S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Features * RoHS lead-free-solder and lead-solder-exempted products are available. * Compliant with EN 50155, EN 50121-3-2, EN 45545. * Class I equipment * Extremly wide input voltage ranges from 8 to 385 VDC, and 85 to 264 VAC, 47 to 440 Hz * Input over- and undervoltage lockout * Adjustable output voltage with remote on/off * 1 or 2 outputs: SELV, no load, overload, and shortcircuit proof * Rectangular current limiting characteristic * PCBs protected by lacquer * Very high reliability Safety-approved according to IEC/EN 60950-1, UL/CSA 60950-1 2nd Ed. 111 4.4" 3U 60 2.4" 12 TE 168 6.6" Description The S Series of DC-DC and AC-DC converters represents a broad and flexible range of power supplies for use in advanced electronic systems. Features include high efficiency, high reliability, low output voltage noise and excellent dynamic response to load/line changes. LS models can be powered by DC or AC with a wide-input frequency range (without PFC). The converter inputs are protected against surges and transients. An input over- and undervoltage lockout circuitry disables the outputs, if the input voltage is outside of the specified range. Certain types include an inrush current limiter preventing circuit breakers and fuses from tripping at switchon. All outputs are open- and short-circuit proof, and are protected against overvoltages by means of built-in suppressor diodes. The output can be inhibited by a logic signal applied to pin 18 (i). The inhibit function is not used, pin 18 must be connected with pin 14 to enable the outputs. LED indicators display the status of the converter and allow for visual monitoring of the system at any time. Table of Contents Full input-to-output, input-to-case, output-to-case, and output to output isolation is provided. The converters are designed, built, and safety-approved to the international safety standards IEC/EN 60950-1. They are particulary suitable for railway applications and comply with EN 50155 and EN 50121-3-2. The case design allows operation at nominal load up to 71 C in a free-air ambient temperature. If forced cooling is provided, the ambient temperature may exceed 71 C, but the case temperature must remain below 95 C under all conditions. A temperature sensor generates an inhibit signal, which disables the outputs when the case temperature TC exceeds the limit. The outputs are automatically re-enabled, when the temperature drops below the limit. Various options are available to adapt the converters to individual applications. The converters may either be plugged into a 19" rack system according to IEC 60297-3, or be chassis mounted. They are ideally suited for Railway applications. Important: For applications requiring compliance with IEC/EN 61000-3-2 (harmonic distortion), please use our LS4000 or LS5000 Series with incorporated power factor correction (PFC). Page Description .......................................................................... 1 Model Selection .................................................................. 2 Functional Description ........................................................ 4 Electrical Input Data ............................................................ 5 Electrical Output Data ......................................................... 8 Auxiliary Functions ............................................................ 12 Page Electromagnetic Compatibility (EMC) ............................... Immunity to Environmental Conditions ............................. Mechanical Data ............................................................... Safety and Installation Instructions ................................... Description of Options ...................................................... Accessories ....................................................................... 15 17 18 20 23 30 MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 1 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Model Selection Non-standard input/output configurations or special customer adaptations are available on request. Table 1a: Models AS Output 1 Vo nom Io nom [VDC] [A] Output 2 Vo nom Io nom [VDC] [A] Input Voltage Vi min - Vi max 8 - 35 VDC Effic.1 min [%] Input Voltage Vi min - Vi max 14 - 70 VDC Effic.1 min [%] Options 5.1 16 - - AS1001-9R 76 BS1001-9R 77 -7, P, D, V 2, T, B, B1, G 12 15 24 8 6.5 4.2 - - - - - - AS1301-9R AS1501-9R AS1601-9R 81 83 84 BS1301-9R BS1501-9R BS1601-9R 83 85 86 -7, P, D, T, B, B1, G 12 15 24 4 3.2 2 12 3 15 3 24 3 4 3.2 2 AS2320-9R AS2540-9R AS2660-9R 79 80 80 BS2320-9R BS2540-9R BS2660-9R 80 82 82 -7, P, D, T, B, B1, G Input Voltage Vi min - Vi max 20 - 100 VDC Effic.1 min [%] Input Voltage Vi min - Vi max 28 - 140 VDC Table 1b: Models BS, FS, CS Output 1 Vo nom Io nom [VDC] [A] Output 2 Vo nom Io nom [VDC] [A] Effic.1 min [%] Options 5.1 16 - - FS1001-9ER 77 CS1001-9ER 77 -7, P, D, V 2, T, B, B1, G 12 15 24 8 6.5 4.2 - - - - - - FS1301-9ER FS1501-9ER FS1601-9ER 83 84 86 CS1301-9ER CS1501-9ER CS1601-9ER 83 84 85 -7, P, D, T, B, B1, G 12 15 24 4 3.2 2 12 3 15 3 24 3 4 3.2 2 FS2320-9ER FS2540-9ER FS2660-9ER 80 82 82 CS2320-9ER CS2540-9ER CS2660-9ER 80 82 82 -7, P, D, T, B, B1, G Table 1c: Models DS, ES, LS Output 1 Vo nom Io nom [VDC] [A] Output 2 Vo nom Io nom [VDC] [A] Input Voltage Vi min - Vi max 44 - 220 VDC Effic.1 Input Voltage min Vi min - Vi max [%] 67 - 385 VDC Effic.1 min [%] Input Voltage Vi min - Vi max 88 - 372 VDC 85 - 264 VAC Effic.1 min [%] Options 5.1 16 - - DS1001-9ER 79 --- -- LS1001-9ER 78 -7, P, D, V 2, T, B, B1, G 12 12.84 5 15 24 8 7.5 6.5 4.2 - - - - - - - - DS1301-9ER DS1740-9ER 5 DS1501-9ER DS1601-9ER 84 83 -84 86 LS1301-9ER LS1740 -9ER 5 LS1501-9ER LS1601-9ER 83 -7, P, D, T, B, B1, G 86 86 ES1301-9ER --ES1501-9ER ES1601-9ER 84 85 12 15 24 4 3.2 2 12 3 15 3 24 3 4 3.2 2 DS2320-9ER DS2540-9ER DS2660-9ER 81 82 83 ES2320 -9ER ES2540-9ER ES2660-9ER 81 83 83 LS2320-9ER LS2540-9ER LS2660 -9ER 80 81 81 25.68 6 1.8 25.68 3 1.8 DS2740-9ER 6 --- -- LS2740-9ER 6 1 2 3 4 5 6 6 -7, P, D, T, B, B1, G -7, T, B, B1, G Min. efficiency at Vi nom, Io nom and TA = 25 C. Typical values are approximately 2% better. Option V excludes option D and vice versa. For models with 5.1 V output only. Second output semi-regulated Models FS, CS, DS, ES, LS are available as -7 or -9E. Battery loader for 12 V batteries. Vo is controlled by the battery temperature sensor (see Accessories) within 12.62 - 14.12 V. Options P, D, and V are not available. Battery loader for 24 V (and 48 V batteries with series-connected outputs). Vo is controlled by the battery temperature sensor (see Accessories) within 25.25 - 28.25 V (50.5 - 56.5 V for 48 V batteries). Options P, D, and V are not available. NFND: Not for new designs Preferred for new designs MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 2 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Part Number Description Operating input voltage Vi: 8 - 35 VDC ................................................................ AS 14 - 70 VDC .............................................................. BS 20 - 100 VDC ............................................................ FS 28 - 140 VDC ........................................................... CS 44 - 220 VDC .......................................................... DS 67 - 385 VDC ........................................................... ES 85 - 264 VAC or 88 - 372 VDC ................................ LS CS 2 5 40 -9 E R D3 T B1 G Number of outputs .......................................................... 1, 2 Nominal voltage of output 1 (main output) Vo1 nom 5.1 V .................................................................... 0, 1, 2 12 V ............................................................................ 3 15 V ........................................................................ 4, 5 24 V ............................................................................ 6 Other voltages 1 ....................................................... 7, 8 Nominal voltage of output 2 Vo2 nom None (single-output models) ..................................... 12 V, 12 V .................................................................. 15 V, 15 V .................................................................. 24 V, 24 V .................................................................. Other specifications or additional features 1 ...... 21 - 00 20 40 60 99 Operational ambient temperature range TA: -25 to 71 C ............................................................... -7 - 40 to 71 C ............................................................... -9 Other 1 ............................................................... -0, -5, -6 Auxiliary functions and options: Inrush current limitation ............................................. E 2 Output voltage control input ....................................... R 3 Potentiometer (output voltage adjustment) ................ P 3 Undervoltage monitor (D0 - DD, to be specified) ...... D 4 ACFAIL signal (V2, V3, to be specified) .................... V 4 Current share control ................................................... T Cooling plate standard case .............................. B or B1 Cooling plate for long case 220 mm 1 ............................... B 2 1 RoHS-compliant for all 6 substances 5 ................................... G 1 2 3 4 Customer-specific models Option E is mandatory for all -9 models, except AS and BS. Feature R excludes option P and vice versa. Option P is not available for battery charger models. Option D excludes option V and vice versa; option V is only available for models with 5.1 V single output. Note: The sequence of options must follow the order above. This part number description is descriptive only; it is not inteded for creating part numbers. Example: CS2540-9ERD3T B1G: DC-DC converter, operating input voltage range 28 - 140 VDC, 2 electrically isolated outputs, each providing 15 V, 3.2 A, input current limiter E, control input R to adjust the output voltages, undervoltage monitor D3, current share feature T, cooling plate B1, and RoHS-compliant for all six substances. Product Marking Basic type designation, applicable approval marks, CE mark, warnings, pin designation, patents and company logo, identification of LEDs, test sockets, and potentiometer. Specific type designation, input voltage range, nominal output voltages and currents, degree of protection, batch no., serial no., and data code including production site, modification status, and date of production. MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 3 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Functional Description The input voltage is fed via an input fuse, an input filter, a bridge rectifier (LS models only), and an inrush current limiter to the input capacitor C1. This capacitor sources a singletransistor forward converter with a special clamping circuit and provides the power during the hold-up time. Each output is powered by a separate secondary winding of the main transformer. The resultant voltages are rectified and their ripple smoothed by a power choke and an output filter. The control logic senses the main output voltage Vo1 and generates, with respect to the maximum admissible output currents, the control signal for the switching transistor of the forward converter. The second output of double-output models is tracking to the main output, but has its own current limiting circuit. If the main output voltage drops due to current limitation, the second output voltage will fall as well and vice versa. 03057b 26 Vi+ 28 18 i 20 D/V 4 Ci + 4 CY 22 T 12 S+ 4 Vo- 10 30 Vi- 32 14 S- CY - Fig. 1 Block diagram of single-output converters 2 3 4 8 CY 3 24 1 Vo+ 6 Output filter Forward converter (approx. 120 kHz) Fuse 1 Bridge rectifier 4 Input filter 2 L 16 R CY Control circuit 4 N Opt. P + Transient suppressor (VDR) Suppressor diode (AS, BS, FS models) For CS, DS, ES, LS: Either NTC (-7 models only) or option E LS models only 03058b Opt. P Vi+ 28 18 i 4 20 D 4 Vi- Forward converter (approx. 120 kHz) 22 T CY CY 12 Vo1+ 14 Vo1- CY 4 3 6 Output 2 filter L Ci + Bridge rectifier 4 Fuse 1 Input filter 2 Output 1 filter 4 16 R CY Control circuit N 26 30 32 CY 8 CY 10 24 Fig. 2 Block diagram of double-output models 1 2 3 4 Vo2+ - Vo2- + Transient suppressor (VDR) Suppressor diode (AS, BS, FS models) For CS, DS, ES, LS: Either NTC (-7 models only) or option E LS models only MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 4 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Electrical Input Data General Conditions - TA = 25C, unless TC is specified. - Pin 18 connected to pin 14, Vo adjusted to Vo nom (if option P); R input not connected. - Sense line pins S+ and S- connected to Vo+ and Vo- respectively. Table 2a: Input data Input AS Characteristics Conditions Vi Operating input voltage V i nom Nominal input voltage Io = 0 - Io nom TC min -TC max Ii Input current Vi nom, Io nom 1 Pi 0 No-load input power Vi min - Vi max P i inh Idle input power unit inhibited Ri Input resistance TC = 25 C NTC resistance Ci Input capacitance V i RFI Conducted input RFI typ 8 max min 35 14 15 typ max min 70 20 m no NTC 1200 1500 A F B A 40 W 1.5 370 A 0 2.5 70 no NTC 300 VDC A 1.5 1040 100 2.6 100 A Input voltage limits without damage max 2.5 1.5 832 typ 4.3 65 EN 55022 V i nom, I o nom Unit 50 2.5 no NTC Radiated input RFI FS 30 7.5 2 R NTC V i abs min BS A 0 84 0 100 VDC Table 2b: Input data Input CS Characteristics Vi Conditions Operating input voltage Io = 0 - Io nom TC min - TC max min typ 28 DS max min 140 44 typ ES max min 220 67 typ LS max min 385 88 85 typ Unit max 372 4 264 4 V i nom Nominal input voltage Ii Input current Vi nom, Io nom 1 Pi 0 No-load input power Vi min - Vi max 2.5 2.5 2.5 2.5 P i inh Idle input power unit inhibited 1.5 1.5 1.5 4.5 TC = 25 C Ri Input resistance R NTC NTC resistance 2 Ci Input capacitance V i RFI Conducted input RFI Radiated input RFI V i abs 1 2 3 4 60 110 220 310 VDC 1.1 0.55 0.37 A 170 1000 EN 55022 V i nom, I o nom Input voltage limits without damage 0 VAC 2.1 150 960 VDC 180 2000 1200 264 330 216 m 480 4000 4000 270 216 270 B B B B B A A A 154 0 400 3 0 W 400 -400 F 400 VDC Both outputs of double-output models are loaded with Io nom. Valid for -7 versions without option E (-9 versions exclude NTC). This is the nominal value at 25 C and applies to cold converters at initial switch-on cycle. Subsequent switch-on/off cycles increase the inrush current peak value. For 1 s max. Nominal frequency range is 50 - 60 Hz. Operating frequency range is 47 - 440 Hz (440 Hz for 115 V mains). For frequencies 63 Hz, refer to Installation Instructions. MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 5 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Input Transient Protection Inrush Current Limitation A suppressor diode or a VDR (depending upon the input voltage range) together with the input fuse and a symmetrical input filter form an effective protection against high input transient voltages which, typically occur in most installations, but especially in battery-driven mobile applications. The FS, CS, DS, ES, LS models incorporate an NTC resistor in the input circuitry, which at initial turn-on reduces the peak inrush current value by a factor of 5 - 10 such protecting connectors and switching devices from damage. Subsequent switch-on cycles within short periods will cause an increase of the peak inrush current value due to the warming-up of the NTC resistor. See also Option E. Standard nominal battery voltages are: 12, 24, 36, 48, 60, 72, 110, and 220 V. Railway batteries are specified with a tolerance of -30% to +25%, with short excursions up to 40%. In certain applications, additional surges according to RIA 12 are specified. The power supply must not switch off during these surges, and since their energy can practically not be absorbed, an extremely wide input range is required. The ES input range for 110 V batteries has been designed and tested to meet this requirement. Input Fuse 05109a Rs ext + A fuse mounted inside the converter protects against severe defects. This fuse may not fully protect the converter, when the input voltage exceeds 200 VDC. In applications, where the converters operate at source voltages above 200 VDC, an external fuse or a circuit breaker at system level should be installed. Table 3: Fuse Specification Fuse type Reference AS BS FS CS DS ES LS fast-blow 1 fast-blow 1 slow-blow 2 slow-blow 2 slow-blow 2 slow-blow 2 slow-blow 2 Littlefuse 314 Littlefuse 314 Schurter SPT Schurter SPT Schurter SPT Schurter SPT Schurter SPT Fuse size 6.3 x 32 mm Iinr p RNTC Ri Ci int Vi source Fig. 4 Equivalent input ciruit Static Input Current Characteristic Model 1 The inrush current peak value (initial switch-on cycle) can be determined by following calculation; see also fig. 3: Vi source Iinr p = ---------------- (Rs ext + Ri + RNTC) 2 Rating 30 A, 125 V 25 A, 125 V 16 A, 250 V 12.5 A, 250 V 8 A, 250 V 4 A, 250 V 4 A, 250 V Ii (A) 20 04037a 10 5 Fuse size 5 x 20 mm AS Ii inr [A] 2 BS 1 FS CS 04038a 150 DS 0.5 ES 100 1 2 CS ES, LS DS 3 4 5 6 Vi Vi min LS (DC input) Fig. 5 Typical input current versus relative input voltage 50 Reverse Polarity 0 0.1 1 2 3 t [ms] Fig. 3 Typical inrush current versus time at Vi max, Rext = 0 . For AS, BS, FS, and for application-related values, use the formula in this section to get realistic results. The converters (except LS models) are not protected against reverse polarity at the input to avoid unwanted power losses. In general, only the input fuse will trip. LS models are fully protected by the built-in bridge rectifier. MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 6 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Input Under-/Overvoltage Lockout If the input voltage remains below approx. 