S-Family PFC AC-DC Converters <100W Rugged Environment 100 W AC-DC Converters with PFC Input to: output isolation Single: output: LS:4000:5.15:12;:15,24-V Double:output::: LS 5000:::2'<12):2' 15, 2 24-V Universal: input voltage range : Power: factor: >0.95, harmonics:<IEC/EN 61000-3-2 Input over-and:undervoltage lock-out > Efficient input: fitter: and built-in: surge: and: transient Suppression: circuitry 4 KVime Input to:output:electric: strength: test Fully isolated outouts +: Outputs: overload, open--and: short-circuit: proof -: No: derating over entire:operating temperature:range Safety according: to: IEC/EN 60950 Aww C Summary The S 4000/S 5000-family of AC-DC converters represents a flexible range of power supplies for use in advanced elec- tronic systems. Features include full power factor correc- tion, high efficiency, high reliability, low output voltage noise and excellent dynamic response to load/line changes. The converter inputs are protected against surges and tran- sients occurring at the source lines. An input over- and undervoltage lock-out circuitry disables the outputs if the input voltage is outside the specified range. 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 func- tion is not used pin 18 must be connected to pin 14 to en- able 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 Page SUMIMALY 0. ee ceceeee cee eeeeeneeeeeeeeeeeneeeeeeaeeeseeaeeeeneeees 10-104 Type Survey and Key Datta .......eeeeeeeesreeeeeees 10-105 Type Key and Product Marking ..........:cceesseeeees 10-105 Functional D@SCTiPtion ......... ee eeesseeeeseeetenneeeeenees 10-106 Electrical Input Data... eee eeeseeeesseeeeenneeesenees 10-107 Electrical Output Datta... eee eeesseeeseeeeesneeeeenees 10-109 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 au- thorities in provinces across Canada. The case design allows operation at nominal load up to 71C in a free air ambient temperature. If forced cooling is provided, the ambient temperature may exceed 71C but the case temperature must remain below 95C under all conditions. A temperature sensor generates an inhibit signal which disables the outputs if the case temperature 7c. exceeds the limit. The outputs are automatically re-enabled when the temperature drops below the limit. Various options are available to adapt the converters to in- dividual applications. The modules may either be plugged into 19" rack systems according to DIN 41494, or be chassis mounted. Important: These products: are: intended to: replace the: LS'1:000:and ES:2000:in:erder-to:comply with: IEC/EN:61000-3-2: Page Auxiliary FUNCTIONS 0.0... eee eeeeeeeeeeeeeeenteeeeeaeeeeaes 10-114 Electromagnetic Compatibility (EMC) ............ 10-117 Immunity to Environmental Conditions................. 10 - 119 Mechanical Datta... eeeeeeeseeeeneeeeenreeeeeeeeenneeees 10 - 120 Safety and Installation Instructions ..........ce 10-121 Description Of OPtionS .........ceeececeeeeeeteeeeeeeeeeeees 10-123 10 - 104 Edition 3/1.98/IN 1.98 - Melcher AGRugged Environment AC-DC Converters <100 W S-Family PFC Type Survey and Key Data Non standard input/output configuration or special custom adaptions are available on request. See also Commercial Infor- mation: Inquiry Form for Customized Power Supply. Table 1: Type survey LS Output1 Output:2 Input Voltage: Range Efficiency: Options Us nom Ig nom: OU, nom: Is nom ui imines max Denia [VBC] fAl2 [V:BC} [A}@ 85...255 VAC [%] 5 16.0 LS 4001-7R 77 9 12.0 8.0 LS 4301-7R 81 E 15.0 6.5 LS 4501-7R 83 D 24.0 4.2 LS 4601-7R 83 vs 24.03 4.0 LS 5320-7R 81 P 30.03 3.2 LS 5540-7R 81 qT 48.09 20 LS 5660-7R 81 BI 12.0 4.0 12.04 4.0 LS 5320-7R 81 15.0 3.2 15.04 3.2 LS 5540-7R 81 24.0 2.0 24.04 2.0 LS 5660-7R 81 1 Efficiency at Ujnom and fy nom- 3 Series connection of output 1 and 2, see R-Function for differ- 2 If the output voltages are increased above Up nom via R-input ent output configurations. control, option P setting, remote sensing or option T, the output 4 Second output semi-regulated. currents must be reduced accordingly so that P5 nom is not ex- 5 Option V for LS 4000 types with 5 V outputs. ceeded. For DC-input please ask your local Melcher partner. Type Key and Product Marking Type Key LS 5540-7ERPDVTBI1 Input voltage range U;: 85...255 VAC ou... L od FAMILY oo... eee eceeeeeeee ee eeeee ee eree teense eeeeeeetaeeeneaeeeeneeeeeneeeneaa S Number of outputs (4 for single, 5 for double outputs) 4...5 Single output units: Nominal voltage output 1 (main output), Uo nom BTV icccccccccccessseeeeeesseaeseseesseseeeeesenses other voltages Other specifications for single output modules ....... 01...99 Symmetrical double output units: Nominal voltage output 1/output 2, Uo4/2 nom 12 V/12 V1 (24 V series CONN.) .......cceeeee 20 15 V/15 V1 (30 V series Conn.) .........ceeee 40 24 V/24 V1 (48 V series COND.) ......ceeeeeee 60 other symmetrical voltages .............4 70...99 Operational ambient temperature range Ta: 25 TT OS iaccecce tenet ence cee eeenaeteeeetieeeeeeeneeeeas -7 AOL 71 ecececeeete ete eeeeeetteetteeeneeeeaas -9 customer SpeCifiC ...... ee eee eee eeteeeeeeeee 6 Auxiliary functions and options: Inrush current limitation 0.00... eee rere E Output voltage control input... eee R? Potentiometer (output voltage adjustment) .. P 2 Save data signal (DO...DD, to be specified) D3 ACFAIL signal (V2, V3)... eeceeeeeeeseeeeeees V4 Current SNAring 2... eeeeeeesseeeesneeeeeneeenees T COOling Plate ...... eee eeteeeeeseeeeeeeeeeeseeeeenees Bi 1 External wiring of main and second output depending upon the desired output configuration (see A-Function for different output con- figurations). 2 Feature R excludes option P and vice versa. 3 Option D excludes option V and vice versa. 4 Option V available for LS 4000 types with 5V output. Edition 3/1.98/IN 1.98 - Melcher AG 410 - 105S-Family PFC AC-DC Converters <100 W Rugged Environment LS 5540-7PD3: Power factor corrected AC-DC converter, input voltage range 85...255 V AC, double output each providing 15 V/3.2 A, equipped with potentiometer and undervoltage monitoring option. Ambient tem- Example: perature 25...71C. Product Marking Main face: Melcher patents and company logo. Basic type designation, applicable safety approval and recognition marks, CE-mark, warnings, pin allocation, Front plate: Identification of LED's, test sockets and potentiometers. Back plate: Specific type designation, input voltage range, nominal output voltages and output currents, pin allocation of options and auxiliary functions, fuse specification and degree of protection. Rear face: Label with batch no., serial no. and data code comprising production site, modification status and date of pro- duction. Confirmation of successfully passed final test. 