W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 1 of 25
MELCHER
The Power Partners.
• RoHS lead-free-solder and lead-solder-exempted
products are available
• Rugged 35 mm DIN-rail snap-fit design
• Class I equipment
• Universal AC-input or DC-input (66 – 150 or 90 – 350
VDC) with single stage conversion
• Power factor correction, harmonics IEC/EN 61000-3-2
• Virtually no inrush current
• Immunity to IEC/EN 61000-4-2, -3, -4, -5, -6, -8, -11
• Emissions according to EN 55011/022
• Very high efficiency; up to 89%
• Short-term output peak power capability, rectangular
current limiting characteristic
• Single or two independently regulated outputs with 12,
24, 36, or 48 V
• Outputs no-load, overload, and short-circuit proof
• PCBs coated by protective lacquer
• Very high reliability
Description
The Convert Select front end series represents a family of
DIN-rail mountable DC-DC and AC-DC converters with power
factor correction. The converters have been designed
according to the latest industry requirements and standards.
The converters are ideal for use in outdoor and other
demanding applications to power building control systems,
factory automation, industrial controls, instrumentation,
electromagnetic drives, fans, and other DC loads. Different
models are available with a single output or two independently
regulated, electrically isolated outputs with 12, 24, 36, or 48 V.
Special models for battery charging are available. The EW
Safety-approved to IEC/EN 60950-1 and UL/CSA 60950-1
2nd Ed., UL 508 listed components
models are particularly suitable for 110 V railway applications;
they have been designed in accordance with the railway
standards EN 50155 and EN 50121.
Key features of the Convert Select line include power factor
correction with low harmonic distortion, negligibly low inrush
current, high immunity to transients and surges, and low
electromagnetic emissions. Internal protection circuits such as
input over- and undervoltage lockout, thermal protection, as
well as output overvoltage protection by a second control loop
ensure safe operation of the final system.
The outputs deliver an electrically-isolated Safety Extra Low
Voltage (SELV) and low output noise. They are no-load,
Table of Contents Page Page
Features
114
4.49"
103
4.05"
138
5.43"
Description .......................................................................... 1
Model Selection .................................................................. 2
Functional Description ........................................................ 4
Electrical Input Data............................................................ 6
Electrical Output Data ......................................................... 8
Electromagnetic Compatibility (EMC) ............................... 13
Immunity to Environmental Conditions ................................. 16
Mechanical Data ...................................................................17
Safety and Installation Instruction.........................................18
Description of Options .......................................................... 21
Accessories...........................................................................24
Copyright © 2018, Bel Power Solutions Inc. All rights reserved.
125, 250 Watt AC-DC (DC-DC) Converters Convert Select
1
1 not EW
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 2 of 25
MELCHER
The Power Partners.
Model Selection
Table 1: Standard models
Output 1 Output 2 Output Power Operating Input Type Effic. Options 3, 5
Vo1 nom1Io1 nom Vo2 nom1Io2 nom Po nom Voltage Designation6ηη
ηη
ηmin
8
[VDC] [A] [VDC] [A] [W] Vi min - Vi max [%]
12.35 7.5* - - 93* 85 2 – 264 VAC, LWR1301-6E 383* R
12.35 14* - - 173* 47 – 63 Hz 4,LWN1301-6E 383* D1, D2, D5
24.7 5 - - 124 902 – 350 VDC 7 LWR1601-6E 87 M1, M2
24.7 10 - - 247 LWN1601-6E 87 F
37 3.3 - - 122 LWR1701-6E 388
K2, G
37 6.6 - - 244 LWN1701-6E 388
49.4 2.5 - - 124 LWR1801-6E 88
49.4 5 - - 247 LWN1801-6E 88
12.35 7* 12.35 7* 173* LWN2320-6E 383*
24.7 5 24.7 5 247 LWN2660-6E 87
37 3.3 37 3.3 244 LWN2770-6E 389
49.4 2.5 49.4 2.5 247 LWN2880-6E 89
24.7 5 - - 120 66 – 150 VDC EWR1601-0 987 R, M1, M2
24.7 5 24.7 5 240 EWN2660-0 987 Q, K2, G
* Version 106 or higher
1R-input not connected.
2For derating at low input voltage see section Output Power Derating.
3For minimum quantity and lead times contact the Company.
4The converters have been tested up to 440 Hz; operation at 162/3 Hz is also possible, but the output ripple is slightly higher. For questions
when operating at frequencies <47 Hz or >63 Hz, consult the Company.
5On double-output models the options R, M2, D1, D2, D5 are related to the second output only.
6Improved EMC performance for LWN/LWR models. Former models without E are still available on request.
7Vi ≤ 250 VDC for models with option F
8Min. efficiency at Vi nom, Io nom, and TA = 25 °C. Typical values are approx. 2% better.
9EWN and EWR models are designed for railway applications according to EN 50155 and EN 50121.
overload, and short-circuit proof. The electronically controlled
short-term peak power capability of up to 150% of the rated
output power enables the front end converters to deliver
additional power to start-up motors or to safely operate
subsequent circuit breakers. Built-in large sized output
capacitors absorb possible reverse energy, which may be
caused by quick deceleration of electromagnetic drives
connected directly to the output. A green LED at the front cover
displays the status of the output(s).
The Convert Select Series was designed according to all
relevant international safety standards. The converters are
approved by TÜV and UL, and are UL 508 listed. Adequate
clearances and creepage distances allow operation in
pollution degree 3 environment (with AC input). All board
assemblies are coated with a protective lacquer.
The thermal concept allows operation at full load up to an
ambient temperature of 60 °C (LW models) or 70 °C (EW
models) in free air without forced cooling. A rugged DIN snap-fit
device allows easy and reliable fixing onto the various 35 mm
DIN rail models. The converters are fitted with cage clamp
terminals which are easily accessible from the front. System
connectors with screw terminals for use with pre-assembled
harnesses, external adjustment of the output voltage as well as
various auxiliary functions are available as options.
The letter E stands for improved EMC performance of LW
models. Models without E are obsolete.
NFND: Not for new designs. Preferred for new designs
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 3 of 25
MELCHER
The Power Partners.
Table 2: Battery charger models (M1 included)
Output Voltage Nominal Output ValuesOperating InputType Designation6Effic. Options 3
VBat Vo safe1Vo max Vo nom 5Io nom 5Po nom 5Voltage ηη
ηη
ηmin 8
[VDC] [VDC] [VDC] [VDC] [A] [W] Vi min - Vi max [%]
12 12.84114.65 13.8 7.5* 104* 85 2 – 264 VAC, LWR1140-6EM1 383* F
14* 194* 47 – 63 Hz 4,LWN1140-6EM1 385* K2, G
24 25.681 29.3 27.3 4.2 115 902 – 350 VDC 7 LWR1240-6EM1 86
8.4 230 LWN1240-6EM1 85
36 38.52143.95 40.88 2.8 115 LWR1840-6EM1 386
5.6 230 LWN1840-6EM1
386
48 51.36158.6 54.5 2.1 115 LWR1740-6EM1 86
4.2 230 LWN1740-6EM1 87
* Version 106 or higher
1Setting voltage (typ.) with open R-input
2For derating at low input voltage, see section Output Power Derating.
3For minimum quantity and lead times, contact the Company.
4The converters have been tested up to 440 Hz; for operating frequency <47 Hz or >63 Hz consult the Company.
5Nominal output figures, calculated with a cell voltage of 2.27 V at 20 °C.
6Improved EMC performance. Former models without E are still available on request.
7Vi ≤ 250 VDC for models with option F.
8Min. efficiency at Vi nom, Vo nom, Io nom, and TA = 25 °C. Typical values are approx. 2% better.
Part Number Description
L W N 2 660 -6 E D2 F K2 G
Input voltage range .......................................................... E, L
Series.................................................................................. W
Nominal output power
125 W .............................................................. R
250 W .............................................................. N
Number of outputs ............................................................1, 2
Type specification .................................................. 000 – 999
Operational ambient temperature range TA
–40 to 60 °C ................................................... -6
EW or customer-specific ........................... -0, -5
Improved EMC performance................................................ E
Options Output voltage control input 1.......................................R
Save data signal 1.......................................... D1, D2, D5
Multiple functions via
D-SUB
connector 1.. M1, M2
Built-in second fuse, input diode .................F, Q
System connector.......................................... K2
RoHS compliant for all six substances ............G
1Only one of these options is possible.
Note: The sequence of options must follow the order above.
NFND: Not for new designs Preferred for new designs.
Example: LWN2660-6ED2FK2G: Power factor corrected AC-DC converter, operating input voltage range 85 – 264 VAC,
2 electrically isolated and individually regulated outputs, each providing 24.7 V, 5 A, improved EMC performance,
options D2, F, K2, and RoHS-compatible for all 6 substances.
