Benign Environment AC-DC Converters >100 W VRW-Family
Edition 2/96 - © Melcher AG 11 - 99
MELCHER
The Power Partners.
11.3
150 / 200 / 300 / 450 W AC-DC Conver ters VRW-Family
Single output
• Universal AC input (VRW 200, VRW 300, VRW 450)
• 3000 Vrms input to output isolation
• Compact design
• Excellent line/load regulation
• High efficiency
Safety according to IEC 950
Table of Contents Page
Type Survey ............................................................11 - 99
Description ..............................................................11 - 99
Safety and Installation Instructions .......................11 - 100
Electromagnetic compatibility EMC.......................11 - 100
Electrical Input and Output Data ...........................11 - 101
Operation Instructions ........................................... 11 - 104
Mounting Instructions ............................................ 11 - 105
Immunity to Environmental Conditions.................. 11 - 106
Type Key and Product Marking ............................. 11 - 106
Mechanical Data, Input and Output Terminals ...... 11 - 107
Type Survey
Table 1: Type survey
Output configuration Input voltage Rated power Type designation
U
o nom
I
o nom range
P
o tot Open frame Chassis cover
[V DC]
T
A = 40°C [A]
U
i min...
U
i max
T
A = 40°C [W]
3 40 120 VRW 200-03 VRW 200-03A
60 180 VRW 300-03 VRW 300-03A
5 30 150 VRW 150-05 VRW 150-05A
40 VRW 150: 200 VRW 200-05 VRW 200-05A
60 85...132 V AC 300 VRW 300-05 VRW 300-05A
90 or 170...265 V AC 450 VRW 450-05 VRW 450-05A
12 13 47...440 Hz 150 VRW 150-12 VRW 150-12A
19 230...330 V DC 200 VRW 200-12 VRW 200-12A
26 jumper selectable 300 VRW 300-12 VRW 300-12A
40 450 VRW 450-12 VRW 450-12A
15 10 150 VRW 150-15 VRW 150-15A
15 200 VRW 200 -15 VRW 200-15A
21 VRW 200, VRW 300 300 VRW 300-15 VRW 300-15A
32 VRW 450: 450 VRW 450-15 VRW 450-15A
24 6.5 85...265 V AC 150 VRW 150-24 VRW 150-24A
9 200 VRW 200-24 VRW 200-24A
13 47...63 Hz 300 VRW 300-24 VRW 300-24A
20 PF = 0.95 450 VRW 450-24 VRW 450-24A
28 4.5 150 VRW 150-28 VRW 150-28A
48 3.2 150 VRW 150-48 VRW 150-48A
Description
The VR W family of s witching power supplies is a single out-
put family of AC-DC converters. Compact size and high re-
liability make the VRW family an excellent choice. Five
standard single output ratings are available. All types have
sense lines, the VRW 300 and VRW 450 provide also for
inhibit function. The units are UL 1950 (D3), CSA 1402C
und EN 60950 approved.
Key applications
Factory automation, test and measurement, point-of-sales
and communications equipment.
VRW-Family AC-DC Converters >100 W Benign Environment
11 - 100 Edition 2/96 - © Melcher AG
MELCHER
The Power Partners.
11.3
Safety and Installation Instructions
Safety
If the output circuit of an AC-DC conver ter is operator-ac-
cessible according to the IEC 950 related safety standards,
it shall be an SELV circuit (Safety Extr a Low Voltage circuit,
i.e. a circuit, separated from mains by at least basic insula-
tion, that is so designed and protected that under normal
and single fault conditions, the voltage between any two
conductors and between any conductor and earth does not
exceed 60 V DC).
In the following section an interpretation is provided of the
IEC 950 safety standard with respect to the safety status of
the output circuit. Howev er , it is the sole responsibility of the
installer or user to assure the compliance with the relevant
and applicable safety standards:
If the AC-DC con verter is installed acoording to the relev ant
safety regulations, its output is considered to be an SELV
circuit up to a nominal output voltage of 36 V, provided the
output is connected to ground according to the relevant
safety standard, a suitable input line fuse is installed and an
adequate voltage limiting device is connected across the
output.
