Rugged Environment AC-DC Converters >100 Watt 150 Watt AC-DC Converters with PFC K Series K-Series Input to output isolation Single output: LK 4000 5.1, 12, 15, 24 V Double output: LK 5000 2 x 12, 2 x 15, 2 x 24 V * Universal input voltage range * Power factor >0.95, harmonics <IEC/EN 61000-3-2 * Input over- and undervoltage lock-out * Efficient input filter and built-in surge and transient suppression circuitry * 4 kVrms input to output electric strength test * Fully isolated outputs * Outputs overload, open- and short-circuit proof * No derating over entire operating temperature range Safety according to IEC/EN 60950 LGA 111 4.4" 3U C 80 3.2" 16 TE 168 6.6" Summary The K 4000/5000-series of AC-DC converters represents a flexible range of power supplies for use in advanced electronic systems. Features include full power factor correction, high efficiency, high reliability, low output voltage noise and excellent dynamic response to load/line changes. The converter inputs are protected against surges and transients occurring at the source lines. An input over- and undervoltage lock-out circuitry disables the outputs if the input voltage is outside the specified ranges. Inrush current limitation is included preventing circuit breakers and fuses from being damaged at switch-on. All outputs are overload, open- and short-circuit proof and are protected against overvoltages by means of a built-in suppressor diode. The outputs can be inhibited by a logic signal applied to the connector pin 18 (i). If the inhibit function is not used pin 18 must be connected with pin 14 to enable the outputs. LED indicators display the status of the converter and allow visual monitoring of the system at any time. Full input to output, input to case, output to case and output to output isolation is provided. The modules are designed and built according to the international safety standards Table of Contents The Power Partners. The case design allows operation at nominal load up to 71C in a free air ambient temperature. If forced cooling is provided, the ambient temperature may exceed 71C but the case temperature must remain below 95C under all conditions. A temperature sensor generates an inhibit signal which disables the outputs if the case temperature TC exceeds the limit. The outputs are automatically re-enabled when the temperature drops below the limit. Various options are available to adapt the converters to individual applications. The modules may either be plugged into 19 inch rack systems according to DIN 41494, or be chassis mounted. Important: These products are intended to replace the LK 1000 and LK 2000 in order to comply with IEC/EN 61000-3-2. Page Summary .......................................................................... 1 Type Survey and Key Data .............................................. 2 Type Key .......................................................................... 2 Functional Description ...................................................... 3 Electrical Input Data ......................................................... 4 Electrical Output Data ...................................................... 6 Auxiliary Functions ......................................................... 12 MELCHER IEC/EN 60950 and have been approved by the safety agencies LGA (Germany) and UL (USA). The UL Mark for Canada has been officially recognized by regulatory authorities in provinces across Canada. Page Electromagnetic Compatibility (EMC) ............................ 16 Immunity to Environmental Conditions ........................... 17 Mechanical Data ............................................................ 18 Safety and Installation Instructions ................................ 19 Description of Options .................................................... 22 Accessories .................................................................... 28 Edition 4/4.99 1/28 K Series AC-DC Converters >100 Watt Rugged Environment Type Survey and Key Data Non standard input/output configurations or special custom adaptions are available on request. See also: Commercial Information: Inquiry Form for Customized Power Supply. 1 Table 1: Type survey LK Output 1 2 Output 2 Input voltage range and efficiency 1 Uo nom [V DC] Io nom [A] 2 Uo nom [V DC] Io nom [A] 2 Ui min...Ui max 85...255 V AC 7 hmin [%] 5.1 12.0 15.0 24.0 25.0 12.0 10.0 6.0 - - LK 4003-6R 6 LK 4301-7R LK 4501-7R LK 4601-7R 78 85 85 86 24.0 3 30.0 3 48.0 3 6.0 5.0 3.0 - - LK 5320-7R LK 5540-7R LK 5660-7R 83 83 84 12.0 15.0 24.0 6.0 5.0 3.0 12.0 4 15.0 4 24.0 4 6.0 5.0 3.0 LK 5320-7R LK 5540-7R LK 5660-7R 83 83 84 Options -9 E D V5 P T B1 B2 3 4 5 6 7 Efficiency at Ui nom and Io nom. If the output voltages are increased above Uo nom via R-input control, option P setting, remote sensing or option T, the output currents must be reduced accordingly so that Po nom is not exceeded. Series connection of output 1 and 2 see: R-Function for different output configurations. Second output semi-regulated. Option V for K 4003 types only. LK 4003-6R types are specified for a max. ambient temperature TA = 60C and a max. case temperature TC = 90C. (see: Output power derating). For DC-input please ask your local Melcher partner. Type Key Type Key L K 5 5 40 -7 E R P D V T B1 Input voltage range Ui: 85...255 V AC ............................. L Series ............................................................................... K Number of outputs (4 for single, 5 for double outputs) 4...5 Single output units: Nominal voltage output 1 (main output), Uo1 nom 5.1 V .................................................... 0, 1, 2 12 V ............................................................. 3 15 V ......................................................... 4, 5 24 V ............................................................. 6 other voltages .......................................... 7, 8 Other specifications for single output modules ....... 01...99 Symmetrical double output units: Nominal voltage output 1/output 2, Uo1/2 nom 12 V/12 V 1 (24 V series connection) ......... 20 15 V/15 V 1 (30 V series connection) ......... 40 24 V/24 V 1 (48 V series connection) ......... 60 other symmetrical voltages ................. 70...99 Operational ambient temperature range TA: -25...71C .................................................. -7 -40...71C .................................................. -9 -25...60C .................................................. -6 customer specific ................................... 0...-6 Auxiliary functions and options: Inrush current limitation ............................... E Output voltage control input ........................ R Potentiometer (output voltage adjustment) .. P Save data signal (D0...DD, to be specified) D ACFAIL signal (V2, V3) ................................ V Current sharing ............................................ T Cooling plate standard case ...................... B1 Cooling plate for long case 220 mm .......... B2 1 3 2 2 3 3, 4 External wiring of main and second output depending upon the desired output configuration (see: R-Function for different output con2 Feature R excludes option P and vice versa. figurations. 4 Option V for LK 4000 types with 5 V outputs. Option D excludes option V and vice versa. Example: LK 5540-7PD3: Power factor corrected AC-DC converter, input voltage range 85...255 V AC, double output, each providing 15 V/5 A, equipped with potentiometer and undervoltage monitoring option. Ambient temperature -25...71C. MELCHER The Power Partners. Edition 4/4.99 2/28 Rugged Environment AC-DC Converters >100 Watt K Series Functional Description The input voltage is fed via an input fuse, an input filter, a rectifier and an inrush current limiter to a single transistor boost converter. This converter provides a sinusoidal input current (IEC/EN 61000-3-2, class D equipment) and sources a capacitor with a voltage of 360-370 VDC. This capacitor sources a single transistor forward converter. Each output is powered by a separate secondary winding on the main transformer. The resultant voltages are rectified and their ripples smoothed by a power choke and an output filter. The control logic senses the main output voltage Uo1 and generates, with respect to the maximum admissible output currents, the control signal for the primary switching transistor. The second output of double output units is controlled by the main output but has independent current limiting. If the main output is driven into current limitation, the second output voltage will fall as well and vice versa. 