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 4 of 25
MELCHER
The Power Partners.
Functional Description
The W Series converters are primary controlled AC-DC or DC-
DC flyback converters with a constant switching frequency of
130 kHz. The power-factor-corrected single-step conversion of
the input voltage to a low output voltage results in extremely
high efficiency. Depending upon the output power, the
converters are fitted with one (125 W) or two (250 W)
powertrains. Models with two powertrains have one or two
outputs. Double-output models exhibit individually regulated
powertrains.
The input voltage is fed via fuse, filter, and rectifier to the main
transformer, designed in planar technique. The input filter with
very small input capacitance generates virtually no inrush
current. An input transient suppressor protects the converter
against high voltage peaks and surges. Input over- and
undervoltage lockout as well as input current limitation protect
the converter from operation outside of its specification. The
input voltage waveform is sensed by the primary control logic
to allow active power factor correction, forcing the input current
to follow the input voltage waveform.
The secondary side of the main transformer supplies via the
rectifier diode a large electrolytic output storage capacitor
providing for the hold-up time. Double-output models exhibit an
individual control logic each. The output voltage and the output
current are measured and fed back to the primary control logic
via an optocoupler. A second control loop monitors the output
voltage. It disables the output in the case of a failure in the
control logic and limits the output voltage.
Built-in temperature sensors monitor the internal temperature
of each powertrain. If the temperature exceeds the limit, the
converter reduces the output power continuously to keep the
temperature below its limit. A green LED on the front cover
confirms the presence of the output voltage(s).
The R input (option R, M1, or M2) allows for external adjustment
of the output voltage by means of a resistor or an external
voltage source. An external sensor can be connected to the R
input and allows for temperature-controlled battery charging
(see Accessories).
Fig. 1
Single-output converters (125 W).
Product Marking
Basic type designation, applicable safety approval and
recognition marks, CE mark, warnings, pin designation,
company logo.
Specific type designation, input voltage range, nominal output
voltages and currents, degree of protection, batch no., serial
no., and data code including production site, version, and date
of production.
Input filter
Input filter
V
o
/I
o
control
Output filter
2
nd
control loop (SELV)
Control circuit
including
PFC and
input OVP/UVP
L
N
Vo+
Vo–
C
y
C
y
C
y
C
Y
C
Y
AUX
Fuse
2
nd
fuse
(option F)
2
1
03103b
Shunt Shunt
3
4
5
8
9
2
3
6
7
1
11
10
Vi–
Vi+
Rectifier
1
+
1
EW models
have a link or a
decoupling diode
(opt. Q) in the
Vi+ line.
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 5 of 25
MELCHER
The Power Partners.
Fig. 2
250 W converters.
The figure shows a double-output model.
For the pinout of 250 W single-output
models, see fig. 1 or table 13.
Input filter
C
y
C
y
Fuse
2
1
03104b
3
Input filter
V
o
/I
o
control
Output filter
2
nd
control loop
Control circuit
including
PFC and
input OVP/UVP
Vo1+
Vo1–
C
y
C
y
C
y
Shunt Shunt
4
5
2
3
Input filter
V
o
/I
o
control
Output filter
2
nd
control loop
Control circuit
including
PFC and
input OVP/UVP
Vo2+
Vo2–
C
y
C
y
C
y
AUX
Shunt Shunt
8
9
6
7
11
10
1
L
N
Vi–
Vi+
2
nd
fuse
(option F)
Rectifier
1
+
+
1
EW models
have a link or a
decoupling diode
(opt. Q) in the
Vi+ line.
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 6 of 25
MELCHER
The Power Partners.
Electrical Input Data
General conditions:
TA = 25 °C, unless TC is specified.
Table 4a: Input data of LW models
Input LWR LWN Unit
AC-Input DC-Input AC-Input DC-Input
Characteristic Conditions min typ max min typ max min typ max min typ max
ViOperating input voltage Io = 0 – Io nom 852264 902350 4 852264 902350 4 V
range Tc – Tc max
Vi nom Rated input volt. range 100 (230) 240 220 100 (230) 240 220
fiRated input frequency150 – 60 -- 50 – 60 -- Hz
IiInput current Io nom, Vi = Vi nom 0.63 0.65 1.25 1.3 A
Io nom, Vi = Vi min 1.75 1.67 3.5 3.3
Pi0 No-load input power Vi min – Vi max 1.2 0.9 1.3 1 W
Iinrush Inrush current Vi max, t > 0.1 ms 3 3 5 5 A
CiInput capacitance 5 5 6 6 µ F
PF Power factor Vi nom = 230 V, Io nom 0.865-- 0.865--
Vi RFI Conducted input RFI EN 55011/55022 A, B3A, B3A, B 3A, B 3
Radiated input RFI Vi nom, Io nom B3B3B3B3
fswitch Switching frequency 130 130 130 130 kHz
1For operating frequencies <47 Hz and >63 Hz consult the Company. The converters have been tested up to 440 Hz.
2Output power derating at low input voltage and/or high case temperature TC (see Output power derating).
3Models with feature E (type test with LWN1801-6E)
4Vi ≤ 250 VDC for models with option F.
5Models with 12 V output: ≥0.70 for LWR, ≥0.75 for LWN
Table 4b: Input data of EW models
Input EWR EWN Unit
DC-Input DC-Input
Characteristic Conditions min typ max min typ max
ViOperating input voltage Io = 0 – Io nom 66 150166 1501V
range Tc to Tc max
Vi nom Nominal input voltage 110 110
VUVT Undervoltage trigger 54 60 54 60
IiInput current Io nom, Vi = Vi nom 1.25 2.5 A
Io nom, Vi = 66 V 2.2 4.4
Pi0 No-load input power Vi min – Vi max 0.8 1.3 W
Iinrush Inrush current Vi max, t > 0.1 ms 6 12 A
CiInput capacitance 2.5 4.5 µF
Vi RFI Conducted input RFI EN 55011/55022 A A
Radiated input RFI Vi nom, Io nom -- --
fswitch Switching frequency 130 130 kHz
1Vi ≤ 168 VDC for 3 s. Overvoltage trigger adjusted to 170 – 182 V.
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 7 of 25
MELCHER
The Power Partners.
Table 5b: Po derating according to UL 60950 at TA = 50 °C, or according to UL 508 at Tout = 40 °C
Model Po nom TC max Derate below derate by
[W] [°C] Vi [VAC] Vi [VDC] [W/V]
LWR1601-6E 124 76 98 no derating –0.67
LWN1601/2660-6E 247 86 115 105 –1.25
LWR1801-6E 124 76 93 no derating –0.67
LWN1801/2880-6E 247 86 105 95 –1.25
Output Power Derating
The output power of LW models must be decreased at low
input voltage and/or powertrain temperature above 125 °C.
The powertrain temperature depends on the output power, the
input voltage, and the cooling method. At low input voltage the
losses increase. At the maximum specified environment
temperature TA free air convection cooling might be insufficient
approaching maximum ambient conditions. As a result, the
output power has to be reduced according to the tables below.
Input Fuse and Protection
A fast-blow fuse (Schurter F 6.3A, 5 × 20 mm), protected by a
sleeve, is connected to the input L or Vi+. EW models have a
smaller fuse (250 V, 4 × 9 mm, SOC NT3 6.3A V009, UL-
recognized E-39265). For DC input voltages above 250 V
consult the Installation Instructions.
Converters with option F have 2 small fuses, one in each input
line. Converters with option EF (E and F) have 2 large fuses
(F6.3A, 5 × 20 mm). The DC input voltage for converters with
option F is limited to 250 V.
A VDR and a symmetrical input filter form an effective
protection against input transients.
An under- and an overvoltage lockout protect the converter,
which is disabled below Vi min and above Vi max by an internally
generated inhibit signal.
The built-in bridge rectifier (LW models) provides reverse
polarity protection at the input if operated from DC.
EW models are protected by the (blowing) input fuse in
connection with the body diode of the main transistor . Option Q
offers a serial diode, but this reduces the efficiency by approx.
1%.
Note: The measurements have been made by the approval
boards with free air convection cooling according to UL 60950
specified ambient temperature TA and with the converter built in a
cardboard box according to UL 508 and a specified temperature
outside the box Tout. The tables give a correlation between TA or
Tout and the case temperature TC (measuring point TC see
Mechanical Data). For models not specified, please contact the
Company.
EW models need no derating.
