M- Family Triple oatpad series CMZ/DMZILMZ soon Extremely: wide input se onene range suitable for : * Outputs fully protected cane overload Belety acoorang to IEC 950. Table of Contents 0. Page De@SCIIPTION 0... ccc cceeceeestecesssesseecseeeeseeecaeensneesneecnea 7-2 Type Survey ec ceeeeeeeernereeee Safety and Installation Instructions . Functional Description 0.0.0... cecceeseeeeceeceeereeneeeee 7-6 Electrical Input Data oo... teeter eres 7-7 Electrical Output Data... ccscsessseessessseeeaeree 7-9 Description The M-family of DC-DC (AC-DC) converters represents a broad and flexible range of power supplies for use in ad- vanced industrial electronic systems. Features include high efficiency, reliability, low output voltage noise and excellent dynamic response to load/line changes due to individual regulation of each output. The converter inputs are protected against surges and tran- sients occuring at the source lines. An input over- and undervoltage cut-out circuitry disables the outputs if the in- put voliage is outside the specified range. Certain types in- clude an inrush current limitation preventing circuit break- ers anci fuses from being damaged at switch-on. All outputs are open- and short-circuit proof and are pro- tected against overvoltages by means of built-in suppres- sor diodes. The outputs can be inhibited by a logic signal appliec to the connector pin 2 (i). If the inhibit function is not used pin 2 should be connected with pin 23 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 DC-DC Converters <100 W 50 W Dc- DC (AC- DC) Converters Rugged Environment M-Family EMC and Immunity to input Transients ...........0....06 7-13 Supplementary Data 2.0... ec ccccetseseteeseseseeeeneeeees Description of Options ........ cee cccceeeeceeeeeeeeteestens Immunity to Environmental Conditions... we Mechanical Data 0. erence reneeteeesenetaeees to output isolation is provided. The modules are designed and built according to the international safety standard IEC 950 and have been approved by the safety agencies LGA (Germany) and UL (USA). The UL Mark for Canada has been officially recognized be regulatory authorities 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 should remain below 95C under all conditions. A temperature sensor generates an inhibit signal which disables the outputs if the case temperature 7; 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 inch rack sys- tems according to DIN 41494, or be chassis mounted. Case: aluminium, black finish, self cooling. Dimensions: 38.7 x 111.2 x 168.5 mm. Weight: 770 g. MELCHER Fhe Boye fae Edition 1/96 - Melcher AGRugged Environment DC-DC Converters <100 W M-Family Type Survey Options see "Descriptions of Options" General note The type survey tables provide an overview of the basic input and output configurations. More than 500 different types have been manufactured providing different output configurations and customized specialities. Please consult Melcher's field sales engineers for specific requirements. The best technical solution will carefully be considered and a detailed pro- posal submitted. Table 1a: Class | equipment Useors foram | Vans ax VDC Ao) vp Md BvoC | & ve 51 8.0 'AM1001-7R | 72 | BM1001-7R_ | 74 | FM 1001-7R 12.0 4.0 AM 1301-7R ~~, 79 | BM1301-7R_ | 80 | FM 1301-7R 15.0 34 AM 1501-7R | 79 | BM1501-7R_ | 81 | FM1501-7R_ | 81 | DO...D9 24.0 2.0 AM 1601-7R | 81 | BM1601-7R_ | 83 | FM1601-7R_ | 82 | Vo,V2,V3 48.0 1.0 AM 1901-7R | 81 | BM1901-72_ | 83 | FM1901-7R_ | 83 A 126 20 | 120 20 | AM 2820-7 77 | BM 2320-7 79 | FM 2320-7 80 H 15.0 17 | 150 17 , AM 2540-7 78 | BM 2540-7 80 | FM 2540-7 79 F 51 5.0 | 120 07 | 120 0.7 | AM3020-7 75 | BM 3020-7 76 | FM 3020-7 76 U 51 50 | 150 06 | 15.0 06 | AM3040-7 75 | BM 3040-7 76 | FM3040-7 76 5.1 8.0 CM 1001-7R 74 | DM 1001-7R 74 | LM 1001-7R 73 ~9 12.0 4.0 CM 1301-7R 80 | DM 1301-7A 81 LM 1301-7R 79 E 150 3.4 CM 1501-7R 82 | DM 1501-7AR 82 | LM 1501-7R 78 P 24.0 2.0 j CM 1601-7R 82 | DM 1601-7R 83 | LM 1601-7R 81 Do...D9 48.0 1.0 CM 1901-7R 82 | DM 1901-7R 83 | LM 1901-7R 81 V0,V2,V3 12.0 2.0 12.0 2.0 GM 2320-7 79 | DM 2320-7 80 | LM 2320-7 77 A 15.0 1.7 15.0 1.7 CM 2540-7 80 | DM 2540-7 80 | LM 2540-7 78 H ee 5.14 5.0 12.0 0.7 12.0 0.7 CM 3020-7 76 | DM 3020-7 77 | LM 3020-7 73 F 5.1 5.0 15.0 06 15.0 0.6 CM 3040-7 76 | DM 3040-7 76 } LM 3040-7 71 U Table 2: Class If equipment (double insulation) [oD] Output 1 : 5 . 3 fae @ - _ CMZ 1001-7A DMZ 1001-7R LMZ 1001-7R 120 40 CMZ 1301-7R 80 | DMZ 1301-7R 81 | LMZ 1301-7R 79 E 15.0 3.4 CMZ 1501-7R 82 | DMZ 1501-7R 82 | LMZ 1501-7R 78 P 24.0 2.0 _ CMZ 1601-7R 82 | DMZ 1601-7R 83 | LMZ 1601-7R 31 DO...D9 | 48.0 1.0 | CMZ 1901-7A 82 | DMZ 1901-7R 83 | LMZ 1901-7R 81 | VO0,V2,V3 | 120 20 12.0 2.0 | CMZ 2320-7 79 | DMZ 2320-7 80 | LMZ 2320-7 77 A 15.0 1.7 15.0 17 , CMZ 2540-7 80 | DMZ 2540-7 80 | LMZ 2540-7 78 H 5.1 5.0 12.0 07 12.0 0.7 | GMZ 3020-7 76 | DMZ 3020-7 77 | LMZ 3020-7 73 F 5.1 5.0 15.0 06 15.0 0.6 CMZ 3040-7 76 | DMZ 3040-7 76 | LMZ 3040-7 71 U ' Efficiency measured at Unom ANd fo nom Notes: EM types with an input voltage range of 67...385 V DC are available upon request Remarks: LM types may be operated in AC mode within a frequency range of 47...440 Hz and LMZ types within a fre- quency range of 47...65 Hz. Edition 1/96 - Melcher AG MELCHER 7-3 The Power Partners.M- Family Safety and Installation Instructions Safety DC- DC Converters <100 W Rugged Environment For salety reasons, the power supply modules must be wired via the female connector H11 (according to: DIN 41642, see section * *Accessories) in order to meet national and international safety requirements! If the cutput circuit of a DC-DC converter is operator-acces- sible according to the IEC 950 related safety standards, it shall ke an SELV circuit (Safety Extra Low Voltage circuit, i.e. a circuit, separated from mains by at least basic insula- tion, that means designed and protected such that under normai and single fault conditions, the voltage between any two conductors and between any conductor and earth does not ex::eed 60 V DC). In the ollowing section an interpretation is provided of the IEC 9&0 safety standard with respect to the safety status of Table :3: Insulation concept the output circuit. However, it is the sole responsibility of the installer or user to assure the compliance with the rel- evant and applicable safety standards. Since the M-family DC-DC converters provide double or reinforced insulation between input and output, based on an input voltage of 250 V AC and 400 V DC, only opera- tional insulation between the AC mains and the input of the DC-DC converter is needed according to the following ta- ble. lf the table below is observed, the output of a DC-DC con- verter is considered to be an SELV circuit up to a nominal output voltage of 36 V. Nominal Minimum required gracte of} Maximum. Minimum required safety Minimum required grade| Resulting mains _Qutput | status of the frontend . en the | safety supply | eAC-DC frontend, _| voltage saa eit : : Voltage | Including mains supplied | fromthe of the (ACy battery charger front end pc-pc <250V Operational <400 VV Primary circuit Reinforced, based on SELV / AC 250 V and DC 400 V_ | circuit AM...LM types correspond to class | equipment, while the C/D/LMZ types correspond to class I! equipment. In