2 P~ 30 32 Y 24 16 18 20 22 12 4 6 Output filter 4 Y 03001 Control circuit Ci + 360 V DC 3 Input filter 1 Boost converter (PFC) Y 26 N 28 Forward converter (approx. 80 kHz) P 8 Y 10 - Y 16 18 20 22 14 Vo1- 4 Vo2+ 6 Y 8 Vo2- 10 Y 24 Fig. 2 Block diagram of symmetrical double output converters LK 5000 1 2 3 4 Transient suppressor (VDR). Inrush current limiter (NTC or option E), -9 versions exclude the NTC. Input fuse. Hold-up capacitor. MELCHER The Power Partners. Edition 4/4.99 3/28 R i D T 12 Vo1+ Output 2 filter Y 03002 Output 1 filter Y Control circuit 4 Forward converter (approx. 80 kHz) P~ 30 32 Ci + 360 V DC 2 Boost converter (PFC) 3 Input filter 1 Vo- + P Y Vo+ 14 S- Fig. 1 Block diagram of single output converters LK 4000 N~ 26 28 R i D/V T S+ - + K Series AC-DC Converters >100 Watt Rugged Environment Electrical Input Data General Conditions - TA = 25C, unless TC is specified. - Pin 18 connected to pin 14, Uo adjusted to Uo nom (option P); R input not connected. - Sense line pins S+ and S- connected to Vo+ and Vo- respectively. Table 2: Input data Input LK Characteristics Ui U i nom Conditions min Operating input voltage Io = 0...Io nom TC min...TC max Nominal input voltage 85 max Unit 255 V AC 3, 4 230 1 Ii Input current Pi o No-load input power Ui min...Ui max 9.0 10 P i inh Idle input power unit inhibited 3.5 5 Ri Input resistance TC = 25C R NTC NTC resistance 2 Ci Input capacitance U i RFI Conducted input RFI Radiated input RFI U i abs Ui nom, Io nom typ 0.8 Arms 480 W m 3200 4000 120 F -400 400 V DC -400 400 VP 80 EN 55022 Ui nom, I o nom Input voltage limits (without damage) 100 B B 1 With double output modules, both outputs loaded with Io nom. Valid for -7, -6, versions with NTC, (-9 versions exclude the NTC). Initial switch-on cycle. Subsequent switch-on/off cycles increase the inrush current peak value. 3 AC frequency range 47...63 Hz. 4 For DC-input please ask your local Melcher partner 2 Input Fuse Reverse Polarity Protection A fuse mounted inside the converter protects the module against severe defects. (If operated from a DC-source this fuse may not fully protect the module when the input voltage exceeds 200 V DC! In applications where the converters operate at source voltages above 200 V DC an external fuse or a circuit breaker at system level should be installed!) Should the input voltage to the unit be supplied from a DC source the built-in bridge rectifier provides reverse polarity protection. Table 3: Fuse Specification Module LK4/5000 1 1 Fuse type Fuse rating slow-blow SP T 4 A, 250 V Fuse size 5 x 20 mm Inrush Current Limitation The modules of the versions -7, -6, incorporate an NTC resistor in the input circuitry which - at initial turn on - reduces the peak inrush current value by a factor of 5...10 to protect connectors and switching devices from damage. Subsequent switch-on cycles within short periods will cause an increase of the peak inrush current value due to the warming-up of the NTC resistor. See also: E option. Inrush Current Peak Value Input Under-/Overvoltage Lock-out If the input voltage remains below approx. 65 V AC or exceeds approx. 280 V AC an internally generated inhibit signal disables the output(s). When checking this function the absolute maximum input voltage rating U i abs should be considered! Between Ui min and the undervoltage lock-out level the output voltage may be below the value defined in table: Output data (see: Technical Information: Measuring and Testing). The inrush current peak value (initial switch-on cycle) can be determined by following calculation: Ui rms * 2 Iinr p = ---------------- (Rs ext + Ri + RNTC) 04001 Rs ext Iinr p Ri RNTC Ui rms Input Transient Protection A VDR together with the input fuse and a symmetrical input filter form an effective protection against high input transient voltages. MELCHER The Power Partners. Fig. 3 Equivalent circuit diagram for input impedance Edition 4/4.99 4/28 Ci Rugged Environment AC-DC Converters >100 Watt Input Inrush Current Characteristic K Series Static Input current Characteristic I inr [A] li [Arms] 3 04006 130 04002 2.5 2 100 1.5 1 Ui = 255 Vrms Ui = 115 Vrms 0.5 50 100 150 200 250 Ui [V AC] 300 Fig. 6 Input current versus input voltage at Io nom 50 1 0 2 1 3 t [ms] Fig. 4 Theoretical input inrush current versus time at Ui 255 Vrms and 115 Vrms, Rext = 0 Harmonic Currents Power Factor, Harmonics The harmonic distortion is well below the limits specified in IEC/EN 61000-3-2, class D. Power factor correction is achieved by controlling the input current waveform synchronously with the input voltage waveform. The power factor control is active under all operating conditions. I i [mA/W] 3.5 04042 Power Factor 1 3.0 Limit class D according to IEC/EN 61000-3-2 2.5 0.95 2.0 0.9 1.5 0.85 1.0 0.8 0.5 0.75 0 04004 3 5 7 9 11 13 15 17 19 Harm. Fig. 5 Harmonic currents at the input, IEC/EN 61000-3-2, class D. Ui = Ui nom, Io = Io nom. MELCHER The Power Partners. Ui = 230 V AC Ui = 85 V AC 0.7 0 0.2 0.4 0.6 0.8 1 Io /Io nom Fig. 7 Power factor versus output power at Ui 230 V AC and 85 V AC. Edition 4/4.99 5/28 K Series AC-DC Converters >100 Watt Rugged Environment Electrical Output Data General Conditions - TA = 25C, unless TC is specified. - Pin 18 (i) connected to pin 14 (S-/Vo1-), Uo adjusted to Uo nom (option P), R input not connected. - Sense line pins 12 (S+) and 14 (S-) connected to 4 (Vo1+) and 8 (Vo1-) respectively. Table 4a: Output data single output modules Output LK 4003-6 5.1 V Characteristics Conditions min Uo Output voltage Ui nom, Io nom 5.07 Uo P Overvoltage protection Io nom Output current 1 IoL Output current limit 4 uo 7 Ui min...Ui max TC min...TC max Ui min...Ui max Output Low frequency Ui nom, Io nom voltage IEC/EN 6120 Switching freq. noise BW = 20 MHz Total typ max LK 4301 12.0 V min typ 5.13 11.93 LK 4501 15.0 V max min typ 12.07 14.91 LK 4601 24.0 V max min typ 15.09 23.86 max Unit 24.14 V 7.6 21 26.5 43.5 25.0 12.0 10.0 6.0 A 2 mVpp 26 12.2 2 10.2 2 6.2 2 15 5 5 5 50 40 40 50 D Uo u Static line regulation Ui min...Ui nom, Ui nom...Ui max Io nom 5 12 15 24 D Uo I Static load regulation Ui nom, Io = (0.1...1) Io nom 20 24 30 48 uo d 5 Dynamic load regulation Ui nom Io nom 1/2 Io nom IEC/EN 61204 t d5 aUo Voltage deviation Recovery time Temperature coefficient TC min...TC max of output voltage 6 0...Io nom mV 170 150 150 100 0.3 0.4 0.4 0.3 ms -0.5 -1.5 -1.5 -1.5 mV/K 1 If the output voltages are increased above Uo nom through R-input control, option P setting, remote sensing or option T, the output currents should be reduced accordingly so that Po nom is not exceeded. 4 See: Typical Output Voltage Regulation of Single or Double Output Modules with Outputs 1 and 2 Connected in Series. 5 See: Typical dynamic load regulation of U and U . o1 o2 6 Negative temperature coefficient (0...-3 mV/cell and K) available on request. 