ae bow BS & E = a. * * P-Family DC-DC Converters >100 W Industrial Environment 120/150 W DC-DC Converters Input to: output: isolation Single output: 3:3,:5.1:V:-DC Double: output::3.3/5.152: $1; 2: 12.2% 1552: <24-V Triple: output: 5.1/2:<12;5:4/:2 15 VDC Quadruple: output: 5.1/3.3: with:2::12, 2x24 with: 2: 24. V:DC =: Extremely: high: efficiency * Flex: power: Flexible load distribution = Excellent'surge: and: transient protection *: 4242 VDC: input to output electric:strength test + Redundant operation: (n+1),current:sharing:option Extremely low: inrush: current, hot plug-in Externally adjustable output voltage *IAibit primary: or secondary referenced + Very compact:and fully functional -unit(20:mm: wide) + Telecoms: compatible input voltage: range of DP.units according: to prETS 300132-2 (40..:101: VDC} Safety according to IEC/EN 60950; UL:1950 LGA rl TAL AL Safety approvals in progress C Summary These extremely compact DC-DC converters incorporate all necessary input and output filtering, signalling and pro- tection features which according to the latest industry standards are required in the majority of applications. The converters provide important advantages such as flexible output power through primary current limitation, extremely high efficiency, excellent reliability, very low ripple and RFI noise levels, full input to output isolation, negligible inrush current, soft start, overtemperature protection and input over-/undervoltage lock-out. The converter inputs are pro- tected against surges and transients occurring on the source lines, covering a total input voltage range from 16 V DC up to 150 V DC with five different types. The outputs are continuously open- and short-circuit proof. LEDs at the front panel and an isolated output power good option indicate the status of the power supply modules. Voltage suppressor diodes protect the outputs against an internally generated overvoltage. Full system flexibility and n+1 redundant operating mode are possible due to virtually unrestricted series or parallel connection capabilities of all outputs. In parallel connection Table of Contents Page SUMIMALY eee ee ceeeeeeene ee eeeeeeeeneeeeeaeeeseneeeesnaeeeeenaeeenaees 8 - 26 Type Survey and Key Datta... eeeeeeeeseeeeenneeeeees 8-27 Type Key and Product Marking .........:c:csceeeesreeeeees 8 - 29 P-Family 114 44 3U 164 6.5" ROM ao ne of several units, current sharing option is provided by a sin- gle wire interconnection. As a modular power supply or as part of a distributed power supply system, the low profile design significantly reduces the necessary power supply volume without sacrificing high reliability. The units are designed as forward converters using planar magnetics and control circuits in hybrid technology. The switching frequency is fix at 307 kHz under normal operat- ing conditions. Triple and quadruple output modules have their voltage regulation of output 3 and 4 relying on the close magnetic coupling of transformer and output conduc- tor together with the circuit symmetry of their main outputs 2, respectively 1. Outputs with an equal output voltage can either be series or parallel connected. The fully enclosed, black coated aluminium case acts as heat sink and RFI shield. It is particularly suitable for 19" rack systems occupying 3U/4TE only, but can also be chassis-mounted by means of four M3 screws. Connector type is H15 and for single output modules H15 S2. Page Mechanical Data... eeeeeeesneeeeeeeeeenneeeeenaeeeseeeees 8 - 30 Safety and Installation Instructions .......... eee 8-31 8 - 26 Edition 3/3.98/CD 1.98 - Melcher AGIndustrial Environment DC-DC Converters >100 W P-Family Type Survey and Key Data on Table 1a: Type survey BP, CP S Ouiput'1,4 Output:2,'3: Input voltage range and efficiency? Options oo Oo:nom TRE OOSC Tae 712 Us irom Ty 50C) Ta PAC Minin Ui ia mac? Amin Ui ia mac? bo IVDCE | Po max [WE | Po nom TW]: TV DCT} Po max EWI} -Poinom [WT | [2%] 16...36 V:DC [Mo] 3}: 33.6..72:V DC =e 3.3 125 106 - - - BP 1101-7R CP 1101-7R 9 & 5A 152 122 - - - BP 1001-7R CP 1001-7R D % 6 3.3 62 53 5.4 76 61 BP 2101-7R CP 2101-7R 5.1 76 61 5.4 76 61 BP 2001-7R CP 2001-7R Te 12 90 72 12 90 72 BP 2320-7R CP 2320-7R . 15 82 60 15 82 60 BP 2540-7R CP 2540-7R W 24 84 60 24 84 60 BP 2660-7R CP 2660-7R 5.1 76 61 12,12 721 601 BP 3020-7R CP 3020-7R 5.1 76 61 15,15 751 601 BP 3040-7R CP 3040-7R 5.1, 3.35 501 401 12,12 721 601 BP 4720-7R CP 4720-7R 24, 24 841 601 24, 24 841 601 BP 4660-7R CP 4660-7R Table 1b: Type survey DP, EP Output 1,49 Output 2;'3 Input voltage range and efficiency Options Os nom Ty 5OeG TK aTTEG Us nom Tx = 50C Tp STE Timin U, prin: OA fae Tein U prin: OA fae [VDC] | Pomac [WI | Psnom [WI] IV DCT | Pomax TW} Ponom (WI! [%] | 40.:101VDC | [%] | 66.150 VDC 3.3 125 106 - - - DP 1101-7R EP 1101-7R 9 5.1 152 122 - - - DP 1001-7R EP 1001-7R D 6 3.3 62 53 5.4 76 61 DP 2101-7R EP 2101-7R 5.1 76 61 5.4 76 61 DP 2001-7R EP 2001-7R Te 12 90 72 12 90 72 DP 2320-7R EP 2320-7R . 15 82 60 15 82 60 DP 2540-7R EP 2540-7R W 24 84 60 24 84 60 DP 2660-7R EP 2660-7R 5.1 76 61 12,12 721 601 DP 3020-7R EP 3020-7R 5.1 76 61 15,15 751 601 DP 3040-7R EP 3040-7R 5.1, 3.35 501 401 12,12 721 601 DP 4720-7R EP 4720-7R 24, 24 841 601 24, 24 841 601 DP 4660-7R EP 4660-7R Table 1c: Type survey GP Output-1,:4 Output :2,;3% Input: voltage range and efficiency? Options Us nom Ths S026 Tes FALC Us nem: TA = 50C Th ert. Troth Urpin: Ok max BDO} Po max [WE Po nom DT fo Me DG) Po max: BA) Po nom IE [So]: 19.2...5 7.6 DC 3.3 100 80 - - - GP 1101-7R -9 51 120 92 - - - GP 1001-7R D 6 3.3 50 40 51 60 46 GP 2101-7R 51 60 46 51 60 46 GP 2001-7R Te 12 72 54 12 72 54 GP 2320-7R . 15 68 50 15 68 50 GP 2540-7R W 24 70 48 24 70 48 GP 2660-7R 51 60 46 12,12 661 481 GP 3020-7R 51 60 46 15,15 681 501 GP 3040-7R 5.1,3.35 401 301 12,12 661 481 GP 4720-7R 24, 24 701 481 24, 24 701 481 GP 4660-7R 1 The cumulated power of both outputs may not exceed the total power for the specified ambient temperature. 2 Minimum efficiency at Uj nom, Ponom and Ta = 25C 3 Output configuration with second output semi-regulated (45% Up nom if each output is loaded with 25% P, nom). Parallel or series con- figuration possible. 4 Short deviations of U; min/Uj max according to EN 50155 possible. 5 Internal common ground. 8 Not available for all types. Edition 3/3.98/CD 1.98 - Melcher AGP-Family DC-DC Converters >100 W Industrial Environment Output Configuration The P unit design allows high flexibility in output configura- tion to cover almost every individual requirement, by simply wiring the separated outputs in parallel, series or independ- ent configurations as per following figures. Parallel and se- ries operation of several modules with equal output voltage is possible also. z z iminary Double output! Vo2+ (6 S2+ oD a Vot+ oS Fig. 4 atalalalalatelaiateiaietaiaiaiaiaiats ----9--@ i S14 GH... Parallel configurration of output 2 and 3 Vie St1- Qe q Load 1 +-@ Vir Vo1- oa $2-@)--" Vo2- 49 Prel Fig. 1 Double output! Vo2+ ) S24 ra a S2- ) Fig. 5 Roonconcosc econo ns Vo2- 49 Series configurration of output 2 and 3 1 : o Load 1 9 @i Vo1+@) : . ! : wee eee OL