class | equipment the connector protective earthing pin is leading while it is omitted in class Il equipment (no protec- tive earthing is required). Class || equipment provides rein- forced insulation between input and output circuitry and also between input and case. There are two class II Y-ca- pacitors connected in series between input and output cir- cuitry instead of having Y-capacitors connected to the case. During the production process, all transformers and each of Important Advice the fully assembled modules are individually tested for electric strength and earth continuity (see Supplementary Data"). All electric strength tests are performed as factory tests. The UL 1950 recognition limits the maximum ambient op- erational temperature of the standard modules to Ty, = Ta max 15 K. Option U allows the operation in applications where the full operational temperature range according to the relevant data sheet and UL 1950 recognition is re- quired. Electric strength tests should not be peated in the field. neta test methods, for i xs overshooting oF oscillating voltage field fests. 7-4 MELCHER Edition 1/96 - Meicher AG ihe Power PartnersRugged Environment instalation Instructions Instaliation of the power supply must strictly follow the na- tional safety regulations. To observe the safety require- ments according to EN 60950/IEC 950, the module shall be connected via the female connector type H11 (see section "Accessories). Other installation methods may not meet the safety requirements. A second fuse should be installed in the wiring to pin 29 if: Local requirements demand an individual fuse in each source line Whenever the inhibit function is not required, pin 2 (i) should be connected to pin 23 to enable the output(s). Table 4: Hi1 connector pin allocation DC-DC Converters <100 W M-Family Input to earth impedance is high or undefined ~ Phase and neutral of the mains are not defined (AC-DC converters) Reverse polarity at the input of A...D/FM and C/DMZ types will cause the fuse to biow. In E/LM and LMZ types a series diode will protect the module. A series diode is not incorpo- rated in A...D/FM and C/DMZ types to avoid unwanted power loss. Electrical Determination | A... Inhibit control input 2 i 2 i 2 i 2 i 2 i 2 i Safe Data or ACFAIL 5 DorV | 5 Dorv | 5 DorvV | 5 DorV | 5 Dorv | 5 Dorv Output voltage (positive) 8 Vol+ 8 Vol+ 8 8 | 8 Vo3+ 8 Vo3+ : Output voltage (negative) 11 Vo1- 11 Vol- 11 11 i Vo3- W Vo3- Control input +! 14 R 14 AR Control input 17 G 17 G Output voltage (positive) 14 Vo2+ 14 Vo2+ 14 Vo2+ 14 Vo2+ Output voltage (negative) 7 Vo2 17 Vo2- 7 Vo2- 17 Vo2 Output voltage (positive) 20 Vol+ 20 Vo1+ 20 Vol+ 20 Vot+ 20 Vot+ 20 Vot+ Output voltage (negative) 23 Vot- 23 Vol- 23 Vol- 23 Vo1i- 23 Vot- 23 Vol- Protective earthing 2 26 26 26 DC input voltage * 29 Vi+ 29 Vi+ 29 Vi+ 29 Vi+ 29 Vi+ 2 Vie DC input voltage 32 Vi- 32 Vi- 32 Vi- 32 Vi- 32 Vi- 32 Vi- AC input voltage * 29 N= 29 N= 29 Nx 29 N= 29 Ne 29 N= AC input voltage 32 Px 32 Ps 32 Px 32 Pe 32 Ps 32 P 1 This function is not simultaneously available with option P 2 Leading pin (pregrounding) 3 A/B/G/D/E/FM and C/DMZ types 4 LM/LMZ types Degree of Protection Condition: Female connector fitted to the unit IP 40: All units, except those with options P, A, K, D or V with potentiometer adjustment. IP 30: All units, except those with option P, D or V_ with potentiometer adjustment. {IP 20: All units fitted with options which include potentiometer setting. Leakage Currents and Insulation Please refer to Supplementary Data Edition 1/96 - Melcher AG MELCHER 7-5 The Pawer Partners,M-Femily Functional Description The input voltage is fed via an input fuse, an input filter, a rectifier 3 and an inrush current limiter 4 to the input capaci- tor. This capacitor sources a single transistor forward con- verter. 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 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 pri- DC-DC Converters <100 W Rugged Environment mary switching transistor. This signal is fed back via a cou- pling transformer. The auxiliary outputs Up2 and Ugg are individually regulated by means of secondary switching transistors. Each aux- iiary output's current is sensed using a current transformer. If one of the outputs is driven into current limit, the other outputs will reduce their output voltages as well because all output currents are controlled by the same control circuit. Pp Pee : ee @ Main control circuit [7 (5A WE | wee fo TT 8@ 1 5 * ms rrr @ a _______, 3 = 20 i Output 1 @ | a filter Bw 12 3 ' bs By MKT = : IS & : 5 s 2z~< 44 2 i 52 mw Control Output 2 =o 2 , Res circuit fitter a. $5 17 : k g : zc MKT == : ; |. = Control Output 3 circuit filter KR @ 7 ' : Yo =o , - ' Fig. la 2n ot = z= = ge s px && za og aw > pA Main controf circuit Contral circuit Control circuit Fig. 1b DC-DC (AC-DC) converter biock diagram, class I! equipment (double insulation) 1 Transient suppressor (VDR) in C/D/E/F/LM and C/D/LMZ 2 Transient suppressor diode in A/B/C/FM and CMZ types 3 Bridge rectifier in LM/LMZ, series diode in EM types 4 Inrush current limiter (NTC) in C/D/E/LM and C/D/LMZ types (option E: refer to the description of option E) 5 Single output modules A...LM 1000 and C/D/LMZ 1000 with feature R MELCHER The Power Partners Edition 1/96 - Melcher AGRugged Environment DC-DC Converters <100 W M-Family Electrical Input Data General conditions: Ty = 25C, unless Te is specified. ~ Cornector pins 2 and 23 interconnected, with option P: Up = Up nom, R input not connected. Table 5a: Input data u Input voltage range ly = 0... ho nom 8 35 14 70 20 100 | 28 140 | voc Usnor | Nominal input voltage Te min--- Te max 15 30 50 f Input current Uinom: fo nom? 4.0 2.0 2.0 1.0 A Pig | No-load input power: | Uj nom Singie output Iora3=0 1 1.5 1 15 1 1.5 1 15 Ww Double output 7 9 7 9 7 9 7 9 Triple output 6 9 6 9 6 9 6 9 Piinn | Idle input power inhibit mode 15 1.5 1.5 1.5 WwW fine p | Peak inrush current U = Umax 400 500 400 1704 A = 3 finer _| Rise time i bere 60 50 40 60 us tinrn | Traiting edge half-life 170 100 60 280 R Input resistance Te = 25C 87.5 140 250 8244 mQ G Input capacitance 2600 4000 | 670 4100 | 370 600 | 370 600 pF Ui abs | Input voltage limits 0 40 0 80 0 120 0 160 | VDC without any damage Table 5b: input data Input voltage range fo = 0...fo nom Te min... Te max 44 220 | 67 385 | 88 372 | vbc U nom Nominal input voltage 110 220 310 fh Input current U nom: fo nom 0.55 0.275 0.20 A P., No-load input power: | U; nom Single output hies=0 1 15 1 15 1 16 Ww Double output 7 9 7 9 7 9 Triple output 6 9 6 9 6 9 Pin | Idle input power inhibit mode 15 15 15 w harp | Peak inrush current U, = U max 1104 1604 604 A ae Ag =0 28 I, 40 40 300 S ty, | Rise time Te = 25C re tien | Trailing edge half-life 250 240 900 R, | Input resistance Te = 25C 2000 + 24004 62004 mQ C, | input capacitance 140 270 | 140 270 | 140 270 HF U, aps | Input voltage limits 0 4005 | -400 400 | -400 400 voc without any damage _ _ _ _ 0 284 VAC 1 In AC powered mode: LM types: 47...440 Hz; LMZ types: 47...65 Hz 2 With multiple output modules, the same condition for each output applies. 3 Ag = source resistance. 4 Value for initial switch-on cycle. 