Efficiency
Table 5a: Po derating according to UL 60950 at TA = 60 °C, or according to UL 508 at Tout = 50 °C
Model Po nom TC max Derate below derate by
[W] [°C] Vi [VAC] Vi [VDC] [W/V]
LWR1601-6E 124 80 108 98 –0.67
LWN1601/2660-6E 247 89 125 115 –1.25
LWR1701-6E 122 80 125 115 –1.25
LWN1701-6E 244 90 125 115 –1.25
LWR1801-6E 124 80 98 93 –0.67
LWN1801/2880-6E 247 89 125 115 –1.25
Fig. 3
Efficiency versus load (LWN2660-6)
0 0.2 0.4 0.6 0.8 1
0
30
40
10
20
50
60
70
80
90
I
o
I
o nom
V
i
= 125 VAC V
i
= 230 VAC
04071
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 8 of 25
MELCHER
The Power Partners.
0 0.2 0.4 0.6 0.8 1
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
PF
Vi = 125 VAC
Vi = 230 VAC
04069a
Io
Io nom
0
1
2
3
4
35791113
mA/W
04070b
Limit class D according
to IEC/EN 61000-3-2
Harm.
LWN1701-6E
Fig. 5
Power factor versus load (LWN2660-6)
Fig. 4
Harmonic currents at input current, measured at Vi = 230
VAC, Io = Io nom (LWN1701-6E).
Power Factor, Harmonics
All converters feature active power factor correction.
Electrical Output Data
Table 6a: Output data of 125 Watt standard models. General conditions: TA = 25 °C, unless TA is specified; R input open-circuit
Model LWR1301 EWR/LWR1601 LWR1701 LWR1801 Unit
Characteristic Conditions min typ max min typ max min typ max min typ max
Vo nom Output voltage nominal1Vi nom, Io nom 12.0 24.25 24.7 25.2 36.4 37 37.8 48.5 49.36 50.4 V
* 12.2 12.35 12.5 24.55 24.7 24.85 36.8 37 37.2 49.06 49.36 49.66
Vo worst Output voltage range Vi min – Vi max, 11.9 13.0 24.0 25.8 36.0 38.7 48.0 51.6
of tolerance Io = (0.1 – 1) Io nom
Vo L Overvoltage protection 14 * 15 * 28.5 30 42.7 45 57 60
Po nom Nominal output power Vi = 100 V – Vi max 105 * 124 122 124 W
Io nom Output current nominal 7.5 * 5.0 3.3 2.5 A
Io L Output current limit 3Vi min – Vi max 7.6 8.5 5.1 5.7 3.4 3.8 2.53 2.9
Iop Output current boost 4typ. 1 s 11.3 7.5 5.0 3.75
voRipple and noise EWR Vi = 110 VDC, Io nom - 500 - - mVpp
LWR Vi = 230 VAC, 100 100 100 100
fi = 50 Hz , Io nom 1100 21100 21200 21200 2
∆Vo u Static line regulation 100 V – Vi max, Io nom ±0.08 ±0.1 ±0.15 ±0.15 V
∆Vo l Static load regulation Vi nom, –0.2 –0.4 –0.6 –0.8
(droop) Io = (0.1 – 1) Io nom
vod Dynamic load regulation Vi nom, ±1 ±1.2 ±1.5 ±1.8
Voltage deviation Io = (0.5 ↔ 1) Io nom
Recovery time 40 40 80 80 ms
αvoTemperature coefficient TC min – TC max ±0.02 ±0.02 ±0.02 ±0.02 %/K
tor Start-up time Vi = 0 → Vi nom, Io nom 700 700 700 700 ms
toh min Hold-up time Io nom, 10 6/15 20 25
Vo nom → 0.8 Vo nom
* Converters with feature E and version ≥106
1Setting voltage with open R-input
2Superimposed low frequency ripple at 2 • fi
3Rectangular current limit characteristic (continuous operation)
4Short-term peak power capability 150% of Po nom for approx. 1 s
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 9 of 25
MELCHER
The Power Partners.
Table 6b: Output data of 250 Watt single-output standard models. General conditions as in table 6a
Model LWN1301 LWN1601 LWN1701 LWN1801 Unit
Characteristic Conditions min typ max min typ max min typ max min typ max
Vo nom Output voltage nominal1Vi nom, Io nom -- 24.25 24.7 25.2 36.4 37 37.8 48.5 49.36 50.4 V
* 12.2 12.35 12.5 24.55 24.7 24.85 36.8 37 37.2 49.06 49.36 49.66
Vo worst Output voltage range Vi min – Vi max, 11.9 13.0 24.0 25.8 36.0 38.7 48.0 51.6
of tolerance Io = (0.1 – 1) Io nom
Vo L Overvoltage protection 14 * 15 * 28.5 30 42.7 45 57 60
Po nom Nominal output power Vi = 100 V – Vi max 173 * 247 244 247 W
Io nom Output current nominal 14 * 10 6.6 5.0 A
Io L Output current limit 3Vi min – Vi max 14.1 * 16* 10.2 11.4 6.7 7.6 5.1 5.6
Iop Output current boost 4typ. 1 s 21 15 10 7.5
voRipple and noise Vi = 230 VAC, 100 100 100 100 m Vpp
fi = 50 Hz, Io nom 1100 21100 21200 21200 2
∆Vo u Static line regulation 100 V – Vi max, Io nom ±0.08 ±0.1 ±0.15 ±0.15 V
∆Vo l Static load regul. (droop) Vi nom, (0.1 – 1) Io nom –0.2 –0.4 –0.6 –0.8
vod Dynamic load regulation Vi nom, ±1 ±1.2 ±1.5 ±1.8
Voltage deviation Io = (0.5 ↔ 1) Io nom
Recovery time 40 40 80 80 ms
αvoTemperature coefficient TC min – TC max ±0.02 ±0.02 ±0.02 ±0.02 %/K
tor Start-up time Vi = 0 → Vi nom, Io nom 700 700 700 700 ms
toh min Hold-up time Io nom,10152025
Vo nom → 0.8 Vo nom
Table 6c: Output data of 250 Watt double-output standard models. General conditions as in table 6a
Model LWN2320 EWN/LWN2660 LWN2770 LWN2880 Unit
Characteristic Conditions min typ max min typ max min typ max min typ max
Vo1 nom Output voltage nominal1Vi nom, Io nom -- 24.25 24.7 25.2 37 48.5 49.36 50.4 V
Vo2 nom * 12.2 12.35 12.5 24.55 24.7 24.85 36.8 37 37.2 49.06 49.36 49.66
Vo worst Output voltage range Vi min – Vi max, 11.9 13.0 24.0 25.8 36.0 38.7 48.0 51.6
of tolerance Io = (0.1 – 1) Io nom
Vo L Overvoltage protection 14 * 15 * 28.5 30 42.7 45 57 60
Po nom Nominal output power Vi = 100 V – Vi max 173* 247 244 247 W
Io nom Output current nominal 2×7 * 2×52×3.3 2×2.5 A
Io L Output current limit 3Vi min – Vi max 7.1 * 7.8* 5.1 5.7 3.4 3.8 2.53 2.9
Iop Output current boost 4
voRipple and noise Vi = 230 VAC, 100 1 00 5100 100 mVpp
fi = 50 Hz, Io nom 1100 21100 21200 21200 2
∆Vo u Static line regulation 100 V – Vi max, Io nom ±0.08 ±0.1 ±0.15 ±0.15 V
∆Vo l Static load regul. (droop) Vi nom, (0.1 – 1) Io nom –0.2 –0.4 –0.6 –0.8
vod Dynamic load regulation Vi nom, ±1 ±1.2 ± 1.5 ±1.8
Voltage deviation Io = (0.5 ↔ 1) Io nom
Recovery time 40 40 80 80 ms
αvoTemperature coefficient TC min – TC max ±0.02 ±0.02 ±0.02 ±0.02 %/K
tor Start-up time Vi = 0 → Vi nom, Io nom 700 700 700 700 ms
toh min Hold-up time Io nom, 10 6/15 20 25
Vo nom → 0.8 Vo nom
* Converters with feature E and version ≥106
1Setting voltage with open R-input
2Superimposed low frequency ripple at 2 • fi
3Rectangular current limit characteristic (continuous operation)
4Short-term peak power capability 150% of Po nom for approx. 1 s
5EWN2660: 500 mV @ Vi = 110 VDC
typ. 1 s 2×10.5* 2×7.5 2×5.0 2×3.75
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 10 of 25
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Table 7a: Output data of 125 Watt battery charger models. General conditions: TA = 25 °C, unless TA is specified; R input left
open-circuit, unless otherwise specified
Model LWR1140-6EM1 LWR1240-6EM1 LWR1840-6EM1 LWR1740-6EM1 Unit
Characteristic Conditions min typ max min typ max min typ max min typ max
Vo safe Output setting voltage 1Vi nom, Io nom 12.25 12.84 13.15 24.5 25.68 26.3 36.75 38.52 39.5 49 51.36 52.6 V
VBat Output voltage (max.) Vi min – Vi max, 14.65 29.3 43.95 58.6
controlled by R input Io = (0.1 – 1) Io nom
Vo L Overvoltage protection 15.4* 16.3* 30.9 32.5 46 48.8 61.8 65
Po nom Nominal output power Vi = 100 V – Vi max 104 * 115 115 115 W
Io nom Output current nominal 7.5 * 4.2 2.8 2.1 A
Io L Output current limit3Vi min – Vi max 7.6* 8.4 * 4.3 4.8 3.2 3.7 2.2 2.5
Iop Output current boost 4
voRipple and noise Vi = 230 VAC, 100 100 100 100 mVpp