Installation instruction
Installation of the power supply m ust 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 or terminal block.
Other installation methods may not meet the safety require-
ments. At least one external fuse, installed in the wiring to
the input is essential!
Table 2: Immunity type tests
Phenomenon Standard Class Coupling Value Waveform Source Test In Per-
Level mode 3 applied Imped. procedure oper. form.
Electrostatic IEC 801-2 4 air discharge 15 kVp1/50 ns 330 Ω10 positive and yes 1
discharge (1991-04) to frame 10 negative
discharges
Fast transient/ IEC 801-4 3 i/c, +i/–i 2000 Vp5/50 ns 50 Ω1 min positive yes 1
burst (1988) 1 min negative
bursts per
coupling mode
Transient IEC 801-5 4 i/c 4000 Vp1.2/50 µs 12 Ω5 pos. and 5 neg. yes 21
(Draft 1993-01 ) impulses per
coupling mode
1Normal operation, no deviation from specifications
2No load
3 i = input, o = output, c = case
Electromagnetic compatibility EMC
Immunity
A metal oxide VDR together with an input fuse and an input
filter form an effective protection against high input tran-
sient voltages which typically occur in most installations,
but especially in battery driven mobile applications. The
VRW family has been successfully tested to the following
specifications:
Emission
Suitable input filtering keeps the conducted noise of the
units within the frequency range of 10 kHz to 30 MHz belo w
level B according to EN 55011 and EN 55022 standards
(CISPR 11/22 respectively). In some applications, it ma y be
necessary to add an external input filter to reach level B.
Refer also to table "Input Data".
Benign Environment AC-DC Converters >100 W VRW-Family
Edition 2/96 - © Melcher AG 11 - 101
MELCHER
The Power Partners.
11.3
Electrical Input and Output Data
General Condition:
T
A = 25°C unless otherwise specified
Table 3: Input data
Characteristics VRW 150-.. VRW 200-.. VRW 300-.. VRW 450-.. Unit
U
i rated Rated input voltage 100-120/200-240 100-120/200-240 V AC
U
iInput voltage range 85...132/170...265 1 85...265
230...330 2 –V DC
f
i
Line frequency 47...440 47...63 Hz
I
iInput current 3 100/200 V AC 3.2/1.7 3.0/1.5 4.0/2.0 6.2/3.1 A
l
inr Inrush current 3100/200 V AC 15/30 14.0/28.0 14/28 14/28
PF Power Factor 3 – 0.95
I
i leak Leakage current 3 100/200 V AC 0.25/0.40 0.6/0.4 0.6/0.4 0.8/0.4 mA
U
i RFI Input RFI level EN 55011/22 B B B B
1Jumper selectable.
2Terminals A and B not connected.
3At rated input and output.
General Condition:
T
A = 25°C unless otherwise specified
Table 4a: Output data 150 W types
Type VRW 150-05 VRW 150-12 VRW 150-15
Characteristics Unit
U
o nom Output voltage nom. 5 12 15 V
U
o adj Adjustable voltage range ±10 %
I
o nom Rated output current 30 13 10 A
I
oOutput current range min./max. 0...100 %
u
oRipple-noise 1 max. 120 150 150 mVpp
∆
U
o U Line regulation
U
i min...
U
i max ±0.4 %
∆
U
o I Load regulation 0...100% ±0.8
α
u
oTemperature coefficient max. ±1
I
o L Overcurrent protection 2 105
U
o L Overvoltage protection 3 5.75...6.75 13.8...16.2 17.3...20.3 V
t
Uo r Rise time 1 typ. 20 ms
t
hHold-up time 1 typ. 20
η
Effciency 1 typ. 78 80 82 %
Output indicator not provided
Outputs connected in series possible
Outputs connnected in parallel not possible
Remote sensing possible
Remote shut-down not possible
1At rated input and output.
