. For safety reasons it is essential Table 13b: Input terminals of EW models Pin designation 1 Electrical determination Protective earth PE 2 Vi- Input negative 3 Vi+ Input positive Table 13c: Terminal allocation output side Pin no. Pin des. 1 Single output Double output Functional earth to load Functional earth to load Output 1 positive 2 + Output positive 3 + Output positive Output 1 positive 4 - Output negative Output 1 negative 5 - Output negative Output 1 negative 6 + Output positive Output 2 positive 7 + Output positive Output 2 positive 8 - Output negative Output 2 negative 9 - Output negative Output 2 negative 10 AUX 11 Option Option Functional earth to load Functional earth to load BCD20020-G Rev AE, 25-APR-2018 Fig. 18a Snap-fit mounting to DIN-Rail. 10072 Pin no. 10073 Fig. 18b Dismounting from DIN-rail. Use proper tool (min. 3 mm screwdriver) and adequate force. to connect the input terminal 1 ( ) with protective earth. Output terminals 1 and 11 can be used to connect the output voltage(s) or the load to functional earth. MELCHER The Power Partners. Page 18 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters (models without E: IEC 61010-1), and EN 50178:1997 (with and without E). 10074 1 The converters are UL508-listed components. The EW models are safety-approved to IEC/EN 60950-1 and UL/CSA 60950-1 2nd Ed. 3 The converters have been designed in accordance with said standards for: 2 * Class I equipment * Power supply for building-in, vertical mounting on 35 mm DIN-rail or on a wall * Overvoltage category II (III for 110 VAC supply) Fig. 19 Cage clamp terminals. Use 0.5 to 2.5 mm2 (AWG 20 to 12) solid or stranded wires depending on local requirements. * Basic insulation between input and case, based on 250 VAC * Double or reinforced insulation between input and output, based on 250 VAC and 350 VDC. The phase input (L or Vi+) is internally fused; see Input Fuse. This fuse is designed to break an overcurrent in case of a malfunction of the converter and is not customer-accessible. External fuses in the wiring to one or both input lines (L and/ or N ) may be necessary to ensure compliance with local requirements. A built-in second fuse in the neutral path is available as option F. A second fuse in the wiring to the neutral terminal N or option F is needed if: * Local requirements demand an individual fuse in each source line * Neutral and earth impedance is high or undefined * Phase and neutral of the mains are not defined or cannot be assigned to the corresponding terminals (L to phase and N to neutral). Models with Option F: Caution! Double-pole/neutral fusing. If the converters operate at source voltages above 250 VDC, an external fuse or a circuit breaker at system level should be installed. Caution: * Installation must strictly follow the national safety regulations. * Functional insulation between outputs and case. * Functional insulation between outputs. * Pollution degree 3 environment (AC-input) and degree 2 (DC input). The converters are subject to manufacturing surveillance in accordance with the above mentioned standards and with ISO9001:2000. Operation at Frequencies Greater 60 Hz The LW Series converters have been tested for operation up to 440 Hz. However, the Y and X caps are not approved to such frequency. The leakage currents are higher than at 60 Hz, whereas the output ripple voltage is lower. Leakage Currents with AC Supply Leakage currents flow due to internal leakage capacitance and RFI suppression Y-capacitors. The current values are proportional to the mains voltage and nearly proportional to the mains frequency. They are specified at maximum operating input voltage where phase, neutral, and protective earth are correctly connected as required for class I equipment. Leakage current may exceed 3.5 mA, if fi > 63 Hz. * Do not open this apparatus! Railway Applications Protection