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 sour- ces a capacitor with a voltage of 360-370 V DC. This ca- pacitor sources a single transistor forward converter. Each output is powered by a separate secondary winding of the main transformer. The resultant voltages are rectified and their ripples smoothed by a power choke and an output Input filter Boost converter (PFC) 360 VDC 4 sf Forward converter (approx. 80 kHz) Fig. 1 40 Block diagram of single output converters LS 4000 360 V DC | Fig. 2 WL 5 poo O 22 T filter. The control logic senses the main output voltage Up 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 out- put voltage will fall as well and vice versa. _ a Oo Oo Yl o oat Cc oO 14 S- f < >| Control circui r ey rS Input filter Boost converter (PFC) + D lll Forward converter (approx. 80 kHz) a X Ny wi rlfll wi Output 2 filter ty vA Block diagram of symmetrical double output converters LS 5000 1 Transient suppressor (VDR) 2 Inrush current limiter (NTC or Opt. E), -9 versions exclude the NTC 3 Input fuse 4 Hold-up capacitor 10 - 106 Edition 3/1.98/IN 1.98 - Melcher AGRugged Environment AC-DC Converters <100 W S-Family PFC Electrical Input Data General Conditions Ta = 25C, unless Tc is specified. Pin 18 connected to pin 14, U, adjusted to Up nom (option P); R input not connected. Sense line pins S+ and S connected to Vo+ and Vo- respectively. Table 2: input data Input Ls Characteristics Conditions mn typ es omax Unit U; Operating Input voltage | fy = 0...fy nom 85 255 V AC 34 Ui nom | Nominal Input voltage To min--- Te max 230 I Input current Ui nom: fo nom | 0.55 Ams Pio No-load input power Uy min... Ui max 9.0 10 Ww Piinn | Idle input power unit inhibited 3.5 5 BR; Input resistance Te = 25C 480 mQ Rytc | NTC resistance 2 3200 4000 C; Input capacitance 80 100 120 uF Uirpri | Conducted input RFI EN 55022 B Radiated input RFI Ui nom: fo nom B Ui abs | Input voltage limits 400 400 Vv DC without damage 400 400 Vp 1 With double output modules, both outputs loaded with h nom- 2 Valid for -7 versions with NTC, (-9 versions exclude the NTC). Initial switch-on cycle. Subsequent switch-on/off cycles increase the in- rush current peak value. 3 AC frequency range 47...63 Hz. 4 For DC-input please ask your local Melcher partner. Input Fuse 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 volt- age exceeds 200 V DC! In applications where the convert- ers operate at source voltages above 200 V DC an external fuse or a circuit breaker at system level should be installed!) Table 3: Fuse Specification Module Fuse type Fuse rating SP T Ls! slow-blow 4A, 250 V 1 Fuse size 5 x 20 mm Input Under-/Overvoltage Lock-out If the input voltage remains below approx. 65 V AC or ex- ceeds approx. 280 V AC an internally generated inhibit sig- nal disables the output(s). When checking this function the absolute maximum input voltage rating Ujaps should be considered! Input Transient Protection A VDR together with the input fuse and a symmetrical input filter form an effective protection against high input tran- sient voltages. Reverse Polarity Protection Should the input voltage to the unit be supplied from a DC source the built-in bridge rectifier provides reverse polarity protection. (For DC-input operation, please consult your lo- cal Melcher partner.) Inrush Current Limitation The modules of the versions -7, incorporate an NTC resis- tor 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. Subse- quent switch-on cycles within short periods will cause an increase of the peak inrush current value due to the warm- ing-up of the NTC resistor. See also E option. Inrush Current Peak Value The inrush current peak value (initial switch-on cycle) can be determined by following calculation: , Yims *V2 mr (Re ext + Fy + Rytc) Ry ext har p A Fig. 3 Equivalent circuit diagram for input impedance. Edition 3/1.98/IN 1.98 - Melcher AG 10 - 107 40S-Family PFC Input Inrush Current Characteristic Fine [A] 130 04006 100 3 t[ms] Fig. 4 Theoretical input inrush current versus time at Ui 255 Vims and 115 Vims, Frext = 0. Harmonic Currents The harmonic distortion is well below the limits specified in IEC/EN 61000-3-2, class D. fj [MAM] 04042 3.5 | 3.0 | Limit class D according 25 + to IEC/EN 61000-3-2 2.0 | 1.5] 1.0 1 0.5 | 0 4 Harm. 7 9 14613 615 =~ 1 19 Fig. 5 Harmonic currents at the input, IEC/EN 61000-3-2, class D. U; = U; noms Ig = I nom: AC-DC Converters <100 W Rugged Environment Static Input current Characteristic f [Arms] 3 2.5 2 1.5 1 0.5 04005 U,[V AC] 50 100 150 200 250 300 Fig. 6 Input current versus input voltage at Ip nom Power Factor, Harmonics 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 oper- ating conditions. Power Factor odooa 0.95 09 U, = 230 V AC 0.85 0.8 U,= 85 VAC 0.75 0.7 0 0.2 0.4 0.6 0.8 1 bo/lo nom Fig. 7 Power factor versus output current at U, 230 V AC and 85 VAC. 10 - 108 Edition 3/1.98/IN 1.98 - Melcher AGRugged Environment AC-DC Converters <100 W Electrical Output Data General Conditions Ta = 25C, unless Tc is specified. Pin 18 (i) connected to pin 14 (S/Vo1-), Up adjusted to Up nom (option P), R input not connected. Sense line pins 12 (S+) and 14 (S) connected to pins 4 (Vo1+) and 8 (Vo1-) respectively. Table 4a: Ouiput data single output modules S-Family PFC Output LS:4001 LS:4301 LS:4501 LS'4601 BA: 12:0:V. 15.0:V. 24:0:V: Characteristics Gonditions mins otypoomaxe fom ir typ oma min type maxominetypeomax fh Unit Us Output voltage Ui nom: fo nom 5.07 5.13 |11.93 12.07 |14.91 15.09 |23.86 24.14) V Usp Overvoltage protection 7.6 21 26.5 43.5 (supressor diode) lonom | Output current Ui min--- Ui max 16.0 8.0 6.5 4.2 A To min--- FC max lot Output current limit 2 Ui min--- Ui max 16.2 8.2 6.7 4.4 Uy > Output | Low frequency | Uj nom, fo nom 2 2 2 2 MVpp voltage ap: IEC/EN 61204 Switching freq. 15 5 noise |= wtening Tred | aw 20 MHz Total 50 39 ats 4a AU, u | Static line regulation Uy min--- Ui nom: +5 +12 #15 +24 | mV Uj nom-::- Uj max: I nom AU, | Static load regulation Urnom, fo = 20 24 30 48 (0.1...1) fonom Usa? | Dynamic | Voltage Urnom, fo = +170 +150 +150 +100 load deviation Io nom '/2 to nom ty? regulat. Recovery time IEC/EN 61204 0.3 0.4 0.4 0.3 ms Odo Temperature coefficient | Uj min... Uj max -0.5 -1.5 -1.5 1.5 mV/K of output voltage + 0...o nom 1 If the output voltages are increased above Us nom through R-input control, option P setting, remote sensing or option T, the output cur- rents should be reduced accordingly so that P, nom is not exceeded. 2 See Output Voltage Regulation of Single or Double Output Modules with Outputs 1 and 2 Connected in Series. 3 See Typical dynamic load regulation of U,, and Up. 4 Negative temperature coefficient (0..3 mV/cell and K) available on request. 5 Measured according to IEC/EN 61204 sub clause 3.10 with a probe acc. to annex A of the same standards. (See Technical Informa- tion: Measuring and Testing) Edition 3/1.98/IN 1.98 - Melcher AG 410 - 109S-Family PFC Table 4b: Output data double output modules AC-DC Converters <100 W Rugged Environment Output L:$'5320 LS:5540 LS'5660 (Outputs: connected: in:Series) 24. (2:%:12:-V) 80:V.