0.8 Vi min or exceeds approx. 1.1 Vi max, an internally generated inhibit signal disables the output(s). When checking this function, the absolute maximum input voltage V i abs should be observed. Between Vi min and the undervoltage lock-out level the output voltage may be below the value defined in table Electrical Output data. Hold-Up Time th [ms] 04041a ES CS FS DS 100 10 AS BS 1 0.30 1 2 3 4 5 6 Vi ----- Vi min Fig. 6a Typical hold-up time t h versus relative DC input voltage. Vi /Vi min. DC-DC converters require an external series diode in the input path, if other loads are connected to the same input supply lines. th [ms] 04049a 100 10 V i _______ 2 1 2 3 4 Vi min Fig. 6b Typical hold-up time t h versus relative AC input voltage (LS models) MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 7 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Electrical Output Data General Conditions: - TA = 25 C, unless TC is specified. - Pin 18 (i) connected to pin 14 (S- or Vo1-), R input not connected, Vo adjusted to Vo nom (option P), - Sense line pins 12 (S+) and 14 (S-) connected to pins 4 (Vo1+) and 8 (Vo1-), respectively. Table 5: Output data of single-output models Model Nom. output voltage Characteristics Vo AS - LS1001 5.1 V Conditions Output voltage Vi nom, Io nom Vo BR Overvoltage protection (suppressor diode) 7 Io nom Output current nom. 1 Vi min - Vi max TC min - TC max IoL Output current limit Vi min - Vi max vo Output noise 3 Low frequency8 Switching frequ. min typ 5.07 max min 5.13 11.935 Total incl. spikes typ AS - LS1501 15 V max min 12.075 14.91 15.2/17.55 6.0 Vi nom, I o nom BW = 20 MHz AS - LS1301/1740 5 12 V / 12.84 V 5 typ 15.09 23.86 Unit max 24.14 V 28.5 4.2 6.7 5 min 6.5 8.2/7.7 5 16.2 max 19.6 8/7.55 16 typ AS - LS1601 24 V A 4.4 5 5 10 5 5 5 50 50 60 90 5 mVpp mV Vo u Static line regulation with respect to Vi nom Vi min - Vi max Io nom 15 20 25 30 Vo I Static load regulation 10 Vi nom (0.1 - 1) Io nom -20 -25 -30 - 40 vo d Dynamic Voltage Vi nom load deviation 6 Io nom 1/2 Io nom regulat.3 6 Recovery time 100 100 100 100 0.4 0.5 0.5 0.5 ms Temperature coefficient of output voltage 4 0.02 0.02 0.02 0.02 %/K td vo 1 2 3 4 5 6 7 8 TC min - TCmax Io nom If the output voltages are increased above Vo nom through R-input control, option P setting, remote sensing or option T, the output currents should be reduced accordingly so that Po nom is not exceeded. See Output voltage regulation Measured according to IEC/EN 61204 with a probe according to annex A For battery charger applications, a defined negative temperature coefficient can be provided by using a temperature sensor (see Accessories), but we recommend choosing the special battery charger models. Especially designed for battery charging using the temperature sensor (see Accessories). Vo is set to 12.84 V 1% (R-input open) See Dynamic load regulation Breakdown voltage of the incorporated suppressor diode (1 mA; 10 mA for 5 V output). Exceeding Vo BR is dangerous for the suppressor diode. LS models only (twice the input frequency) MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 8 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Table 6a: Output data of double-output models. General conditions as per table 5. Model Nom. output voltage AS - LS2320 2 x 12 V Output 1 Vo Vi nom, Io1 nom, Io2 nom 11.93 12.07 11.82 12.18 14.91 15.2 15.2 19.6 Vo BR Overvoltage protection (suppressor diode) Io nom Output current nom. 2 Vi min - Vi max TC min - TC max IoL Output current limit 9 Vi min - Vi max vo Output noise 3 Low frequency 8 min typ max 4 15.09 14.78 5 50 50 Vi nom (0.1 - 1) Io nom -40 5 vo d Dynamic Voltage load deviation 4 regulat. Recovery time 4 Vi nom, Io1 nom 1/2 Io1 nom Temperature coefficient of output voltage 6 TC min - TC max Io nom 100 150 100 Vi nom, Io1 nom, Io2 nom 23.86 7 Vo BR Output voltage Io nom Output current nom.2 Vi min - Vi max TC min - TC max IoL Output current limit 9 Vi min - Vi max vo Output Low frequency8 noise 3 Switching freq. Vi nom, I o nom BW = 20 MHz Total incl. spikes %/K 1 typ max min typ 24.14 7 23.64 7 2 max 24.36 7 V 28.5/347 2 / 1.8 7 2 / 1.8 7 2 .2/ 2.0 7 A 2 .2/ 2.0 7 3 4 5 5 5 5 50 50 Vi min - Vi max Io nom 30 5 Vo I Static load regulation Vi nom (0.1 - 1) Io nom -60 5 v o Unit Output 2 Static line regulation with respect to Vi nom td 150 0.02 Vo u vo d 5 0.02 28.5/347 Overvoltage protection (suppressor diode) -50 mV ms Output 1 1 5 0.2 AS - LS2660 / 2740 7 2 x 24 V / 2 x 25.68 V 7 Vo 25 mVpp 0.2 Table 6b: Output data of double-output models. General conditions as per table 5. min A 5 40 Static load regulation V 3.4 40 Vo I Conditions 3.2 5 20 Characteristics 15.22 5 Vi min - Vi max I o nom max 19.6 5 Static line regulation with respect to Vi nom Model Nom. output voltage typ 5 Vo u v o min 5 5 /2 Io2 nom Unit Output 2 max 3.4 5 1 typ 3.2 4.2 Total incl. spikes td min 4 4.2 Vi nom, Io nom BW = 20 MHz Switching freq. max Output 1 Conditions Output voltage typ Output 2 Characteristics 1 min AS - LS2540 2 x 15 V mVpp 5 6 mV 7 Dynamic Voltage Vi nom Io1 nom 1/2 Io1 nom load deviation 4 1 regulat. 4 /2 Io2 nom Recovery time 100 150 0.2 ms Temperature coefficient TC min - TC max of output voltage 6 Io nom 0.02 %/K 8 9 Breakdown voltage of the incorporated suppressor diodes (1 m A). Exceeding Vo BR is dangerous for the suppressor diodes. If the output voltages are increased above Vo nom via Rinput control, option P setting, remote sensing, or option T, the output currents should be reduced accordingly, so that Po nom is not exceeded. Measured according to IEC/EN 61204 with a probe annex A See Dynamic Load Regulation See Output Voltage Regulation of Double-Output Models For battery charger applications, a defined negative temperature coefficient can be provided by using a temperature sensor; see Accessories. Especially designed for battery charging using the battery temperature sensor; see Accessories. Vo1 is set to 25.68 V 1% (Rinput open-circuit). LS models only (twice the input frequency) Both outputs connected in series. MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 9 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Thermal Considerations If a converter is located in free, quasi-stationary air (convection cooling) at the indicated maximum ambient temperature TA max (see table Temperature specifications) and is operated at its nominal input voltage and output power, the temperature measured at the Measuring point of case temperature TC (see Mechanical Data) will approach the indicated value TC max after the warm-up phase. However, the relationship between TA and TC depends heavily upon the conditions of operation and integration into a system. The thermal conditions are influenced by input voltage, output current, airflow, and temperature of surrounding components and surfaces. 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. Notes: Sufficient forced cooling or an additional heat sink allows TA to be higher than 71 C (e.g., 85 C), as long as TC max is not exceeded. Details are specified in fig.7 applied overvoltages. Overload at any of the outputs will cause a shut-down of all outputs. A red LED indicates the overload condition. Note: Vo BR is specified in Electrical Output Data. If this voltage is exceeded, the suppressor diode generates losses and may become a short circuit. Parallel and Series Connection Single- or double-output models with equal output voltage can be connected in parallel using option T (current sharing). If the T pins are interconnected, all converters share the output current equally. Single-output models and/or main and second outputs of double-output models can be connected in series with any other (similar) output. Notes: - Parallel connection of double-output models should always include both, main and second output to maintain good regulation. - Not more than 5 converters should be connected in parallel. Io /Io nom - Series connection of second outputs without involving their main outputs should be avoided, as regulation may be poor. 1.0 05089a 0.8 - The maximum output current is limited by the output with the lowest current limitation, if several outputs are connected in series. Forced cooling Convection cooling 0.6 TC max 0.4 Vo/Vo nom 0.2 0.98 0 TA min 50 60 70 80 90 100 TA [C] Fig. 7 Output current derating versus temperature for -7 and -9 models. 