2Operating in foldback method, automatic recovery. Overload for more than 30 seconds should be avoided.
3Shut down of output. Turn-on by br ief removal of the input voltage. Over voltage protection is not adjustable.
VRW-Family AC-DC Converters >100 W Benign Environment
11 - 102 Edition 2/96 - © Melcher AG
MELCHER
The Power Partners.
11.3
General Condition:
T
A = 25°C unless otherwise specified
Table 4b: Output data 150 W types
Type VRW 150-24 VRW 150-28 VRW 150-48
Characteristics Unit
U
o nom Output voltage nom. 24 28 48 V
U
o adj Adjustable voltage range ±10 %
I
o nom Rated output current 6.5 4.5 3.2 A
I
oOutput current range min./max. 0...100 %
u
oRipple-noise 1 max. 150 150 200 mVpp
∆
U
o U Line regulation
U
i min...
U
i max ±0.4 %
∆
U
o I Load regulation 0...100% ±0.8
α
u
oTemperature coefficient max. ±1
I
o L Overcurrent protection 2 105
U
o L Overvoltage protection 3 27.6...32.4 32.2...37.8 55.2...64.8 V
t
Uo r Rise time 1 typ. 20 ms
t
hHold-up time 1 typ. 20
η
Effciency 1 typ. 84 84 84 %
Output indicator not provided
Outputs connected in series possible
Outputs connnected in parallel not possible
Remote sensing possible
Remote shut-down not possible
1At rated input and output.
2Operating in foldback method, automatic recovery. Overload for more than 30 seconds should be avoided.
3Shut down of output. Tur n-on by br ief removal of the input voltage. Overvoltage protection is not adjustable.
General Condition:
T
A = 25°C unless otherwise specified
Table 4c: Output data 200 W types
Type VRW 200-05 VRW 200-12 VRW 200-15 VRW 200-24
Characteristics Unit
U
o nom Output voltage nom. 5 12 15 24 V
U
o adj Adjustable voltage range ±10 %
I
o nom Rated output current 40 19 15 9 A
I
oOutput current range min./max. 0…100 %
u
oRipple-noise 1 max. 150 180 180 240 mVpp
∆
U
o U Line regulation
U
i min…
U
i max ±0.4 %
∆
U
o I Load regulation 0…100% ±0.8
α
u
oTemperature coefficient max. ±1
I
o L Overcurrent protection 2 42.0...50.0 19.9...23.7 15.7...18.7 9.4...11.2 A
U
o L Overvoltage protection 3 6.0…7.0 14.4…16.8 18.0…21.0 28.0…32.0 V
t
Uo r Rise time 1 typ. 20 ms
t
hHold-up time 1 typ. 20
η
Effciency 1 typ. 75 77 78 81 %
Output indicator not provided
Outputs connected in series possible
Outputs connnected in parallel not possible
Remote sensing possible
Remote shut-down possible
1At rated input and output.
2Operating in foldback method, automatic recovery. Overload for more than 30 seconds should be avoided.
3Shut down of output. Turn-on by br ief removal of the input voltage. Over voltage protection is not adjustable.
Benign Environment AC-DC Converters >100 W VRW-Family
Edition 2/96 - © Melcher AG 11 - 103
MELCHER
The Power Partners.