(2:<:15:V) 48.V.(2:'x 24-V) Characteristics Conditions mine types ax min type max TARE ype Sax Unit Uy Output voltage 2 Us nom: fo nom 24.0 30.0 48.0 Vv Uop Overvoltage protection 38 48 74 (supressor diode) lonom | Output current 4 U; min---U; max 4.0 3.2 2.0 A To min: To max fo Output current limit4 Uy min--- Ui max 4.2 3.4 2.1 Up 7 Output | Low frequency] Ui nom, fo nom 3 5 MVpp voltage a: IEC/EN 61204 Switching freq. 15 15 20 noise? | Stoning Fea] Bw 20 MHz Total 1G VO 150 AU, y | Static line regulation Uy min--- Ui max +12 +15 +24 mV I nom AU, | Static load regulation Urnom, bo = 40 60 96 (0.1...1) fo nom Uog> | Dynamic] Voltage Urnom, fo = +250 +200 +150 load deviation Io nom 1/2 Ip nom tg regulat. Recovery time IEC/EN 61204 0.3 0.3 0.3 ms Odo Temperature coefficient] Uj; min... Ui max 2.2 2.2 2.6 mV/K of output voltage 0...f6 nom 1 If the output voltages are increased above Us nom through R-input control, option P setting, remote sensing or option T, the output cur- rents should be reduced accordingly so that P, nom is not exceeded. 2 Series connection for Us nom = 24 V, 30 V or 48 V, see A-Function for different output configurations. 3 Shortest possible wiring for series connection at the connector. 4 See 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 Ugo. 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 Informa- tion: Measuring and Testing) 10 - 110 Edition 3/1.98/IN 1.98 - Melcher AGRugged Environment AC-DC Converters <100 W Table 4c: Output data double output modules S-Family PFC Output LS:'5320 LS:5540 (Outputs: independently loaded):! 12: V/12:V. TE V/TSV: Characteristics Conditions Output Output:2 Output! Output 2 RAR typ SSAA mE typ oma maine type mae Eom type max Unit Us Output voltage Unnom fonom? |11.93 12.07 |11.82 12.18 |14.91 15.09 | 14.78 15.23) V Uop Overvoltage protection 19 19 24 24 (supressor diode) lynom | Output current? Ui min--- Ui max 4.0 4.0 3.2 3.2 A To min--- IC max fot Output current limit 4 Ui min.-- Uj max 4.2 4.2 3.4 3.4 Up 8 Output | Low frequency] Uj nom, fo nom 3 3 3 3 MVpp voltage pe IEC/EN 61204 Switching freq. 12 12 10 10 noise | WNCMNS T89-| Bw - 20 MHz Total ae an 460 AG AUpy | Static line regulation U, min--- Ui nom +12 +12 +15 +15 | mV Uj nom-::+ Uj max lL nom AUp, | Static load regulation Unom b= 48 5 60 5 (0.1...1) fy nom Ua | Dynamic|Voltage Uinom: b= +100 +100 load deviation Io nom 2 to nom tg regulat. Recovery time IEC/EN 61204 0.3 0.3 ms Odo Temperature coefficient | Uj min... Ui max -1.5 -1.5 mV/K of output voltage 0...45 nom Table 4d: Output data double output modules Output LS:5660 1 . . : Depending upon the desired out- i (Outputs: independently.:loaded) 24-NI24N put configuration the wiring should Characteristics Conditions Output: Output: 2 be made as shown in A-Function i j for different output configurations. min yp max | min typ max | Unit 2 Same conditions for both outputs. Uy Output voltage Unnom: fonom? [23.86 24.14 |23.64 24.36) V 3 If the control voltages are in- Upp Overvoltage protection 37 37 creased above U, nom Via R-input (supressor diode) control, option Psetting, remote P sensing or option T, the output lonom | Output current? U, min... Ui max 2.0 2.0 A currentsshould be reduced ac- Te min--- To max cordingly so that Py nom is not ex- A og ceeded. fot Output current limit Ui min... U; max 2.1 2.1 4 See Output Voltage Regulation of Up & Output | Low frequency] Uj nom, fo nom 3 MVpp Single or Double Output Modules voltage ap: IEC/EN 61204 with Outputs 1 and 2 Connected noise | Switching freq. | Bw 20 MHz 10 10 in Series. Total Fae ae 5 Condition for specified output. a : Other output loaded with constant AU, y_ | Static line regulation O rine Oh nom +24 +24 | mV current Iy = ly nom. S@0 Output volt- | Pnomes ma age regulation of double output 9 nem units. AU,| | Static load regulation Urnom, bo = 96 5 8 See Typical dynamic load regula- (0.1...1) fy nom tion of Up, and Upp. - 7 Negative temperature coefficient 6 , = Uo d iemamie vonage "| nom: be +80 (0....-3 mV/cell and K) available loa leviation flo nom */2 to nom on request. igo | reguiat. Recovery time IEC/EN 61204 0.3 ms | Measured according to IEC/EN _ 61204 sub clause 3.10 witha Qo Temperature coefficient Ui min... Ui max 0.5 mvV/K probe acc. to annex A of the same of output voltage 0...fo nom standards. Edition 3/1.98/IN 1.98 - Melcher AG 10-111 40S-Family PFC Thermal Considerations If a converter is located in free, quasi-stationary air (con- vection cooling) at the indicated maximum ambient tem- perature Ta max (see table Temperature specifications) and is operated at its nominal input voltage and output power, the temperature measured at the Measuring point of case temperature Tc; (see Mechanical Data) will approach the in- dicated value Tc max after the warm-up phase. However, the relationship between 7a and 7c 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 compo- nents and surfaces. 7a max is therefore, contrary to To max, an indicative value only. Caution: The: installer must ensure that under all operat- ing conditions :7e:remains: within: the: limits: stated inthe table: Temperature specifications. Notes: Sufficient forced cooling or an additional heat sink allows T, to be higher than 71C (e.g. 85C) if Te max is not exceeded. For -7 or -9 units at an ambient temperature 7, of 85C with only convection cooling, the maximum permissible current for each output is approx. 40% of its nominal value as per figure. lolly nom A Forced cooling \ 1.0*~ 0.9 7 0.8 7 0.7 4 0.6 0.5 4 0.4 7-7 t ttt ttt ttt 0.3 4 0.2 4 0.1 = 0 z i i i i 1 i Lp J, [C] Tamn BO 60 70 80 #90 100 * Fig. 8 Ouiput current derating versus temperature for -7 and -9 units. 68080 | | | 1 Convection coolin | | | | ile max + Thermal Protection A temperature sensor generates an internal inhibit signal which disables the outputs if the case temperature exceeds Tc max. The outputs are automatically re-enabled if the tem- perature drops below this limit. It is recommended that continuous operation under simul- taneous extreme worst case conditions of the following three parameters be avoided: Minimum input voltage, maximum output power and maximum temperature. Output Protection 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 condi- tions, may become a short circuit. The suppressor diodes are not designed to withstand externally applied over- voltages. Overload at any of the two outputs will cause a shut-down of both outputs. A red LED indicates the over- load condition. AC-DC Converters <100 W Rugged Environment Parallel or Series Connection of Units Single or double output units with equal nominal output volt- age can be connected in parallel without any precautions using option T. With option T (current sharing), all