fi = 50 Hz, Io nom 110021100 2 120021200 2
∆Vo u Static line regulation 100 V – Vi max, Io nom ±0.08 ±0.1 ±0.15 ±0.15 V
∆Vo l Static load regulation Vi nom, –0.2 –0.4 –0.6 –0.8
(droop) Io = (0.1 – 1) Io nom
vod Dynamic load regulation Vi nom, ±1.2 ±1.2 ±1.6 ±1.9
Voltage deviation Io = (0.5 ↔ 1) Io nom
Recovery time 40 40 80 80 ms
αvoTemperature coefficient TC min – TC max ±0.02 ±0.02 ±0.02 ±0.02 %/K
tor Start-up time Vi = 0 → Vi nom, Io nom 700 700 700 700 ms
Table 7b: Output data of 250 Watt battery charger models. General conditions as in table 7a
Model LWN1140-6EM1 LWN1240-6EM1 LWN1840-6EM1 LWN1740-6EM1 Unit
Characteristic Conditions min typ max min typ max min typ max min typ max
Vo safe Output setting voltage 1Vi nom, Io nom 12.25 12.84 13.15 24.5 25.68 26.3 36.75 38.52 39.5 49 51.3 6 52.6 V
VBat Output voltage (max.) Vi min – Vi max, 14.65 29.3 43.95 58.6
controlled by R input Io = (0.1 – 1) Io nom
Vo L Overvoltage protection 15.4* 16.3* 30.9 32.5 46 48.8 61.8 65
Po nom Nominal output power Vi = 100 V – Vi max 194* 230 230 230 W
Io nom
Io L Output current limit 3Vi min – Vi max 14.2 * 15.6 * 8.6 9.6 6.4 7.4 4.4 5.0
Iop Output current boost 4
voRipple and noise Vi = 230 VAC, 100 100 100 100 mVpp
fi = 50 Hz, Io nom 1100211002 1200 21200 2
∆Vo u Static line regulation 100 V – Vi max, Io nom ±0.08 ±0.1 ±0.15 ±0.15 V
∆Vo l Static load regulation Vi nom, –0.2 –0.4 –0.6 –0.8
(droop) Io = (0.1 – 1) Io nom
vod Dynamic load regulation Vi nom, ±1.2 ±1.2 ±1.6 ±1.9
Voltage deviation Io = (0.5 ↔ 1) Io nom
Recovery time 40 40 80 80 ms
αvoTemperature coefficient TC min – TC max ±0.02 ±0.02 ±0.02 ±0.02 %/K
tor Start-up time Vi = 0 → Vi nom, Io nom 700 700 700 700 ms
* Converters with feature E and version ≥106
1Setting voltage with open R-input = Vo safe
2Superimposed low frequency ripple at 2 • fi
3Rectangular current limit characteristic (continuous operation)
4Short-term peak power capability 150% of Po nom for approx. 1 s
typ. 1 s 11.2 * 6.3 4.23.2
Output current nominal 14 * 8.4 5.6 4.2 A
typ. 1 s 21 * 12.6 8.4 6.3
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 11 of 25
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Parallel Operation
Double-output models exhibit an independent
control logic each. Both outputs can be
connected in parallel, provided that options S
(included in M1) and R are not used, since
they influence only the 2nd output. The two
power trains share the current due to their
output voltage droop characteristic.
Up to 3 converters with the same output
voltage may be operated in parallel. It is
possible to parallel W Series with X Series
converters.
Reasonable current sharing is achieved by
the droop characteristic. Correct mode of
operation is highly dependent upon the wiring
of the converters and the impedance of these
wires. Use wires with equal length and equal
cross sections of min. 1.5 mm2. The best
results for parallel operation can be achieved
with the wiring shown in fig. 6.
Parallel operation of single-output models
using the option R (output voltage adjust) is
possible, but not recommended. Refer to fig.
6; the connections between the pins 8 and 9
(both Vo–) should be as short as possible.
Note: Parallel operation is not possible, if a
temperature sensor is connected, as the
sensor eliminates the output voltage droop.
Note: For ORing diodes, we recommend to
use Schottky diodes, mounted on a common
heatsink to avoid thermal run away (or the use
of double diodes).
Series Connection
Series connection of several outputs up to 150
V is possible. Exceeding an output voltage of
60 V, the output is not SELV.
Output Characteristic and Protection
The output characteristic, individual for each
powertrain, is rectangular with a droop to ease
parallel operation; see fig. 7.
However, a 50% higher output current is
possible for a short time, such allowing start-
up of loads or charging of capacitors; see fig. 8.
Each output is independently protected
against internal overvoltage by means of a second control
loop. When the output voltage exceeds Vo L, the respective
output is disabled.
Overtemperature Protection
A built-in temperature sensor protects each powertrain is
independently protected against overtemperature. When a Fig. 7
Vo versus Io (single-output model, typical values).
Vo+ 2
Vo+ 3
Vo- 4
Vo- 5
Vo- 8
Vo- 9
Vo+ 6
Vo+ 7
AUX 10
Vo+ 2
Vo+ 3
Vo- 4
Vo- 5
Vo- 8
Vo- 9
Vo+ 6
Vo+ 7
AUX 10
Vo+ 2
Vo+ 3
Vo- 4
Vo- 5
Vo- 8
Vo- 9
Vo+ 6
Vo+ 7
AUX 10
V
i
V
i
V
i
Load
11054b
Additional wiring for output currents I
o
≥ 10 A
Additional wiring, if using the R-input
V
R
+
_
Fig. 6
Wiring for single-output converters connected in parallel. Additional wiring
for higher output currents and with the use of option R is shown.
0.8
1.0
0.6
0.4
0.2
0
00.2 0.4 0.6 0.8 1.0 1.2
I
o
/I
o nom
V
o
/V
o nom
05181a
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 12 of 25
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1.4
1.6
1.2
1.0
0.8
0.6
-- 0.5 0.5 1.5 2.5 s
I
o
/ I
o nom
05194b
012
Fig. 9
Trickle charge voltage versus temperature for different
temperature coefficients (Vo safe with disconnected sensor)
Fig. 10
Schematic circuit diagram of a system with battery backup
and temperature-controlled charging.
Fig. 8
Short term peak power characteristic: overcurrent versus
time (typical values).
certain temperature is reached, the concerned powertrain
reduces its output power continuously.
Thermal Considerations
The thermal conditions are influenced by input voltage, output
current, airflow, and temperature of surrounding components.
TA max is therefore, contrary to TC max, an indicative value only.
Caution: The installer must ensure that under all operating
conditions TC remains within the limits stated in the table
Temperature specifications.
Note: Sufficient forced cooling allows TA to be higher than TA max
provided that TC max is not exceeded. It is recommended that
continuous operation under worst case conditions of the
following 3 parameters be avoided: Minimum input voltage,
maximum output power, and maximum temperature.
Battery Charging and Temperature Sensor
The battery charger models exhibit the option M1 and have
been designed to charge lead-acid batteries. The R-input
allows for connecting a battery-specific temperature sensor,
which provides temperature controlled adjust of the trickle
charge voltage. This optimizes charging as well as battery life
time. Depending upon the cell voltage and the temperature
coefficient of the battery, different sensor types are available;
see Accessories.
Note: Parallel operation is not possible, if the temperature sensor is
connected to the paralleled outputs Vo+, as the sensor eliminates
the output voltage droop.
However , it is possible to insert bleeding resistors in the Vo+ output
lines of each converter in order to create a droop of approx. 0.6 V @
Io nom for 24 V outputs (1.2 V @ Io nom for 48V outputs), but this
creates considerable power losses.