7 Measured according to IEC/EN 61204 sub clause 3.10 with a probe acc. to annex A of the same standards. (See: Technical Information: Measuring and Testing.) MELCHER The Power Partners. Edition 4/4.99 6/28 Rugged Environment AC-DC Converters >100 Watt K Series Table 4b: Output data double output modules Output (Outputs connected in Series) Characteristics Output Uo P Overvoltage protection Io nom Output current 1 Ui min...Ui max TC min...TC max IoL Output current limit 4 Ui min...Ui max 7 4 5 6 7 Ui nom, Io nom Output Low frequency Ui nom, Io nom voltage IEC/EN 61204 Switching freq. noise 3 BW = 20 MHz Total typ max min typ max LK 5660 48 V (2 x 24 V) min typ max 30.0 48.0 38 48 74 6.0 5.0 3.0 A mVpp 6.2 5.2 3.2 3 3 5 15 15 20 100 V 100 180 Ui min...Ui nom Ui nom...Ui max Io nom 12 15 24 DUo I Static load regulation Ui nom, Io = (0.1...1) Io nom 48 60 96 uo d 5 Dynamic load regulation Ui nom Io nom 1/2 Io nom IEC/EN 61204 Voltage deviation Recovery time Temperature coefficient TC min...TC max of output voltage 6 0...I o nom Unit 24.0 Static line regulation aUo 3 min LK 5540 30 V (2 x 15 V) DUo U td 5 2 Conditions voltage 2 Uo uo 1 LK 5320 24 V (2 x 12 V) mV 250 200 150 0.3 0.3 0.3 ms -2.2 -2.2 -2.6 mV/K If the output voltages are increased above Uo nom through R-input control, option P setting, remote sensing or option T, the output currents should be reduced accordingly so that Po nom is not exceeded. Series connection for Uo nom = 24 V, 30 V or 48 V, see: R-Function for different output configurations. Shortest possible wiring for series connection at the connector. See: Typical Output Voltage Regulation of Single or Double Output Modules with Outputs 1 and 2 Connected in Series. See: Typical dynamic load regulation of Uo1 and Uo2 . Negative temperature coefficient (0...-3 mV/cell and K) available on request. Measured according to IEC/EN 61204 sub clause 3.10 with a probe acc. to annex A of the same standards. (See: Technical Information: Measuring and Testing.) MELCHER The Power Partners. Edition 4/4.99 7/28 K Series AC-DC Converters >100 Watt Rugged Environment Table 4c: Output data double output modules Output (Outputs independently loaded) 1 LK 5320 12 V/12 V Characteristics Conditions Uo Output voltage Ui nom, Io nom 2 Uo P Overvoltage protection Io nom Output current 3 IoL Output current limit 4 uo 8 Output Low frequency Ui nom, Io nom voltage IEC/EN 61204 Switching freq. noise BW = 20 MHz Total Output 1 min 3 4 5 6 7 8 max min typ 12.07 11.82 max Output 1 min typ 12.18 14.91 Output 2 max min typ 15.09 14.78 max Unit 15.22 V 19 19 24 24 6.0 6.0 5.0 5.0 A 3 3 mVpp 6.2 6.2 3 5.2 3 5.2 12 12 10 10 80 40 100 40 Static line regulation Ui min...Ui nom Ui nom...Ui max Io nom 12 D Uo I Static load regulation Ui nom, Io = (0.1...1) Io nom 5 48 uo d 6 Dynamic load regulation Ui nom Io nom 1/2 Io nom IEC/EN 61204 100 100 0.3 0.3 ms TC min...TC max 0...Io nom -1.5 -1.5 mV/K aUo 2 Output 2 D Uo U td 6 1 Ui min...Ui max TC min...TC max Ui min...Ui max typ 11.93 LK 5540 15 V/15 V Voltage deviation Recovery time Temperature coefficient of output voltage 7 12 15 5 60 15 mV 5 Depending upon the desired output configuration the wiring should be made as shown in: R-Function for different output configurations. Same conditions for both outputs. If the output voltages are increased above Uo nom via R-input control, option P setting, remote sensing or option T, the output currents should be reduced accordingly so that Po nom is not exceeded. See: Typical Output Voltage Regulation of Single or Double Output Modules with Outputs 1 and 2 Connected in Series. Condition for specified output. Other output loaded with constant current Io = Io nom . See fig.: Output voltage regulation of double output units. See: Typical dynamic load regulation of Uo1 and Uo2 . Negative temperature coefficient (0...-3 mV/cell and K) available on request. Measured according to IEC/EN 61204 sub clause 3.10 with a probe acc. to annex A of the same standards. (see: Technical Information: Measuring and Testing) MELCHER The Power Partners. Edition 4/4.99 8/28 Rugged Environment AC-DC Converters >100 Watt K Series Table 4d: Output data double output modules Output (Outputs independently loaded) 1 LK 5660 24 V/24 V Characteristics Conditions Uo Output voltage Ui nom, Io nom 2 Uo P Overvoltage protection Io nom Output current 3 IoL Output current limit 4 uo 8 Output Low frequency Ui nom, Io nom voltage IEC/EN 61204 Switching freq. noise BW = 20 MHz Total Output 1 min 3 4 5 6 7 8 min typ max Unit 24.36 V 37 37 3.0 3.0 A 3 3 mVpp 10 10 100 40 3.2 3.2 Static line regulation Ui min...Ui nom, Ui nom...Ui max, Io nom 24 DUo I Static load regulation Ui nom, Io = (0.1...1) Io nom 5 96 uo d 6 Dynamic load regulation Ui nom, Io = Io nom 1/2 Io nom IEC/EN 61204 80 0.3 ms TC min...TC max 0...Io nom -1.5 mV/K aUo 2 max 24.14 23.64 DUo U td 6 1 Ui min...Ui max TC min...TC max Ui min...Ui max typ 23.86 Output 2 Voltage deviation Recovery time Temperature coefficient of output voltage 7 24 mV 5 Depending upon the desired output configuration the wiring should be made as shown in: R-Function for different output configurations. Same conditions for both outputs. If the output voltages are increased above Uo nom via R-input control, option P setting, remote sensing or option T, the output currents should be reduced accordingly so that Po nom is not exceeded. See: Typical Output Voltage Regulation of Single or Double Output Modules with Outputs 1 and 2 Connected in Series. Condition for specified output. Other output loaded with constant current Io = Io nom. See fig.: Output voltage regulation of double output units. See: Typical dynamic load regulation of Uo1 and Uo2 . Negative temperature coefficient (0...-3 mV/cell and K) available on request. Measured according to IEC/EN 61204 sub clause 3.10 with a probe acc. to annex A of the same standards. (See: Technical Information: Measuring and Testing.) MELCHER The Power Partners. Edition 4/4.99 9/28 K Series AC-DC Converters >100 Watt Rugged Environment Thermal Considerations Parallel or Series Connection of Units If a converter is located in free, quasi-stationary air (convection cooling) at the indicated maximum ambient temperature TA max (see table: Temperature specifications) and is operated at its nominal input voltage and output power, the temperature measured at the Measuring point of case temperature TC (see: Mechanical Data) will approach the indicated value TC max after the warm-up phase. However, the relationship between TA and TC depends heavily on the conditions of operation and integration into a system. The thermal conditions are influenced by input voltage, output current, airflow and temperature of surrounding components and surfaces. TA max is therefore, contrary to TC max, an indicative value only. Single or double output units with equal nominal output voltage can be connected in parallel without any precautions using option T. Caution: The installer must ensure that under all operating conditions TC remains within the limits stated in the table: Temperature specifications. Notes: Sufficient forced cooling or an additional heat sink allows TA to be higher than 71C (e.g. 85C) if TC max is not exceeded. For -7 or -9 units at an ambient temperature TA of 85C with only convection cooling, the maximum permissible current for each output is approx. 40% of its nominal value as per figure. It is recommended that continuous operation under simultaneous extreme worst case conditions of the following three parameters be avoided: Minimum input voltage, maximum output power and maximum temperature. With option T (current sharing), all units share the current approximately equally. Single output units and/or main and second outputs of double output units can be connected in series with any other (similar) output. Note: - Parallel connection of double output units should always include both, main and second output to maintain good regulation of both outputs. - Not more than 5 units should be connected in parallel. - Series connection of second outputs without involving their main outputs should be avoided as regulation may be poor. - The maximum output current is limited by the output with the lowest current limitation if several outputs are connected in series. Efficiency versus Load Efficiency 0.90 05007 0.80 U i = 230 V AC U i = 85 V AC 0.70 0.60 -6 versions have reduced TA and TC 0.50 Io/Io nom convection cooling 1.00 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 forced cooling 0.40 05139 0.30 0 0.2 0.4 0.6 0.8 1 Io/Io nom Fig. 9 Efficiency versus load at Ui; 230 V AC and 88 V AC -6 -7 TC max -6 Switching Frequency versus Load -7 Frequency [kHz] 80 TA min 50 60 70 80 90 100 TA [C] 70 60 Fig. 8 Output current derating versus temperature for -7 and -9 units. 