units share the current approximately equally. Single output units and/or main and second outputs of dou- ble 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 con- nected in series. Output Voltage Regulation of Single or Double Output Modules with Outputs 1 and 2 Connected in Series U, U, nom 05001 0.98 {=--------- === 0.5+ 0 + I 0.5 Fig. 9 Ups VS. loi (typ.) of single output uniis Output Voltage Regulation of Double Output Modules Output 1 is under normal conditions regulated to Uo1 nom; independent of the output currents. Upe is dependent upon the load distribution. If both outputs are loaded with more than 10% of hb nom, the deviation of Ups remains within +5% of the value of U41. The following 3 figures show the regulation with varying load distribution. If Io1 = bpp or the two outputs are connected in series, the de- viation of Use remains within +1% of the value of U,1 pro- vided that a total load of more than 10% of fo nom is applied. Two outputs of a single S 5000 module connected in paral- lel will behave like the output of a S 4000 module; the paral- leled output is fully regulated. No precautions are neces- sary in using the R-input and the test sockets. 10-112 Edition 3/1.98/IN 1.98 - Melcher AGRugged Environment AC-DC Converters <100 W S-Family PFC [V] Uge Dynamic Load Regulation 05088 05005 8 \ lo, =100% Yor uy 12.5 S a 61 = 50% ord U, U, | A] | ly = 10% s 7 i | [> 12.0 NS = tt Uotd ___| Pt os 4 hy 11.5 t 14 Uoa Uoed ( 10.5 0 02 04 O06 O08 1 hotloe nom t Fig. 10 hoa nom LS 5320: AUpo (typ.) VS. loo with different Ipy. loalloanom | [V] Use 5) <104s <10 ps 16.5 ores 0 t log = 100% 16 It = 50% Fig. 14 Io = 10% Typical dynamic load regulation of Up; and Ube. 15.5 15 Hold-up Time versus Output Power time [ms] 14.5 180 05013 14 160 13.5 140 0 02 04 O06 O8 1 lool lop nom 120 Fig. 11 100 LS 5540: AUpp (typ.) VS. Io2 with different Io1. 80 [V] Use 60 27 05085 40 Lf, = 100% 26 ZAR, = 50% 20 \ L/L bt = 10% 0 25 AG ar 0 0.2 0.4 0.6 0.8 1 bo nom QRH 24 KS C+ Fig. 15 PEE ES Hold-up time t, versus output power. 23 ro 29 | Efficiency versus Load 24 | Efficiency sot 0.90 0 02 O04 O06 08 { lool loo mom Fig. 12 U; = 230 V AC LS 5660: AUpo (typ.) VS. loo with different Io4. 0.70 U, = 85 VAG 0.60 Switching Frequency versus Load 0.50 annuency [KHz] 05008 0.40 70 0.30 0 0.2 0.4 0.6 0.8 1 /lo nom 60 Fig. 16 50 Efficiency versus load at U,; 230 V AC and 85 VAC 40 30 20 10 0 0 02 04 06 O08 1 12 load[h/lynom Fig. 13 Switching frequency versus load. (The boost converter at the input stage has a fixed frequency of 100 kHz) Edition 3/1.98/IN 1.98 - Melcher AG 10 - 11340 S-Family PFC Auxiliary Functions i Inhibit for Remote On and Off Note: With open i input: Output is disabled (Up = 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 (Vot1-). In systems with several units, this feature can be used, for ex- ample, 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 Out- put Response. pot tcoc ooo recor I 06031 o Vit Vos OW i I ; Finn I l 1 I 1 1 Vion I I o Vvi- Vo QW Looe Fig. 17 Definition of Vinh and Inn. finn [MA] Uh = 0.8 V Upn = 2.4 V 2.0 9 1.6 " 1.2 0.8 0.4 0 0.4 -0.8 Vinh [V] 50 -30 -10 O 10 30 50 Fig. 18 Typical inhibit current lin, versus inhibit voltage Uinn Table 5: Inhibit characteristics AC-DC Converters <100 W Characteristic Conditions :| min typ: :max:}-Unit Uinn | Inhibit | Up =on | Uimin...Uimax| 50 08) V voltage | 1, = off 2.4 50 finn | Inhibit current Uinn = 0 400/ pA t Rise time 30 ms k Fall time depending on U,/U, nom 06001 1 0.1 0 Inhibit 1 0 Fig. 19 Ouiput response as a function of inhibit control Rugged Environment Sense Lines (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 Up max (between Vo1+ and Vo1-) is not exceeded. We recommend connecting the sense lines directly at the fe- male connector. 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 meas- ured on the connector) should not exceed the following val- ues: Table 6: Maximum Voltage compensation allowed using sense lines Output Total voltage: difference: Voltage difference voltage between:sense lines and between their: respective outputs Vo and S 51V <0.5V <0.25 V 12V,15V <1.0V <0.25 V If the output voltages are increased above U, nom via R-in- put 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: Vot+:and: Vot= must always: be connected to: the:load: before: connecting: the sense: lines: S+:and:S-,; otherwise the: unit: willbe: dam- aged: 10-114 Edition 3/1.98/IN 1.98 - Melcher AGRugged Environment AC-DC Converters <100 W S-Family PFC Programmable Output Voltage (R-Function) As a standard feature, the modules offer an adjustable out- put voltage, identified by letter R in the type designation. The control input R (pin 16) accepts either a control voltage Usy, or a resistor Ax to adjust the desired output voltage. When not connected, the control input automatically sets the output voltage to Us nom- a) Adjustment by means of an external control voltage Uext between pin 16 (R) and pin 14: If the output voltages are increased above Us 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. The R-input (as well as option P) is related to the main output. With double output units the second output follows the value of the controlled main output. Resistor values as The control voltage range is 0...2.75 V DC and allows an output voltage adjustment in the range of approximately 0...110% Up nom: U, Uext = < Uy nom * 2.5 V (approximate formula) 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 accord- ing to fig. R-Function for different output configuration depending upon the desired output configuration. b) Adjustment by means of an external resistor: Incase of parallel connection the output voltages should Depending upon the value of the required output voltage be individually set within a tolerance of 1...2%. the resistor shall be connected either: Between pin 16 and pin 14 (Uy < Ub nom) to achieve an output voltage adjustment range of approxi- mately 0...100% Usnom or: Between pin 16 and pin 12 (Up > Up nom) to achieve an output voltage adjustment range of approximately 100...110% Ups nom. Warning: NO Vot+ = ~ Us shall never exceed 2.75 VDC. ae | Rog The value of Asg shall never be less than the lowest ; Module @c=------- I I Valuie'as indicated: in:table: Rey (for Up +O ram) to avoid damage to: the: unit! Remarks: The R-Function excludes option P (output voltage ad- justment by potentiometer). Fig. 20 Ouiput voliage control for single output units LS 4000 by means of the R input Table 7a: Rey, for Uy < Uo nom; approximate values (Uj nom; lonom, series E 96 resistors); Flex, = Up nein = 5.1-V. Up nein = 12.