0.5 Io1 IoL Thermal Protection 05098a 0 A temperature sensor generates an internal inhibit signal, which disables the outputs, when the case temperature exceeds TC max. The outputs automatically recover, when the temperature drops below this limit. Continuous operation under simultaneous extreme worst-case conditions of the following three parameters should be avoided: Minimum input voltage, maximum output power, and maximum temperature. 0.5 1.0 Io/Io nom Fig. 8 Output characteristic Vo versus Io (single-output models or double-output models with parallel-connected outputs). Output Protection Each output is protected against overvoltages, which could occur due to a failure of the internal control circuit. Voltage suppressor diodes (which under worst case condition may become a short circuit) provide the required protection. The suppressor diodes are not designed to withstand externally MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 10 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Vo2 [V] Vo Vod Vo 1 % Vo 1 % 05137a 16.0 Io1 = 3.2 A Io1 = 2.5 A Io1 = 1.7 A Io1 = 1.0 A Io1 = 0.3 A 15.75 Vod td td 15.5 t Io /Io nom 15.25 1 15.0 0.5 10 s 10 s 0 14.75 05102c t 14.5 Fig. 9 Typical dynamic load regulation of Vo. Io2 [A] 14.25 0 Output Voltage Regulation figure 9 applies to single-output or double-output models with parallel-connected outputs. For independant configuration, output 1 is under normal conditions regulated to Vo nom, irrespective of the output currents. Vo2 depends upon the load distribution. If both outputs are loaded with more than 10% of Io nom, the deviation of Vo2 remains within 5% of Vo1. Fig. 10 to 12 show the regulation depending on load distribution. Two outputs of a double-output model connected in parallel behave like the output of a single-output model. Note: If output 2 is not used, connect it in parallel with output 1! This ensures good regulation and efficiency. 1 2 3 4 Fig. 11 Models with 2 outputs 15 V: Vo2 versus Io2 with various Io1 (typ) Vo2 [V] 05138a 26 Io1 = 2.00 A Io1 = 1.55 A Io1 = 1.10 A Io1 = 0.65 A Io1 = 0.20 A 25.5 25 24.5 24 Vo2 [V] 23.5 05136a 12.75 Io1 = 4.0 A Io1 = 3.1 A Io1 = 2.2 A Io1 = 1.3 A Io1 = 0.4 A 12.50 12.25 Io2 [A] 23 0 1 2 3 Fig. 12 Models with 2 outputs 24 V: Vo2 versus Io2 with various Io1 (typ) 12.0 11.75 11.50 Io2 [A] 11.25 0 1 2 3 4 5 Fig. 10 Models with 2 outputs 12 V: Vo2 versus Io2 with various Io1 (typ) MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 11 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Sense Lines (Single-Output Models) Auxiliary Functions Inhibit for Remote On/Off The outputs may be enabled or disabled by means of a logic signal (TTL, CMOS, etc.) applied between the inhibit input i (pin 18) and pin 14 (S- or Vo1-). In systems with several converters, this feature can be used to control the activation sequence of the converters. If the inhibit function is not required, connect the inhibit pin 18 with pin 14! Note: If pin 18 is not connected, the output is disabled. 06031b Vo+ Input Iinh i 18 S-/Vo1- 14 Fig. 13 Definition of Vinh and Iinh. Table 7: Inhibit characteristics Characteristic Conditions min max Unit Vinh - 50 0.8 V 2.4 50 Vi min - Vi max I inh Inhibit current Vinh = 0 tr Rise time tf Fall time Iinh [mA] typ - 400 30 06032a 1.6 Output voltage Total voltage difference between sense lines and their respective outputs Voltage difference between Vo- and S- 5.1 V <0.5 V <0.25 V 12 V, 15 V, 24 V <1.0 V <0.25 V Programmable Output Voltage (R-Function) As a standard feature, the converters offer an adjustable output voltage, identified by letter R in the type designation. The control input R (pin 16) accepts either a control voltage Vext or a resistor Rext to adjust the desired output voltage. When input R is not connected, the output voltage is set to Vo nom. The control voltage range is 0 - 2.75 VDC and allows for an adjustment in the range of approximately 0 - 110% of Vo nom. Vo Vext ------ * 2.5 V Vo nom 1.2 0.8 Vo = on To ensure correct operation, both sense lines (S+, S-) should be connected to their respective power outputs (Vo+ and Vo-), and the voltage difference between any sense line and its respective power output (as measured on the connector) should not exceed the following values: a) Adjustment by means of an external control voltage Vext between pin 16 (R) and pin 14 (S-): Vinh = 2.4 V 2.0 0.4 A ms depending on Io Vinh = 0.8 V This feature allows for compensation of voltage drops across the connector contacts and if necessary, across the load lines. We recommend connecting the sense lines directly at the female connector. Table 7: Maximum voltage compensation allowed using sense lines Vinh Inhibit Vo = on voltage Vo = off Important: Sense lines must always be connected! Incorrectly connected sense lines may activate the overvoltage protection resulting in a permanent short-circuit of the output. Vo = off 05074a Vi+ 0 16 R + S-/Vo1- - -0.4 14 -0.8 -40 -20 0 20 40 Vinh [V] Vi- Fig. 14 Typical inhibit current I inh versus inhibit voltage Vinh 06001 Vo /Vo nom 1 0.1 0 Vext Vi+ 12 t tr tf 16 14 Inhibit 1 0 Fig. 15 Output response as a function of inhibit control S+/Vo1+ R'ext R S-/Vo1- Rext Vi- t Fig. 16 Output voltage control for single-output models MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 12 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters b) Adjustment by means of an external resistor: Depending upon the value of the required output voltage, the resistor shall be connected either: Between pin 16 and pin 14 to achieve an output voltage adjustment range of approximately 0 - 100% of Vo nom. or: Between pin 16 and pin 12 to achieve an output voltage adjustment range of 100 - 110% of Vo nom. Warnings: Vo2+ 4 Vo2+ 6 Vo2- 8 Vo2- 10 Vo1+ 12 Vo1- 14 R 16 - Vext shall never exceed 2.75 VDC. - The value of R'ext shall never be less than the lowest value as indicated in table R'ext (for V0 > V0 nom) to avoid damage to the converter! 06004a + 24 V Vo1 30 V 48 V Co - R'ext Rext Fig. 17 Double-output models: Wiring of the R-input for output voltages 24 V, 30 V, or 48 V with both outputs in series. A ceramic capacitor (Co ) across the load reduces ripple and spikes. Notes: - The R-Function excludes option P (output voltage adjustment by potentiometer). If the output voltages are increased above Vo nom via R-input control, option P setting, remote sensing, or option T, the output currents should be reduced, so that Po nom is not exceeded. - With double-output models, the second output follows the voltage of the controlled main output. positive test jack is protected by a series resistor (see: Functional Description, block diagrams). - In case of parallel connection the output voltages should be individually set within a tolerance of 1 - 2%. The voltage measured at the test jacks is slightly lower than the value at the output terminals. Test Jacks Test jacks (pin diameter 2 mm) for measuring the main output voltage Vo or Vo1 are located at the front of the converter. The Table 8a: Rext for Vo < Vo nom; approximate values (Vi nom, Io nom, series E 96 resistors); R'ext = not fitted Vo nom = 5.1 V Vo [V] Rext [k ] 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 0.432 0.976 1.65 2.61 3.83 5.76 8.66 14.7 30.1 200 Vo nom = 12 V 2 3 4 5 6 7 8 9 10 11 Vo nom = 15 V ] Rext [k Vo [V] 1 4 6 8 10 12 14 16 18 20 22 0.806 1.33 2 2.87 4.02 5.62 8.06 12.1 20 42.2 Vo nom = 24 V ] Rext [k Vo [V] 1 2 4 6 8 9 10 11 12 13 14 4 8 12 16 18 20 22 24 26 28 0.619 1.47 2.67 4.53 6.04 8.06 11 16.2 26.1 56.2 ] Rext [k Vo [V] 1 4 6 8 10 12 14 16 18 20 22 8 12 16 20 24 28 32 36 40 44 0.806 1.33 2.0 2.87 4.02 5.62 8.06 12.1 20 44.2 Table 8b: R'ext for Vo > Vo nom; approximate values (Vi nom, Io nom, series E 96 resistors); Rext = not fitted Vo nom = 5.1 V 1 Vo [V] ] R'ext [k 5.15 5.2 5.25 5.3 5.35 5.4 5.45 5.5 432 215 147 110 88.7 75 64.9 57.6 Vo nom = 12 V Vo [V] 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 13.0 13.2 Vo nom = 15 V ] R'ext [k 1 24.2 24.4 24.6 24.8 25.0 25.2 25.4 25.6 26.0 26.4 1820 931 619 475 383 316 274 243 196 169 Vo [V] 1 15.2 15.4 15.6 15.8 16.0 16.2 16.4 16.5 30.4 30.8 31.2 31.6 32.0 32.4 32.8 33.0 Vo nom = 24 V ] R'ext [k 1500 768 523 392 316 267 232 221 Vo [V] 1 24.25 24.5 24.75 25.0 25.25 25.5 25.75 26.0 26.25 26.4 48.5 49.0 49.5 50.0 50.5 51.0 51.5 52.0 52.5 52.8 ] R'ext [k 3320 1690 1130 845 698 590 511 442 402 383 First column: Vo or Vo1; second column: double-output models with series-connected outputs MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 13 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Display Status of LEDs Vo1 > 0.95 to 0.98Vo1 adj 06002_011106 OK i Io L LEDs "OK ", "i " and "Io L" status versus input voltage Conditions: Io Io nom, TC TC max, Vinh 0.8 V Vi uv = undervoltage lock-out, Vi ov = overvoltage lock-out Vi Vi uv Vi min Vi max Vi ov Vo1 > 0.95 to 0.98Vo1 adj Vi abs Vo1 < 0.95 to 0.98Vo1 adj OK Io L Io nom Io LEDs "OK" and "Io L" status versus output current Conditions: Vi min - Vi max, TC TC max, Vinh 0.8 V TC LED "i " versus case temperature Conditions: Vi min - Vi max , Io Io nom, Vinh 0.8 V Vi inh LED "i " versus Vinh Conditions: Vi min - Vi max , Io Io nom, TC TC max IoL i TC max TPTC threshold Vinh threshold i -50 V LED off +0.8 V +2.4 V LED Status undefined +50 V LED on Fig. 18 LED indicators Battery Charging / Temperature Sensor All converters with an R-input are suitable for battery charger applications, but we recommend choosing the models especially designed for this application DK/LK1740 pr DK/ LK2740; see Model Selection. Cell voltage [V] 2.45 2.40 2.35 For optimal battery charging and life expectancy of the battery an external temperature sensor can be connected to the Rinput. The sensor is mounted as close as possible to the battery and adjusts the output voltage accoring to the battery temperature. 