50 40 30 20 Thermal Protection A temperature sensor generates an internal inhibit signal which disables the outputs if the case temperature exceeds TC max. The outputs are automatically re-enabled if the temperature drops below this limit. Output Protection 10 0 The Power Partners. 0 0.2 0.4 0.6 0.8 1 1.2 load [Io/Io nom] Fig. 10 Switching frequency versus load. (The boost converter at the input stage has a fixed frequency of 100 kHz) Each output is protected against overvoltage which could occur due to a failure of the control circuit by means of a voltage suppressor diode which, under worst case conditions, may become a short circuit. The suppressor diodes are not designed to withstand externally applied overvoltages. Overload at any of the two outputs will cause a shut-down of both outputs. A red LED indicates the overload condition. MELCHER 05008 Edition 4/4.99 10/28 Rugged Environment AC-DC Converters >100 Watt Output Voltage Regulation of Double Output Modules Output 1 is under normal conditions regulated to Uo1 nom, independent of the output currents. Uo2 is dependent upon the load distribution. If both outputs are loaded with more than 10% of Io nom, the deviation of Uo2 remains within 5% of the value of Uo1. The following 3 figures show the regulation with varying load distribution. If Io1 = Io2 or the two outputs are connected in series, the deviation of Uo2 remains within 1% of the value of Uo1 provided that a total load of more than 10% of Io nom is applied. K Series Output Voltage Regulation of Single or Double Output Modules with Outputs 1 and 2 Connected in Series Uo Uo nom 05001 0.98 0.5 Io1 Two outputs of a single K 5000 module connected in parallel will behave like the output of a K 4000 module; the paralleled output is fully regulated. No precautions are necessary in using the R-input and the test sockets. IoL [V] Uo2 Io Io nom 0 05002 13 Fig. 14 Uo1 vs. Io1 (typ.) of single output units Io1 =100% Io1 = 50% Io1 = 10% 12.5 1.0 0.5 Dynamic Load Regulation 12.0 05005 Uo1 11.5 Uo1d Ur Ur 11 Uo1d 10.5 td 0 0.4 0.2 0.6 0.8 1 td Io2 /Io2 nom t Fig. 11 LK 5320: DUo2 (typ.) vs. Io2 with different Io1 Uo2 Uo2d [V] Uo2 t Io1/Io1 nom Io2/Io2 nom 1 05003 16.5 Io1 = 100% Io1 = 50% Io1 = 10% 16 0.5 15.5 <10 s <10 s 0 15 t Fig. 15 Typical dynamic load regulation of Uo1 and Uo2. 14.5 14 Hold-up Time versus Output Power 13.5 0 0.2 0.4 0.6 0.8 1 Io2 /Io2 nom Fig. 12 LK 5540: DUo2 (typ.) vs. Io2 with different Io1 time [ms] 180 05006 160 140 120 [V] Uo2 27 100 05004 Io1 = 100% Io1 = 50% Io1 = 10% 26 80 60 25 40 24 20 23 0 0 0.2 0.4 0.6 Fig. 16 Hold-up time t h versus output power 22 21 0 0.2 0.4 0.6 0.8 1 Io2 /Io2 nom Fig. 13 LK 5660: DUo2 (typ.) vs. Io2 with different Io1 MELCHER The Power Partners. Edition 4/4.99 11/28 0.8 1 Io /Io nom K Series AC-DC Converters >100 Watt Rugged Environment Auxiliary Functions i Inhibit for Remote On and Off The outputs of the module may be enabled or disabled by means of a logic signal (TTL, CMOS, etc.) applied between the inhibit input i and the negative pin of output 1 (Vo1-). In systems with several units, this feature can be used, for example, to control the activation sequence of the converters. If the inhibit function is not required, connect the inhibit pin 18 to pin 14 to enable the outputs (active low logic, fail safe). For output response refer to: Hold-up Time and Output Response. 06031 Vo+ Vi+ i 06001 Uo /Uo nom 1 Note: With open i input: Output is disabled (Uo = off). 0.1 0 t tf tr Inhibit 1 t 0 Fig. 19 Output response as a function of inhibit control I inh Sense Lines U inh (Only for single output units 5.1 V, 12 V, 15 V, 24 V) This feature enables for compensation of voltage drops across the connector contacts and if necessary, across the load lines. If the sense lines are connected at the load rather than directly at the connector, the user should ensure that Uo max (between Vo1+ and Vo1-) is not exceeded. We recommend connecting the sense lines directly at the female connector. Vo- Vi- Fig. 17 Definition of Uinh and Iinh. Iinh [mA] Uinh = 2.4 V Uinh = 0.8 V 06032 2.0 1.6 For further information, please refer to: Application Notes. To ensure correct operation, both sense lines (S+ and S-) should be connected to their respective power outputs (Vo1+ and Vo1-) and the voltage difference between any sense line and its respective power output pin (as measured on the connector) should not exceed the following values: 1.2 0.8 Uo = on 0.4 Uo = off 0 Table 6: Maximum Voltage compensation allowed using sense lines -0.4 -0.8 -50 -30 -10 0 10 30 50 Uinh [V] Fig. 18 Typical inhibit current I inh versus inhibit voltage U inh Output voltage Total voltage difference between sense lines and their respective outputs Voltage difference between Vo- and S- 5.1 V <0.5 V <0.25 V 12 V, 15 V <1.0 V <0.25 V Table 5: Inhibit characteristics Characteristic Conditions min Uinh Inhibit Uo = on voltage Uo = off Ui min...Ui max -50 Iinh Inhibit current Uinh = 0 tr Rise time tf Fall time typ 0.8 2.4 MELCHER The Power Partners. max Unit V 50 -400 30 depending on Io A ms If the output voltages are increased above Uo nom via R-input control, option P setting, remote sensing or option T, the output currents must be reduced accordingly so that Po nom is not exceeded. Important: The output terminals Vo1+ and Vo1- must always be connected to the load before connecting the sense lines S+ and S-, otherwise the unit will be damaged. Edition 4/4.99 12/28 Rugged Environment AC-DC Converters >100 Watt K Series Programmable Output Voltage (R-Function) Remarks: As a standard feature, the modules offer an adjustable output voltage, identified by letter R in the type designation. The control input R (pin 16) accepts either a control voltage Uext or a resistor Rext to adjust the desired output voltage. When not connected, the control input automatically sets the output voltage to Uo nom. - The R-Function excludes option P (output voltage adjustment by potentiometer). - If the output voltages are increased above Uo nom via Rinput control, option P setting, remote sensing or option T, the output current(s) should be reduced accordingly so that Po nom is not exceeded. a) Adjustment by means of an external control voltage Uext between pin 16 (R) and pin 14: - The R-input (as well as option P) is related to the main output. The control voltage range is 0...2.75 V DC and allows an output voltage adjustment in the range of approximately 0...110% Uo nom. Uo Uext = ------ * 2.5 V (approximate formula) Uo nom b) Adjustment by means of an external resistor: - With double output units the second output follows the value of the controlled main output. Resistor values as indicated for the single output units should be used. - For correct output voltage adjustment of double output units the external wiring of the outputs should be according to: R-function for different output configurations depending upon the desired output configuration. Depending upon the value of the required output voltage the resistor shall be connected either: Between pin 16 and pin 14 (Uo < Uo nom) to achieve an output voltage adjustment range of approximately 0...100% Uo nom - In case of parallel connection the output voltages should be individually set within a tolerance of 1...2%. 