5 1s max., duty cycle 1% max. 6 fine p = U/(R, + Fi) Editior: 1/96 - Melcher AG MELCHER 7-7 Powar Eaetners,M-Family Input fuse A fuse older containing a slow-blow type fuse (Dimension: 5 x 20 mm) is mounted in the converters back plate. The fuse protects the module against severe defects. It may not fully protect the module at input voltages exceeding 200 V DC. In applications where the converters operate at DC source voltages above 200 V DC, an external fuse or a circuit breaker at system level should be installed. For applications where the fuse should be inaccessible: see option F. Input Under-/Overvoitage Cut-out If the input voltage remains below 0.8 U min or exceeds 1.14, max (approx. values), an internally generated inhibit signal disables the output(s). When checking this function the absolute maximum input voltage rating Uj ap; must be carefully considered (see table "Input Data). FTA 10.00 AM BM FM CM/CMZ DM/DMZ EM LM/LMZ U 0.10 ioe Ui min oc Fig. 2 Typica! input current versus relative input voltage at nominal output load DC-DC Converters <100 W Rugged Environment Table 6: Fuse types (siow-blow) Series | Schurter type Part number AM 1000...3000 SPT10A 250V | 0001.2514 BM 1000..3000 SPT8A 250V | 0001.2513 | FM 1000..3000 | SPT5A 250V | 0001.2511 CM/CMZ 1000...3000 | SPT3.15 A 250V |; 0001.2509 DM/DMZ 1000...3000 | SPT2.5A 250V , 0001.2508 EM 1000...3000 LM/LMZ 1000...3000 Inrush Current The C...LM and C/D/LMZ (excluding FM) modules incorpo- tate a NTC resistor in the input circuitry which (during the initial switch-on cycle) limits the peak inrush current to avoid damage to connectors and switching devices. Subse- quent switch-on cycles within a short interval will cause an increase of the peak inrush current due to the warming up of the NTC resistor. Refer also to option E description. 4 {Al A...FM LM 400 -| 350 4 300 ~ 50; 250| } 40; 200-4 , LM/LMZ f 30; 150-] EM // owowz 20; 100-4 \ / cwomz 10; 50~ F IT 14 pet ims 0 02 04 06 08 10 42 14 1.6 A.EM 05 10 15 20 25 30 35 40 LM Fig. 3 Typical inrush current at initial switch-on cycle and at U max {DC] versus time Edition 1/96 - Melcher AG MELCHER The Power FartnersRugged Environment Electrical Output Data General conditions Ta = 25C, unless Tc is specified. DC-DC Converters <100 W M-Family ~ Connector pins 2 and 23 interconnected, Us = Us nom (option P), R input not connected. Table 7: Output data LCF arecte ristics : a ee : U, Output voltage Uinom: fo nom ' 5.07 5.13] 11.93 12.07|14.91 15.09/23.86 24.14/47.72 48.28] V Up | Overvoltage prot. to nom 7.5 21 25 41 85 | fo nom | | Output current Ui min. Uj max see tables 1 and 2 fo | Output current To min--- To max see fig. 4 limitation response Uo | Output voltage noise | Ui nom, fo nom | 2 4 3.6 366 3 6 4 8 |MVing Bandwidth = ue 1 ot 20 MHz 5 30 25 50 35 70 40 80 50 100 | MVpp Uoa/3 60 120 40 80 40 80 40 80 - AU, y | Static tine regulation | Uj min..-Ui nom +10 +30 +12 +50 +15 +60 +15 +60 +15 +60 | mV Ui nom: Uj max Io nom 1 AU,, | Static toad regulation! Uj nom 6 25 13 50 17 60 30 80 60 150 Io = Iq nom--.0? AUp {c | Static cross load Ui nam QO +15 oO +20 Q +30 0 +40 - regulation ty = fonom--.0% Usa | Dynamic load Uinom, 4220 +110 150 +130 +150 regulation Ig = . 2 tg | Dynamic load regu- x 089! Velo nom 06 06 05 1 2 | ms lation time constant | "9 i Uode | Dynamic cross load | Ujnom, +10 +10 +10 +20 - | mv regulation he -100 -75 -140 -200 - 3 tic Dynamic cross load Ho esitele rom 0.05 0.2 05 1 - ms reg. time constant* 9- 0.5 0.3 0.7 2 - Ou | Output voltage To mins+ To max +0.02 +0.02 +0.02 +0,02 +0.02 IK deviation versus case temperature +1.0 +2.4 +3.0 +4.8 +9.6 mV/K 1 With multiple output modules, the same condition for each output appfies. 2 Condition for specified output. With multiple output modules, other output(s) loaded with constant current fo = /o nom- 3 Condition for non-specitied output, individually tested, other output(s) loaded with constant current / = fonom- 4 Multiple output modules. Output Protection Each output is protected against overvoltages which could occur due to a failure of the internal control circuit. Voltage suppressor diodes (which under worst case condition may become a short circuit) provide the required protection. The suppressor diodes are not designed to withstand externally applied overvoltages. Overload at any of the outputs will cause a shut-down of all outputs. A red LED indicates the overload condition of the respective output. Paraliel and Series Connection Main outputs of equal nominal voltage can be connected in parallel. It is important to assure that the main output of a multiple output module is forced to supply a minimum cur- rent of 0.1 A to enable correct operation of its own auxiliary outputs. In parallel operation, one or more of the main outputs may operate continuously in current limit which will cause an in- crease in case temperature. Consequently, a reduction of the max. ambient temperature by 10 K is recommended. Main or auxiliary outputs can be connected in series with any other output of the same or another module. In series connection, the maximum output current is limited by the lowest current limit. Output ripple and regulation values are added. Connection wiring should be kept as short as possi- ble. If output terminals are connected together in order to estab- lish multi-voltage configurations, e.g. +5.1 V, +12 V etc. the common ground connecting point should be as close as possible to the connector of the converter to avoid exces- sive output ripple voltages. Auxiliary outputs should never be connected in parallel! Edition 1/96 - Melcher AG comenneneee:Up _ oe I, nom - four Y 1.0 nee 1 bot avtorg Q5]- -------- 6-5 n= - Lye: AM...LM and C/D/LMZ 1 bot * hodd 0.5 po bo res tot I | | | yoo | yl I Ce i | ; oa o i tL nb 0.5 10 12 bonom Fig. 4 Typical output voltage Up, versus output currents |, Output Current Allocation for special Types Output currents differing from those given for standard types (as per "Type Survey") can be provided. A maximum output power of 50 W should be considered, if an ambient temperature range of -25...71C is required. The maximum permissible output currents are indicated in the table below. lf (upon customer's request) output voltages are different from standard values, the relevant output currents have to be adapted accordingly. Table 3: Current allocation with special types DC-DC Converters <100 W Rugged Environment AU, | i oo i follo nom ry 3/3 Fig. 5 Control deviation of U, versus dynamic load change With reduced maximum ambient temperature or with forced cooling, the total output power may exceed 50 W. Custom- ized configurations always need to be checked by a feasi- bility study first. Please ask Melcher's sales engineers for a proposal appropriate to your specific needs. Output voltage Output 1 Output2. Output 2 Output 3: Temperature alltypes alltypes A...LM2000 ALM 3000: A...LM 3000 a - Usveianom 1] tetas Al fog max [AY heomax (AT: Feamax (AP oo) TalC] | Te PC] 5.1 8.0 4.0 1.8 (2.51) 1.5 ~25..71 | -25...95 12 4.0 2.0 15 1.2 15 3.4 17 1.2 1.0 24 2.0 1.0 0.7 0.5 2 5.1 10.0 45 2.1 (2.81) 1.8 -25...60 | -25...90 12 5.0 25 17 15 15 4.0 2.0 1.5 1.3 24 2.5 1.3 0.9 0.7 54 11.0 5.0 2.4 (3.01) 2.0 -25...50 | -25...85 12 6.0 3.0 2.0 17 15 46 2.3 17 1.5 24 3.0 15 1.0 0.8 1 Special high current components required, ? Ujmin has to be increased inhibit (i Input) The outputs of the module may be enabled or disabled by means of a logic signal (TTL, CMOS, etc.) applied to the inhibit input. If the inhibit function is not required, connect the inhibit pin 2 to pin 23 to enable the outputs (active low logic, fail safe). Vit Vo+ bi gn ' | i | An ves Vo- Fig. 6 Definition of inhibit voltage and current The reference for the inhibit signal is the negative pin of output 1. finn [MA] 2.0 1.6 1.2 0.8 0.4 0 -0.4 -0.8 50 | -30 40%? 