2.30 Depending upon cell voltage and the temperature coefficient of the battery, different sensor types are available, see Accessories. 2.15 Vo safe 2.25 2.20 2.10 -20 Input Power supply Load R -10 0 10 VC = 2.27 V, -3 mV/K VC = 2.23 V, -3 mV/K 03099d Vo+ Vo- 06139b 20 30 40 50 C VC = 2.27 V, -3.5 mV/K VC = 2.23 V, -3.5 mV/K Fig. 20 Trickle charge voltage versus temperature for defined temperature coefficient. Vo nom is the output voltage with open R-input. + - Temperature sensor + Battery Fig. 19 Connection of a temperature sensor MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 14 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Electromagnetic Compatibility (EMC) A metal oxide VDR together with the input fuse and an input filter form an effective protection against high input transient voltages, which typically occur in most installations. The converters have been successfully tested to the following specifications: Electromagnetic Immunity Table 9: Electromagnetic immunity (type tests) Phenomenon Standard Level Coupling mode 1 Supply related surge RIA 12 3 A4 +i/- i B Direct transients C +i/- i, - i/c Waveform Source imped. Test procedure In oper. Perf. crit.2 0.2 1 positive surge yes A 5 5 pos and 5 neg. yes B 3.5 VBat 2/20/2 ms 1.5 VBat 0.1/1/0.1 s 960 V p 10/100 s 1800 V p 5/50 s E 3600 V p 0.5/5 s F 4800 V p 0.1/1 s G3 8400 V p 0.05/0.1 s D3 Indirect couples transients Value applied H +o/c, - o/c 100 1800 V p 5/50 s J 3600 V p 0.5/5 s K 4800 V p 0.1/1 s L 8400 V p 0.05/0.1 s contact discharge 8000 Vp 1/50 ns 10 positive and 10 negative discharges A 15000 Vp 330 150 pF yes air discharge 80 - 1000 MHz yes A 800 - 1000 MHz yes A Electrostatic discharge (to case) IEC / EN 61000-4-2 45 Electromagnetic field IEC / EN 61000-4-3 x6 antenna 20 V/m AM 80% /1 kHz n.a. 7 antenna 20 V/m AM 80% /1 kHz n.a. 10 V/m 1400 - 2100 MHz 5 V/m 2100 - 2500 MHz 3 antenna 10 V/m 50% duty cycle, 200 Hz rep. rate n.a. 900 5 MHz yes A 50 60 s positive 60 s negative transients per coupling mode yes A 12 yes A3 2 5 pos. and 5 neg. surges per coupling mode 150 0.15 - 80 MHz yes A Electrical fast transients/burst IEC / EN 61000-4-4 38 capacitive, o/c 2000 Vp 4 i/c, +i/-i direct 4000 Vp bursts of 5/50 ns 2.5/5 kHz over 15 ms; burst period: 300 ms Surges IEC / EN 61000-4-5 39 i/c 2000 Vp 1.2/50 s +i/- i 1000 Vp IEC / EN 61000-4-6 3 10 i, o, signal wires 10 VAC (140 dBV) Conducted disturbances 1 2 3 4 5 6 7 8 9 10 AM 80% 1 kHz i = input, o = output, c = case A = normal operation, no deviation from specs.; B = temporary loss of function or deviation from specs possible RIA 12 covers or exceeds IEC 60571-1 and EN 50155:1995. Surge D corresponds to EN 50155:2001, waveform A; surge G corresponds to EN 50155:2001, waveform B Only met with extended input voltage range of CS (for 48 V battery) and ES (for 110 V battery) types. Such CS models are available on customer's request. Standard DS models (110 V battery) will not be damaged, but overvoltage lockout will occur during the surge. Exceeds EN 50121-3-2:2006 table 9.3 and EN 50121-4:2006 table 1.4. Corresponds to EN 50121-3-2:2006 table 9.1 and exceeds EN 50121-4:2006 table 1.1. Valid for version V104 or higher. Corresponds to EN 50121-3-2:2006 table 9.2 and EN 50121-4:2006 table 1.2 (compliance with digital mobile phones). Corresponds to EN 50121-3-2:2006 table 7.2 and EN 50121-4:2006 table 2.2. Covers or exceeds EN 50121-3-2:2006 table 7.3 and EN 50121-4:2006 table 2.3. Corresponds to EN 50121-3-2:2006 table 7.1 and EN 50121-4:2006 table 3.1 (radio frequency common mode). MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 15 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Electromagnetic Emissions dBV/m dBV 80 TUV-Divina, Testdistance 10 m, 2006-10-01 CS1601-7R Ui=110 V, Uo=12 V Io= 8 A CS1601-7R, Peak Vi+, Conducted 0,15 / 30 MHz, Divina, 2006-10-01 50 JM061 70 EN 55022 B 40 EN 55022 B 60 50 30 40 20 30 20 10 10 0 0.2 0.5 1 2 5 10 20 MHz Fig. 21a Typical conducted emissions (peak) at the positive input according to EN 55011/22, measured at Vi nom and Io nom (CS1601-7R) dBV 80 0 30 50 200 500 1000 MHz Fig. 22a Radiated emissions according to EN 55011/22, antenna 10 m distance, measured at Vi nom and Io nom (CS1601-7R) dBV/m LS1301-7R, Peak Vi+, Conducted 0,15 / 30 MHz, Divina, 2006-11-01 100 TUV-Divina, QP, 2006-11-01 Testdistance 10 m, LS1301-7R, Uo=12 V Io= 8 A 50 EN 55011 A 70 JM057 EN 55022 B 40 60 50 30 40 20 30 20 10 10 0 0.2 0.5 1 2 5 10 20 MHz Fig. 21b Typical conducted emissions (peak) at the positive input according to EN 55011/22, measured at Vi nom and Io nom (LS1301-7R). 0 30 50 100 200 500 1000 MHz Fig. 22b Radiated emissions according to EN 55011/22, antenna 10 m distance, measured at Vi nom and Io nom (LS1301-7R) MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 16 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Immunity to Environmental Conditions Table 10: Mechanical and climatic stress Test Method Standard Test Conditions Cab Damp heat steady state IEC/EN 60068-2-78 MIL-STD-810D sect. 507.2 Temperature: Relative humidity: Duration: 40 2 C 93 +2/-3 % 56 days Converter not operating Status Kb Salt mist, cyclic (sodium chloride NaCl solution) IEC/EN 60068-2-52 Concentration: Storage: Duration: 5% (30 C) for 2 h 40 C, 93% rel. humidity 3 cycles of 22 h Converter not operating Fc Vibration (sinusoidal) IEC/EN 60068-2-6 MIL-STD-810D sect. 514.3 Acceleration amplitude: Converter operating Frequency (1 Oct/min): Test duration: 0.35 mm (10 - 60 Hz) 5 gn = 49 m/s2 (60 - 2000 Hz) 10 - 2000 Hz 7.5 h (2.5 h each axis) Fh Random vibration broad band (digital control) IEC/EN 60068-2-64 Acceleration spectral density: Frequency band: Acceleration magnitude: Test duration: 0.05 gn2 /Hz 8 - 500 Hz 4.9 gn rms 1.5 h (0.5 h each axis) Converter operating Eb Bump (half-sinusoidal) IEC/EN 60068-2-29 MIL-STD-810D sect. 516.3 Acceleration amplitude: Bump duration: Number of bumps: 25 g n = 245 m/s2 6 ms 6000 (1000 each direction) Converter operating Ea Shock (half-sinusoidal) IEC/EN 60068-2-27 MIL-STD-810D sect. 516.3 Acceleration amplitude: Bump duration: Number of bumps: 50 g n = 490 m/s2 11 ms 18 (3 each direction) Converter operating -- Shock EN 50155:2007 sect. 12.2.11, EN 61373 sect. 10, class B, body mounted 1 Acceleration amplitude: Bump duration: Number of bumps: 5.1 gn 30 ms 18 (3 in each direction) Converter operating -- Simulated long life EN 50155:2007 sect. 12.2.11, testing at EN 61373 sect. 8 and 9, increased random class B, body mounted 1 vibration levels Acceleration spectral density: Frequency band: Acceleration magnitude: Test duration: 0.02 g n2 /Hz 5 - 150 Hz 0.8 gn rm s 15 h (5 h in each axis) Converter operating 1 Body mounted = chassis of a railway coach Temperatures Table 11: Temperature specifications, values given are for an air pressure of 800 - 1200 hPa (800 - 1200 mbar) -5 2 Temperature Characteristics TA Ambient temperature TC Case temperature TS Storage temperature 1 2 1 Conditions min Converter operating Not operating -6 2 max min -25 50 -25 85 1 -40 100 -7 (standard) max min -25 60 -25 90 1 -40 100 -9 (option) max min -25 71 -40 71 -25 95 1 -40 95 1 -40 100 -55 100 Unit max C Overtemperature lockout at TC > 95 C Customer-specific models Reliability and Device Hours Table 12: MTBF calculated according to MIL-HDBK 217F Values at specified case temperature Model MTBF 1 AS - LS Device hours 2 AS - LS 1 2 Ground benign 40 C 500 000 Ground fixed 40 C 70 C 150 000 80 000 Ground mobile 50 C Unit 50 000 h 500 000 Calculated according to MIL-HDBK-217F Statistic values, based on an average of 4300 working hours per year, over 3 years in general field use. MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 17 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Mechanical Data Dimensions in mm. The converters are designed to be inserted into a 19" rack, 160 mm long, according to IEC 60297-3. European Projection 7 TE 09004f 7.0 10.3 12.1 20.3 30.3 (171.0 to 171.9) 50 5 TE 3.27 5 M4 9.5 4.5 LED i (red) LED OK (green) LED IoL (red) = O 3.5 = O 4.1 51.5 Measuring point of case temperature TC Option P (Vo) Option D (Vto) Option D (Vti ) 29.9 19.7 111 (3U) 100 Test jacks (+/-) 5 d 8 152 8 60 Front plate Back plate Main face 168.5 5 x 90 25.9 2.8 0.2 11.8 = O 4.1 = O 3.5 Screw holes of the frontplate Notes: - d 15 mm, recommended minimum distance to next part in order to ensure proper air circulation at full output power. Fig. 23 Aluminum case S02 with heat sink; black finish (EP powder coated); weight approx. 