-V. Uginior = 15:N Us nom = 24V U5) Ra [KO] Uy {vy Asa {kQ] Us [VI]! Rese {KQ] Us [VJ Asa [KO] 0.5 0.422 2 4 0.825 2 4 0.56 4 8 0.825 1.0 1.0 3 6 1.3 4 8 1.47 6 12 1.33 1.5 1.62 4 8 1.96 6 12 2.61 8 16 1.96 2.0 2.16 5 10 2.87 8 16 4.64 10 20 2.87 2.5 3.83 6 12 3.83 9 18 6.19 12 24 3.83 3.0 5.61 7 14 5.62 10 20 8.25 14 28 5.61 3.5 9.09 8 16 8.28 11 22 11.0 16 32 8.25 4.0 14.7 9 18 12.1 12 24 16.2 18 36 124 45 28.7 10 20 19.6 13 26 26.1 20 40 19.6 5.0 196 11 22 42.2 14 28 56.2 22 44 46.4 Table 7b: Reyt for Up > Us nom; approximate values (Uj nom, fo nom, series E 96 resistors); Rext = Usnom =D: 4 Vv. Usinom = 12:V. Usnom= 15-V Up inom = 24. Oe IV Ret kQ] Up [V] * Fea tk] Up [V] ' Ren [kQ] U, [V]' ext [KO] 5.15 422 124 24.2 1780 15.2 30.4 1470 24.25 48.5 3160 5.2 215 12.2 24.4 909 15.4 30.8 750 24.5 49.0 1620 5.25 147 12.3 246 623 15.6 31.2 511 24.75 49.5 1100 5.3 110 12.4 24.8 464 15.8 31.6 383 25.0 50.0 825 5.35 90.9 12.5 25.0 383 16.0 32.0 316 25.25 50.5 681 5.4 75 126 25.2 316 16.2 32.4 261 25.5 51.0 562 5.45 61.9 12.7 25.4 286 16.4 32.8 237 25.75 51.5 511 5.5 56.2 12.8 25.6 234 16.5 33.0 215 26.0 52.0 464 13.0 26.0 196 26.25 52.5 422 13.2 26.4 162 26.4 52.8 383 1 First column: single output units or double output units with separated outputs, second column: outputs in series connection Edition 3/1.98/IN 1.98 - Melcher AG 10-115S-Family PFC Fig. 21a LS 5000 with H15 connector. R-input for output voliage control. Wiring for output voliage 24 V or 30 V or 48 V with main and second output connected in series. Vo2+ 4 ov ete ue Vo2- A 12/-15/-24 V +12/415/+24 V Fig. 21 LS 5000 with H15 connector. R-inout for output voltage control. Wiring of main and second output for two sym- metrical output voltages Uj, and Uj2: +12 Vor +15 Vor +24 V. Fig. 21e LS 5000 with H15 connector. R-input for output voliage conirol. Wiring of main and second output for two output voltages Up; and Ups: 12 V/12 Vor 15 V/15 Vor 24 V/24 V, the outputs are galvanically isolated. AC-DC Converters <100 W Rugged Environment Fig. 21b LS 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. +24/+30/+48 V 06007 +12/+15/+24 V Fig. 21d LS 5000 with H15 connector. R-input for output voltage control. Wiring of main and second output for two output voltages Up, and U2: +12 V and +24 Vor +15 Vand +30 Vor +24 V and +48 V. 1 A ceramic multilayer capacitor connected across the load re- duces ripple and spikes. 2 Shortest possible wiring for series connection at the female con- nector Remarks: Double output units fitted with H15 connectors have the output pins of the second output, pins 4/6 and 8/10, inter- nally paralleled. It is recommended that pins 4/6 and 8/10 be directly paral- leled at the female connector as well to reduce the voltage drop across the connector. Please note: U2 varies depending upon its own load and the load on output 1. 10 - 116 Edition 3/1.98/IN 1.98 - Melcher AGRugged Environment Display Status of LEDs 06002 Up, > 0.95. ,.0.98U 54 agj Uj U; uv U; min U; max U; ov U; abs U5, > 0.95...0.98U,, adj U5, < 0.95...0.98U,, adj OK lo a 1 1 I nom fot i = i To Tomax TTC threshold Minh threshold jE 1 1 re Ui inh -50 V 40.8V 42.4V +50 V (1 LED off LED Status undefined ME LED on Test Sockets (Main output only ) Test sockets for measuring the output voltage Up, are lo- cated 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 se- ries for U = 24 V, 30 Vor 48 V the monitored output volt- age is 12 V, 15 V or 24 V respectively. Electromagnetic Compatibility (EMC) Electromagnetic Emission [dBuV] 90 07063 80 70 60 50 40 30 20 10 MHz - N WwW 10 20 30 7 wo oO oO 0.01 0.02 0.05 Fig. 23 Typical disturbance voliage (quasi-peak) at the input accora- ing to CISPR 11/22 and EN 5501 1/22, measured at Uinom and Io nom- AC-DC Converters <100 W S-Family PFC Fig. 22 LEDs OK","? and "|, "status versus input voltage Conditions: lo Slo nom, To < Tc max; Vinh $0.8 V Ui w = undervoltage lock-out, Uj oy = overvoitage lock-out LEDs "OK" and l."status versus output current Conditions: U; min...Ui max, To S To max, Vinh $0.8 V LED "versus case temperature Conditions: U; min... U; max: fo Slo nom, Vinh $0.8 V LED i versus Unn Conditions: Uj min... Ui max: fo Sto nom, Te S Te max [dBuV/m] 50 07038 40 30 20 10 0 [MHz] oO Qo Qo Qo Oo Oo oO Ww oO oO Oo Oo - N ito) 2 Fig. 24 Typical radiated electromagnetic field strength (quasi- peak) according to CISPR 11/22 and EN 5501 1/22, nor- malized to a distance of 10 m, measured at Uj nom and l nom- Edition 3/1.98/IN 1.98 - Melcher AG 10-11740 S-Family PFC AC-DC Converters <100W Rugged Environment A metal oxide VDR together with an input fuse and aninput The S-family has been successfully tested to the following filter form an effective protection against high input tran- _ specifications: sient voltages which typically occur in most installations. Electromagnetic Immunity Table 8: Immunity type tests Phenomenon: |: Standard | Level Coupling Value Waveform Source Test In Per- mode? applied imped, procedure oper. form. * Voltage surge IEC 60571-1 i/e, +i/-i 800 V, 100 us 100 2 | 1 pos. and1neg. | yes 4 1500 Vp 50 us voltage surge per coupling mode 3000 V, 5 us 4000 V, ius 7000 Vp 100 ns Supply related RIA 12 B +i/-i 1.5 Upat 1s 0.22 1 positive yes 4 surge surge Direct transient Cc ti/c, i/c 960 V, 10/100 ps 5Q 5 pos. and5 neg. | yes 4 D 1800 Vp 5/50 us impulses E 3600 V, 0.5/5 ps 100 2 F 4800 V, 0.1/1 ps G 8400 V, 0.05/0.1 us Indirect coupled H o/c, +0/c 1800 V, 5/50 us transient J 3600 V> 0.5/5 us K 4800 V, 0.1/1 ps L 8400 V, 0.05/0.1 us Electrostatic IEC/EN 4 | contact discharge} 8000 V, 1/50 ns 330 10 positive and yes A discharge 61000-4-2 air discharge 15000 V, 10 negative (to case) discharges Electromagnetic | IEC/EN 3 antenna 10 V/m AM 80% na. 26...1000 MHz yes 4 field 61000-4-3 1 kHz Electromagnetic | ENV 50204 50% duty cycle, 900 +5 MHz yes 4 field, 200 Hz repetition pulse modulated frequency Electrical fast IEC/EN 4 capacitive, o/c 2000 V, |bursts of 5/50 ns} 502 1 min positive yes A transient/burst | 61000-4-4 ile, +i/-i 4000 Vp 2.5/5 KHz over 1 min negative A direct 15 ms; burst transients per period: 300 ms coupling mode Surge IEC/EN 3 i/c 2000 V, 1.2/50 us 12Q | 5pos.and5neg. | yes A 61000-4-5 4 +i/-j 20 surges per i/c, +i/-i 2500 Vp 10/700 us 409 Conducted IEC/EN 3 i, 0, signal wires 10 Vims AM 80% 15092 0.15...80 MHz yes 4 disturbances 61000-4-6 (140 dBuv) 1 kHz 1 Related and previous standards are referenced in Technical Information: Standards. 2 | = input, o = output, c = case. 3 A= Normal operation, no deviation from specifications, B = Normal operation, temporary deviation from specs possible. 