16 Module 14 Warning: - Uext shall never exceed 2.75 V DC. - The value of R'ext shall never be less than the lowest value as indicated in table R'ext (for U0 > U0 nom) to avoid damage to the unit! R + Uext S- P Vo1- N Vo1+ 12 Module Fig. 20 Output voltage control for single output units LK 4000 by means of the R input 06003 Vo1+ N or: Between pin 16 and pin 12 (Uo > Uo nom) to achieve an output voltage adjustment range of approximately 100...110% Uo nom. S+ R'ext R 16 14 S- Rext Vo1- P Table 7a: Rext for Uo < Uo nom; approximate values (Ui nom, Io nom, series E 96 resistors); R'ext = Uo nom = 5.1 V Uo (V) Rext [k] 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 0.422 1.0 1.62 2.16 3.83 5.61 9.09 14.7 28.7 196 Uo nom = 12 V Uo [V] 1 Uo nom = 15 V Uo [V] 1 Rext [k] 2 3 4 5 6 7 8 9 10 11 4 6 8 10 12 14 16 18 20 22 0.825 1.3 1.96 2.87 3.83 5.62 8.28 12.1 19.6 42.2 2 4 6 8 9 10 11 12 13 14 Uo nom = 24 V Uo [V] 1 Rext [k] 4 8 12 16 18 20 22 24 26 28 0.56 1.47 2.61 4.64 6.19 8.25 11.0 16.2 26.1 56.2 Rext [k] 4 6 8 10 12 14 16 18 20 22 8 12 16 20 24 28 32 36 40 44 0.825 1.33 1.96 2.87 3.83 5.61 8.25 12.1 19.6 46.4 Table 7b: R'ext for Uo > Uo nom; approximate values (Ui nom, Io nom, series E 96 resistors); Rext = Uo nom = 5.1 V 1 Uo [V] R'ext [k] 5.15 5.2 5.25 5.3 5.35 5.4 5.45 5.5 422 215 147 110 90.9 75 61.9 56.2 Uo nom = 12 V Uo nom = 15 V [V] 1 [V] 1 Uo 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 13.0 13.2 24.2 24.4 24.6 24.8 25.0 25.2 25.4 25.6 26.0 26.4 R'ext [k] 1780 909 623 464 383 316 286 234 196 162 Uo 15.2 15.4 15.6 15.8 16.0 16.2 16.4 16.5 30.4 30.8 31.2 31.6 32.0 32.4 32.8 33.0 Uo nom = 24 V R'ext [k] 1470 750 511 383 316 261 237 215 Uo [V] 1 24.25 24.5 24.75 25.0 25.25 25.5 25.75 26.0 26.25 26.4 R'ext [k] 48.5 49.0 49.5 50.0 50.5 51.0 51.5 52.0 52.5 52.8 First column: single output units or double output units with separated outputs, second column: outputs in series connection MELCHER The Power Partners. Edition 4/4.99 13/28 3160 1620 1100 825 681 562 511 464 422 383 K Series AC-DC Converters >100 Watt Rugged Environment R-Function for different output configurations 06004 Vo2+ 4 Vo2+ 6 Vo2- 8 Vo2- 10 Vo1+ Vo1- + Uo1 2 1 12 - 14 Rext R 24 V 30 V 48 V Vo2+ 6 Vo2- 8 Vo2- 10 Vo1+ 12 Vo1- 14 R 16 4 Vo2+ 6 1 Uo2 Vo1+ 12 Vo1- 14 R 16 1 -12/-15/-24 V - Uo1 10 + Vo2+ 4 Vo2+ 6 Vo2- 8 Vo2- 10 Vo1+ 12 Vo1- 14 R 16 Vo2+ 6 Vo2- 8 Vo2- 10 Vo1+ 12 Vo1- 14 Uo1 Rext R 12 V 15 V 24 V 12 V 15 V 24 V 2 1 + 1 1 R'ext A ceramic multilayer capacitor connected across the load reduces ripple and spikes. Shortest possible wiring for series connection at the female connector + 1 - Remarks: Double output units fitted with H15 connectors have the output pins of the second output, pins 4/6 and 8/10, internally paralleled. 16 Fig. 21e LK 5000 with H15 connector. R-input for output voltage control. Wiring of main and second output for two output voltages Uo1 and Uo2: 12 V/12 V or 15 V/15 V or 24 V/ 24 V, the outputs are galvanically isolated. The Power Partners. Uo1 - R'ext MELCHER +12/+15/+24 V Fig. 21d LK 5000 with H15 connector. R-input for output voltage control. Wiring of main and second output for two output voltages Uo1 and Uo2: +12 V and +24 V or +15 V and +30 V or +24 V and +48 V. + Uo2 + Uo2 Rext 1 4 06007 +24/+30/+48 V 0V 06008 Vo2+ R'ext Fig. 21b LK 5000 with H15 connector. R-input for output voltage control. Wiring for output voltage 12 V or 15 V or 24 V with main and second output connected in parallel. R'ext Fig. 21c LK 5000 with H15 connector. R-input for output voltage control. Wiring of main and second output for two symmetrical output voltages Uo1 and Uo2: 12 V or 15 V or 24 V. 1 - 2 +12/+15/+24 V Rext 12 V Uo1 15 V 24 V 06006 0V 8 + Rext 16 Vo2+ Vo2- 4 R'ext Fig. 21a LK 5000 with H15 connector. R-input for output voltage control. Wiring for output voltage 24 V or 30 V or 48 V with main and second output connected in series. Vo2- 06005 Vo2+ It is recommended that pins 4/6 and 8/10 be directly paralleled at the female connector as well to reduce the voltage drop across the connector. Please note: Uo2 varies depending upon its own load and the load on output 1. Edition 4/4.99 14/28 Rugged Environment AC-DC Converters >100 Watt K Series Display Status of LEDs 06002 Uo1 > 0.95...0.98Uo1 adj OK i Io L Ui Ui uv Ui min Ui max Ui ov Uo1 > 0.95...0.98Uo1 adj Fig. 22 LEDs "OK", "i" and "Io L"status versus input voltage Conditions: Io Io nom, TC TC max, Uinh 0.8 V Ui uv = undervoltage lock-out, Ui ov = overvoltage lock-out Ui abs Uo1 < 0.95...0.98Uo1 adj OK Io L Io nom Io LEDs "OK" and "Io L"status versus output current Conditions: Ui min...Ui max, TC TC max, Uinh 0.8 V TC LED "i"versus case temperature Conditions: Ui min...Ui max, Io Io nom, Uinh 0.8 V Ui inh LED "i"versus Uinh Conditions: Ui min...Ui max, Io Io nom, TC TC max IoL i TC max TPTC threshold Uinh threshold i -50 V LED off +0.8 V +2.4 V LED Status undefined +50 V LED on Test Sockets (Main output only ) Test sockets for measuring the output voltage Uo1 are located at the front of the module. The positive test socket is protected by a series resistor (see: Functional Description, block diagrams). The voltage measured at the test sockets is approximately 30 mV lower than the value measured at the output terminals. In case of double output units externally connected in series for Uo = 24 V, 30 V or 48 V the monitored output voltage is 12 V, 15 V or 24 V respectively. MELCHER The Power Partners. Edition 4/4.99 15/28 K Series AC-DC Converters >100 Watt Rugged Environment Electromagnetic Compatibility (EMC) A metal oxide VDR together with an input fuse and an input filter form an effective protection against high input transient voltages which typically occur in most installations. The K series has been successfully tested to the following specifications: Electromagnetic Immunity Table 8: Immunity type tests Phenomenon Standard 1 Voltage surge IEC 60571-1 Supply related surge RIA 12 Direct transient Level Coupling mode 2 Value applied Waveform Source imped. Test procedure i/c, +i/-i 800 Vp 100 s 100 yes 4 1500 Vp 50 s 1 pos. and 1 neg. voltage surge per coupling mode Electrostatic discharge (to case) 5 s 1 s 7000 Vp 100 ns B +i/-i 1.5 * Ubatt 0.1/1/0.1 s 0.2 1 positive surge yes 4 C +i/c, -i/c 960 Vp 10/100 s 5 yes 4 D 1800 Vp 5/50 s 5 pos. and 5 neg. impulses E 3600 Vp 0.5/5 s F 4800 Vp 0.1/1 s 8400 Vp 0.05/0.1 s 5/50 s J 3600 Vp 0.5/5 s K 4800 Vp 0.1/1 s L 8400 Vp 0.05/0.1 s contact discharge 8000 Vp 1/50 ns 330 A 15000 Vp 10 positive and 10 negative discharges yes air discharge antenna 10 V/m AM 80% 1 kHz n.a. 26...1000 MHz yes 4 900 5 MHz yes A H IEC/EN 61000-4-2 4 Electromagnetic IEC/EN field 61000-4-3 3 +o/c, -o/c Electromagnetic ENV 50204 field, pulse modulated Electrical fast transient/burst IEC/EN 61000-4-4 Surge IEC/EN 61000-4-5 Conducted disturbances 1 2 3 4 IEC/EN 61000-4-6 100 1800 Vp G Indirect coupled transient 3000 Vp 4000 Vp 50% duty cycle, 200 Hz repetition frequency 4 50 1 min positive 1 min negative transients per coupling mode yes A 4000 Vp bursts of 5/50 ns 2.5/5 kHz over 15 ms; burst period: 300 ms 2000 Vp 1.2/50 s 12 5 pos. and 5 neg. surges per yes A 0.15...80 MHz yes 4 capacitive, o/c 2000 Vp i/c, +i/-i direct 3 i/c 4 +i/-i 3 i, o, signal wires 2 10 Vrms (140 dBV) AM 80% 1 kHz 150 Related and previous standards are referenced in: Technical Information: Standards. i = input, o = output, c = case. A = Normal operation, no deviation from specifications, B = Normal operation, temporary deviation from specs possible. Test in progress, please consult factory. Note: Previous standards are referenced in: Technical Information: Standards. MELCHER The Power Partners. In Peroper. form. 3 Edition 4/4.99 16/28 Rugged Environment AC-DC Converters >100 Watt [dBV] 90 07063 K Series [dBV/m] 50 80 07038 A A 70 40 B B 60 30 50 40 20 30 20 10 10 Fig. 23 Typical disturbance voltage (quasi-peak) at the input according to CISPR 11/22 and EN 55011/22, measured at Ui nom and Io nom. 1000 500 200 100 50 30 20 30 10 5 2 1 0.5 0.1 0.05 [MHz] 0 MHz 0.02 0.01 0 Fig. 24 Typical radiated electromagnetic field strength (quasi-peak) according to CISPR 11/22 and EN 55011/22, normalized to a distance of 10 m, measured at Ui nom and Io nom. Immunity to Environmental Conditions Table 9: Mechanical stress Test method Standard Test conditions Status Damp heat steady state IEC/DIN IEC 60068-2-3 MIL-STD-810D section 507.2 Temperature: Relative humidity: Duration: 40 2 C Ea Shock (half-sinusoidal) IEC/EN/DIN EN 60068-2-27 MIL-STD-810D section 516.3 Acceleration amplitude: Bump duration: Number of bumps: 100 gn = 981 m/s2 6 ms 18 (3 each direction) Unit operating Eb Bump (half-sinusoidal) IEC/EN/DIN EN 60068-2-29 MIL-STD-810D section 516.3 Acceleration amplitude: Bump duration: Number of bumps: 40 gn = 392 m/s2 6 ms 6000 (1000 each direction) Unit operating Fc Vibration (sinusoidal) IEC/EN/DIN EN 60068-2-6 MIL-STD-810D section 514.3 Acceleration amplitude: Unit operating Frequency (1 Oct/min): Test duration: 0.35 mm (10...60 Hz) 5 gn = 49 m/s2 (60...2000 Hz) 10...2000 Hz 7.5 h (2.5 h each axis) Ca Unit not operating 93 +2/-3 % 56 days Fda Random vibration wide band Reproducibility high IEC 60068-2-35 DIN 40046 part 23 Acceleration spectral density: Frequency band: Acceleration magnitude: Test duration: 0.05 g n2 /Hz 20...500 Hz 4.9 gn rms 3 h (1 h each axis) Unit operating Kb Salt mist, cyclic (sodium chloride NaCl solution) IEC/EN/DIN IEC 60068-2-52 Concentration: Duration: Storage: Storage duration: Number of cycles: 5% (30C) 2 h per cycle 40C, 93% rel. humidity 22 h per cycle 3 Unit not operating Table 10: Temperature specifications, values given are for an air pressure of 800...1200 hPa (800...1200 mbar) Temperature -6 (LK 4003) Standard -7 Option -9 Characteristics Conditions min max min max min max Unit TA Ambient temperature -25 60 -25 71 -40 71 C TC Case temperature U i min...U i max I o = 0...I o nom -25 90 -25 95 -40 95 TS Storage temperature Not operational -40 100 -40 100 -55 100 Table 11: MTBF 1 Values at Specified Case Temperature Type MTBF1 LK 4301-7ER Ground Benign 40C 514'000 Calculated in accordance with MIL-HDBK 217F. MELCHER The Power Partners. Edition 4/4.99 17/28 Ground Fixed 40C 70C 88'000 38'000 Ground Mobile 50C Unit 35'000 h AC-DC Converters >100 Watt Rugged Environment 7 TE 159 7.0 10.3 12.1 20.3 Dimensions in mm. Tolerances 0.3 mm unless otherwise indicated. 29.9 19.7 9.5 4.5 LED i (red) Gravitational axis 6.5 Measuring point of case temperature TC Test jacks (+/-) Option P (Uo) Option D (Uto) Option D (Uti) 51.5 89 111 (3U) 4.5 9 TE 3.27 30.3 Mechanical Data 09002 K Series LED OK (green) LED IoL (red) = O 3.5 = O 4.1 50 42 171.93 (DIN 41494) 80 Front plate d Back plate 168.5 0.5 11.8 Main face 25.9 European Projection Note: - d 15 mm, recommended minimum distance to next part to ensure proper air circulation at full output power. 7 TE 3.27 5 50 5 - free air locations: the module should be mounted with fins in vertical position to achieve a maximum air flow through the heat sink. 158 4 TE 09003 Fig. 25 Case K02 with heatsink, case aluminium, black finish and self cooling, weight: Approx. 1.55 kg 101 111 (3U) M4 Measuring point of case temperature TC 17.3 47.2 133.4 168 0.5 171.93 (DIN 41494) Fig. 26 Case K02 with option B1 (cooling plate), case aluminium, black finish and self cooling, weight: Approx. 1.15 kg MELCHER The Power Partners. Edition 4/4.99 18/28 5 Note: Long case with S-type heatsink or cooling plate B2 elongated by 60 mm for 220 mm rack depth, is available on request. (Front panel will have no LEDs and no test jacks.) Rugged Environment AC-DC Converters >100 Watt K Series 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. 24, the protective earth pin present on all LK AC-DC converters is leading, ensuring that it makes contact with the female connector first. Table 12: H15 and H15 S2 Connector pin allocation Pin No. 4 6 8 10 Connector type H15 S2 LK 4003 Vo1+ Output 1 Vo1- Output 1 3 LK 5000 Vo2+ Output 1 Vo1+ Vo1- Vo2+ Vo2- Output 1 Vo1- Vo2- Output 2 Output 2 S+ Sense S+ Sense Vo1+ Output 1 14 S- Sense S- Sense Vo1- Output 1 16 R1 Control of U o1 R1 Control of U o1 R1 Control of U o1 18 i Inhibit i Inhibit i Inhibit 20 D3 Save data D Save data D Save data T Current sharing T Current sharing V3 ACFAIL T Current sharing 24 2 2 LK 4301, LK 4501, LK 4601 Vo1+ 12 22 1 Connector type H 15 Protective earth 26 N 28 N 30 P 32 P Protective earth N Neutral Neutral N P Phase Protective earth N P Phase P Neutral N Phase P Feature R excludes option P and vice versa Leading pin (pregrounding) Option D excludes option V and vice versa 10002 10001 30/32 32 4/6 4 Type H15 Type H15 S2 Fig. 27 View of module's male connectors Installation Instructions The K series AC-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. An input fuse is built-in in the connection from pins no. 30 and 32 (P~) of the unit. Since this fuse is designed to protect the unit in case of an overcurrent and does not necessarily cover all customer needs, an external fuse suitable for the application and in compliance with the local requirements might be necessary in the wiring to one or both input potentials, pins nos. 26 and 28 and/or nos. 30 and 32. Connection to the system shall be made via the female connector H15/H15 S2 (see: Accessories). Other installation methods may not meet the safety requirements. Important: Whenever the inhibit function is not in use, pin no. 18 (i) should be connected to pin no. 14 (S-/Vo1-) to enable the output(s). The AC-DC converters are provided with pin no. 24 ( ), which is reliably connected with their case. For safety reasons it is essential to connect this pin with the protective earth of the supply system. Do not open the modules, or guarantee will be invalidated. MELCHER The Power Partners. Edition 4/4.99 19/28 K Series AC-DC Converters >100 Watt Due to high current values, all LK units provide two internally parallel connected contacts for certain paths (pins 4/6, 8/10, 26/28 and 30/32, respectively). It is recommended to connect load and supply to both female connector pins of each path in order to keep the voltage drop across the connector pins to an absolute minimum and to not overstress the connector contacts if currents are higher than approx. 8 A. The connector contacts are rated 8 A over the whole temperature range. 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 shall not be exceeded. See also: Thermal Considerations. Check for hazardous voltages before altering any connections. 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. Protection Degree Condition: Female connector fitted to the unit. IP 30: All units except those with option P, and except those with option D or V with potentiometer. IP 20: All units fitted with option P, or with option D or V with potentiometer. Rugged Environment Standards and Approvals All AC-DC converters correspond to class I equipment. They are UL recognized according to UL 1950, UL recognized for Canada to CAN/CSA C22.2 No. 950-95 and LGA approved to IEC/EN 60950 standards. The units have been evaluated for: * Building in * Basic insulation between input and case, based on 250 V AC and 400 V DC * Double or reinforced insulation between input and output, based on 250 V AC and 400 V DC * Basic insulation between output and case based on 200 V AC and DC. * Operational insulation between output and output * The use in a pollution degree 2 environment * Connecting the input to a primary or secondary circuit which is subject to a maximum transient rating of 2500 V (overvoltage category III based on a 110 V primary circuit, overvoltage category II based on a 230 V primary circuit). * The UL 1950 recognition limits the maximum case temperature of the standard modules to TC = TC max - 10 K = 95C. The AC-DC converters are subject to manufacturing surveillance in accordance with the above mentioned UL, CSA, EN and with ISO 9001 standards. 