11.3
General Condition:
T
A = 25°C unless otherwise specified
Table 4d: Output data 300 W types
Type VRW 300-05 VRW 300-12 VRW 300-15 VRW 300-24
Characteristics Unit
U
o nom Output voltage nom. 5 12 15 24 V
U
o adj Adjustable voltage range ±10 %
I
o nom Rated output current 60 26 21 13 A
I
oOutput current range min./max. 0…100 %
u
oRipple-noise 1 max. 150 180 180 240 mVpp
∆
U
o U Line regulation
U
i min…
U
i max ±0.4 %
∆
U
o I Load regulation 0…100% ±0.8
α
u
oTemperature coefficient max. ±1
I
o L Overcurrent protection 2 63.0...75.0 27.3...32.5 22.1...26.2 13.7...16.2 A
U
o L Overvoltage protection 3 6.0…7.0 14.4…16.8 18.0…21.0 28.0…32.0 V
t
Uo r Rise time 1 typ. 50 ms
t
hHold-up time 1 typ. 20
η
Effciency 1 typ. 76 78 78 82 %
Output indicator not provided
Outputs connected in series possible
Outputs connnected in parallel not possible
Remote sensing possible
Remote shut-down possible
1At rated input and output.
2Operating in foldback method, automatic recover y. Overload for more than 30 seconds should be avoided.
3Shut down of output. Turn-on by brief removal of the input voltage. Overvoltage protection is not adjustable .
General Condition:
T
A = 25°C unless otherwise specified
Table 4e: Output data 450 W types
Type VRW 450-05 VRW 450-12 VRW 450-15 VRW 450-24
Characteristics Unit
U
o nom Output voltage nom. 5 12 15 24 V
U
o adj Adjustable voltage range ±10 %
I
o nom Rated output current 90 40 32 20 A
I
oOutput current range min./max. 0…100 %
u
oRipple-noise 1 max. 150 180 300 400 mVpp
∆
U
o U Line regulation
U
i min…
U
i max ±0.4 %
∆
U
o I Load regulation 0…100% ±0.8
α
u
oTemperature coefficient max. ±1
I
o L Overcurrent protection 2 94.5...103.5 42.0...46.0 33.6...36.8 21.0...23.0 A
U
o L Overvoltage protection 3 6.0…7.0 14.4…16.8 18.0…21.0 28.0…32.0 V
t
Uo r Rise time 1 typ. 50 ms
t
hHold-up time 1 typ. 20
η
Effciency 1 typ. 76 78 78 82 %
Output indicator not provided
Outputs connected in series possible
Outputs connnected in parallel not possible
Remote sensing possible
Remote shut-down possible
1At rated input and output.
2Operating in foldback method, automatic recover y. Overload for more than 30 seconds should be avoided.
3Shut down of output. Turn-on by brief removal of the input voltage. Overvoltage protection is not adjustable.
VRW-Family AC-DC Converters >100 W Benign Environment
11 - 104 Edition 2/96 - © Melcher AG
MELCHER
The Power Partners.
11.3
Operation Instructions
VRW 150: AC Input Voltage Range Selection
The AC input voltage range can be selected by means of
wiring at the connector barrier as per the following table:
Table 5: Input voltage range selection
Input voltage range Terminals A and B
85...132 V AC interconnected
170...265 V AC open
230...330 V DC (not connected)
Output Power Rating
The relation between the rated output power
P
o and the
ambient temperature
T
A is shown in fig. 1.
Output Voltage Adjustment
The output voltage may be adjusted within ±10% of
U
o nom
by means of the internal potentiometer . If the output voltage
setting should be excessively high, the overvoltage protec-
tion circuit may shut-down the output.
Output Overvoltage Protection
If the built-in overvoltage protection circuit becomes active,
the output is shut down and a reset can only be achieved by
brief removal of the input voltage after a minimum interval
time. The overvoltage threshold level is not adjustable.
Output Overload Protection
An overload condition at the output should not last for more
than 30 seconds. After removal of the overload, the over-
load protection circuit will automatically recover.
Sense Lines (S, VRW 200, VRW 300, VRW 450 series)
Remote sensing provides compensation of voltage drops
between power supply and load, caused by connectors and
load feeding wires. The sense lines should consist of
shielded cables or be twisted. If remote sensing is not
reqiured, the +S should be connected to the +V and the –S
to the –V terminals respectively applying shortest possible
links. The compensation r ange is 10% of
U
o nom.