Degree and Cleaning Liquids The protection degree of the converters is IP 20. Protective covers over input and output terminals are available on request; see Accessories. Any penetration of liquid or foreign solid objects is to be prevented, since the converters are not hermetically sealed. The W Series converters have been designed observing the railway standards EN 50155 and EN 50121. All boards are coated with a protective lacquer. The EW Series is particularly suitable for connection to 110 V railway batteries. Standards and Approvals The converters of the LW Series with feature E were safetyapproved to EC/EN 60950-1 and UL/CSA 60950-1 2nd Ed. (models without E: IEC/EN 60950), IEC 61010-1:C11:2002 BCD20020-G Rev AE, 25-APR-2018 MELCHER The Power Partners. Page 19 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters Table 14: Isolation Characteristic Electric strength test Input to case and output(s) Output(s) to case Output 1 to output 2 and AUX Unit Factory test 1 s 2.8 1 1.4 0.5 kVDC AC test voltage equivalent to factory test 2.0 1.0 0.35 kVAC >300 2 >300 2 >100 M Insulation resistance 1 2 In accordance with IEC/EN 60950-1, subassemblies are pretested with 4.2 kVDC. Tested at 500 VDC. Isolation The electric strength test is performed in the factory as routine test in accordance with EN 50514 and IEC/EN 60950 and should not be repeated in the field. The Company will not honor warranty claims resulting from incorrectly executed electric strength field tests. Safety of Operator-Accessible Output Circuits If the output circuit of a converter is operator accessible, it shall be a SELV circuit according to IEC/EN 60950 related safety standards. The converters have SELV output circuits up to an output voltage of 57.5 V. However, if the isolated outputs are connected to another voltage source or connected in series with a total of >57.5 V the outputs are hazardous. It is the sole responsibility of the installer to ensure the compliance with the relevant and applicable safety regulations. LED Indicator A green LED is activated, when the output voltage Vo is within the normal operating tolerance band. Note: This LED is also activated, when the converter is not powered by the input, but a loaded battery is connected to the output. BCD20020-G Rev AE, 25-APR-2018 MELCHER The Power Partners. Page 20 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters Description of Options Table 16a: Option board M1 E designates LW models with improved EMC performance. Refer to the EC Declaration of Conformity (last page). Feature E is standard for new designs. Function Description R Output voltage adjust 1 D1 Output voltage monitor Vo low D1 1 Single options D1, D2, D5, R are available (as single choice options) on the AUX terminal (10), referenced to Vo-. D2 Input voltage monitor Vi low D5 Option M1 and M2 designate a combination of several options accessible via a D-SUB connector. Option M1 includes the function SD (shutdown). Output 2 voltage monitor 1 (battery deep discharged): Vo low D5 Sys-OK Note: In double-output models, the options D1, D5, R, and SD concern only output 2. D-adj SD 1 Single Options Using the AUX Pin The connection is shown in the figure below. For the description refer to Adjustment of Vo or Vo2 (next section). Function D2 Input voltage monitor Vi low D5 Output voltage monitor 1 (battery deep discharged): Vo low D5 + Vext D-adjust 1 Output voltage adjust 1 Adjustment of trigger values D1 and D5 In double-output models, only output 2 is concerned. D2: Input Voltage Monitor (Power Fail) D2 monitors the input voltage V i. When V i drops below 653 VAC or 92 VDC, the D2 signal output is high impedance (opencollector, max. 50 V). Fig. 20 Connection of adjust resistors or an external voltage source to adjust the output voltage Vo or Vo2 (option M1 or M2 not fitted) When V i is greater then said