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. Important: Testing by applying AC voltages will result in high and dangerous leakage currents flowing through the Y-capacitors (see fig.: Block diagram). Table 13: Isolation Characteristic Electric strength test voltage Input to case Input to output Required according to IEC/EN 60950 1.5 3.0 1 - - kVrms 2.1 4.2 1 - - kV DC Actual factory test 1 s 2.8 5.6 1 1.4 0.14 AC test voltage equivalent to actual factory test 2.0 4.0 1 1.0 0.1 kVrms >300 >300 >300 >100 2 M Insulation resistance at 500 V DC 1 2 Output to Output to case output Unit In accordance with IEC/EN 60950 only subassemblies are tested in factory with this voltage. Tested at 100 V DC. For creepage distances and clearances refer to: Technical Information: Safety. MELCHER The Power Partners. Edition 4/4.99 20/28 Rugged Environment AC-DC Converters >100 Watt K Series Leakage Currents in AC-DC operation 1500 MI 10061 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 and are specified at an input voltage of 254 V (50 Hz) where phase, neutral and protective earth are correctly connected as required for class I equipment. 500 Under test conditions the leakage current flows through a measuring instrument (MI) as described in fig.: Measuring instrument for earth leakage current tests, which takes into account impedance and sensitivity of a person touching unearthed accessible parts. The current value is calculated by dividing the measured voltage by 500 . If inputs of Kunits are connected in parallel, their individual leakage currents are added. 10062 P P Vo+ N Vo- N 10 k 220 nF MI for earth leakage current 22 nF V Fig. 28 Measuring instrument (MI) for earth leaking current tests according to IEC/EN 60950. Fig. 29 Test set-up Table 14: Leakage currents Characteristic Maximum earth leakage current Class I LK 4000, LK 5000 Unit Permissible according to IEC/EN 60950 3.5 mA Specified value at 254 V, 50 Hz 0.82 Safety of operator accessible output circuit If the output circuit of an AC-DC converter is operator accessible, it shall be an SELV circuit according to the IEC/EN 60950 related safety standards. The following table shows a possible installation configuration, compliance with which causes the output circuit of an K series AC-DC converter to be an SELV circuit according to IEC/EN 60950 up to a configured output voltage (sum of nominal voltages if in series or +/- configuration) of 36 V. However, it is the sole responsibility of the installer to assure the compliance with the relevant and applicable safety regulations. More information is given in: Technical Information: Safety. Table 15: Safety concept leading to an SELV output circuit 1 Conditions AC-DC converter Installation Result Nominal voltage Grade of insulation between input and output provided by the AC-DC converter Measures to achieve the resulting safety status of the output circuit Safety status of the AC-DC converter output circuit Mains 250 V AC Double or reinforced Earthed case 1 and installation according to the applicable standards SELV circuit The earth connection has to be provided by the installer according to the relevant safety standards, e.g. IEC/EN 60950. Mains ~ ~ 10021 Fuse Fuse + AC-DC converter SELV - Earth connection Fig. 30 Schematic safety concept. Use fuses and earth connection as per: Installation Instructions and table: Safety concept leading to an SELV output circuit. MELCHER The Power Partners. Edition 4/4.99 21/28 K Series AC-DC Converters >100 Watt Rugged Environment Description of Options Table 16: Survey of options Option -9 3 Extended operational ambient temperature range TA = -40...71C E Electronic inrush current limitation circuitry Active inrush current limitation Potentiometer for fine adjustment of output voltage Adjustment range +10/-60% of Uo nom excludes R input D2 Input and/or output undervoltage monitoring circuitry Safe data signal output (Versions D0...DD) V23 Input (and output) undervoltage monitoring circuitry ACFAIL signal according to VME specs (Versions V0, V2, V3) T 2 Characteristics P1 B1, B2 1 Function of Option Current sharing Interconnect T-pins if paralleling outputs (5 units max.) Cooling plate Replaces standard heat sink, allowing direct chassis-mounting Option R excludes option P and vice versa Option D excludes Option V and vice versa Only available if main output voltage Uo1 = 5.1 E Inrush Current Limitation -9 Extended Temperature Range The converters may be supplemented by an electronic circuit (option E, replacing the standard built-in NTC) to achieve an enhanced inrush current limiting function. Option -9 extends the operational ambient temperature range from -25...71C (standard) to -40...71C. The power supplies provide full nominal output power with free air convection cooling. Option -9 excludes inrush current limitation by NTC. Table 17: Inrush current characteristics with option E Characteristics Ui = 230 V AC LK Unit typ max - 21.7 A t inr Inrush current duration 35 50 ms Rectifier RS If the output voltages are increased above Uo nom via R-input control, option P setting, remote sensing or option T, the output current(s) should be reduced accordingly so that Po nom is not exceeded. Ci RI The potentiometer provides an output voltage adjustment range of +10/-60% of Uo nom and is accessible through a hole in the front cover. This feature enables compensation for voltage drops across the connector and wiring. Option P is not recommended if units are connected in parallel. Option P excludes the R-function. With double output units both outputs are affected by the potentiometer setting (doubling the voltage setting if the outputs are in series). Converter FET PFC - Control Control 11001 Peak inrush current Input Filter Iinr p P Potentiometer Fig. 31 Option E block diagram FET Rectifier RS RI 11001 Converter Control PFC - Control Input Filter T Current Sharing Ci This option ensures that the output currents are approximately shared between all paralleled modules and increases system reliability. To use this facility, simply interconnect the T pins of all modules and make sure, that pins 14, the S- pins (K 4000) or the Vo1- pins (K 5000) are also connected together. The load leads should have equal length and cross section to ensure equal voltage drops. Not more than 5 units should be connected in parallel. If output voltage adjustment is requested we strongly recommend to use the R-input instead of option P, as with option P the required setting accuracy is difficult to achieve. The output voltages must be individually set prior to paralleling to within a tolerance of 1...2% or the R pins should be connected together. 11003 Vo+ Load Fig. 32 Inrush current with option E, Ui = 230 V AC, Po = Po nom Vo- Vo+ Precaution: Vo- Subsequent switch-on cycles at start-up are limited to max. 10 cycles during the first 20 seconds (cold unit) and at continuing on/off (TC = 95C) max. 1 cycle every 8 sec. Vo+ MELCHER The Power Partners. Vo- Fig. 33 An example of poor wiring for connection in parallel Edition 4/4.99 22/28 Rugged Environment N Vo+ AC-DC Converters >100 Watt 2 S+ T P 1 11004 Vo2+ 1 3 P Vo+ Module 2 3 S+ T 1 S- Vo- 1 Load 3 Vo2+ Vo2- Module Fig. 34 Paralleling of single output units using option T with the sense lines connected at the load The Power Partners. 