Outputs Connected in Series
Two or more units supplying the same or different output
voltages may be connected in series. The value of the
maximum output current to be taken is defined by that unit
providing the lowest current limiting value. It should be as-
sured that the outputs do not feed backwards into each
other caused by their diff erent rise/f all times at switch-on/off
cycles by adding reverse polarity diodes across each out-
put.
0302010 40 50 60 70
60
100
P
O [%]
0
T
A
[°C]
–10–20
VRW 150
VRW 200/VRW 300/VRW 450
50
Fig. 2
Definition of inhibit voltage and current
Table 6: Inhibit characteristics
Characteristic Conditions min typ max Unit
U
inh Inhibit
U
o = on
U
i min…
U
i max –0.7 0.8 V
voltage
U
o = off 2.0 7
I
inh Inhibit sink curr.
U
inh = 0 6 mA
Fig. 1:
Output power vs. ambient temperature
Outputs Connected in Parallel
Parallel connection of several identical modules is not pos-
sible.
Inhibit (R, VRW 200, VRW 300 and VRW 450 series)
The output may be enabled or disabled by means of a logic
signal (TTL, CMOS etc.) or a mechanical contact applied to
the inhibit input which is isolated from input and output by
means of an opto-coupler. This provides independency
from other voltages polar ity. If the inhibit function is not re-
quired, connect the inhibit input +R to return pin -R to en-
able the output (active low logic, fail safe).
-R
I
inh
U
inh
L
N
+R
Benign Environment AC-DC Converters >100 W VRW-Family
Edition 2/96 - © Melcher AG 11 - 105
MELCHER
The Power Partners.
11.3
Mounting Instructions
VRW 150
Table 9: Output derating without chassis cover
for VRW 200, VRW 300 and VRW 450
T
ALoad
[°C] Mounting A Mounting B
Convection 40 100% 90%
cooling 50 80% 70%
60 60% 50%
Forced air 50 100% 90%
cooling 60 80% 70%
70 60% 50%
Mounting A
standard Mounting B Mounting C Mounting D
Fig. 3
Mounting instruction for VRW 150
Table 7: Output derating without chassis cover for VRW 150
T
ALoad
[°C] Mounting A Mounting B Mounting C Mounting D
30 100% 100% 100% 100%
40 100% 100% 100% 80%
50 100% 80% 80% 60%
60 50%40%40%40%
VRW 200, VRW 300 and VRW 450
Table 10: Output derating with chassis cover
for VRW 200, VRW 300 and VRW 450
T
ALoad
[°C] Mounting A Mounting B
Convection 30 80% 80%
cooling 40 80% 80%
50 60% 60%
Forced air 40 100% 90%
cooling 50 80% 70%
60 60% 50%
Mounting A
without cover Mounting B
without cover Mounting A
with cover Mounting B
with cover
Fig. 4
Mounting instruction for VRW 200, VRW 300, VRW 450
Table 8: Output derating with chassis cover for VRW 150
T
ALoad
[°C] Mounting A Mounting B Mounting C Mounting D
30 100% 100% 100% 100%
40 100% 70% 70% 70%
50 80% 60% 60% 60%
60 40% 40% 40% 40%
VRW-Family AC-DC Converters >100 W Benign Environment
11 - 106 Edition 2/96 - © Melcher AG
MELCHER
The Power Partners.
11.3
Type Key and Product Marking
Type Key VRW 450 - 12 A
Family ........................................................................VRW
Blank ..................................................................................
Nominal output power [W].................... 150, 200, 300, 450
Dash ................................................................................
Nominal output voltage [V]....................................... 5…48
Structure and connectors:
– Open frame..........................................................
– With chassis cover.............................................A
Example: VRW 450-12A = AC-DC converter providing 12 V/40 A, 480 W output, module with chassis cover
Produkt Marking
Label: Type designation, applicable safety approvals and recognition mar ks, specific type designation, input voltage
range, nominal output voltage and current and pin allocation.