Vit S1+ @ o : Quadruple output +) Vi- S1-@}4---" Vot+ (4) Vo1- @) Vo1 Fig. 2 9 Bi Vo4d @ Series output configuration ; 6) Vit Vo4+ 63 -@ Vi- Vo2+ 5 i | | Load 2 Vo2- 49 5 Vo3+ (19) 9 ' . |] Load 3 ' Vo3- 20) O Fig. 6 Common ground configuration of output 1 with 4 and in- dependent configuration of output 2 and 3 Fig. 3 Independent output configuration (all outputs) Load 1 Load 2 Fig. 7 Parallel configuration of output 1 with 4 and series con- figuration of output 2 with 3 Edition 3/3.98/CD 1.98 - Melcher AGIndustrial Environment DC-DC Converters >100 W P-Family Type Key and Product Marking on Type Key CP 2540-7RDVGTiIW & Input voltage range U;: Loa 16...36 V DC weeeecceccecseseestesteeeeteeeestesneeeeeeeeees B on 33.6...72 V DC woeeeeccecceeereecteeeneeeeeeeeteeeeeeees Cc bo AO...101 VDC veeceececcecssecsteesessnsereesnsesteeseeeee D men 66...150 V DC vssccsssescssscssecsseesseessnecsneeeseeesesens E @ 19.2...57.6 V DC veecssssessssssosssiesssseenssseeteeeeen G % FAMILY oo... eee eceeeeeeee ee eeeee ee eree teense eeeeeeetaeeeneaeeeeneeeeeneeeneaa P Number of outputs: SINQlO OUTPUt oo... eee eeeeeee eter eeeenaeeeseneeeesaees 1 Double OUtDUE 0... eee eect eeere ee eeteeeeenaeeeeees 2 Triple OUTOUT oo... eect eeeneeeeeeeeeeereeeeenaeeenaees 3 Quadruple OULPUT eee eeeeeeesteeeeereeeeneeees 4 Nominal voltage output 1/output 4, Uot/4 nom! BDV ice ccc eeeee eee eeeaaeteeeeseeeeaeeeneeeseeteeeeeees 0 BiG cece cet ceeee eee eeeaeeeeeeseeeteeeeneeesneeneeeennes 1 V2 ieee cece eetetee erent eteeeeeneeeeaeeeneetaeeteeeenaees 3 TBO cece teeter etter taeteeeetieeetaeeeeeeeaees 4,5 OA cieecceettectteeee cent eeeee teen ees aesteeeenneetiaeeeeeeenaees 6 B18. OV occ ee eeeeeteee eee eeeeeeeneeetaeeeeeeenees 7 Other VOMAGES 0... eee esteeeeeneeeeeeneeeeseeees 2,8 Other specifications for main output.......... eee 01...99 Nominal voltage output 2/output 3, Uo2/3 nom BDV eect cceeceeee ene eeeaeeeeeeseeeeeeesneeeteeeeeeeaes 01 TOV ieee eect eneeete ee eaeeeee ee aeeteeeenteesaeenneetaas 20 TBO eet tenet eter eee eeeeeeaeeteeeeneesaeeneeetaas 40 OA cieecccecceeeteeee tenet eeeee eee etaeeeeeeenneetiaeenneetaas 60 Other VOMAGES 0... eee ee esteeeeeeeeeenteeeeeee 70...99 Operational ambient temperature range Ta: 25. TT OO eecccecte cent eeeee tte eeseeeeeeeteeeeeeeeeeeeaas -7 40...71 C (OPTION) 2... eee eect eeeeeeeeteeeeees -9 customer SpeCifiC 0... eee eeeeeeeteeeeeeeeteee -0...-6 Output voltage control input (auxiliary function) ............. R Options: Out OK Output 0. eee eeeeeeeesneeeeeneeeeenes D VME compatible monitoring circuit ............... Vv Second control loop (OVP) ooo... eee G Current SNAriNG ..... eee eeeeeeeeeeeeneeeeeeeeeeeneeees T Isolated inhibit on secondary side .............. i Synchronisation of switching frequency ....... W Example: CP 2540-7R: DC-DC converter, input voltage range 33.6...72 V, each providing 15 V, equipped with R-control for output 1 and operating ambient temperature of 25...71C. Note: All units feature the following auxiliary functions which are not shown in the type designation: input and output filter, inhibit (primary referenced), sense lines (single, double and triple output modules only) and LED indicators. Product Marking Main face: Basic type designation, applicable safety approval and recognition marks, CE mark, warnings, pin allocation of input, output and auxiliary functions, Melcher patents and company logo. Label with specific type designation, input voltage range, nominal output voltage and output current, degree of protection, batch no., serial no. and data code