2 Upn= 0.8 V Upp 2.4 V Unn [V -10 0 10 mm 0 9 20 30 40 50 Fig. 7 Typical inhibit current lin, versus inhibit voltage Uinn 7-10 MELCHER The Power Partaers Edition 1/96 - Melcher AGRugged Environment Table 9: Inhibit data DC-DC Converters <100 W Vinh Inhibit input voltage causing switched on Ui min... Ui max VDC output voltage being... wit che: dott | fio Inhibit current Unh = 0 ~60 -100 ~220 pA Hold-up Time and Output Response When the input voltage is switched off the output voitage will rernain high for a certain hold-up time (fig. 8) before the output voltage falls below 0.95 U, nom. To achieve the hold-up times indicated in fig. 9, A/B/C/D/FM and C/DMZ modules require an external series diode in the input path. This is necessary to prevent the discharge of the input ca- pacitor through the source impedance or other circuits con- nectec to the same source. E/LM and LMZ modules have a built-in series diode. In A/B/C/D/FM and C/DMZ modules, no series diode is built-in, since it would generate up to 10 W of additional power loss inside the converter. Conse- quently the maximum operational ambient temperature would have to be reduced accordingly. Output U, onOM 0.95U, nom 0 Inhibit 1 Fig. 8 Output response as a function of input voltage (on/off switching) or inhibit control The behavior of the outputs is similar with either the input voltage applied or the inhibit switched low. An output voltage overshoot will not occur when the module is turned on or off. , [ms] 1000.00 LM/LMZ 100.00 C/DM, C/DMZ A/BIFM 10.00 U; 0.10 spe U min Dc 1 2 3 4 5 6 Fig. 9 Typical hold-up time t, versus relative input voltage at Ip nom Table 10: Output response time t,, values not applicable for modules equipped with option E Type of Converter [fat Pe od an Ps te | A...LM 1001-7R and C/D/LMZ 1001-7R 5 10 A...LM 1301-7R and C/D/LMZ 1301-7R 10 20 . A...LM 1501-7R and C/D/LMZ 1501-7R 5 10 A...LM 1601-7R and C/D/LMZ 1601-7R 15 30 A...LM 1901-7R and C/D/LMZ 1901-7R 65 130 A...LM 2320-7 and C/D/LMZ 2320-7 20 40 A...LM 2540-7 and C/D/LMZ 2540-7 15 30 A...LM 3020-7 and C/D/LMZ 3020-7 55 110 A...LM 3040-7 and C/D/LMZ 3040-7 40 80 Conditions: R input not used. For multiple output modules the figures indicated in the table above relate to the output which reacts slowest. All outputs are resistively loaded. Variation of the input voltage within U; min--.U, max does not influence the values. Edition 1/96 - Melcher AG MELCHER 7-11 The Power Pariners ~ NnM-Family Programmable Voltage (R Input) As a standard feature single output modules offer an adjustable output voltage identified by letter R in the type desigration. The control input R (pin 14) accepts either a contre! voltage Ux or a resistor Aas to adjust the desired output voltage. When not connected, the control input auto- matically sets the output voltage to Up nom. The control input is protacted against external overvoltage up to 8 V max. a) Adj.istment by means of an external control voltage Uex: between pin 14 (R) and pin 17 (G): The control voltage range is 0...2.75 V and allows an adjustment in the range of approximately Ug =: 0...110% Uo nom. Up Yer = Tom e2.5V b) Adjustment by means of an external resistor: Depending upon the value of the required output volt- age, the resistor shall be connected either: Between pin 14 and pin 17 (U5 < Up nom) to achieve an output voltage adjustment range of approx. Up =: 0...100% Uo nom Uy Fea Trem = Up or: Between pin 14 and pin 20 (U, > Uy nom) to achieve an output voltage adjustment range of approximately U, = 100...110 % of U, onom: (U,- 2.5 V) Flor = 4KQ* FE 8(Oq/Uynm= 1) For output voltages Uy > Up nom, the minimum input voltage according to Electrical Input Data" increases proportionally to Up/Uo nom- Warning DC-DC Converters <100 W Rugged Environment The value of Fax should never be less than 47 kQ. to avoid damage to the unit! R inputs may be parallel connected, but 1/Rio = 1/R; + 1/Re +.... should be considered. Remark The R-feature excludes option P (output voltage adjust- ment by potentiometer). Vi+ ~ Vol+ 20 1 26V 4kQ ig : 14 , T + ; control ; (= oe ' =)U, : circuit : ont Ga : 7 t 1 Vie AM...LM 1000 ~~ Vot- 32) C/DALMZ 1000 23 control circuit AM...LM 1000 C/D/LMZ 1000 Fig. 10 Output voltage control by means of the R input Table 11a: Rex for Us < Us nom (conditions: Uj nom, bo nom. founded up to resistor values E 96, Rexy = -) Uo. v 05 0.432 2.0 0.806 2.0 1.0 0.976 3.0 1.33 4.0 15 1.65 4.0 2.0 6.0 20 2.61 5.0 2.87 8.0 25 3.83 6.0 4.02 9.0 30 5.76 7.0 5.62 10.0 35 8.66 8.0 8.06 11.0 49 14.7 9.0 12.1 12.0 45 30.1 10.0 20.0 13.0 59 200.0 11.0 44.2 14.0 0.619 4.0 0.806 1.47 6.0 1.33 2.67 8.0 2.0 4.53 10.0 2.87 6.04 12.0 4,02 8.06 14.0 5.62 11.0 16.0 8.06 16.2 18.0 12.1 26.1 20.0 20.0 56.2 22.0 44.2 1780 5.15 464 12.1 1470 48.5 15.2 3160 | 6810 5.20 215 12.2 909 15.4 750 24,50 1620 | 49.0 3480 5.25 147 12.3 619 15.6 511 24.75 1100 | 49.5 2370 5.30 110 12.4 464 15.8 383 25.00 825 | 50.0 1780 5.35 90.9 12.5 383 16.0 332 25.25 715 | (50.5 1470 5.40 78.7 12.6 316 16.2 274 25.50 590 ~s 51.0 1270 5.45 68.1 12.7 274 16.4 237 25,75 511, S15 1100 5.50 61.9 12.8 249 16.5 226 26.00 453; 52.0 953 13.0 200 26.25 402 52.5 845 13.2 169 26.40 383 52.8 806 7-12 MELCHER Edition 1/96 - Melcher AG The Power PartaersRugged Environment DC-DC Converters <100 W M-Family EMC and Immunity to Input Transients A suppressor diode or a metal oxide VDR (depending upon _ which typically occur in most installations, but especially in the type) together with an input fuse and an input filter form battery driven mobile applications. The M-family has been an effective protection against high input transient voltages successfully tested to the following specifications: Electromagnetic Immunity Table 12: immunity type tests go 5 Impulse voltage | [EC 255-4 ut i/o, ifc, ofe 5000 V, 1.2/50 ps 500@ | 3pos. and3neg. | no App. E46 +i/-i, +0/-0 impulses per (1976) coupling mode High frequency | IEC 255-4 I i/o, i/c, ofo, ofc 2500 V, | 400 damped 200 Q 2s per yes | 1 disturbance App. E5& +i/4, +0/-0 1000 V, 1 MHz waves/s coupling mode (1976) Voltage surge 1EC 571-13 ic, +i/-i 800 Vp 100 is 100Q | 1pos.andineg. | yes| ' (1990-07) 1500 V> 50 us voltage surge per coupling mode 3000 V, 5 ys 4000 V, tus 7000 V, 100 ns Supply related | RIA 12 AS +i/-i 3.5 Ubatt 20 ms 0.22 1 positive yes | 1 surge (1984) B 1.5 eUban 1s surge Direct transient Cc 960 V, 10/100 Ls 5Q | 5 pos. and 5 neg. _ D 1800V,| 5/50 us impulses S E 3600 V, 0.5/5 ps 100 Q F 4800 V, 0.1/1 ps G 8400 V, 0.05/0.1 us Indirect coupled H ifc 1800 Vp 5/50 us transient J 3600V, | 0.5/5 us K 4800 V> 0.1/1 us L 8400 V, 0.05/0.1 s Electrostatic IEC 801-2 4 contact discharge | 8000 V, 1/50 ns 330 2 10 positive and yes | 1 discharge (1991-04) to case, 10 negative air dischg. to case | 15000 V, discharges Electric field IEC 801-3 3 antenna in 10 Vim | AM modulated 26...1000 MHz yes | 2 (1984) 1 m distance 80%, 