2.10
2.15
2.20
2.25
2.30
2.35
2.40
2.45
Cell voltage [V]
–20 –10 0 10 20 30 40 50 °C
06139b
V
C
= 2.27 V, –3 mV/K V
C
= 2.27 V, –3.5 mV/K
V
C
= 2.23 V, –3 mV/K V
C
= 2.23 V, –3.5 mV/K
V
o safe
Power
supply
Load
–
+
Input Vo–
R
Temperature sensor
ϑ
03099d
Battery
Vo+
+
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 13 of 25
MELCHER
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Electromagnetic Comp atibility (EMC)
Electromagnetic Immunity
The W Series has been successfully tested to the following specifications:
Table 8: Electromagnetic immunity (type tests)
Phenomenon Standard Level Coupling Value Waveform Source Test In Perf.
mode 1 applied imped. procedure oper. criter. 2
Electrostatic IEC/EN 4 3 contact discharge 8000 Vp1/50 ns 330 Ω10 positive and yes A
discharge 61000-4-2 air discharge 15000 Vp10 negative
(to case) discharges
Electromagnetic IEC/EN 3 4 antenna 10 V/m 4 AM 80%, 1 kHz n.a. 80 – 1000 MHz yes A
field RF 61000-4-3 sinusoidal
ENV 50204 3 antenna 10 V/m 50% duty cycle, n.a. 900 ±5 MHz yes A
200 Hz repet. frequ.
IEC/EN 5antenna 20 V/m 80% AM, 1 kHz n.a. 800 – 1000 MHz yes A
61000-4-3 10 Vm sinusoidal 1400 – 2100 MHz
(EW models) 5 V/m 2100 – 2500 MHz
Electrical fast IEC /EN 3 capacitive, o/c ±2000 Vpbursts of 5/50 ns, 50 Ω60 s positive + yes A
transients/burst 61000-4-4 36±i/c, +i/ –i ±2000 Vp65 kHz over 15 ms, 60 s negative
direct coupling burst period: 300 transients per
m s coupling mode
Surges IEC/EN 37+i / c, –i/c ±2000 Vp1.2/50 µs 12 Ω5 pos. and 5 neg. yes B
61000-4-5 +i/–i ±1000 Vp1.2/50 µs 2 Ωsurges per
coupling mode
Conducted IEC/EN 38i, o, signal wires 10 VAC AM 80% 150 Ω0.15 – 80 MHz yes A
disturbances 61000-4-6 (140 dBµV) 1 kHz
Power frequency IEC/EN -- -- 100 A/m 50 and 60 Hz -- x, y, and z axis yes A
magnetic field 61000-4-8
Surges IEC/EN wave +i/c, –i/c 1800 Vp5/50 µs 5 Ω5 pos. and 5 neg. yes B
(EW models) 50155:2001 A 9 pulses
1i = input, o = output, c = case.
2A = Normal operation, no deviation from specifications, B = Normal operation, temporary loss of function or deviation from specs. possible.
3Exceeds EN 50121-3-2:2006 table 9.3 and EN 50121-4:2006 table 1.4.
4EW models: 20 V/m, which corresponds to EN 50121-3-2:2006 table 9.1 and exceeds EN 50121-4:2006 table 1.1.
5EW models only. Corresponds to EN 50121-3-2:2006 table 9.2 and EN 50121-4:2006 table 1.2 (compliance with digital mobile phones).
6Corresponds to EN 50121-3-2:2006 table 7.2 and EN 50121-4:2006 table 2.2.
7Complies with EN 50121-3-2:2006 table 7.3 and EN 50121-4:2006 table 2.3.
8Corresponds to EN 50121-3-2:2006 table 8.1 and EN 50121-4:2006 table 3.1 (radio frequency common mode).
9Corresponds to EN 50121-3-2:2000. Covers EN 50155:1995, RIA12, direct transients, waveform D (EW models only).
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 14 of 25
MELCHER
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Fig. 12a
Conducted emissions of LW models with feature E:
Disturbances (quasi-peak) at the phase input according to
EN 55022, measured at Vi nom and Io nom. (LWN1801-6E)
Fig. 11b
Radiated emissions for LW models without feature E:
Typical electromagnetic field strength (quasi-peak) according
to EN 55014, measured at Vi nom and Io nom.
Fig. 11a
Conducted emissions for LW models without feature E: Typical
disturbances (quasi-peak) at the input according to EN 55022,
measured at Vi nom and Io nom.
07118b
EN 55022 B
80
70
60
50
40
30
20
10
0
0.03 0.3
0.1
1
3 10
dBµV
30 MHz
EN 55022 A
Emissions
Table 9: Electromagnetic emissions for LW models with feature E: (type tests with LWN1801-6E)
Phenomenon Standards Conditions Results
Harmonics EN 61000-3-2:2006 Vi = 230 V, Vo nom, Io nom Class A, D
Voltage fluctuation and flicker EN 61000-3-3 + A2:2005 Vi = 230 V, Vo nom, Io nom Complied
80
60
40
20
0
dBpW
50 100 150 200 250 300 MHz
07119a
Fig. 12b
Radiated emissions measured according to
EN 55022:2001 for LW models with feature E
(LWN1801-6E, antenna 3 m distance, horizontal polarized)
Note: An external toroid ferrite core across the input lines reduces
the emissions considerably.
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 15 of 25
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JM038a
30 50 100 200 500 1000 MHz
dBµV/m
10
20
30
40
0
50
TÜV-Divina, ESVS 30:R&S, BBA 9106/UHALP 9107:Schwarzb., QP, 2006-05-29
Testdistance 10 m, EWN2660-0 Ui=110 V, Uo=24 V Io= 2 x 5 A
EN 55011 A
<25 dbµV/m
L'
N'
Converter
PE' PE
PE
L
N
Choke
JM007
Fig. 13a
Conducted emissions of EW models:
Disturbances (peak) at the phase input according to EN 55011,
measured at Vi nom and Io nom. (EWN2660-0 )
Fig. 14a
Conducted disturbances (peak) of LW models (feature E)
with external filter at phase input according to EN 55011/
55022, at Vi = 230 VAC, Io nom (LWN1701-6E).
Fig. 14b
Conducted disturbances (average) of LW models (feature E)
with external filter at phase input according to EN 55011/
55022, at Vi = 230 VAC, Io nom (LWN1701-6E).
Fig. 15a
External filter to reduce conducted emissions of LW models
with feature E (L1 = L2 = 1.6 mH, Cx = 47 nF,
Cy = 2.2 nF)
Fig. 15b
External inlet filter
PMM 8000 PLUS Limit: 61204bqp Detector: Peak Phase Line Filter3 01.09.06
LWN1701-6E Ui=230VAC, Ponom, Schurter-Filter 4A + Drossel 11µH/4A
EN 55022 B
dBµV
60
40
20
0
0.2 0.5 1 2 5 10 20 MHz
JM005
PMM 8000 PLUS Limit: 61204bqp Detector: Peak, conducted Vi+, 6.6.06
EWN2660-0 Ui=110VDC, Io=10A, outputs in parallel configuration
EN 55011 B
dBµV
60
40
20
0
0.2 0.5 1 2 5 10 20 MHz
JM008
PMM 8000 PLUS
EN 55022 B
Limit: 61204aqp Detector: Average Phase line Filter3 01.09.06
LWN1701-6E Ui=230VAC, Ponom, Schurter-Filter 4A + Drossel 11µH/4A
dBµV
60
40
20
0
0.2 0.5 1 2 5 10 20 MHz
JM006
Fig. 13b
Radiated emissions of EW models, measured at Vi nom, I o nom ,
accord. to EN 55011, antenna 3 m distance, (EWN2660-0)
External EMC Filter for Models with Feature E
An external EMC filter can be connected to the inputs lines of
the converter . However , a small choke has to be included in the
phase line to avoid interferences between the internal and
external filter, which would cause dramatically increased low
harmonics.
Fig. 14a and 14b show the conducted emissions smoothed by
an external filter. The standards EN 55011 and 55022 define
limits for conducted (quasi)peak and conducted average
emissions. In general the limits for average emissions are more
difficult to meet.
The figure below shows the used external filter configuration
consisting of the inlet filter KMF1.1241.11 (4 A, Schurter
www.schurter.com) and the decoupling choke EPCOS
B82111B0000C018, 11 µH, 4 A, 6 × 20 mm.
Note: This filter allows for connection of an IEC inlet and is
available with 1 or 2 incorporated fuses.
A similar filter with AMP terminals (6.3 × 20 mm) is also available
(Schurter FMLB 5500.2028).