including production site, modification status and date of production. Confirmation of success fully passed final test. Front plate: Identification of LED's. Edition 3/3.98/CD 1.98 - Melcher AGP-Family DC-DC Converters >100 W Industrial Environment oe Mechanical Data 8 Dimensions in mm. Tolerances +0.3 mm unless otherwise indicated. European Projection = 09099 & _LLei III I @l__ Boog: ee en = EI --I-i_Je- - Boas 0 a. LL 104 40.15 | frent plate | | a / nN | af S | a | 2 | off Ou M8; through | | | | | | | | | | | _ 8 | o | | < 3 i Measuring point of | 2 g | easuring point o : z e Ss ! case temperature 7, | Rear @ Main x ~ | face 8 face ~ | | KR | phy | Sepp he | | i | | | | | | | | | | | | | | | | | | | ee ee Oo i | od | 3 | y a L | 1 1] | 70 tack plate _ 111 | co. _ FE A LY) o_o Oo - N wt ao 3 a1 c g Y q Jt... .. > LED "Out OK" green _ Fig. 8 Case P01, weight 480 g Aluminium, fully enclosed, LED "In OK" green Note: Long Cases, elogated by 60 mm for 220 mm rack black finish and self cooling depth is available on request. Edition 3/3.98/CD 1.98 - Melcher AGIndustrial Environment DC-DC Converters >100 W P-Family Safety and Installation Instructions on Connector Pin Allocation s) The connector pin allocation table defines the electrical potentials and the physical pin positions on the H15 connector. Pin os no. 26, the protective earth pin present on all BP...GP DC-DC converters is leading, ensuring that it makes contact with the bo female connector first. 2mm 30 26 22 18 14 10 6 10025 30 26 22 18 14 8/10 10051 e a. & 32 28 24 20 16 12 8 4 32 28 24 20 16 12 4/6 Fig. 9 Fig. 10 View of male H15 connector View of male H15 S2 connector for P 1000 Table 2: Pin allocation of the H15 S2 and H 15 connector Pin P1000 P:2000 P3000 P:4000 4 Vol+! Output 1 Vo1+ Output 1 Vo1+ Output 1 Vo1+ Output 1 6 Vo2+ Output 2 Vo2+ Output 2 Vo2+ Output 2 8 Vo1-1 Output 1 Vo1 Output 1 Vo1 Output 1 Vo1 Output 1 10 Vo2 Output 2 Vo2 Output 2 Vo2 Output 2 12 | S+? Sense S1+2 Sense 1 S1+? Sense 1 Vo4+ Output 4 14 |S-? Sense si-2 Sense 1 s1-2 Sense 1 Vo4 Output 4 16 /R Control of U, R1 Control of Up; R1 Control of Up; R1/4 Control of Upii4 T1 Current sharing T1 Current sharing 183 | T Current sharing | T1 Current sharing | Vo3+ Output 3 Vo3 Output 3 S2+ Sense 2 203 | n.c. Not connected $2- Sense 2 Vo3 Output 3 Vo3 Output 3 Pdin Power down Pdin Power down 223 | Out OK+ | Output good Out OK+ =| Output good Out OK+ | Output good Out OK+ =| Output good i+ Inhibit secondary | i+ Inhibit secondary | i+ Inhibit secondary | i+ Inhibit secondary D Save data D Save data 243 | Out OK | Output good Out OK | Output good Out OK- | Output good Out OK | Output good i- Inhibit secondary | i- Inhibit secondary | i- Inhibit secondary | i- Inhibit secondary Rst Reset Rst Reset 262 |@ Prot. ground Prot. ground Prot. ground Prot. ground 283 | i Inhibit i Inhibit i Inhibit i Inhibit WwW Synchronisat. WwW Synchronisat. WwW Synchronisat. WwW Synchronisat. 30 | Vit Input Vi+ Input Vi+ Input Vi+ Input 32 | ViF Input Vi- Input Vi- Input Vi- Input 1 H15 S2 connector with two high current contacts. 2 Leading pin (pre-connecting). 