level, the signal output D2 is conducting: VD2 < 1.5 V, I D2 max < 50 mA. D1: Output Voltage Monitor D-SUB (female) Multiple Options M1 or M2 via D-SUB Connector Pin Description 1 GND11 System ground / common signal return 2 R R input 3 3 VCC2 Positive supply voltage ( output 2) 4 D1 Output voltage monitor Vo low D1 3 5 D5 Output 2 voltage monitor Vo low D5 3 6 SD Shutdown 3 7 D-adj Adjustment of threshold values of D1 or D5 8 D2 Input voltage monitor Vi low 9 Sys-OK System okay (all outputs are okay) 1 2 3 9 8 7 6 + 11 10 9 8 Vo2+ 7 or Vo+ 6 5 4 3 2 1 Fig. 21 Option D2: Examples of relay control to monitor a power failure. + D-SUB (female) 5 4 3 2 1 9 8 7 6 06140b Designation 5 4 3 2 1 VCC Table 15: Pin allocation of the 9 pin D-SUB connector 11 AUX 10 9 8 Vo2+ 7 or Vo+ 6 5 4 3 2 1 06141b The option board is suitable for applications, where several options are needed. Option M1 is standard for battery charger models, option M2 is suitable for applications without battery or for simple applications with battery. Power-Fail D2 06142b Description Power-Fail D2 11 AUX 10 Vo2- 9 or Vo- 8 7 6 5 4 3 2 1 Adjustment of trigger values D1 and D5 Table 16b: Option board M2 Adjustment with Vext Rext2 Rext1 11 AUX 10 Vo2- 9 or Vo- 8 Vo2+ 7 or Vo+ 6 5 4 3 2 1 Shutdown 1 In double-output models, only output 2 is concerned. R Adjustment with Rext System okay + Do not connect GND1 (pin 1) with the neg. output (-) Do not connect VCC (pin 3) with the positive output (+) In double-output models, R, D1, D5, SD concern output 2 only. BCD20020-G Rev AE, 25-APR-2018 MELCHER The Power Partners. Page 21 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters D1: Output Voltage Monitor D-SUB (female) When Vo is lower, the D1 signal output is high impedance (open-collector, max. 58.6 V). In double-output models, D1 monitors only output 2 (Vo2). In applications without battery-buffering the D1 signal may not be suitable, since smaller dynamic load changes may cause D1 to trigger. For such applications, D5 with a trigger level of approx. 85% of Vo nom should be chosen (e.g., for a bus voltage of 24.7 V: trigger level at 21 V). D5: System Voltage Monitor (Battery Low) D5 monitors the output voltage Vo (Vo2 in double-output models) or the lowest admissible voltage of a connected battery (battery deep discharge). The definition of D5 is similar to D1, but the trigger level is lower. When Vo (or Vo2) is greater than Vo low D5 specified in table 17, the D2 signal output is conducting: VD5 < 1.5 V, I D5 max < 50 mA. 5 4 3 2 1 VCC Table 17: Options D1 and D5: Trigger and switch-on levels Model Battery VBat [ V] Vo low D1 Vo low D 5 trigger switch on trigger switch on [ V] [ V] [ V] [ V] 7 6 Rx GND1 Ry Change threshold Fig. 22 Wiring to adjust both threshold levels of option D1 or D5 SD: Shutdown Reduces the output power to approx. 1 W, but the converter is not fully disabled. In a no-load condition, Vo drops below 6.2 V; see fig. 23. In double-output models, only output 2 is influenced. Output voltage 05175b V 5 3 1 0 In systems without battery support, D5 signals that Vo (or Vo2 ) is going to drop below a safe value. The D5 signal can be used for instance to disable loads, save data, or to start a controlled switch-off of running processes. 8 D-adj 9 When Vo is lower, the D5 signal output is high impedance (open-collector, max. 58.6 V). In double-output models, D5 monitors only output 2 (Vo2). In battery-buffered systems, D5 indicates that the battery has reached its deepest discharge level prior to getting damaged. 06148b D1 is intended for monitoring the bus voltage of a batterybuffered system. It indicates that the system is powered from the battery and can for instance be used as a warning signal or to switch off a part of the load. When the output voltage Vo (or Vo2) is greater than Vo low D1 specified in table 17, the D1 signal output is conducting: VD1 < 1.5 V, I D1 max < 50 mA. 0.2 0.4 0.6 0.8 1 1.2 A Output current Fig. 23 Output voltage versus output current, while the shutdown is activated (Vi = Vi nom). Table 18: Shutdown conditions Voltage VSD on shutdown pin < 0.7 V 2.0 V or open Result Converter disabled (Po approx. 