1 kHz Fast transient/ | IEC 801-4 3 ife, +i/-i 2000 V, |bursts of 5/50 ns} 50Q 1 min positive yes | ' burst (1988) 5 kHz rep. rate 1 min negative transients with bursts per 15 ms burst coupling mode [J duration and a 4000 V, | 300 ms period 2 Transient IEC 801-5 4; ifc 4000 V> 1.2/50 ps 12Q | Spos.and5neg. | yes| 1 (Draft 1993-01) Hii 2000 V, 2a impulses per coupling mode Conducted IEC 801-6 3 i, o, signal wires [140 dBuV | AM modulated | 1502 0.15...80 MHz yes | ? disturbance (Draft 1992-12) (10 Vims) | 80%, 1 kHz Normal operation, no deviation from specifications units are available on customer's request. Standard DM units 2 Normal operation, temporary deviation from specs possible (110 V battery) will not be damaged, but overvoltage lock-out 3 Will be replaced by EN 50155 will occur during the surge 4) = input, o = output, c = case 5 In correspondence with DIN 57435 part 303 and VDE 0435 part 5 Only met with extended input voltage range of BM (24 V bat- 303 (1984-09) tery), OM (48 V battery) and EM (110 V battery) types. These Edition 1/96 - Melcher AG MELCHER 7-13 The Power PartnersM-Family DC-DC Converters <100 W Rugged Environment Electromagnetic Emissions Table 13: Emissions at Ui nom @nd Io nom (LM/LMZ at 230 V AC) Types Level: VDE 0871 VDE.0875 part 3 EN 55011, 19911 FOC: 47. CFR 15.0% 6.78 12.88 EN 55022, 19872 15.107 15.103 <$30MHz | 230.MHz | <30 MHz 230 MHz S$30MHz | 230 MHz < 30 MHz 230 MHz AM 1000 B B N K B B B B AM 2000 B B N K B B B B AM 3000 B A N K B A B A BM 1000 B B N K B B B B BM 2000 B B N K B B B B BM 3000 B A N K B A B A rom 1000 B B N K B B B B CM 2000 B B N K B B B B CM 3000 B A ND K B A B A DM (000 B B N K B B B B DM 2000 B B N K B B B B DM 3000 B A N K B A |. B A EM 1000 B B N K B B B B EM 2000 B B N K B B B B EM 3000 B A N K B A B A FM 1000 A B N K B B A B FM 2000 A B N K B B A B FM 3000 A A N K B A A A LM 000 B B N K B B B B LM 2000 B B N K B B B B LM 3000 B A _N K B A B A CMZz" 1000 B A N K B A B A CMZ 2000 . - - - - - . - CMz 3000 >A >A G G A >A A >A DMZ 1000 - . . 7 ; ~ : DMZ 2000 - - - - - - DMz 3000 - - : - - - LMzZ 1000 >A >A G K A >A >A >A LMZ 2000 - - - - - - - - LMZ 3000 A >A N N B >A A >A 1 Ider tical with CISPR 11 (1990-09) and VDE 0875 part 11 (1992-07) 2 Idertical with CISPR 22 (1985) and VDE 0878 part 3 (1989-11) {dBuv | [dBuV/m) 400 100 90 90 80 80 70 70 60 60 50 50 40 40 30 30 20 20 40 10 0 0 58 859 8 7% 2 BB 8 8 8 3 8 3 o 9 Frequency [MHz] --> Frequency [MHz] = Fig. 11a Fig. 11b Conducted RFI at input according to EN 55011 (quasi peak) Radiated RFI according to EN 55011 (Distance 10 m) 7-14 MELCHER Edition 1/96 - Melcher AG Phe Powe: PartaersRugged Environment Supplementary Data Isolation Input to output electric strength tests, in accordance with the safety standards IEC 950, EN 60950, VDE 0805 and EN 41003 are performed as factory tests and should not be repeated in the field. Table 1 4 Electric strength test voltage, insulation resistance, DC-DC Converters <100 W M-Family Important Advice sess by apehing A soe na will fesult in high and ty clair 3 resulting from. high legs field tests. Rel- erence is also made. to chapter: Safety and Installation Instructions. clearance and creepage distances Inpuvoutput | npu inpudiCase: | Output/Case Output/Output) Unit ance a) Bb) a) by | a). by aay 8} a) b) Electric strength DC: 1s 42431) 56001 | 2122 , 2800 | 4243 |se00 | 707 | 1414, | goo Vv ML test voltage AC:50Hz,tmin |30001! 40001 | 1500 ; 2000 | 3000 | 4000 | 500 | 1000/ - | 200 Insulation resistance | at 500 V DC - 2300 - 2300 - 2300 - >100 - - MQ Clearance and AM/BM 4.0 5.0 2.0 4.0 4.0 5.0 1.0 2.0 - 0.9 mm Creepage distances [> imandcy/D/LMz| 40 | 80 | 20 | 40] 40 | 50 | 10 20/ - | o9 1 Only subassemblies performance in accordance with IEC 950 Leakage Currents in AC-DC operation Leakage currents will flow due to internal leakage capa- citances and RFI suppression Y-capacitors. The current values are proportional to the mains voltage and nearly pro- portional to the mains frequency and are specified at an in- put condition of 264 V/50 Hz where phase, neutral and pro- tective earth are correctly connected as required for class | equipment. Under test conditions the leakage currents flow 77 MD for earth = teakage current 1. MD for output leakage current MD || 150 nF | - Table 15: Leakage currents through a measurement circuit, consisting of a 1500 Q re- sistance with a 150 nF capacitor connected in parallel. The voltage drop across this element is measured and the cur- rent value caicuiated from the measured voltage divided by 1500 Q. lf inputs of M-units are connected in parallel, their individual leakage currents are added. ~ 0 yt : LMZ1000...LMZ 3000 (63) to ~ O T connection to case { + MD for enclosure - leakage current L MD for output nee - leakage current Fig. 12 Definition of leakage currents and measurement proce- dure by means of the measuring device MD Unit Earth leakage current mA Enclosure leakage current : i san a | Output leakage current 0.25 0.005 0.25 0. 15 Edition 1/96 - Melcher AG 7-15 f Phe MEL CHER RarknersM-Family Display Status of LEDs Up; > 0.95...0.98Up4 aaj * > ur r t T min Uoy U abs U max Ups > 0.95...0.9BUg; ag) Up < 0.95...0.98U py ag Te max Tero threshold Unn threshoid a UY, inh -30 V +408V 42.4V [7 LED off #3 LED Status undefined +50 V Mma LED on Description of Options Table 16: Survey of options DC-DC Converters <100 W Rugged Environment Fig. 13 LEDs "OK" and "i" status versus input voltage Conditions: ly < lo nom, Te S Tomax, Uinn S 0.8 V Uw = undervoitage lock-out, U; oy = overvoltage lock-out LED "OK" and "I, "status versus output current Conditions: Uj min...Ui max, To S$ To max, Uinn $ 0.8 V LED "i"versus case temperature Conditions: Uj min...Uj max fo S lo nom, Uinh $ 0.8 V LED "i"versus Vinh Conditions: U; min. Uj max to S$ fo nom, Te $ Te max Option | Function of Option _____| Characteristic - Extended operational ambient temperature range Ta= 40...71 C E Electronic inrush current limitation circuitry Extended inrush current limitation for C/E/LM, C/LMZ P Potentiometer for fine adjustment of output voltage Adjustment range +5% of Up nom, excludes FR input D? Input and/or output undervoitage monitoring circuitry | Safe data signal output (DO...D9) yea Input and/or output undervoltage monitoring circuitry | ACFAIL signal according to VME specifications (VO, V2, V3) A Test sockets at front panel for check of output voltage | U, internally measured at the connector terminals H Enhanced output to case electric strength test voltage | 2000 V AC (standard: 1000 V AC) F Input fuse built-in inside case Fuse not externally accessible U UL recognized full ambient temperature range Fuil temperature range according to temperature suffix 1 Function R excludes option P and vice versa 3 Only available if main output voltage Up; = 5.1 V Option -9 Extended temperature range Option -9 extends the operational ambient temperature range from 25...71C (standard) to 40...71C. The power supplizs provide full nominal output power with convection cooling. Option A Test sockets Test sockets (pin @ = 2 mm, distance d = 5.08 mm) are Io- cated at the front of the module. The output voltage is sensed at the connector pins inside the module. Table 17: Configuration of option A and option P 2 Option D excludes option V and vice versa Option P Potentiometer Optionally built-in multi-turn potentiometers provide an out- put voltage adjustment range of minimum +5% of Ub nom and are accessible through holes in the front cover. Com- pensation of voltage drop across connector and wiring be- comes easily achievable. For output voltages Up > Us nom, the minimum input voltage according to "Electrical Input Data" increases proportionally to Up/Uo nom- Note: Potentiometers are not recommended for mobile ap- plications Tye opin Potentiometer * yes yes yes yes no no Test sockets yes yes yes yes no no 1 AM...LM 1000 types equipped with option P do not provide the R input simultaneously, pins 14 and 17 are not connected. 