3 One function/option per pin possible only. Edition 3/3.98/CD 1.98 - Melcher AGz z iminary = a. P-Family DC-DC Converters >100 W Industrial Environment Installation Instruction The P-family DC-DC converters are components, intended exclusively for inclusion within other equipment by an in- dustrial assembly operation or by professional installers. Installation must strictly follow the national safety regula- tions in compliance with the enclosure, mounting, creepage, clearance, casualty, markings and segregation requirements of the end-use application. See also Techni- cal Information: Installation and Application. Connection to the system shall be made via the female connector H15 or H15 S2 (see Accessories) according to Connector pin allocation. Other installation methods may not meet the safety requirements. Check for hazardous voltages before altering any connec- tions. The DC-DC converters are provided with pin no. 26 (), which is reliably connected to the case. For safety reasons it is essential to connect these pins to the protective earth of the supply system if required in Safety of operator accessi- ble output circuit. The Vi input (pin no. 32) is internally fused. This fuse is de- signed to protect the unit in case of overcurrent and may not be able to satisfy all customer requirements. External fuses in the wiring to one or both input pins (no. 30 and/or no. 32) may therefore be necessary to ensure compliance with local requirements. Important: Whenever the: inhibit function is:not:in:use, pin:28: (i): should: be:cannected: to: pin: 32:(ViF):to:enable the:output(s): Do not open the modules, or guarantee will be invalidated. 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 7; max must not be overridden. 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. Isolation 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. Standards and approvals All P-family DC-DC converters correspond to class | equip- ment. They are pending to be UL recognized according to UL 1950, UL recognized for Canada to CAN/CSA C22.2 No. 950-95 and LGA approved to IEC/EN 60950 standards and have been designed in accordance with these standards for: * Building in * Basic insulation between input and case, based on 250 V AC or 240 V DC * Double or reinforced insulation between input and out- put, based on 250 V AC or 240 V DC * Operational insulation between output(s) and case * Operational insulation between the outputs * Operational insulation between option D or i and out- put(s) * Operational insulation between option D or i and case * The use in a pollution degree 2 environment * Connecting the input to a primary circuit with a maximum transient rating of 2500 V (overvoltage class III based on a 110 V primary circuit, overvoltage class Il based on a 230 V primary circuit). After approvals, the AC-DC converters are subject to manufacturing surveillance in accordance with the above mentioned UL, CSA, EN and with ISO 9001 standards. Protection Degree Condition: Female connector fitted to the unit. The protection degree of the DC-DC converters is IP 40. The electric strength test is performed as factory test in accordance with IEC/EN 60950 and UL 1950 and should not be repeated in the field. Melcher will not honour any guarantee claims resulting from electric strength field tests. Table 3: Isolation Characteristic Inputto |) Inputto | Output:to:| Output to) Auxiliary "| Auxiliary? Auxiliary! |}: Unit case output(s) case output(s):|::to:input::|::to: case: to: output Electric Required according to 15 3.02 0.5 - 3.02 0.5 0.5 kV ims strength | IEC/EN 60950 24 4.22 0.7 - 4.22 07 07 |kVDC test voltage Actual factory test 1s 2.1 4.22 1.5 0.5 4.22 15 0.5 AC test voltage equivalent 15 3.02 14 0.35 3.02 11 0.35 kV ims to actual factory test Insulation resistance at 500 V DC >300 >300 >300 >100 >300 >100 >100 MQ 1 Insulated auxiliary circuits, e.g. Out OK output circuit (option D), inhibit on output side (option i). 