11037 Vo1- 2 Leads should have equal length and cross sections and should run in the same cable loom. Diodes recommended in redundant operation only DC common point MELCHER T Vo1+ max. 5 units connected in parallel 1 Power bus + - Vo2- S- Vo- Load N K Series T Vo1+ Vo1- max. 5 units in parallel connection Fig. 35 Paralleling of double output units using option T with Power Bus Edition 4/4.99 23/28 K Series AC-DC Converters >100 Watt Rugged Environment Option D Undervoltage monitor The input and/or output undervoltage monitoring circuit operates independently of the built-in input undervoltage lockout circuit. A logic "low" (JFET output) or "high" signal (NPN output) is generated at pin 20 as soon as one of the monitored voltages drops below the preselected threshold level Ut. The return for this signal is Vo1-. The D output recovers when the monitored voltage(s) exceed(s) Ut + Uh. The threshold level U ti is adjusted in the factory. The threshold level U to is either adjusted by a potentiometer, accessible through a hole in the front cover, or factory adjusted to a fixed value specified by the customer. Option D exists in various versions D0...DD as shown in the following table. Table 18: Undervoltage monitoring functions Output type JFET NPN D1 D5 2 3 4 no yes Minimum adjustment range of threshold level U t U ti U to 3.5...40 V 1 4 Typical hysteresis Uho [% of Ut] for U t min...U t max U ho 2.5...0.6 D2 D6 yes no 355 V DC D3 D7 yes yes 355 V DC 4 (0.95...0.985 Uo1) 2 D4 D8 no yes - (0.95...0.985 Uo1) 2 D0 D9 no yes - 3.5...40 V 3 2.5...0.6 yes yes 355 V DC 4 3.5...40 V 3 2.5...0.6 yes DC4 V1 2.5...0.6 DD 1 Monitoring Ui Uo1 yes 355 V - - 3.5...40 "0" "0" Threshold level adjustable by potentiometer Fixed value. Tracking if Uo1 adjusted via R-input, option P or sense lines. The threshold level permanently adjusted according to customer specification 2% at 25C. Any value within the specified range is basically possible but causes a special type designation in addition to the standard option designations (D0/D9)! Option D monitors the boost regulator output voltage. The trigger level is adjusted in the factory to 355 V DC. JFET output (D0...D4): 11006 Connector pin D is internally connected via the drainsource path of a JFET (self-conducting type) to the negative potential of output 1. UD 0.4 V (logic low) corresponds to a monitored voltage level (Ui and/or Uo1) <U t. The current ID through the JFET should not exceed 2.5 mA. The JFET is protected by a 0.5 W Zener diode of 8.2 V against external overvoltages. U i , U o1 status D output, U D U i or U o1 < U t low, L, UD 0.4 V at I D = 2.5 mA U i and U o1 > U t + U h high, H, ID 25 A at U D = 5.25 V Vo1+ Rp Input ID D UD Vo1- Fig. 36 Option D0...D4: JFET output, ID 2.5 mA NPN output (D5...DD): 11007 Vo1+ Connector pin D is internally connected via the collectoremitter path of a NPN transistor to the negative potential of output 1. UD < 0.4 V (logic low) corresponds to a monitored voltage level (U i and/or Uo1) > U t + U h. The current ID through the open collector should not exceed 20 mA. The NPN output is not protected against external overvoltages. UD should not exceed 40 V. U i , U o1 status D output, U D U i or U o1 < U t high, H, I D 25 A at U D = 40 V U i and U o1 > U t + U h low, L, U D 0.4 V at I D = 20 mA Rp Input ID D UD Vo1- Fig. 37 Option D5...DD: NPN output, Uo1 40 V, ID 20 mA Table 19: D-output logic signals U i < U t resp. U o < U t U i > U t + U h resp. U o > U t Configuration D1, D2, D3, D4, D0 low high JFET D5, D6, D7, D8, D9, DD high low NPN Version of D MELCHER The Power Partners. Edition 4/4.99 24/28 Rugged Environment AC-DC Converters >100 Watt K Series D-signal with respect to input and output voltage versus time: Input voltage monitoring NPN UD UD high 11044 3 3 3 3 UD low t 0 ID ID high ID low 0 t JFET UD UD high UD low 0 t th1 tlow min4 tlow min4 Uo1 Uo1 nom 1 0.95 tlow min4 thigh min th1 t 0 Uci [V DC] 358 355 t 0 Input voltage failure Input voltage sag Switch-on cycle Output voltage monitoring NPN UD UD high Switch-on cycle and subsequent input voltage failure 2 UD low t 0 ID ID high ID low 0 t JFET UD UD high UD low 0 t tlow min 4 Uo1 Uo1 nom Uto +Uho Uto 1 2 3 t 0 4 Output voltage failure Fig. 38 Relationship between Uci, Uo1, UD, Uo1 /Uo nom versus time MELCHER The Power Partners. Edition 4/4.99 25/28 Hold-up time see section: Electrical Input Data. With output voltage monitoring, hold-up time th = 0. The signal will remain high if the D output is connected to an external source. t low min = 100...170 ms, typically 130 ms. K Series AC-DC Converters >100 Watt Rugged Environment V ACFAIL Signal (VME) Available for units with Uo1 = 5.1 V. V output (V2, V3): This option defines an undervoltage monitoring circuit for the input or input and main output voltage equivalent to option D and generates the ACFAIL signal (V signal) which conforms to the VME standard. Connector pin V is internally connected to the open collector of a NPN transistor. The emitter is connected to the negative potential of output 1. U V 0.6 V (logic low) corresponds to a monitored voltage level (U i and/or Uo1) <U t. The current I V through the open collector should not exceed 50 mA. The NPN output is not protected against external overvoltages. U V should not exceed 60 V. The low state level of the ACFAIL signal is specified at a sink current of IV 48 mA to U V 0.6 V (open-collector output of a NPN transistor). The pull-up resistor feeding the open-collector output should be placed on the VME back plane. After the ACFAIL signal has gone low, the VME standard requires a hold-up time t h of at least 4 ms before the 5.1 V output drops to 4.875 V when the output is fully loaded. This hold-up time t h is provided by the internal input capacitance. See also fig.: Hold-up Time versus Output Power. Ui, Uo1 status V output, UV U i or U o1 < U t low, L, U V 0.6 V at I V = 50 mA U i and U o1 > U t + U h high, H, I V 25 A at U V = 5.1 V 11009 Vo1+ Table 20: Undervoltage monitor functions V2 V3 1 2 Monitoring Ui U o1 yes yes no yes Rp Minimum adjustment range of threshold level U ti U to 355V DC 1 355V DC 1 Input V output (VME compatible) UV 0.95...0.985 U o1 2 Option V operates independently of the built-in input undervoltage lock-out circuit. A logic "low" signal is generated at pin 20 as soon as one of the monitored voltages drops below the preselected threshold level U t. The return for this signal is Vo1-. The V output recovers when the monitored voltage(s) exceed(s) U t + U h. The threshold level U ti is adjusted in the factory to 355 V DC. The threshold level U to either is adjusted during manufacture to a determined customer specified value. The Power Partners. V - Option D monitors the boost regulator output voltage. The trigger level is adjusted in the factory to 355 V DC. Fixed value between 95% and 98.5% of Uo1. MELCHER IV Vo1- Fig. 39 Output configuration of options V2 and V3 Edition 4/4.99 26/28 Rugged Environment AC-DC Converters >100 Watt Input voltage monitoring V2 UV UV high 11045 t low min 2 t low min 2 t low min 2 3 K Series 3 3 4 4 2 2 UV low t 0 t low min V3 UV UV high 3 t low min 3 3 UV low t 0 th 1 th 1 Uo1 5.1 V 4.875 V 2.0 V 0 t Uci [V DC] 358 355 t 0 Input voltage failure Input voltage sag Switch-on cycle Switch-on cycle and subsequent input voltage failure Output voltage monitoring V2 UV UV high 4 UV low 4 t 0 V3 UV UV high t low min 2 3 3 4 UV low 0 t Uo1 5.1 V 4.875 V 2.0 V 0 t 1 2 Ui 3 4 Uti + Uhi Uti t 0 VME request: minimum 4 ms t low min = 40...200 ms, typically 80 ms UV level not defined at Uo1 < 2.0 V The V signal drops simultaneously with the output voltage if the pull-up resistor RP is connected to Vo1+. The V signal remains high if RP is connected to an external source. Output voltage failure Fig. 40 Relationship between U ci, Uo1, U V, I V and Uo1/Uo nom versus time. MELCHER The Power Partners. Edition 4/4.99 27/28 K Series AC-DC Converters >100 Watt Rugged Environment B1 Cooling Plate (see: Mechanical Data) Where a cooling surface is available, we recommend the use of a cooling plate (option B1) instead of the standard heatsink. The mounting system should ensure sufficient cooling capacity to guarantee that the maximum case temperature TC max is not exceeded. The cooling capacity is calculated by: (100% - ) PLoss = ---------- (Uo * Io) Efficiency h see: Type survey. Elongated case for 220 mm rack depth: Option B2. Accessories A variety of electrical and mechanical accessories are available including: - Front panels for 19" rack mounting, Schroff and Intermas systems. - Mating H15 and H15 S2 connectors with screw, solder, fast-on or press-fit terminals. - Connector retention facilities. - Code key system for connector coding. - Chassis mounting plates for mounting the 19" cassette to a chassis/wall where only frontal access is given. - Universal mounting bracket for DIN-rail or chassis mounting. For more detailed information please refer to: Accessory Products. Front panels H15 and H15 S2 female connector, Code key system Mounting plate, Connector retention clips Universal mounting bracket for DIN-rail mounting. MELCHER The Power Partners. Edition 4/4.99 28/28