Immunity to Environmental Conditions
Table 11: Mechanical stress
Test Method Test conditions Status
Damp heat Temperature: 40 ±2 °C Operating
steady state Relative humidity: 30...90 –3/+2 %
Shock (half-sinusoidal) Acceleration amplitude: 20 gn = 196.2 m/s2Operating
Vibration (sinusoidal) Frequency (1 Oct/min): 10...55 Hz Operating
Maximum vibration amplitude: 0.83 mm (55 Hz)
Acceleration amplitude: 2 gn = 19.6 m/s2
Test duration: 3 h (1 h each axis)
Table 13: MTBF values
MTBF Ground Benign
MTBF according to MIL-HDBK-217D
T
C = 40°C
VRW 150 types 121'830 h
VRW 200 types 75'789 h
VRW 300 types 60'334 h
VRW 450 types 52'347 h
Table 14: Isolation
Test Input to output Input to case Output to case Unit
Electric strenght test voltage (1 min) 3000 2000 500 V AC
Isolation resistance (500 V DC) >100 >100 >100 MΩ
Table 15: Safety approvals
Safety Approvals UL 1950 CSA 1402C TÜV 1
VRW 150 x x x
VRW 200 x x x
VRW 300 x x x
VRW 450 x x x
1 EN 60950
Table 5: Temperature specifications
Characteristic min max Unit
T
AOperating ambient temperature range without derating –10 40 °C
T
AOperating ambient temperature range with derating (see fig. 1) –10 60
T
SStorage temperature range –30 85
Benign Environment AC-DC Converters >100 W VRW-Family
Edition 2/96 - © Melcher AG 11 - 107
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11.3
7.36.7 10 83 5
93
16.5 65
11 - M4
19 198
4 - M4
21 50
±0.5
40125
±0.5
8
3311.6
37.5
3 - M3
4.5 Ø
100
±0.5
80 7. 5
25
4.5
25
±0.5
LED (on)
Uo adjustment
(Potentiometer)
Output: +V
Output: +V
Sense: +S
Output: –V
Output: –V
Frame ground: FG
Sense: –S
AC input: L
AC input: N
230 V AC: open A
110 V AC short B 24.5 12
Mechanical Data,
Input and Output Terminals
Dimensions in mm. Tolerances ±1 mm unless otherwise indicated European
Projection
Fig. 5
VRW 150, weight 890 g
Fig. 6
VRW 200, weight 1500 g, with cover 1610 g
M4
2 - M4
45
121
90 ±0.5
17
+V
-V
152.5
24
50 ±1.0
28.5
3 - M4
3 - M4
152 ±0.5
233
28 5
62
5.5
11 11
14.7 10.5
2 - 5.5 Ø +V
-V
13.6 5.5
9.5
U
o adjustment (Potentiometer)
+SSense
–SSense
+RInhibit
-R Return for +R 
L AC input
N AC input
48.5
VRW-Family AC-DC Converters >100 W Benign Environment
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11.3
M4
2 - M4
5
121
+V
-V
14.5 6.5
9.7
2 - 14.3
25.4 12.3
+V
-V
6.5
42
9
5
324 ± 0.5
394
10 100 ± 0.5
3 - M4
2 - 8.3 Ø
8.3 3
50
19
139 ± 0.5
266.7 ± 0.5
12.724
3 - M4
+SSense
–SSense
+RInhibit
-R Return for +R
L AC input
N AC input
Uo adjustment (Potentiometer)
M4
2 - M4
45
121
96
± 0.5
14
+V
-V
175 63
14 27
24.5
50
± 1.0
38.3
3 - M4
3 - M4
247
± 0.5
298 5
4
53
5.5
11 11
14.5 9.3
2 - 5.5 Ø +V
-V
13.6 5.5
9.5
Uo adjustment (Potentiometer)
+SSense
–SSense
+RInhibit
-R Return for +R 
L AC input
N AC input
Fig. 8:
VRW 450, weight 2800 g, with cover 3060 g
Fig. 7:
VRW 300, weight 2200 g, with cover 2450 g