7-16 The MELCHER Edition 1/96 - Melcher AG Power Partners,Rugged Environment Option E Extended inrush current limitation Available for C/E/LM and C/LMZ types. The siandard version of the modules C/D/E/LM as well as C/D/LMZ include a passive inrush current limitation in the form cf a NTC resistor. For applications which require an extended inrush current limitation, an active electronic circuit as shown in Option E block diagram" has been developed. Typical inrush current waveforms of units equipped with this option are shown below CM and CMZ units meet the CEPT/ETSI standards for 48 V DC supply voltage according to prETS 300132-2 if fit- ted with option E combined with option D6 (input voltage Table 18: Inrush current characteristics with option E DC-DC Converters <100 W M-Family monitoring). Option D6, externally adjustable via poten- tiometer, is necessary to disable the converter at input volt- ages below the actual service ranges, avoiding an exces- sive input Current when the input voltage is raised slowly according to prETS 300132-2. Option D6 threshold level Ui; + Uni (refer to description of option D) should be adjusted to 36.0...40.5 V for 48 V DC nominal supply voltage (for 60 V DC systems, threshold should be set to 44.0...50.0 V DC). The D output (pin 5) should be connected to the inhibit (pin 2). For applications where potentiometers are not al- lowed refer to option D9. Chatacteristic 4 CMICMZ EM: 7 LM/LMZ Unit | CM/CMZ/EM at r= 110V DC | . ae ae : : : Og : LM/LMZ at U: = 230 VAC eh Ayo max typ max typ max : hor p Peak inrush current 6.5 8 2.2 4 6 10 A tine Inrush current duration 22 30 19 30 35 50 ms Precautions: In order to avoid overload of the series resistor R; the on/off switching cycle should be limited to 12 s if switched on/off continuously. There should not be more than 10 start-up cycles within 20 s at a case temperature of 25C. lf CM and CMZ types are driven by input voltages below 35 V DC or LM and LMZ types below 100 V AC, the maxi- mum case temperature should be derated by 10 K or the to- tal output power should be derated by 20%. EM, LM and LMZ units driven by DC input voltages do not need to be tT Control = ! [FET: 1 ! ' tet Tesh Rectifier (LM/LMZ types) Ag A C; ra o = ub ~ > Q c Converter derated within the full specified input voltage range. Fig. 14 Availahility: Option E block diagram Optior: E is available for C/E/LM and CMZ/LMZ modules with a nominal output power of 51 W maximum. AIA, 4 IA} LM type 12 4 A /% Us = 230 VAC fnrp =U/ (Agt+Fi) 6 - Po nom 10 Capacitor C, 4 4 / fully charged CM type Normal operation 8- / {U= 110 voc 2 | (FET fully conducting) Yv / Po= Ponom A A N e\ / EM type Capacitor C; 9 rt V V / U=110V DC fully charged | / Pe = = Po nom Normal operation 2 ay / (FET fully conducting) nd 4 2, h=Poiyen 6 _ | r | petims) | | | rot imsl 0 10 20 tine 30 40 0 20 tn 40 60 80 Fig. 15 Fig. 16 Typical inrush current waveforms of a CM and an EM type Typical inrush current waveform of a LM type Edition 1/96 - Melcher AG MELCHER 7-17 Tae a Power Partners OrsM-Family Option D Undervoltage monitor The input and/or output undervoltage monitoring circuit op- erates independently of the built-in input undervoltage lock- out cirsuit. A logic "low" (JFET output) or "high" signal (NPN output) is generated at pin 5 as soon as one of the moni- tored voltages drops below the preselected threshold level U4. Tha return for this signal is Yo1 (pin 23). The D output recovers when the monitored voltage(s) exceed(s) U+Up. Table 19: Undervoltage monitor functions DC-DC Converters <100 W Rugged Environment The threshold level U4 is either adjustable by a potentio- meter, accessible through a hole in the front cover, or is fac- tory adjusted to a fixed value specified by the customer. Option D exists in various versions DO...D9 as shown in the following table. FET | NPN (-etthr . of po : ae Be In Us D1 D5 no yes - 3.5 V..48V! - 23.4 De D6 yes no Uys min. Ui max | - 3.0...0.5 - D2 D7 yes yes Uy min. Uj max! 0.95...0.98 Uo 2 3.0...0.5 *o" D4 Ds no yes - 0.95...0.98 Uoi? - "o" | De D9 no yes - 3.5 V...48V3 - 18.1 yes no U; min. Uj max 24 - 2.2...0.4 - [ yes yes U; min. Uj max 34 0.95...0.98 Uo1 2 2.2...0.4 "o" ' Threshold level adjustable by potentiometer (not recommended for mobile applications) 2 Fixed value between 95% and 98% of Up; (tracking) 3 Fixed value, resistor-adjusted according to customer's specifications +2% at 25C; individual type number is determined by Meicher 4 Adjusted at fy nom JFET output (D0...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 (Uj and/or U1) < U4. The cur- rent f, 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 exterr-al overvoltages. Uj, Ur status U;, or Uo, < Uy U, and Ug; > Ur + Un D output, Up low, L, Up $ 0.4 V at Ip = 2.5 mA high, H, /p $ 25 pA at Up = 5.25 V NPN cutput (D5...D9): Connector pin D is intemally 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 (U4 and/or Up1) > Uy + Up. The current /p through the open collector should not exceed 20 mA. The NPN cutput is not protected against external overvoltages. Up should not exceed 40 V. Uj, Up1 status Uj or Ug < U; Uj and Uo1 > Ur+ Un D output, Up high, H, Ip $25 pA at Up = 40 V low, L, Up $0.4 V at Ip = 20 mA | Fig. 17 ig. 18 Options D5...D9, NPN output MELCHER Edition 1/96 - Melcher AG The Power PartaersRugged Environment DC-DC Converters <100 W M-Family Threshold tolerances and hysteresis: Up AU; Ui If U, is monitored, the internal input voltage after the input j filter and rectifier (E/LM and LMZ types) is measured. Con- Up righ sequently this voltage differs from the voltage at the con- nector pins by the voltage drop AU, across input filter and rectifier. The threshold level of the DO and D9 options is fac- oy ore a onom P, nom tory adjusted at nominal output current fy nom and at Ta = ae a 25C. The value of AU depends upon the input voltage range AM, BM, ...}, threshold level U4, temperature and in- Uo iow put current. The input current is a function of the input voit- U eu, age ard the output power. Fig. 19 i Definition of Uj, AU; and U,i (JFET output) input voltage monitoring NPN U, Uriah + Up low 0 Io ongh 15 sm 0 JFET Up Up hh Ub tow 0 Uy) os nem 1 0.95 0 U, [VDC] Oy +, th ~ {nput voltage failure Switch-on cycle Input voltage sag Switch-on cycle and subsequent . input voltage failure Output voltage monitoring NPN U, Upngh f--- ~~~ - =f i i t T 5 ' t al i L b iw 4-H 1 See El. output data", for hold-up time. 2 With output voltage monitoring the hold-up time f, = 0 3 The D signal remains high if the D output is connected to an external source. 