1 W) Converter enabled LWR/LWN1140 12 11.5 12.1 10.5 12.1 LWR/LWN1240 24 23 24.2 21 24.2 LWR/LWN1840 36 34.4 36.3 31.5 36.3 Sys-OK: Status LWR/LWN1740 48 46 48.4 42 48.4 This function allows in a battery charger application for checking, whether the output is correctly following the external control signal at the R-input (coming for instance from the temperature sensor). The logic is shown in table 19. Adjustment of Threshold Levels (D1/D5) Pin 7 of the D-SUB connector allows for adjustment of the threshold levels of D1 and D5. Both levels are influenced by the voltage divider Rx / Ry. Resistor Rx to pin 3 (VCC) lowers the levels, whereas Ry to pin 1 (GND1) increases them (see fig. 22). BCD20020-G Rev AE, 25-APR-2018 MELCHER The Power Partners. Page 22 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters Table 19: System OK (M1 with external battery sensor) System Status Input V control sensor signal VBat theoretical VBat measured Sys-OK output System OK O.K. 2.7 V 27 V 27 V Low ohmic Battery overchared / temp. sensor defect / control voltage to high O.K. 2.7 V 27 V 28 V High ohmic Overload, converter cannot follow the control signal O.K. 2.7 V 27 V 24 V High ohmic Output does not follow control signal, since battery would be overcharged O.K. 3.0 V 30 V 27 V High ohmic System OK O.K. 2.5 V 25 V 25V Low ohmic R: Adjustment of Vo or Vo2 The R input allows external adjustment of the output voltage in the range of 50% to 110% Vo nom. Double-output models allow only adjustment of output 2 (connected to the terminals 6, 7, 8 and 9). This enables asymmetric output voltage configuration. Adjustment can be achieved via a resistor or an external voltage source (in the range of 1.25 - 2.75 V). Note: If the R input is not connected: Vo or Vo2 Vo nom. to-phase connection at low mains voltages (e.g., USA 120 V/ 208 V / 60 Hz systems). The built-in second fuse also enables safe connection to the mains, where phase and neutral are not defined or cannot be identified, as e.g., in the case of plug and socket connection to the mains via German Schuko-plugs; see also Safety and Installation Instructions. Option F limits the DC input voltage to 250 V. Q: Reverse Polarity Protection a) Adjustment by an external resistor: Resistor Rext1, connected between R (pin 2) and GND1 (pin 1) of the D-SUB connector or according to fig. 20. V Vo nom - Vo EW models have no bridge rectifier at the input. To provide reverse polarity protection, an additional diode can be fitted. However this lowers the efficiency by approximately 1%. o Vo = 50 - 100% Vo nom. R ext1 4 k * ------ --- K2: System Connectors Resistor Rext2, connected between R (pin 2) and VCC (pin 3) of the D-SUB connector or according to fig. 20. For installation in systems using pre-assembled harnesses the converters are available with system connectors. They are ULlisted, approved for currents up to 15 A at -40 to 105 C. V - 2.5 V 2.5 V*(Vo / Vo nom -1) o Vo = 100 - 110% Vo nom. R ext2 4 k * ---------------- Note: If the R function is not included in M1 or M2, refer to figure 20 how to connect Rext1 or Rext2 . b) Adjustment by an external control voltage Vext (1.25 - 2.75 V), connected between R (pin 2) and GND (pin 1) of the DSUB connector or according to fig. 20. V o Vext 2.5 V * ----- Vo nom The mating system connectors with screw terminals and retainers are delivered together with every converter with option K2. Use max. 2.5 mm2 (AWG 12) solid or stranded wires, or max. 1.5 mm2 (AWG 14) stranded wires with crimp termination, stripped length 6 mm. Tightening torque of input/ output terminals: max. 0.79 Nm (7 lbs.in.). G: RoHS RoHS compliant for all six substances. V 2.5 V ext Vo Vo nom * ---- Caution: To prevent damage, Vext should not exceed 3 V, nor be negative. Note: If longer wires are used to connect the R input at the D-SUB connector, the wiring to pin 1 (GND1) should be done as star point connection. If wired differently, the output voltage setting may be adversely affected. In battery charging systems, an external battery temperature sensor (see Accessories) can be connected to optimize Vo. However, adjustment using the R input (pin 2 of D-SUB) is possible as well. The above shown formulas are valid, but Vo nom stands for the voltage with open R input (= Vo safe). F: Built-in Second Fuse A built-in second fuse in the neutral line provides safe phase- BCD20020-G Rev AE, 25-APR-2018 Fig. 24 System connectors Option K2 MELCHER The Power Partners. Page 23 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters Accessories Protective Covers over Terminals Shock-Resistant Wall Mounting Protective covers are available to avoid touching of the terminals. HZZ01219-G and HZZ01219A-G (protective covers with cut-outs) contain in a bag a plastic cover with length A = 26.5 mm for the primary terminals and a second one with length A = 59 mm for the secondary terminals; see figures below. Set of wall mounting brackets HZZ00618-G (UMB-W) Content: 2 clamps, 4 countersunk screws M4, washers, and spring washers. 10068 4.2 Content: 2 covers to protect the input and output terminals. 33 0.5 49 8 18 3 12055 Fig. 25 Wall mounting brackets HZZ00618-G Fig. 26 Wall mounting with mounting brackets HZZ00618-G Fig. 28 Protective covers HZZ01219-G DIN-Rail Fixing Brackets HZZ00624-G For DIN-Rail vibration-proof fastening, use a set of brackets HZZ00624-G (DMB-EWG). For heavy-duty application 2 sets ( = 4 brackets) are preferable. Fig. 28A Protective covers with cut outs HZZ01219A-G Fig. 27 DIN-rail fixing bracket HZZ00624-G (DMB-EWG) BCD20020-G Rev AE, 25-APR-2018 MELCHER The Power Partners. Page 24 of 25 W Series Data Sheet 125, 250 Watt AC-DC and DC-DC DIN-Rail Converters Battery Temperature Sensor To charge lead-acid batteries according to their temperature different types of temperature sensors are available, (see Battery Charging and Temperature Sensor in this data sheet and the Temperature Sensor data sheet at www.powerone.com). 05191a + - D-SUB Converter R white n brow en e r g 2 3 VCC 1 GND Vo+ Fuse + Vo- European Projection - Battery Temperature sensor Load 9.8 (0.4") 26 (1.02") 09125a L Fig. 30 Connection of temperature sensor 56 (2.2") adhesive tape L = 2 m (standard length) other cable lengths on request For additional accessory product information, see the accessory data sheets listed with each product series or individual model at our website. Fig. 29 Temperature sensor Table 20: Sensors for converters with standard R-input Battery voltage nom.[V] Sensor type Cell voltage [V] Cell temp. coefficient [mV/K] Cable length [m] 12 S-KSMH12-2.27-30-2 2.27 - 3.0 2 12 S-KSMH12-2.27-35-2 2.27 - 3.5 2 24 S-KSMH24-2.27-30-2 2.27 - 3.0 2 24 S-KSMH24-2.27-35-2 2.27 - 3.5 2 24 S-KSMH24-2.31-35-0 2.31 - 3.5 4.5 24 S-KSMH24-2.31-35-2 2.31 - 3.5 2 24 S-KSMH24-2.35-35-2 2.35 - 3.5 2 48 S-KSMH48-2.27-30-2 2.27 - 3.0 2 48 S-KSMH48-2-27-35-2 2.27 - 3.5 2 NUCLEAR AND MEDICAL APPLICATIONS - These products are not designed or intended for use as critical components in life support systems, equipment used in hazardous environments, or nuclear control systems. TECHNICAL REVISIONS - The appearance of products, including safety agency certifications pictured on labels, may change depending on the date manufactured. Specifications are subject to change without notice. Copyright (c) 2018, Bel Power Solutions Inc. All rights reserved. BCD20020-G Rev AE, 25-APR-2018 MELCHER The Power Partners. belfuse.com/power-solutions Page 25 of 25