2 In accordance with IEC/EN 60950 only subassemblies are tested in factory with this voltage. Edition 3/3.98/CD 1.98 - Melcher AGIndustrial Environment DC-DC Converters >100 W P-Family Safety of operator accessible output circuit If the output circuit of an DC-DC converter is operator ac- nominal voltages if in series or +/ configuration) of 35 V. cessible, it shall be an SELV circuit according to IEC/EN _ However, it is the sole responsibility of the installer to as- 60950 related safety standards sure the compliance with the relevant and applicable safety The following table shows some possible installation con- regulations. More information about this subject and about figurations, compliance with which causes the output circuit output circuits at hazardous voltages are given in Technical of the DC-DC converter to be an SELV circuit according to = Information: Safety. IEC/EN 60950 up to a configured output voltage (sum of Table 4: Safety concept leading to an SELV output circuit Gonditions: |: Frontend DG-DC: converter Result Nominal Minimum: required grade: Maximum:DG:::|:Minimum:required:satety Measures to: achieve the Safety: status supply: of:insolation; to:be pro- output-voltage::|: status of:the front:end:output:| specified safety status:of the:.:|of the: DC-DG voltage vided'by the AC-DG front: trom: the front: circuit output circuit converter end;:including: mains end! output circuit supplied: battery charger Mains Operational (i.e. there is | <168V Primary circuit (The nominal | Double or reinforced insula- | SELV circuit <250 V AC | no need for electrical iso- voltage between any input tion, based on 250 V AC and lation between the mains pin and earth can be up to 240 V DC (provided by the supply circuit and the 250 V AC or 240 V DC.) DC-DC converter) and DC-DC converter input earthed case 3 circuit) Basic Earth related hazardous Double or reinforced insula- voltage secondary circuit 2 tion, based on the maximum (The nominal voltage nominal output voltage from between any input pin and the front end (both provided earth can be up to 250 V AC | by the DC-DC converter) and or 240 V DC.) earthed 2 case Unearded hazardous voltage | Supplementary insulation, secondary circuit based on 250 V AC and DC and double or reinforced insulation, based on the maximum nominal output voltage from the front end (both providedby the DC-DC converter) andearthed 3 case Supplementary Unearded hazardous voltage | Basic insulation, based on secondary circuit 3 250 V AC and DC (provided by theDC-DC converter) 1 The front end output voltage should match the specified input voltage range of the DC-DC converter. 2 The maximum rated input voltage of the EQ units according to IEC/EN 60950/UL 1950 is 150 V. 3 Has to be insulated from earth by at least supplementary insulation (by the installer) according to the relevant safety standards, e.g. IEC/EN 60950, based on the maximum nominal output voltage from the front end. If the converter case is accessible, it has to be earthed or the front end output circuit has to be insulated from the converter case by at least basic insulation, based on the maximum nominal mains supply voltage. T | Max. 250 V AC or 240 V DC Fuse 777777775 10052 cH O O + : DC-DC } =~ Battery 7 ' con- SELV pose A verter 1 | O - | Max. 250 V AC or 240 V DC Leen eee : tL + Earth = connection Fig. 11 Schematic safety concept Use fuse, suppressor diode and earth connections as per table Safety concept leading to an SELV output circuit. Use fuse(s) also if required by the application. See /nstal- lation Instructions. Edition 3/3.98/CD 1.98 - Melcher AG % imingry Pre]