4 flow min = 40...200 ms, typically 80 ms Output voltage failure Fig. 20 Relationship between U,, Uoi, Up, fp and Uo1/Us nom versus time. Edition 1/96 - Melcher AG MELCHER 7-19 The Powe: PartnersM-Family Option V ACFAIL signal (VME) Availadle for units with Up; = 5.1 V. This option defines an undervoltage monitoring circuit for the input or the input and main output voltage equivaient to option D and generates the AGFAIL signal (V signal) which conforms to the VME standard. The low state level of the ACFAIL signal is speci- fied at a sink current of ly = 48 mA to Ly < 0.6 V (open-col- lector output of a NPN transistor). The pull-up resistor feed- ing the open-collector output should be placed on the VME backpiane. After the ACFAIL signal has gone low, the VME standard requires a hold-up time , of at least 4 ms before the 5.1 V outpu' drops to 4.875 V when the 5.1 V output is fully loaded. This hold-up time t, is provided by the internal input capac'tance. Consequently the working input voltage and the threshold level U;; should be adequately above the minimum input voltage Umin of the converter so that enough energy is remaining in the input capacitance. If the input voltage is below the required level, an external hold- up capacitor (Cj ex) should be added. Formcla for threshold level for desired value of t,: 2 Py (ty + 0.3 ms) 100 uy=|/-2rPar teem) 1, Ui min? amin DC-DC Converters <100 W Rugged Environment Formula for additional external input capacitor 2 Po (tf) + 0.3 ms) 100 Cron = rex 7 (Ui? ~ Up min?) 7 C; min where as: Ci min = minimum internal input capacitance [mF], accord- ing to the table below Ciext = external input capacitance [mF] P, = output power [W] 7 = efficiency [%] t, = hold-up time [ms] Ui min = minimum input voltage [V] U,, = threshold level [V] Remarks: The threshold level U4; of option V2 and V3 is ad- justed during manufacture to a value according to the table below. A decoupling diode should be connected in series with the input of A...D/FM converters to avoid the input ca- pacitance discharging through other loads connected to the same source voitage. If LM or LMZ units are AC powered, an external input capacitor cannot be applied unless an ad- ditional rectifier is provided. Table 20: Available internal input capacitance and factory potentiometer setting of U,; with resulting hold-up time Types AM BM FM _ CMICMZ DM/DMZ em LM/LMZ- | Unit Gi min 2.6 0.67 0.37 0.37 0.14 0.14 0.14 mF i 95 19.5 39 39 61 104 120 VDC fh 0.34 0.69 2.92 1.92 1.73 6.69 8.18 ms Optior: V operates independently of the built-in input under- voltage lock-out circuit. A logic "low" signal is generated at pin 5 2s soon as one of the monitored voltages drops below the preselected threshold level U4. The return for this signal is Vot - (pin 23). The V output recovers when the monitored Table 21: Undervoitage monitor functions voltage(s) exceed(s) U,+ Up. The threshold levei U, is either adjustable by a potentiometer, accessible through a hole in the front cover, or is factory adjusted to a determined cus- tomer specified value. Versions VO, V2 and V3 are available as shown below. V.output Monitoring Minimum adjustment range Typical hysteresis U,[% of Ui} (VME compatible) |. 2) of thresheld level U, 7 $68 Ut ental ran Uj Uor Oy he Oni : Uno v2 yes no Ui mine Ui max | - 3.0...0.5 vgs*dC'~Sses yes Uh mines Oi max | 0.95...0.98 Up 2 3.0...0.5 "9" vo yes no Ui min. Ui max 34 - 2.2.0.4 yes yes Ui nin Ui max 34 0.95...0.98 Us; 2 2.2...0.4 *Q" ' Threshold level adjustable by potentiometer (not recommended for mobile applications). ? Fixed value between 95% and 98% of Us; (trackir-g), output undervoltage monitoring is not a requirement of VME standard. 3 Adjusted at by nom- 4 Fixe: value, resistor-adjusted (2% at 25C) acc. to customer's specifications; individual type number is determined by Melcher. V output (VO, 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- sponcs to a monitored voltage level (U; and/or Up1) < Ui. The current /y through the open collector should not exceed 50 mA. The NPN output is not protected against external overvoltages. Uy should not exceed 80 V. Voutput, Uy low, L, Uy < 0.6 V at ly = 50 mA high, H, fy $25 pA at Uy = 5.1 V U, Up; status U; or Ug < U; U; and Us; > Ur + Un Fig. 21 Output configuration of options VO, V2 and V3 7-20 m1 MELCHER The Power Pormors Edition 1/96 - Melcher AGRugged Environment DC-DC Converters <100 W M-Family Threshold tolerances and hysteresis: If Uis monitored, the internal input voltage is measured af- Uy AU, i Uni ter the input filter and rectifier (E/LM and LMZ types). Con- { sequently this voltage differs from the voltage at the con- high nector pins by the voltage drop AU; | across input filter and rectifier. The threshold level of option VO is factory adjusted o 5 o at lonom and Ta = 25C. The value of AU;; depends upon the C a i input voltage range (AM, BM, ...), threshold level U;;, tem- " perature and input current. The input current is a function of input voltage and output power. Wow onom Pies Y " om U, Fig. 22 ui Definition of Uj, AU, and Up Input voltage monitoring 2 2 3 v2 ou fow min bow min how min v at tot et Oy royh Gor Fe 0 ' team? v3 ou, 1) ema Dy high sq - == apes ze EBA BA Win Lo BZ | denen ee Input voltage failure Switch-on cycle Input voltage sag Switch-on cycle and subsequent input voltage failure Output voltage monitoring v2 ly, Worn 4 v4 vo v ' VME request: minimum 4 ms / 2 tow min = 40...200 ms, typically 80 ms At 3 Uy level not defined at Up, < 2.0 V Uj t Uqp po 222222222 ee eo eee we eee eee ee ee eee eee 4 The V signal drops simultaneously with the output voltage, if the Uy poccenr ccc tna pull-up resistor Ap is connected to Vo1+. The V signal remains ze high if Ap is connected to an external source. 0 Fig. 23 Output voltage failure Relationship between Ui, Us, Uy, ly and Up1/Us nom versus time. veer Porters Edition 1/96 - Melcher AG @) MELCHER 7-21 Phi BlyM-Family Option F Fuse not accessible The standard M units have a fuseholder containing a 5 x 20 mm fuse which is externally accessible and to be found in the back plate near the connector. Some applications re- quire an inaccessible fuse. Option F provides a fuse mounted directly onto the main PCB inside the case. The fuil self-protecting functions of the module do normally not lead to broken fuses, except as a result of inverse polar- ity at tne input of an A/B/C/D/FM or C/DMZ type or if a power component inside fails (switching transistor, free- wheeling diode, etc). In such cases the defective unit has to be returned to Melcher for repair. immunity to Environmental Conditions Table 22: Mechanical stress DC-DC Converters <100 W Rugged Environment Option U UL Version Underwriters Laboratories (UL) have approved the M se- ries converters as recognized components up to an ambi- ent temperature of Ta max 15 K given by the upper tem- perature limit of the standard PCB material. If the full maxi- mum ambient temperature Ta max is required with UL ap- proval, option U should be requested. It consists of an alter- native PCB material with a higher maximum temperature specification. The European approval boards have in contrast accepted the converters with the standard PCB material to be ope- rated up to Ta max without any further precautions. Ca Damp heat DIN 40046 part Temperature: 402C steady state IEC 68-2-3 Relative humidity: 93 12/3.