1.25 kg - free air location: the converter should be mounted with fins in a vertical position to achieve maximum airflow through the heat sink. MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 18 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters 7 TE 50 38.5 5 11.8 5 158 4 TE 3.27 09003b 101 111 (3U) M4 Measuring point of case temperature TC 17.3 5 47.2 133.4 168 (171.0 ... 171.9) Fig. 24 Option B1: Aluminum case S02 with small cooling plate; black finish (EP powder coated). Suitable for mounting with access from the backside. Total weight approx. 1.2 kg. 38.5 6.5 11.2 47.2 6.5 5 European Projection 11027 13 140 127 11.8 133.4 0.2 17.3 168 30 Fig. 25 Option B: Aluminum case S02 with large cooling plate; black finish (EP powder coated). Suitable for front mounting. Total weight approx. 1.3 kg Note: Long case with option B2, elongated by 60 mm for 220 mm rack depth, is available on request. (No LEDs, no test jacks.) MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 19 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Installation Instructions Safety and Installation Instructions Connector Pin Allocation The connector pin allocation table defines the electrical potentials and the physical pin positions on the H15 connector. The protective earth is connected by a leading pin (no. 24), ensuring that it makes contact with the female connector first. Fixtures for connector retention clips V (see Accessories) Pin no. 24 ( ) is connected with the case. For safety reasons it is essential to connect this pin reliably to protective earth. 32 The input pins 30/32 (Vi- or L ) are connected via a built-in fuse, which is designed to protect in the case of a converter failure. An additional external fuse, suitable for the application, might be necessary in the wiring to the other input 26 /28 (Vi+ or N ) or even to pins 30/32, particularly if: 4 Type H15 * Local requirements demand an individual fuse in each source line Fig. 26 View of the connector (male contacts) * Phase and neutral of the AC mains are not defined or cannot be assigned to the corresponding terminals. Table 13: H15 connector pin allocation * Neutral and earth impedance is high or undefined. Connector type H15 No. single-output models 4 Vo+ 6 Vo+ 8 Vo- Notes: double-output models - If the inhibit function is not used, pin no. 18 (i) should be connected with pin no. 14 to enable the output(s). Vo2+ Pos. output 1 Pos. output 2 Vo2+ Vo2- Neg. output 1 Neg. output 2 10 Vo- 12 S+ Pos. sense Vo1+ Pos. output 1 14 S- Neg. sense Vo1- Neg. output 1 16 R1 Control of V o R1 Control of V o1 18 i Inhibit i Inhibit D3 Save data V3 ACFAIL D3 Safe data T5 Current sharing T5 Current sharing 20 22 24 2 28 Vi+ N 4 Vi- L 4 30 32 1 2 3 4 5 Vo2- Protective earth 26 Neutral line 4 Vi+ N 4 Vi- L 4 Neg. input Phase line 4 - Do not open the converter, or warranty will be invalidated. - Due to high current values, the converters provide two internally parallel contacts for certain paths (pins 4/6, 8/10, 26/28 and 30/ 32). It is recommended to connect both female connector pins of each path in order to keep the voltage drop low and avoid excessive connector currents. - If the second output of double-output models is not used, connect it parallel with the main output. Make sure that there is sufficient airflow available for convection cooling and verifiy it by measuring the case temperature TC , when the converter is installed and operated in the end-use application; see Thermal Considerations. Protective earth Pos. input The converters are components, intended exclusively for inclusion within other equipment by an industrial assembly operation or 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. Connection to the system shall be made via the female connector H15; see Accessories. Other installation methods may not meet the safety requirements. 10090a Pin Note: These converters have no power factor correction (PFC). The LS4000/5000 models are intended to replace the LS1000 and LS2000 converters in order to comply with IEC/EN 61000-3-2. Ensure that a converter failure (e.g., an internal short-circuit) does not result in a hazardous condition. Pos. input Neutral line 4 Neg. input Phase line 4 Not connected, if option P is fitted. Leading pin (pre-connecting) Option D excludes option V and vice versa. Pin 20 is not connected, unless option D or V is fitted. LS models Only connected, if option T is fitted. Standards and Approvals The converters are safety-approved to UL 60950-1, CSA 60950-1, IEC 60950-1 and EN 60950-1 2nd Edition. The converters correspond to Class I equipment and have been evaluated for: * Building-in * Basic insulation between input and case based on 250 VAC, and double or reinforced insulation between input and output(s) * Functional insulation between outputs MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 20 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Table 14: Isolation Characteristic Electric strength test Input to case and output(s) Output(s) to case Output 1 to output 2 Unit 2.8 1 1.4 0.15 kVDC 1 1.0 0.1 kVAC >300 >100 2 M -- -- mm Factory test >1 s AC test voltage equivalent to factory test 2.0 Insulation resistance at 500 VDC >300 Creepage distances 3.2 1 2 3 3 According to IEC/EN 60950, subassemblies connecting input to output are pre-tested with 5.6 kVDC or 4 kVAC. Tested at 150 VDC Input to outputs: 6.4 mm * Overvoltage category II Leakage Currents * Pollution degree 2 environment Leakage currents flow due to internal leakage capacitances and Y-capacitors. The current values are proportional to the supply voltage and are specified in the table below. * Max. altitude: 2000 m * The converters fulfill the requirements of a fire enclosure. The converters are subject to manufacturing surveillance in accordance with the above mentioned standards and ISO 9001:2008. A CB-scheme is available. Railway Applications and Fire Protection Table 15: Earth leakage currents for LS models CharacteristicClass I Unit Max. leakage Permissible accord. to IEC/EN 60950 current Typ. value at 264 V, 50 Hz 1.43 3.5 mA The converters have been designed by observing the railway standards EN 50155, EN 50121-3-2, and EN 50121-4. All boards are coated with a protective lacquer. LS Models Operated at Greater than 63 Hz The converters with version V108 (or later) comply with NF-F16 (I2/F1). They also comply with EN 45545-1, EN 45545-2 (2013), if installed in a technical compartment or cabinet. Above 63 Hz, the earth leakage current may exceed 3.5 mA, the maximum value allowed in IEC 60950. Frequencies 350 Hz are only permitted with Vi 200 VAC. Protection Degree and Cleaning Liquids The built-in Y-caps are approved for 100 Hz. Safety approvals and CB scheme cover only 50 - 60 Hz. Condition: Female connector fitted to the converter. * IP 30: All models except those with option P, and except those with option D or V including a potentiometer. * IP 20: All models fitted with option P, or with option D or V with potentiometer. In order to avoid damage, any penetration of cleaning fluids has to be prevented, since the power supplies are not hermetically sealed. Isolation and Protective Earth The electric strength test is performed in the factory as routine test according to EN 50514 and IEC/EN 60950 and should not be repeated in the field. Power-One will not honor any warranty claims resulting from electric strength field tests. The resistance of the earth connection to the case (<0.1 ) is tested as well. MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 21 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Safety of Operator-Accessible Output Circuits If the output circuit of a DC-DC converter is operatoraccessible, it shall be an SELV circuit according to the standard IEC 60950-1. The following table shows some possible installation configurations, compliance with which causes the output circuit of the converter to be an SELV circuit according to IEC 60950-1 up to a configured output voltage (sum of nominal voltages if in series or +/- configuration) of 36 V. However, it is the sole responsibility of the installer to assure the compliance with the rapplicable safety regulations. 