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
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Immunity to Environment al Conditions
Table 10: Mechanical stress and climatic
Test method Standard Test conditions Status
C ab Damp heat IEC/EN 60068-2-78 Temperature: 40 ±2 °C Converter
steady state MIL-STD-810D sect. 507.2 Relative humidity: 93 +2/-3 % not
Duration: 56 days operating
K b Salt mist, cyclic IEC/EN 60068-2-52 Concentration: 5% (30 °C) Converter
(sodium chloride Duration: 2 h per cycle not
NaCl solution) Conditions: 40 °C, 93% rel. humidity operating
Storage duration: 3 cycles of 22 h
Eb Bump IEC/EN 60068-2-29 Acceleration amplitude: 25 g n = 245 m/s2Converter
(half-sinusoidal) MIL-STD-810D sect. 516.3 Bump duration: 11 ms not operating,
6000 bumps: 1000 in each direction wall-mounted1
Acceleration amplitude: 10 g n = 98.1 m/s2Converter
Bump duration: 11 ms not operating,
6000 bumps: 1000 in each direction on DIN-rail 2
Fc Vibration IEC/EN 60068-2-6 Acceleration amplitude and 0.35 mm (10 – 60 Hz) Converter
(sinusoidal) MIL-STD-810D sect. 514.3 frequency (1 Octave/min): 5 gn = 49 m/s2 (60 – 2000 Hz) operating,
Test duration: 7.5 h (2.5 h each axis) wall-mounted1
Acceleration amplitude and 0.25 mm (10 – 60 Hz) Converter
frequency (1 Octave/min): 2 gn = 19 m /s2 (60 – 2000 Hz) operating,
Test duration: 7.5 h (2.5 h each axis) on DIN-rail 2
Ea Shock IEC/EN 60068-2-27 Acceleration amplitude: 50 g n = 490 m/s2Converter
(half-sinusoidal) MIL-STD-810D sect. 516.3 Bump duration: 11 ms not operating,
Number of bumps: 18 (3 in each direction) wall-mounted1
-- Shock EN 50155/EN 61373 3Acceleration amplitude: 5.1 gnConverter
sect. 10, class A and B Bump duration: 30 ms operating,
body mounted4Number of bumps: 18 (3 in each direction) on DIN-rail 2
Fh Random vibration IEC/EN 60068-2-64 Acceleration spectral density: 0.05 gn2/Hz Converter
broad band, Frequency band: 8 – 500 Hz operating,
digital control and Acceleration magnitude: 4.9 gn rms wall-mounted1
guidance Test duration: 3 h (1 h each axis)
Fda Random vibration IEC/EN 60068-2-35 Acceleration spectral density: 0. 01 gn2/Hz Converter
wide band, Frequency band: 20 – 500 Hz operating,
high reproducibility Acceleration magnitude: 2.2 gn rms mounted on a
Test duration: 1.5 h (0.5 h each axis) DIN-rail 2
-- Simulated long life EN 50155/ EN 613733Acceleration spectral density: 0.0 1 g n2/Hz Converter
time testing at sect. 8 and 9, class B Frequency band: 5 – 150 Hz operating,
increased random body mounted 3Acceleration magnitude: 0.8 g n rms mounted on a
vibration levels Test duration: 1.5 h (0.5 h each axis) DIN-rail 2
1Wall-mounted with brackets UMB-W [HZZ00618]; see Accessories
2Fastened on a DIN-rail with 2 additional DIN-rail fixing brackets DMB-EWG, see Accessories. This covers also wall-mounting with
brackets, because wall mounting performs better in vibration test.
3EW models (railway standards)
4Body mounted = chassis of a railway coach
Temperatures
Table 11: Temperature specifications, valid for an air pressure of 800 - 1200 hPa (800 - 1200 mbar)
Model LW models -6 EW models -0 Unit
Characteristics Conditions min max min max
TAAmbient temperature Converter –40 60 –40 703°C
TCCase temperature operating1–40 902–40 903
TSStorage temperature Not operating –40 100 – 4 0 100
1See Thermal Considerations
2See table 5 Po derating
3Mounted in vertical position
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 17 of 25
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138 (5.43")
106.6 (4.2")
113.6 (4.47")
15 (0.59")
122.8 (4.84")
103 (4.05")
33 (1.3")
49 (1.93")
09107c
108 (4.25")
Wall mounting
brackets
(accessories)
Measuring point for
case temperature T
C
T
C
Option M
(female connector)
13 (0.51")
31 (1.22")
29.4 (1.16")
43 (1.69")
LED
European
Projection
z axis
(vertical)
x axis
40 (1.6")
Option M
(female connector)
D-SUB Male
connector
Mechanical Data
Dimensions in mm.
Fig. 16
Case W01
EWN/LWN: weight approx. 1400 g
EWR/LWR: weight approx. 1200 g
Case designed by ATP, Munich.
Failure Rates
Table 12: MTBF
Values at specified Module types Ground benign Ground fixed Ground mobile Unit
case temperature 40 °C 40 °C 70 °C 50 °C
MTBF 1 LWR1601 892 000 180 000 197 000 68 000 h
LWN1601 644 000 131 000 72 000 51 000
LWN2660 522 000 101 000 55 000 38 000
1Calculated in accordance with MIL-HDBK-217E, notice 2.
W Series Data Sheet
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AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 18 of 25
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1357911
10067
246810
13
2
10066
Safety and Inst allation Instructions
Terminal Allocation
The terminal allocation tables define the electrical potential
of the converters.
Fig. 17b
View of the output terminals (cage clamp style)
Fig. 17a
View of the input terminals (cage clamp style)
Installation Instructions
The converters of the W Series are components, intended
exclusively for inclusion within other equipment by professional
installers. Installation must strictly follow the national safety
regulations in compliance with the enclosure, mounting,
creepage, clearance, casualty, markings and segregation
requirements of the end-use application.
DIN-rail mounting is possible with the built-in snap-fit device
on a DIN-rail. This fulfills the mechanical transport requirement s
as per ETSI 300019-1-2, class 2 (vertical).
To fulfill the requirements of IEC 721-3-2, class 2.1 (vertical), 2
additional fixing brackets HZZ00624-G (see Accessories) must
be fitted on the bottom side of the DIN-rail. For heavy duty
railway applications, we recommend installing all 4 fixing
brackets HZZ00624-G.
Chassis or wall mounting is possible using the universal
chassis-mounting brackets HZZ00618-G (see Accessories).
Such installation complies with IEC 721-3-2, class 2.2 (vertical
and horizontal).
Caution: Install the converters vertically, and make sure that there
is sufficient airflow available for convection cooling. The minimum
space to the next device should be: top/bottom: 30 mm, left/right:
20 mm.
The converters of the W Series are class I equipment: Input
terminal 1 ( ) and the output terminals 1 and 11 ( ) are
reliably connected to the case. For safety reasons it is essential
Fig. 18b
Dismounting from DIN-rail. Use proper tool (min. 3 mm
screwdriver) and adequate force.
Fig. 18a
Snap-fit mounting to DIN-Rail.
10073
10072
Table 13c: Terminal allocation output side
Pin no. Pin des. Single output Double output
1Functional Functional
earth to load earth to load
2 + Output positive Output 1 positive
3 + Output positive Output 1 positive
4 – Output negative Output 1 negative
5 – Output negative Output 1 negative
6 + Output positive Output 2 positive
7 + Output positive Output 2 positive
8 – Output negative Output 2 negative
9 – Output negative Output 2 negative
10 AUX Option Option
11 Functional Functional
earth to load earth to load
Table 13b: Input terminals of EW models
Pin no. Pin designation Electrical determination
1Protective earth PE
2 Vi– Input negative
3 Vi+ Input positive
Table 13a: Input terminals of LW models
Pin no. Pin designation Electrical determination
1Protective earth PE
2N Input neutral, DC negative
3L Input phase, DC positive
to connect the input terminal 1 ( ) with protective earth. Output
terminals 1 and 11 can be used to connect the output voltage(s)
or the load to functional earth.
W Series Data Sheet
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AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 19 of 25
MELCHER
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1
2
3
1007
4
Fig. 19
Cage clamp terminals. Use 0.5 to 2.5 mm2 (AWG 20 to 12)
solid or stranded wires depending on local requirements.
The phase input (L or Vi+) is internally fused; see Input Fuse.
This fuse is designed to break an overcurrent in case of a
malfunction of the converter and is not customer-accessible.
External fuses in the wiring to one or both input lines (L and/
or N ) may be necessary to ensure compliance with local
requirements. A built-in second fuse in the neutral path is
available as option F.
A second fuse in the wiring to the neutral terminal N or option
F is needed if:
• Local requirements demand an individual fuse in each
source line
• Neutral and earth impedance is high or undefined
• Phase and neutral of the mains are not defined or cannot be
assigned to the corresponding terminals (L to phase and
N to neutral).
Models with Option F: Caution! Double-pole/neutral fusing.
If the converters operate at source voltages above 250 VDC,
an external fuse or a circuit breaker at system level should be
installed.
Caution:
• Installation must strictly follow the national safety regulations.
• Do not open this apparatus!
Protection Degree and Cleaning Liquids
The protection degree of the converters is IP 20. Protective
covers over input and output terminals are available on
request; see Accessories.
Any penetration of liquid or foreign solid objects is to be
prevented, since the converters are not hermetically sealed.