4 Test in progress, please consult factory. Note: Previous standards are referenced in Technical Infor- mation: Standards 10 - 118 Edition 3/1.98/IN 1.98 - Melcher AGRugged Environment AC-DC Converters <100 W S-Family PFC Immunity to Environmental Conditions Table 9: Mechanical stress Test:method Standard Test conditions Status Ca Damp heat IEC/DIN IEC 60068-2-3 Temperature: 40 22C Unit not steady state MIL-STD-810D section 507.2 | Relative humidity: 93 +2/-3 % operating Duration: 56 days Ea Shock IEC/EN/DIN EN 60068-2-27 | Acceleration amplitude: 100 g, = 981 m/s? Unit (half-sinusoidal) MIL-STD-810D section 516.3 | Bump duration: 6 ms operating Number of bumps: 18 (3 each direction) Eb Bump IEC/EN/DIN EN 60068-2-29 | Acceleration amplitude: 40 g, = 392 m/s? Unit (half-sinusoidal) MIL-STD-810D section 516.3 | Bump duration: 6 ms operating Number of bumps: 6000 (1000 each direction) Fe Vibration IEC/EN/DIN EN 60068-2-6 Acceleration amplitude: 0.35 mm (10...60 Hz) Unit (sinusoidal) MIL-STD-810D section 514.3 5 gn = 49 m/s? (60...2000 Hz) | operating Frequency (1 Oct/min): 10...2000 Hz Test duration: 7.5 h (2.5 h each axis) Fda | Random vibration | IEC 60068-2-35 Acceleration spectral density: 0.05 g,2/Hz Unit wide band DIN 40046 part 23 Frequency band: 20...500 Hz operating Reproducibility Acceleration magnitude: 4.9 dnims high Test duration: 3h (1 h each axis) Kb Salt mist, cyclic IEC/EN/DIN IEC 60068-2-52 | Concentration: 5% (30C) Unit not (sodium chloride Duration: 2h per cycle operating NaCl solution) Storage: 40C, 93% rel. humidity Storage duration: 22 h per cycle Number of cycles: 3 Table 10: Temperature specifications, values given are for an air pressure of 800...1200 hPa (800...1200 mbar) Temperature Standard:+7 Option:-9 Characteristics Conditions min max min max Unit Ta | Ambient temperature Ui min. Ui max 25 71 -40 71 C Tc | Case temperature 0 = Me tonom 25 95 40 95 Ts | Storage temperature Not operational -40 100 55 100 Table 11: MTBF Values:at Specified Type Ground: Benign Ground: Fixed Ground: Mobile Unit Case Temperature 40C 40C. FOLG, 50C: MTBF 1 LS 4000/5000 514'000 88'000 38'000 35'000 h 1 Calcualted in accordance with MIL-HDBK217F. Edition 3/1.98/IN 1.98 - Melcher AG 10-119S-Family PFC AC-DC Converters <100 W Mechanical Data Dimensions in mm. Tolerances +0.3 mm unless otherwise indicated. 171.93 (DIN 41494) Rugged Environment European ZTE 1, STE iy Projection 3.27 (8 | | QT 2 | 50 Measuring point of M4 : aN | : case temperature To : ii | aS Sae je i 1 @ i | I yu | | , i TE Hii i | t | ea Test jacks (+/-) | POR Option P (Ug) | | -@:-6 Option D (Ut9) | ! Option D (Uy) q|! : = qd] i 5 LED i (red) He4+]-H 4b WU. Poy ted ee dye tb -H+H+ 8 SO] Pb tf. FAK... Jo.- bee | | = LED OK (green) | | LED |, (red) B @=035 | 22 0-041 | 1) S| | HE let st a 8! 152 18 | 30 t t ~+} 60 Front plate Main face Back plate 168.5405 2 = = Note: Fig. 25 Aluminium case S02 with heatsink, black finish and self cooling, weight: Approx. 1.25 kg 50 5 158 wo I : fee fo 3 SA : | M4 [ ! S q | | 2 8 no a NS ee : a y + Measuring point of | case temperature To | | | | | | Lh ~} @-@ 0 17.3 | 133.4 163 205 171.93 (DIN 41494) Fig. 26 Aluminium case S02 with option B1 (cooling plate), black finish and self cooling. Total weight: Approx. 1.15 kg d2>15 mm, recommended minimum distance to next part to ensure proper air circulation at full output power. free air locations: the module should be moun- ted with fins in vertical position to achieve a maximum air flow through the heat sink. 090038 O00 Oo ef" || 47.2 5 Note: Long case with option B1, elon- gated by 60 mm for 220 mm rack depth, is available on request. (No LEDs, no test jacks.) 10 - 120 Edition 3/1.98/IN 1.98 - Melcher AGRugged Environment Safety and Installation Instructions Connector Pin Allocation The connector pin allocation table defines the electrical potentials and the physical pin positions on the H15 con- nector. Pin no. 24, the protective earth pin present on all LS AC-DC converters is leading, ensuring that it makes con- tact with the female connector first. 10002 AC-DC Converters <100 W @ @ Oo oO @ @ BQ +2 eee eee eee ee eee eee 4 Type H15 Fig. 27 View of modules male H15 connector Table 12: H15 Connector pin allocation Pin::}-Connector type: H:15 No. |: ES:4000 LS:5000 Voi+ Vo2+ Output 1 Output 2 Voi+ Vo2+ Vo1- Vo2- Output 1 Output 2 10 | Vo1- Vo2- 12 | S+ Sense Voi+ Output 1 14 |S Sense Vo1- Output 1 16 | R!1 Control of Uo, R1 Control of Uo, 18 Ji Inhibit i Inhibit 20 |D Save data D Save data v3 ACFAIL 22 |T Current sharing | T Current sharing 242 | Protective earth | Protective earth 26 | N~ N~ , __}__} Neutral Neutral 28 | N~ N~ 30 | P~ P~ Phase Phase 32 | P~ P~ 1 Feature R excludes option P and vice versa 2 Leading pin (pregrounding) 3 Option D excludes option V and vice versa 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. S-Family PFC Installation Instructions The S-family AC-DC converters are components, intended exclusively for inclusion within other equipment by an in- dustrial assembly operation or by professional installers. In- stallation must strictly follow the national safety regulations in compliance with the enclosure, mounting, creepage, clearance, casualty, markings and segregation require- ments of the end-use application. Connection to the system shall be made via the female con- nector H15 (see Accessories). Other installation methods may not meet the safety requirements. The AC-DC converters are provided with pin no. 24 (), which is reliably connected with their case. For safety rea- sons it is essential to connect this pin with the protective earth of the supply system. 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 pro- tect the unit in case of an overcurrent and does not neces- sarily cover all customer needs, an external fuse suitable for the application and in compliance with the local require- ments might be necessary in the wiring to one or both input potentials, pins nos. 26 and 28 and/or nos. 30 and 32. Important: Whenever the inhibit function: is not:in:-use, pin:no::18 (i) should be connected to:pin:no.:14:(S-/Vot) to:enable the: output(s): Do::not-open: the: modules, or guarantee: willbe: invali- dated; Due to high current values, all LS units provide two inter- nally 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 con- nector 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 con- vection cooling. This should be verified by measuring the case temperature when the unit is installed and operated in the end-use application. The maximum specified case tem- perature 7c max shall not be exceeded. See also Thermal Considerations. Check for hazardous voltages before altering any connec- tions. 