% MIL-STD-810D section 507.2 Duration: 56 days Unit not operating Ea Shock DIN 40046 part 7 Acceleration amplitude: 100 gn = 981 m/s? (half-sinusoidal) IEC 68-2-27 Bump duration: 6 ms MIL-STD-810D section 516.3 Number of bumps: 18 (3 each direction) Unit operating Eb Continuous shock DIN 40046 part 26 Acceleration amplitude: 40 gn = 392 m/s? (half-sinusoidal) {EC 68-2-29 Bump duration: 6ms MIL-STD-810D section 516.3 Number of bumps: 6000 (1000 each direction) Unit operating Fe Vibration DIN 40046 part 8 Frequency (1 Oct/min): 10...2000 Hz (sinusoidal) IEC 68-2-6 Maximum vibration amplitude: 0.35 mm (10...60 Hz) MIL-STD-810D section 514.3 Acceleration amplitude: 5 gn = 49 m/s? Test duration: 7.5 h (2.5 h each axis) Unit operating Fda | Random vibration DIN 40046 part 23 Acceleration spectral density: 0.05 g?/Hz wide band IEC 68-2-35 Frequency band: 20...500 Hz reproducibility high Acceleration magnitude: 4.9 Orns Test duration: 3h (1 heach axis) Unit not operating Kb Salt mist DIN 40046 part 105 Concentration: 5% (30C) cyclic IEC 68-2-52 Duration: 2h per cycle (sodium chloride NaCl Storage: 40C, 93% rel. humidity solution) Storage duration: 22 h per cycle Number of cycles: 3 Unit not operating 7-22 MELCHER Edition 1/96 - Melcher AG The Power PartnersRugged Environment Thermal considerations Table 23: Temperature specttications, values given are for an air pressure of 800... 1200 hPa (800... 1200 mbar) DC-DC Converters <100 W M-Family | Characteristic : Ta Standard operational ambient temperature range -7, (MIL- STD. 810D sections 501.2 and 502. 2) 25 71 C | Ta 1 Extended operational ambient temperature range -9, (MIL-STD-810D sections 501.2 and 502.2) 40 71 [vA : Te | Standard operational case temperature range -7, overtemp. lock-out (PTC) at Te > 95C ~-25 95 Tc | Extended operational case temperature range -9, overtemp. lock-out (PTC) at Tc > 95C 40 95 Ts Storage temperature range -7, (MIL-STD-810D sections 501.2 and 502.2) ~40 100 | Ts Extended storage temperature range -9, (MIL-STD-810D sections 501.2 and 502.2) -55 100 | Basically the available output power is limited by thermal fonom [%I characteristics. Customer specific applications requiring slightly higher output power, i.e. increased voltages or cure ''0 o nom (forced cooting) rents, are available on request. Usually the maximum ambi- 100 -~=--_____.-- ---- +--+ 4 ent and case temperatures are reduced compared with 90 -; A + . .. oO nom standard types. Operation at higher temperatures with 80 each output > nominal output currents is also possible if forced cooling 79 (convection cooling) can be provided (heat sink, fan, etc.). 60 Example: Sufficient forced cooling allowsTa max = 85C.A gg To max simple check of the case temperature Tc (Tc < 95C) at full 40 ' load ensures correct operation of the system (temperature ; measurement point on the case see "Mechanical Data"). 30 ~ In gereral: For an ambient temperature of 85C with only 20 convection cooling, the maximum permissible current for = 19 i 2 4 7 . QO 3-1_~.--~-_____-..... Li le T, C each output is approx. 50% of it's nominal value for -7 or ma. 50 60 70 50 90. 100 a (C] -9 units as per figure. Table 24: MTBF Fig. 24 Output derating versus ambient temperature under con- vection and forced cooling conditions wee Ground Benign: . - Ground Mobile Unit ee ' BOG ae Of bee BORG : a A...LM 1000 and C/D/LMZ 1000 320'000 130'000 40'000 35) 000 h A...LM 2000 and C/D/LMZ 2000 | 255'000 105'000 32'000 23'000 A...LM 3000 and C/D/LMZ 3000 225'000 80'000 = 28'000 25'000 Device hours 2 A...LM 1000 and C/D/LMZ 1000 880'000 A...LM 2000 and C/D/LMZ 2000 720'000 A...LM 3000 and C/D/LMZ 3000 740'000 | _| 1 Calculated in accordance with MIL-HDBK-217E (calculation according to edition F would show even better resuits) 2 Statistical values, based on an average of 4300 working hours per year and in general field use, over 3 years Edition 1/96 - Meicher AG MELCHER 7-23 The Power PorinersM-Family DC-DC Converters <100 W Rugged Environment Mechanical Data 5 Dimensions in mm. Tolerances +0.3 mm unless otherwise indicated. European Projection Mounting holes for retaining clips V {-~---- Male connector H 11 according to DIN 41 612 (Gold plated contacts on customer's request) Front plate Fr \ mre ane Ly 5 os 103 i me sean el N I \ 1 4-}@l- --- ee ee ee _ ro l B == M 3; depth = 4 mm | ; i (chassis mount) | i ! : ' i Main face Rear face I i + __ ! | | | bys Zz to | ,|2 nm: OD I . 28 N ; |!) Measurement point for a i Be tTR case temperature 7, - pLo tN | r e- | \ | \ I | I \ t ' 2 | 1 ' | 1 ' | Op eT 9 i | Mounting plane of ' connector H11 4---|- +e -------- ra ype 1 y , : Teel | Lire (11.6) 88 + aa 7 Back plate | oO oO ost e & Loo -9G- : | OK (LED green) 4 L 1, (LED red) Inhibit i (LED red) Test sockets (option A) Poteritiometer (option D) Potentiometer(s) (option P) or potentiometer (option V) Fig. 2& Note: Long case, elongated by 60 mm for 220 mm rack Case (402, weight 770 g (approx.) depth, is available on request. 7-24 MELCHER Edition 1/96 - Meicher AG The Power PartnersRugged Environment DC-DC Converters <100 W M-Family Type Key and Product Marking Type Key Input voltage range U;: 8...35 V DC 14...70V DC .... 20...100 V DC .... 28...140V DC .... 44...220 V DC .... 67...385 V DC 85...264 V AC, 88...372 V DC Family Class li Equipment .... Blank .... Number of outputs .... Output 1, Usi nom! 5.1V 12V 15V.... 24V.... other voltages .... 48 V other specs for single output modules ...... 01...99 Output 2 and 3, Uso nom: Yos nom: B.AV ow. 01...19 12V 00. 20...39 1BV ow. 40...59 24V ow... 60...69 other voltages for multiple output modules ...... 70...99 Ambient temperature range Ty: ~25...71C we. 7 (operational) 40...71C ee -9 customer specific ........ -0...-6 Output voltage control input (single output moduies only) R2 Options: Inrush current limitation (C/E/LM and C/LMZ only) ......... E Potentiometers for fine adjustment of output voltages ..... P 2 Save data signal (DO...D9, to be specified)... D3 ACFAIL signal (VO, V2, V3, to be specified) 00... vs Output voltage test sockets ........ eee . Increased electric strength test voltage (O/C). . Input fuse built-in (not accessible) .............. wi F UL recognized component for Tp may ccs tessseeereeees U 1 EM types upon custom specifications available 2 Feature A excludes option P and vice versa 3 Option D excludes option V and vice versa Example: CM 2540-7PD3A: DC-DC converter, input voltage range 28...140 V, providing output 1 with 15 V/1.7 Aand output 2 with 15 V/1.7 A; equipped with potentiometers, undervoltage monitor and test sockets. Accessories: Front panels, female connectors, mounting facilities, etc. please refer to section Accessories". Product Marking (refer also to Mechanical Data") Main face: Basic type designation, applicable safety approval and recognition marks, warnings, pin allocation, Melcher patents and company logo. Front plate: Identification of LEDs, optional test sockets and potentiometers. Back plate: Specific type designation, input voltage range, nominal output voltage(s) and current(s), pin allocation of op- tions 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 of the main PCB, date of production. Confirmation of successfully passed final test. Edition 1/96 - Meicher AG MELCHER 7-25 The Power Partners