Standards and Approvals
The converters of the LW Series with feature E were safety-
approved to EC/EN 60950-1 and UL/CSA 60950-1 2nd Ed.
(models without E: IEC/EN 60950), IEC 61010-1:C11:2002
(models without E: IEC 61010-1), and EN 50178:1997 (with and
without E).
The converters are UL508-listed components.
The EW models are safety-approved to IEC/EN 60950-1 and
UL/CSA 60950-1 2nd Ed.
The converters have been designed in accordance with said
standards for:
• Class I equipment
• Power supply for building-in, vertical mounting on 35 mm
DIN-rail or on a wall
• Overvoltage category II (III for 110 VAC supply)
• Basic insulation between input and case, based on
250 VAC
• Double or reinforced insulation between input and output,
based on 250 VAC and 350 VDC.
• Functional insulation between outputs and case.
• Functional insulation between outputs.
• Pollution degree 3 environment (AC-input) and degree 2 (DC
input).
The converters are subject to manufacturing surveillance in
accordance with the above mentioned standards and with
ISO9001:2000.
Operation at Frequencies Greater 60 Hz
The LW Series converters have been tested for operation up to
440 Hz. However, the Y and X caps are not approved to such
frequency. The leakage currents are higher than at 60 Hz,
whereas the output ripple voltage is lower.
Leakage Currents with AC Supply
Leakage currents flow due to internal leakage capacitance and
RFI suppression Y-capacitors. The current values are
proportional to the mains voltage and nearly proportional to the
mains frequency. They are specified at maximum operating
input voltage where phase, neutral, and protective earth are
correctly connected as required for class I equipment.
Leakage current may exceed 3.5 mA, if fi > 63 Hz.
Railway Applications
The W Series converters have been designed observing the
railway standards EN 50155 and EN 50121. All boards are
coated with a protective lacquer.
The EW Series is particularly suitable for connection to 110 V
railway batteries.
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 20 of 25
MELCHER
The Power Partners.
Isolation
The electric strength test is performed in the factory as routine
test in accordance with EN 50514 and IEC/EN 60950 and
should not be repeated in the field. The Company will not
honor warranty claims resulting from incorrectly executed
electric strength field tests.
Safety of Operator-Accessible Output Circuits
If the output circuit of a converter is operator accessible, it shall
be a SELV circuit according to IEC/EN 60950 related safety
standards.
The converters have SELV output circuits up to an output
voltage of 57.5 V. However, if the isolated outputs are
connected to another voltage source or connected in series
with a total of >57.5 V the outputs are hazardous.
It is the sole responsibility of the installer to ensure the
compliance with the relevant and applicable safety
regulations.
LED Indicator
A green LED is activated, when the output voltage Vo is within
the normal operating tolerance band.
Note: This LED is also activated, when the converter is not
powered by the input, but a loaded battery is connected to the
output.
Table 14: Isolation
Characteristic Input to case Output(s) to Output 1 to Unit
and output(s) case output 2 and AUX
Electric Factory test ≥1 s 2.8 1 1.4 0.5 kVDC
strength AC test voltage equivalent 2.0 1.0 0.35 kVAC
test to factory test
Insulation resistance >300 2 >300 2 >100 MΩ
1In accordance with IEC/EN 60950-1, subassemblies are pretested with 4.2 kVDC.
2Tested at 500 VDC.
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 21 of 25
MELCHER
The Power Partners.
1234
5
6
789
+
Power-Fail
D-SUB (female)
06141b
1
11
10
9
8
7
6
5
4
3
2
D2
+
AUX
1
11
10
9
8
7
6
5
4
3
2
Vo2+
or Vo+
Vo2+
or Vo+
1234
5
6
789
+
Power-Fail D2
D-SUB (female)
VCC
06140b
Description of Options
E designates LW models with improved EMC performance.
Refer to the EC Declaration of Conformity (last page). Feature
E is standard for new designs.
Single options D1, D2, D5, R are available (as single choice
options) on the AUX terminal (10), referenced to Vo–.
Option M1 and M2 designate a combination of several options
accessible via a D-SUB connector. Option M1 includes the
function SD (shutdown).
Note: In double-output models, the options D1, D5, R, and SD
concern only output 2.
Single Options Using the AUX Pin
The connection is shown in the figure below. For the
description refer to Adjustment of Vo or Vo2 (next section).
Multiple Options M1 or M2 via D-SUB Connector
The option board is suitable for applications, where several
options are needed. Option M1 is standard for battery charger
models, option M2 is suitable for applications without battery or
for simple applications with battery.
Table 16b: Option board M2
Function Description
R Output voltage adjust1
D2 Input voltage monitor Vi low
D5 Output voltage monitor1
(battery deep discharged): Vo low D5
D-adjust Adjustment of trigger values D1 and D5
1In double-output models, only output 2 is concerned.
Table 16a: Option board M1
Function Description
R Output voltage adjust1
D1 Output voltage monitor Vo low D11
D2 Input voltage monitor Vi low
D5 Output 2 voltage monitor1
(battery deep discharged): Vo low D5
Sys-OK System okay
SD Shutdown1
D-adj Adjustment of trigger values D1 and D5
1In double-output models, only output 2 is concerned.
Table 15: Pin allocation of the 9 pin D-SUB connector
Pin Designation Description
1 GND11System ground / common signal return
2 R R input3
3 VCC2Positive supply voltage (≈ output 2)
4 D1 Output voltage monitor Vo low D13
5 D5 Output 2 voltage monitor Vo low D53
6 SD Shutdown3
7 D-adj Adjustment of threshold values of D1 or D5
8 D2 Input voltage monitor Vi low
9 Sys-OK System okay (all outputs are okay)
1Do not connect GND1 (pin 1) with the neg. output (–)
2Do not connect VCC (pin 3) with the positive output (+)
3In double-output models, R, D1, D5, SD concern output 2 only.
Fig. 21
Option D2: Examples of relay
control to monitor a power failure.
Fig. 20
Connection of adjust resistors or an external voltage source to
adjust the output voltage Vo or Vo2 (option M1 or M2 not fitted)
AUX
1
11
10
9
8
7
6
5
4
3
2
Adjustment with V
ext
06142b
AUX
1
11
10
9
8
7
6
5
4
3
2
Adjustment with R
ext
Vo2+
or Vo+
Vo2–
or Vo–
R
ext1
R
ext2
V
ext
+
Vo2–
or Vo–
D2: Input Voltage Monitor (Power Fail)
D2 monitors the input voltage Vi. When Vi drops below 65±3
VAC or 92 VDC, the D2 signal output is high impedance (open-
collector, max. 50 V).
When Vi is greater then said level, the signal output D2 is
conducting: VD2 < 1.5 V , ID2 max < 50 mA. D1: Output Voltage
Monitor
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 22 of 25
MELCHER
The Power Partners.
1234
5
6
789
D-SUB (female)
06148b
Rx
Change threshold
Ry
VCC GND1
D-adj
D1: Output Voltage Monitor
D1 is intended for monitoring the bus voltage of a battery-
buffered system. It indicates that the system is powered from
the battery and can for instance be used as a warning signal or
to switch off a part of the load. When the output voltage Vo (or
Vo2) is greater than Vo low D1 specified in table 17, the D1 signal
output is conducting: VD1 < 1.5 V , ID1 max < 50 mA.
When Vo is lower, the D1 signal output is high impedance
(open-collector, max. 58.6 V). In double-output models, D1
monitors only output 2 (Vo2).
In applications without battery-buffering the D1 signal may not
be suitable, since smaller dynamic load changes may cause
D1 to trigger. For such applications, D 5 with a trigger level of
approx. 85% of Vo nom should be chosen (e.g., for a bus voltage
of 24.7 V: trigger level at 21 V).
D5: System Voltage Monitor (Battery Low)
D5 monitors the output voltage Vo (Vo2 in double-output
models) or the lowest admissible voltage of a connected
battery (battery deep discharge). The definition of D5 is similar
to D1, but the trigger level is lower. When Vo (or Vo2) is greater
than Vo low D5 specified in table 17, the D2 signal output is
conducting:
VD5 < 1.5 V , ID5 max < 50 mA.
When Vo is lower, the D5 signal output is high impedance
(open-collector, max. 58.6 V). In double-output models, D5
monitors only output 2 (Vo2).
In systems without battery support, D5 signals that Vo (or Vo2 )
is going to drop below a safe value.
In battery-buffered systems, D5 indicates that the battery has
reached its deepest discharge level prior to getting damaged.
The D5 signal can be used for instance to disable loads, save
data, or to start a controlled switch-off of running processes.
Adjustment of Threshold Levels (D1/D5)
Pin 7 of the D-SUB connector allows for adjustment of the
threshold levels of D1 and D5. Both levels are influenced by
the voltage divider Rx /Ry. Resistor Rx to pin 3 (VCC) lowers
the levels, whereas Ry to pin 1 (GND1) increases them (see
fig. 22).