150 VAC or VDC for AK, BK 250 VAC or VDC for CK, DK, EK, FK, LK Mains AC-DC front end + 10044a Fuse Battery Fuse DC-DC converter + SELV - 150 VAC or VDC for AK, BK 250 VAC or VDC for CK, DK, EK, FK, LK Fig. 27 Schematic safety concept. Use earth connections as per the table below. Earth connection Table 16: Safety concept leading to an SELV output circuit Conditions Front end Nominal supply voltage Minimum required grade of insulation, to be provided by the AC-DC front end, including mains supplied battery charger Nominal DC output voltage from the front end Mains 150 V AC Functional (i.e. there is no need for electrical insulation between the mains supply voltage and the DC-DC converter input voltage) 100 V (The nominal voltage between any input pin and earth can be up to 150 V AC or DC) Basic Double or reinforced 1 3 4 Result Minimum required safety status of the front end output circuit Types Measures to achieve the specified safety status of the output circuit Safety status of the DC-DC converter output circuit Primary circuit AS BS Double or reinforced insulation, based on the mains voltage and 2 (provided by the DC-DC converter) and earthed case 3 SELV circuit 400 V (The nominal voltage between any input pin and earth can be up to 250 V AC or 400 V DC) Mains 250 V AC 2 DC-DC converter 400 V CS DS ES FS Unearthed hazardous voltage secodary circuit AS BS CS DS ES FS Supplementary insulation, based on 250 V AC and double or reinforced insulation 2 (provided by DC-DC converter) and earthed case 3. Earthed hazardous voltage secondary circuit Double or reinforced insulation 2 (provided by the DC-DC converter) earthed case 3 60 V SELV circuit Functional insulation (provided by the DC-DC converter) 4 120 V TNV-3 circuit Basic insulation (provided by the DC-DC converter) 4 The front end output voltage should match the specified input voltage range of the DC-DC converter. Based on the maximum nominal output voltage from the front end. The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC/EN 60950-1. Earthing of the case is recommended, but not mandatory. MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 22 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters If the output circuit of an AC-DC converter is operatoraccessible, it shall be an SELV circuit accord. to IEC 60950-1. Mains The following table shows some possible installation configurations, compliance with which causes the output circuit of LS models to be SELV according to IEC 60950-1 up to a configured output voltage (sum of nominal voltages if in series or +/- configuration) of 36 V. If the LS converter is used as DC-DC converter, refer to the previous section. ~ ~ 10021a Fuse + AC-DC converter Fuse SELV - Earth connection Fig. 28 Schematic safety concept. Use earth connection as per table 17. Use fuses if required by the application; see also Installation Instructions. Table 17: Safety concept leading to an SELV output circuit Conditions AC-DC converter Installation Result Nominal voltage Grade of insulation between input and output provided by the AC-DC converter Measures to achieve the resulting safety status of the output circuit Safety status of the AC-DC converter output circuit Mains 250 VAC Double or reinforced Earthed case1 and installation according to the applicable standards SELV circuit 1 The earth connection has to be provided by the installer according to the relevant safety standards, e.g. IEC/EN 60950. Description of Options Table 18: Survey of options Option Function of option Characteristic -7 Extended operational ambient temperature range TA = - 25 to 71 C E Electronic inrush current limitation circuitry Active inrush current limitation 2 Potentiometer for fine adjustment of output voltage Adjustment range +10/ - 60% of Vo nom, excludes R input D1 Input and/or output undervoltage monitoring circuitry Safe data signal output (D0 - DD) V1 Input and/or output undervoltage monitoring circuitry ACFAIL signal according to VME specifications (V0, V2, V3) T Current sharing Interconnect T-pins for parallel connection (max 5 converters) B, B1, B2 Cooling plate (160 or 220 mm long) Replaces the standard heat sink, allowing direct chassis-mounting G RoHS-compliant for all 6 substances P 1 2 Option D excludes option V and vice versa; option V only for 5.1 V outputs. Option P is not available for battery charger models. -7 Temperature Range E Inrush Current Limitation Option -7 designates converters with an operational ambient temperature range of - 25 to 71 C. Not for new designs. CS/DS/ES/FS/LS models may be supplemented by an electronic circuit (option E) replacing the standard built-in NTC MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 23 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters resistor) in order to achieve an enhanced inrush current limiting function. Option E is not available with AS/BS models, but mandatory for all CS/DS/ES/FS/LS models with option -9. Option D6 should be adjustded with the potentiometer to a threshold of 36 - 40.5 V for 48 V batteries and to 44 - 50 V for 60 V batteries. Refer also to the description of option D. JM060 + Ci FET RS Note: Subsequent switch-on cycles at start-up are limited to max. 10 cycles during the first 20 seconds (cold converter) and then to max. 1 cycle every 8 s. Converter Input Filter LS models Control monitor) meet the standard ETS 300132-2 for 48 VDC supplies. Option D6 is necessary to disable the converter at low input voltage, such avoiding an excessive input current. Connect output D (pin 20) with inhibit (pin 18). LS models powered by 230 VAC/ 50 Hz exhibit an inrush current as per the fig. below, when switched on at the peak of Vi. In this case, the inrush current I inr p is 21.7 A and its duration tinr is 5 ms. This is the worst case. Ri Fig. 29 Block diagram of option E Current limiting resistance Rv = RS + Ri = 15 If the LS converter is switched on in a different moment, Iinr p is much lower, but tinr rises up to 10 ms. The figure below shows two consecutive peaks of the inrush current, the first one is caused by Vi /Rv and the second one by the rising current across the FET. The shape of the curve depends on model, but the tables below show the higher of both peaks. CS models fitted with option E and option D6 (input voltage Ii [A] 20 15 Capacitor Ci fully charged 10 Normal operation (FET fully conducting) 5 Table 19 a: Inrush current at Vi nom (DC supply) and I o nom 0 Characteristics FS CS DS ES LS Unit Vi nom Input voltage 50 60 110 220 310 V I inr p Peak inrush current 7.5 6.5 7.4 14.6 21 A t inr Inrush current duration 20 25 14 16 16 ms -5 -10 tinr 10065a -15 0 20 40 60 t [ms] 80 Table 19 b: Inrush current at Vi max (DC supply) and I o nom Characteristics FS CS DS ES LS Unit Vi nom Input voltage 100 140 220 385 372 V I inr p Peak inrush current 10 9 t inr Inrush current duration 26 30 14.5 25.7 24.8 14 12 16 Fig. 31 Inrush current for LS models with option E (AC supply) Vi = 230 VAC, f i = 50 Hz, Po = Po nom A ms P Potentiometer Iinr [A] Capacitor Ci fully charged Vi /Rv Normal operation (FET fully conducting) A potentiometer provides an output voltage adjustment range of +10/- 60% of Vo nom. It is accessible through a hole in the front cover. Option P is not available for battery charger models and is not recommended for converters connected in parallel. Ii = Pi /Vi Option P excludes the R-function. With double-output models, both outputs are influenced by the potentiometer (doubling the voltage, if the outputs are connected in series). Note: If the output voltages are increased above Vo nom via R input control, option P setting, remote sensing, or option T, the output 11039a 0 0 tinr t [ms] Fig. 30 Inrush current with option E (DC supply) 2 different wafe shapes depending on model MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 24 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters T Current Sharing 11037b This option ensures that the output currents are approximately shared between the parallel-connected converters, hence increasing system reliability. To use this facility, simply interconnect the T pins of all converters and make sure that the reference for the T signal, pin 14 (S- or Vo1-), are also connected together. The load lines should have equal length and cross section to ensure equal voltage drops. Power bus + - Vo2+ Vo2- Converter T Vo1+ Vo1- Load Not more than 5 converters should be connected in parallel. The R pins should be left open-circuit. If not, the output voltages must be individually adjusted prior to paralleling within 1 to 2% or the R pins should be connected together. Vo2+ Vo2- Converter Note: Parallel connection of converters with option P is not recommended. T Vo1+ Vo1- Vo+ 11003a Load Max. 5 converters in parallel connection Vo- Fig. 34 Parallel connection of double-output models with the outputs connected in series, using option T. The signal at the T pins is referenced to Vo1-. Vo+ Vo- Vo+ Vo- D Undervoltage Monitor Fig.32 Example of poor wiring for parallel connection (unequal length of load lines) 11036b Vo+ 2 1 S+ Converter T 1 S- Option D exists in various versions D0 - DD, as shown in table 20. Vo- Load Vo+ Converter JFET output (D0 - D4): Pin D is internally connected via the drain-source path of a JFET (self-conducting type) to the negative potential of output 1. VD 0.4 V (logic low) corresponds to a monitored voltage 2 S+ T The input and/or output undervoltage monitor operates independently of the built-in input undervoltage lockout circuit. A logic "low" signal (output with self-conducting JFET) or "high" signal (NPN open-collector output) is generated at the D output (pin 20), when one of the monitored voltages drops below the preselected threshold level V t. This signal is referenced to S- / Vo1-. The D output recovers, when the monitored voltages exceed Vt + Vh. The threshold levels Vti and Vto are either adjusted by a potentiometer, accessible through a hole in the front cover, or adjusted in the factory to a fixed value specified by the customer. 