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. Edition 3/1.98/IN 1.98 - Melcher AG 10 - 12140 S-Family PFC Standards and Approvals All AC-DC converters correspond to class | equipment. They are UL recognized according to UL 1950, UL recog- nized for Canada to CAN/CSA C22.2 No. 950-95 and LGA approved to IEC/EN 60950 standards. The units have been evaluated for: e Building in e 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 e Basic insulation between output and case based on 200 V AC and DC Operational insulation between output and output e The use in a pollution degree 2 environment Table 13: Isolation AC-DC Converters <100 W Rugged Environment Connecting the input to a primary or secondary circuit which is subject to a maximum transient rating of 2500 V (overvoltage category Ill based on a 110 V primary cir- cuit, overvoltage category || based on a 230 V primary circuit). The AC-DC converters are subject to manufacturing sur- veillance 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 ac- cordance with IEC/EN 60950 and UL 1950 and should not be repeated in the field. Melcher will not honour any guar- antee 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): Characteristic Inputto::)Input:to::|:Output:to:|: Output to Unit case output case output Electric Required according to 1.5 3.01 - - KVims strength IEC/EN 60950 24 421 _ _ kV DC test voltage : Actual factory test 1s 2.8 5.61 1.4 0.14 AC test voltage equivalent 2.0 4.01 1.0 0.1 kV ims to actual factory test Insulation resistance at 500 V DC >300 >300 >300 >1002 MQ 1 In accordance with IEC/EN 60950 only subassemblies are tested in factory with this voltage. 2 Tested at 100 V DC. For creepage distances and clearances refer to Technical Information: Safety. Leakage Currents in AC-DC operation 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 | equipment. 10061 Ml 1500 2 500 2 || | 10 k2 990 nF 22 nF Fig. 27 Measuring instrument (MI) for earth leaking current tests according to IEC/EN 60950. 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 Q. If inputs of S- units are connected in parallel, their individual leakage cur- rents are added. PN \ i | | ~_dp. Vo+O PN by Vo-O MI for +O @ earth leakage current Fig. 28 Test set-up 10 - 122 Edition 3/1.98/IN 1.98 - Melcher AGRugged Environment Table 14: Leakage currents AC-DC Converters <100 W S-Family PFC Characteristic Class: Unit LS :4000.;:ES 5000 Maximum earth Permissible according to IEC/EN 60950 3.5 mA leakage current 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 ac- cessible, it shall be an SELV circuit according to the IEC/EN 60950 related safety standards. The following table shows a possible installation configura- tion, compliance with which causes the output circuit of an S-family AC-DC converter to be an SELV circuit according Table 15: Safety concept leading to an SELV output circuit 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 as- sure the compliance with the relevant and applicable safety regulations. More information is given in Technical Informa- tion: Safety. Conditions AG-DG: converter Installation Result Gradeof insulation between input and output provided:by:the AG-DC: converter Nominal:voltage Measures:to-achieve the: resulting safety: Status of the: output circuit Safety:status: of the:AC-DC converteroutput circuit Mains Double or reinforced <250 V AC Earthed case ' and installation according to the applicable standards SELV circuit 1 The earth connection has to be provided by the installer according to the relevant safety standards, e.g. IEC/EN 60950. orcs ' 10021 Fuse I Mains Fuse 1 AC-DC : SELV Fig. 30 ~ =+ on- ; Schematic safety concept. Use fuses and earth connec- i verter tion as per Installation Instructions and table Safety con- Earth connection & t pe San y T-------! cept leading to an SELV output circuit. Description of Options Table 16: Survey of options Option:::|: Function: of option Characteristic -9 Extended operational ambient temperature range Ta = 40...71C E Electronic inrush current limitation circuitry Active inrush current limitation Pp! 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 (DO...DD) ves Input and/or output undervoltage monitoring circuitry | ACFAIL signal according to VME specifications (VO, V2, V3) T Current sharing Interconnect T-pins if paralleling outputs (5 units max.) B1 Cooling plate Replaces standard heat sink, allowing direct chassis-mounting 1 Function R excludes option P and vice versa 2 Option D excludes option V and vice versa 3 Only available if main output voltage Up; = 5.1 V -9 Extended Temperature Range Option 9 extends the operational ambient temperature range from 25...71C (standard) to 40...71C. The power supplies provide full nominal output power with convection cooling. Option -9 excludes inrush current limitation by NTC. P Potentiometer The potentiometer provides an output voltage adjustment range of +10/-60% of Up 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 (dou- bling the voltage setting if the outputs are in series). If the output voltages are increased above Us nom via R-in- put control, option P setting, remote sensing or option T, the output current(s) should be reduced accordingly so that Po nom is not exceeded. Edition 3/1.98/IN 1.98 - Melcher AG 10 - 123S-Family PFC E Inrush Current Limitation The converters may be supplemented by an electronic cir- cuit (option E, replacing the standard built-in NTC) to achieve an enhanced inrush current limiting function. Table 17: Inrush current characteristics with option E Gharacteristies LS Unit U)=:230: VAC typ max lint p Peak inrush current - 25.3 A tinr Inrush current duration 35 50 ms - I 2 _ 2 | Control 5 cz] [++ 6] = ]8 2 7 [FET 6 5 Cc ~ a! Il Rectifier Rg A Ci Fig. 31 Option E block diagram KIA] 11002 20 + Capacitor C; fully charged 15 10 Normal operation | (FET fully conducting) 54 a TP nn pee een nee UU cm 5 _| -10 tint i 0 10 20 30 40 50 60 70 80 Fig. 32 Inrush current with option E, U, = 230 V AC, P, = Po nom Precaution: Subsequent: switch-on: cycles at: start-up are: limited: to max. 10:eyeles::during: the: first: 20 seconds: (cold::unit) and at continuing on/off:(Te'=:95 C): maxet:cyele: every 8 sec: T Current Sharing This option ensures that the output currents are approxi- mately shared between all paralleled modules and in- creases system reliability. To use this facility, simply inter- connect the T pins of all modules and make sure, that pin 14, the S pin (S 4000) or the Vo1 pins (S 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 re- quired 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 con- nected together. AC-DC Converters <100 W Rugged Environment Fig. 33 An example of poor wiring for connection in parallel 11011 max. 5 units connected in parallel 1 Leads should have equal length and cross sections and should run in the same cable loom. 2 Diodes recommended in redundant operation only 3 DC common point Fig. 34 Paralleling of single output units using option T with the sense lines connected at the load Power bus + _ T 11037 Load max. 5 units in parallel connection Fig. 35 Paralleling of double output units using option T with Power bus. 10 - 124 Edition 3/1.98/IN 1.98 - Melcher AGRugged Environment D Undervoltage Monitor The input and/or output undervoltage monitoring circuit op- erates independently of the built-in input undervoltage lock- out circuit. A logic "low" (JFET output) or high" signal (NPN output) is generated at pin 20 as soon as one of the moni- tored voltages drops below the preselected threshold level U,. The return for this signal is Vo1. The D output recovers when the monitored voltage(s) exceed(s) U,+ U,. The Table 18: Undervoltage monitoring functions AC-DC Converters <100 W S-Family PFC threshold level U;; is adjusted in the factory. The threshold level U;,. 