SD: Shutdown
Reduces the output power to approx. 1 W, but the converter is
not fully disabled. In a no-load condition, Vo drops below 6.2 V;
see fig. 23. In double-output models, only output 2 is
influenced.
Table 18: Shutdown conditions
Voltage VSD on Result
shutdown pin
<0.7 V Converter disabled (Po approx. 1 W)
≥2.0 V or open Converter enabled
Sys-OK: Status
This function allows in a battery charger application for
checking, whether the output is correctly following the external
control signal at the R-input (coming for instance from the
temperature sensor). The logic is shown in table 19.
Fig. 23
Output voltage versus output current, while the shutdown is
activated (Vi = Vi nom).
05175b
3
1
0 0.2 0.4 0.6 0.8 1.2
1A
5
Output current
V
Output voltage
Fig. 22
Wiring to adjust both threshold levels of option D1 or D5
Table 17: Options D1 and D5: Trigger and switch-on levels
Model Battery Vo low D1 Vo low D 5
VBat trigger switch on trigger switch on
[V] [V] [V] [V] [V]
LWR/LWN1140 12 11.5 12.1 10.5 12.1
LWR/LWN1240 24 23 24.2 21 24.2
LWR/LWN1840 36 34.4 36.3 31.5 36.3
LWR/LWN1740 48 46 48.4 42 48.4
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 23 of 25
MELCHER
The Power Partners.
Fig. 24
System connectors Option K2
R: Adjustment of Vo or Vo2
The R input allows external adjustment of the output voltage in
the range of 50% to 110% Vo nom. Double-output models allow
only adjustment of output 2 (connected to the terminals 6, 7, 8
and 9). This enables asymmetric output voltage configuration.
Adjustment can be achieved via a resistor or an external
voltage source (in the range of 1.25 – 2.75 V).
Note: If the R input is not connected: Vo or Vo2 ≈ Vo nom.
a) Adjustment by an external resistor:
Resistor Rext1, connected between R (pin 2) and GND1 (pin
1) of the D-SUB connector or according to fig. 20.
Vo
Vo= 50 – 100% Vo nom. Rext1 ≈ 4 kΩ • –––––––––
Vo nom – Vo
Resistor Rext2, connected between R (pin 2) and VCC (pin 3)
of the D-SUB connector or according to fig. 20.
Vo – 2.5 V
Vo= 100 – 110% Vo nom. Rext2 ≈ 4 kΩ • ––––––––––––––––
2.5 V•(Vo/Vo nom –1)
Note: If the R function is not included in M1 or M2, refer to figure
20 how to connect Rext1 or Rext2 .
b) Adjustment by an external control voltage Vext (1.25 – 2.75
V), connected between R (pin 2) and GND (pin 1) of the D-
SUB connector or according to fig. 20.
VoVext
Vext ≈ 2.5 V • ––––– Vo ≈ Vo nom • ––––
Vo nom 2.5 V
Caution: To prevent damage, Vext should not exceed 3 V, nor be
negative.
Note: If longer wires are used to connect the R input at the D-SUB
connector, the wiring to pin 1 (GND1) should be done as star point
connection. If wired differently, the output voltage setting may be
adversely affected.
In battery charging systems, an external battery temperature
sensor (see Accessories) can be connected to optimize Vo.
However, adjustment using the R input (pin 2 of D-SUB) is
possible as well. The above shown formulas are valid, but
Vo nom stands for the voltage with open R input (= Vo safe).
F: Built-in Second Fuse
A built-in second fuse in the neutral line provides safe phase-
to-phase connection at low mains voltages (e.g., USA 120 V/
208 V / 60 Hz systems).
The built-in second fuse also enables safe connection to the
mains, where phase and neutral are not defined or cannot be
identified, as e.g., in the case of plug and socket connection to
the mains via German Schuko-plugs; see also Safety and
Installation Instructions.
Option F limits the DC input voltage to ≤ 250 V.
Q: Reverse Polarity Protection
EW models have no bridge rectifier at the input. To provide
reverse polarity protection, an additional diode can be fitted.
However this lowers the efficiency by approximately 1%.
K2: System Connectors
For installation in systems using pre-assembled harnesses the
converters are available with system connectors. They are UL-
listed, approved for currents up to 15 A at –40 to 105 °C.
The mating system connectors with screw terminals and
retainers are delivered together with every converter with
option K2. Use max. 2.5 mm2 (AWG 12) solid or stranded wires,
or max. 1.5 mm2 (AWG 14) stranded wires with crimp
termination, stripped length 6 mm. Tightening torque of input/
output terminals: max. 0.79 Nm (7 lbs.in.).
G: RoHS
RoHS compliant for all six substances.
Table 19: System OK (M1 with external battery sensor)
System Status Input Vcontrol VBat VBat Sys-OK
sensor signal theoretical measured output
System OK O.K. 2.7 V 27 V 27 V Low ohmic
Battery overchared / temp. sensor O.K. 2.7 V 27 V 28 V High ohmic
defect / control voltage to high
Overload, converter cannot follow the O.K. 2.7 V 27 V 24 V High ohmic
control signal
Output does not follow control signal, O.K. 3.0 V 30 V 27 V High ohmic
since battery would be overcharged
System OK O.K. 2.5 V 25 V 25 V Low ohmic
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 24 of 25
MELCHER
The Power Partners.
Accessories
Shock-Resistant Wall Mounting
Set of wall mounting brackets HZZ00618-G (UMB-W)
Content: 2 clamps, 4 countersunk screws M4, washers, and
spring washers.
Fig. 25
Wall mounting brackets
HZZ00618-G Fig. 26
Wall mounting with mounting
brackets HZZ00618-G
DIN-Rail Fixing Brackets HZZ00624-G
For DIN-Rail vibration-proof fastening, use a set of brackets
HZZ00624-G (DMB -EWG). For heavy-duty application 2 sets
(= 4 brackets) are preferable.
Protective Covers over Terminals
Protective covers are available to avoid touching of the
terminals. HZZ01219-G and HZZ01219A-G (protective covers
with cut-outs) contain in a bag a plastic cover with length
A = 26.5 mm for the primary terminals and a second one with
length A = 59 mm for the secondary terminals; see figures below.
Content: 2 covers to protect the input and output terminals.
Fig. 27
DIN-rail fixing bracket HZZ00624-G (DMB-EWG)
Fig. 28
Protective covers HZZ01219-G
49
33 ±0.5
4.2
8
18
3
12055
10068
Fig. 28A
Protective covers with cut outs HZZ01219A-G
W Series Data Sheet
125, 250 W att
AC-DC
and
DC-DC
DIN-Rail Converters
BCD20020-G Rev AE, 25-APR-2018 Page 25 of 25
MELCHER
The Power Partners.
+–
Battery
R
GND
Temperature
sensor
+–
05191a
green
brown
white
D-SUB
Fuse
Load
Vo+
Vo–
Converter
2
3
1
VCC
Fig. 30
Connection of temperature sensor
Fig. 29
Temperature sensor
Battery Temperature Sensor
To charge lead-acid batteries according to their temperature
different types of temperature sensors are available, (see
Battery Charging and Temperature Sensor in this data sheet
and the Temperature Sensor data sheet at www.power-
one.com).
For additional accessory product information, see the
accessory data sheets listed with each product series or
individual model at our website.
European
Projection
56 (2.2")L
L = 2 m (standard length)
other cable lengths on request
adhesive tape
26 (1.02")
9.8 (0.4")
09125a
Table 20: Sensors for converters with standard R-input
Battery Sensor Cell Cell temp. Cable
voltage type voltage
coefficient
length
nom. [V] [V] [mV/K] [m]
12 S-KSMH12-2.27-30-2 2.27 –3.0 2
12 S-KSMH12-2.27-35-2 2.27 –3.5 2
24 S-KSMH24-2.27-30-2 2.27 –3.0 2
24 S-KSMH24-2.27-35-2 2.27 –3.5 2
24 S-KSMH24-2.31-35-0 2.31 –3.5 4.5
24 S-KSMH24-2.31-35-2 2.31 –3.5 2
24 S-KSMH24-2.35-35-2 2.35 –3.5 2
48 S-KSMH48-2.27-30-2 2.27 –3.0 2
48 S-KSMH48-2-27-35-2 2.27 –3.5 2
NUCLEAR AND MEDICAL APPLICATIONS - These products are not designed or intended for use as critical components in life support systems,
equipment used in hazardous environments, or nuclear control systems.
TECHNICAL REVISIONS - The appearance of products, including safety agency certifications pictured on labels, may change depending on the
date manufactured. Specifications are subject to change without notice.
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