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 DO...DD as shown in the following table. Output:type Monitoring Minimum adjustment range Typical:hysteresis: Uy, [%: of Uy] JFET NPN Uj U4 of threshold:level: U; for: Gi mine Uimax Ui Uc Ue D1 D5 no yes - 3.5...40 V1 2.5...0.6 D2 D6 yes no 355V DC 4 - - D3 D7 yes yes 355V DC 4 (0.95...0.985 Up) 2 "0" D4 D8 no yes - (0.95...0.985 Up3) 2 "0" DO D9 no yes - 3.5...40 V3 2.5...0.6 yes yes 355V DC 4 3.5...40 V3 2.5...0.6 DD yes yes 355V DC 4 3.5...40 V1 2.5...0.6 1 Threshold level adjustable by potentiometer 2 Fixed value. Tracking if U1 adjusted via R-input, option P or sense lines. 3 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)! 4 Option D monitors the boost regulator output voltage. The trigger level is adjusted in the factory to 355 VDC. JFET output (DO...D4): Connector pin D is internally connected via the drain- source path of a JFET (self-conducting type) to the nega- tive potential of output 1. Up < 0.4 V (logic low) corresponds to a monitored voltage level (U; and/or Up) <U;. The cur- rent /p 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. Oey status Uj or Uo, < Uy Uj and Uo4 > U, + Ur D:output, Up low, L, Up <0.4 Vat fp =2.5mA high, H, fp < 25 pA at Up = 5.25 V NPN output (D5...DD): Connector pin D is internally connected via the collector- emitter path of a NPN transistor to the negative potential of output 1. Up< 0.4 V (logic low) corresponds to a monitored voltage level (Uj and/or Up1) > U; + Up. The current /p through the open collector should not exceed 20 mA. The NPN output is not protected against external overvoltages. Up should not exceed 40 V. Ue-U5y status Uj or Uoy < Uy Uj and Uot > U, + Ur D-output: G5 high, H, /p < 25 pA at Up = 40 V low, L, Up $0.4 V at fp = 20 mA Table 19: D-output logic signals Input Fig. 36 Input Fig. 37 Option D5...DD: NPN output, Up; < 40 V, Ips 20 MA Version: of D UO < Uy resp.:Ug:<: Uy GO; > Ups: Gy resp. U5 >: 0; Contiguration D1, D2, D3, D4, DO low high JFET D5, D6, D7, D8, DY, DD high low NPN Edition 3/1.98/IN 1.98 - Melcher AG 410 - 125S-Family PFC AC-DC Converters <100W Rugged Environment D-signal with respect to input and output voltage versus time: Input voltage monitoring NPN U, Ud high Up low 0 lp 'b high lp low |------------ 4 $ ep 7 - - 0 JFET Up Up nigh Sane eee a nnn nnn nnn J -- nono Up low -|------------ ' ep 7 - - 4 _4 low min 4 l 1 4 | low min I f I 4 low min Input voltage failure Switch-on cycle Input voltage sag Switch-on cycle and subsequent ae input voltage failure Output voltage monitoring NPN UU Upnign 4------------ U Dlow 2 4 4 low min 1 Hold-up time see section Electrical Input Data. ! ' 2 With output voltage monitoring, hold-up time = 0. 3 The signal will remain high if the D output is connected to an external source. t 4 tlowmin = 100...170 ms, typically 130 ms. Output voltage failure Fig. 38 Relationship between Ug), Uo1, Up, Uoi/Uo nom versus time 10 - 126 Edition 3/1.98/IN 1.98 - Melcher AGRugged Environment V ACFAIL Signal (VME) Available for units with U,, = 5.1V This option defines an undervoltage monitoring circuit for the input or input and main output voltage equivalent to op- tion D and generates the ACFAIL signal (V signal) which conforms to the VME standard. The low state level of the ACFAIL signal is specified at a sink current of ly < 48 mA to Uy < 0.6 V (open-collector out- put 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 7, 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 , is provided by the internal input capaci- tance. See also fig. Hold-up Time versus Output Power. Table 20: Undervoltage monitor functions AC-DC Converters <100 W S-Family PFC V output (V2, V3): Connector pin V is internally connected to the open collec- tor of a NPN transistor. The emitter is connected to the negative potential of output 1. Uy < 0.6 V (logic low) corre- sponds to a monitored voltage level (Uj and/or U1) <Ui. The current /y through the open collector should not ex- ceed 50 mA. The NPN output is not protected against ex- ternal overvoltages. Uy should not exceed 60 V. Geougy status Voutput: hy Uj or Ug, < Uy low, L, Uy <0.6 V at 4y=50 mA U, and Ug; > U,+ Uh high, H, ys 25 pA at Uy=5.1V V- output Monitoring Minimum adjustment (VME: compatible)!:::U; Ug7| Yange: of threshold level Ui Ute v2 yes | no |355V DC" - V3 yes | yes |355V DC "| 0.95...0.985 Up; ? 1 Option D monitors the boost regulator output voltage. The trig- ger level is adjusted in the factory to 355 V DC. 2 Fixed value between 95% and 98.5% of Up. Option V operates independently of the built-in input under- voltage lock-out circuit. A logic "low" signal is generated at pin 20 as soon as one of the monitored voltages drops be- low the preselected threshold level U;. The return for this signal is Voi. The V output recovers when the monitored voltage(s) exceed(s) U; + U,. The threshold level U;; is ad- justed in the factory to 355 V DC. The threshold level U;, either is adjusted during manufacture to a determined cus- tomer specified value. Input Fig. 39 Output configuration of options V2 and V3 Edition 3/1.98/IN 1.98 - Melcher AG 10 - 127S-Family PFC AC-DC Converters <100W Rugged Environment Input voltage monitoring v2 Uy tiow min tow min = 3 30 * Uy high - 4 ------1 BZ Ba ----- 7 * ane ee 1 I U A BA Niow 7-2 LEE ZZAn |__| ween e ene. eee e eee -a-- ' i i: rp i ! V3 oU. i ' rt tow min i i i bow min Lane leds ete it ed gion igh] -- == eee ne por see rp ccc BAB : BZ OV tow fee eee eee en oe Le i a 2a 0 1 1 ri | 1 74 1 t I ' raiol 1 rio I ht | ri 7 Hi ty Up, | it | 1 I > 51AV- ; Lao sc ott ar + went u moO 4.875 V -[or crc rr rr toons PTT 1 UM mm em aprrccsscsscs ta RARE wn nnn n\n nnn nnn ee if: 7 if 2.0 V -L---------- 4----- Wec-n n= -n-- HH b---------------- 0 ---------- Lf----------- Poli -L -- N---- 0 7 T Tt + t ' 1 rt I I tot U, [V DC] 1 I tot ' 1 rt 358 Ls -b-------NXgob------------ 0 ------ ff --------------- ------ NK - Lf ---------- see cpr S core moyfemmm con SSO i 0 + t Input voltage failure Switch-on cycle Input voltage sag Switch-on cycle and subsequent input voltage failure Output voltage monitoring *T + VME request: minimum 4 ms 2 tow min = 40...200 ms, typically 80 ms U 3 Uy level not defined at U,; < 2.0 V 4 The V signal drops simultaneously with the output voltage if the pull-up resistor Ap is connected to Vo1+. The V signal remains high if Ap is connected to an external source. 0 t Output voltage failure Fig. 40 Relationship between U,i, Up, Uy, hy and Up1/U5 nom VEr- sus time. 10 - 128 Edition 3/1.98/IN 1.98 - Melcher AG