1 S- Vo- 11006a Vo+/Vo1+ 1 Max. 5 converters in parallel connection Input 1 Lead lines should have equal length and cross section, and should run in the same cable loom. 2 Diodes recommended in redundant operation only Fig. 33 Parallel connection of single-output models using option T with the sense lines connected at the load Rp ID Self-conducting junction FET 20 D VD 14 S-/Vo1- Fig. 35 Option D0 - D4: JFET output, I D 2.5 mA MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 25 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Table 20: Undervoltage monitoring functions Output type JFET NPN D1 D5 2 3 4 5 no Minimum adjustment range Typ. hysteresis Vho [% of Vt ] of threshold level Vtfor Vt min - Vt max potentioVt i Vt o Vh i Vh o yes -- 3.5 V - Vo BR 1 -- 1 Number of meters 2.5 - 0.6 V 1 D2 D6 yes no Vi min - Vi max -- 3.4 - 0.4 V -- 1 D3 D7 yes yes Vi min - Vi max 1 (0.95 - 0.985 Vo) 2 3.4 - 0.4 V "0" 1 D4 D8 no yes -- (0.95 - 0.985 Vo) 2 -- "0" -- D0 5 D9 5 no yes -- 3.5 V - Vo BR V 3 -- 2.5 - 0.6 V -- yes no Vi min - Vi max 3 4 -- 3.4 - 0.4 V -- yes yes Vi min - Vi max 3 4 3.5 V - Vo BR V 3 4 3.4 - 0.4 V 2.5 - 0.6 V yes yes Vi min - Vi max 3 4 (0.95 - 0.985 Vo) 2 3.4 - 0.4 V "0" 3.4 - 0.4 V 2.5 - 0.6 V -1 Monitoring Vo or Vo1 Vi DD yes yes Vi min - Vi max 1 3.5 V - Vo BR V 1 2 Threshold level adjustable by potentiometer; see Electrical Output Data for Vo BR. Fixed value. Tracking if Vo/Vo1 is adjusted via R-input, option P, or sense lines. The threshold level permanently adjusted according to customer specification 2% at 25 C. Any value within the specified range is basically possible, but causes a special type designation in addition to the standard option designations (D0/D9). See Electrical Output Data for Vo BR. Adjustment at Io nom. Customer-specific part number Vb, Vo1 status D output, VD Vb or Vo1 < Vt low, L, VD 0.4 V at I D = 2.5 mA (logic low) corresponds to a monitored voltage level (Vi and/or Vo1) > Vt + Vh. The current ID through the open collector should not exceed 20 mA. The NPN output is not protected against external overvoltages. VD should not exceed 40 V. Vb and Vo1 > Vt + Vh high, H, I D 25 A at VD = 5.25 V Threshold tolerances and hysteresis: Table 21: JFET output (D0 -- D4) level (Vi and/or Vo1) <Vt. The current I D through the JFET should not exceed 2.5 mA. The JFET is protected by a 0.5 W Zener diode of 8.2 V against external overvoltages. NPN output (D5 - DD): Pin D is internally connected via the collector-emitter path of a NPN transistor to the negative potential of output 1. VD < 0.4 V If Vi is monitored, the internal input voltage after the input filter is measured. Consequently this voltage differs from the voltage at the connector pins by the voltage drop V ti across the input filter. The threshold levels of the D0 and D9 options are factory adjusted at nominal output current Io nom and TA = 25 C. The value of V ti depends upon input voltage range (CK, DK, ..), threshold level Vt, temperature, and input current. The input current is a function of the input voltage and the output power. 11007a Vo+/Vo1+ Rp 20 Vti Vhi 11021a VD high D Po = 0 Po = Po nom VD 14 S-/Vo1- Po = Po nom NPN open collector VD Po = 0 Input ID VD low Fig. 36 Option D5 - DD: NPN output, Vo 40, ID 2.5 mA Table 22: NPN output (D5 - DD) Vb, Vo1 status D output, VD Vb or Vo1 < Vt high, H, I D 25 A at VD = 40 V Vb and Vo1 > Vt + Vh low, L, VD 0.4 V at I D = 20 mA Vti Vi Fig. 37 Definition of Vti, Vt i and Vhi (JFET output) MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 26 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Table 23: D-output logic signals Vi < Vt or Vo < Vt Vi > Vt + Vh or Vo > Vt Configuration D1, D2, D3, D4, D0 Version of D low high JFET D5, D6, D7, D8, D9, DD high low NPN Input voltage monitoring NPN VD VD high 11008a 3 VD low 3 3 3 t 0 ID ID high ID low 0 t JFET VD VD high VD low 0 t th1 Vo1 Vo1 nom 1 0.95 tlow min4 tlow min4 tlow min4 thigh min th1 t 0 Vi [VDC] Vti+Vhi Vti t 0 Input voltage failure Input voltage sag Switch-on cycle Switch-on cycle and subsequent input voltage failure Output voltage monitoring NPN VD VD high 2 3 3 VD low t 0 ID 1 Hold-up time see Electrical Input Data 2 With output voltage monitoring, hold-up time t = 0 h 3 The signal remains high, if the D output is connected ID high ID low 0 t to an external source 4 t l ow min = 100 - 170 ms, typ. 130 ms JFET VD VD high VD low 0 t tlow min4 Vo1 Vo1 nom Vto+Vho Vto t 0 Output voltage failure Fig. 38 Relationship between Vi, Vo, V D, Vo /Vo nom versus time MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 27 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Table 24: Option V: Factory potentiometer setting of Vti with resulting hold-up time Model AS BS FS CS Vt i 9.5 19.5 39 39 th 0.1 0.1 3.4 1.1 V ACFAIL signal (VME) Available for converters with Vo nom = 5.1 V only. This option defines an undervoltage monitoring circuit for the input or for the input and main output voltage ( 5.1 V) similar to option D and generates an ACFAIL signal (V signal), which conforms to the VME standard. The low state level of the ACFAIL signal is specified at a sink current of I V 48 mA to V V 0.6 V (open-collector output of an NPN transistor). The pull-up resistor feeding the open-collector output should be placed on the VME back plane. After the ACFAIL signal has gone low, the VME standard requires a hold-up time t h of at least 4 ms, before the 5.1 V output drops to 4.875 V, when the output is fully loaded. This hold-up time t h is provided by the internal input capacitance Ci; see tab. Input Data. Consequently the working input voltage and the threshold level V t i should be adequately above Vi min of the converter, so that enough energy is remaining in the input capacitance. If V i is below the required level, an external holdup capacitor (Ci ext) should be added; refer to these formulas: Vt i = 1 ES LS Unit 61 97 120 VDC 1.1 2.7 4.2 ms Note: Option V2 and V3 can be adjusted by the potentiometer to a threshold level between Vi min and Vi max. A decoupling diode should be connected in series with the input of AS - FS converters to avoid the input capacitance being discharged through other loads connected to the same source voltage. Option V operates independently of the built-in input undervoltage lockout circuit. A logic "low" signal is generated at pin 20, as soon as one of the monitored voltages drops below the preselected threshold level V t . The return for this signal is S-. The V output recovers, when the monitored voltages exceed V t + V h. The threshold level V t i is either adjustable by a potentiometer, accessible through a hole in the front cover, or adjusted in the factory to a determined customer-specific value. Refer to table 25. V output (V0, V2, V3): Pin V is internally connected to the open collector of an NPN transistor. The emitter is connected to S-. V V 0.6 V (logic low) corresponds to a monitored voltage level (V i and/or Vo) <V t. I V should not exceed 50 mA. The V output is not protected against external overvoltages: V V should not exceed 60 V. Threshold tolerances and hysteresis: 2 * Po * (t h + 0.3 ms) * 100 ------------------------ + Vi min2 Ci min * If Vi is monitored, the internal input voltage is measured after the input filter. Consequently this voltage differs from the 2 * Po * (t h + 0.3 ms) * 100 C i ext = ---------------------- - Ci min * (Vti 2 - Vi min2 ) where as: C i min = C i ext = Po = = th = V i min = V ti = DS Table 26: NPN-output (V0, V2, V3) Vi, Vo status internal input capacitance [mF]; see table 2 external input capacitance [mF] output power [W] efficiency [%] hold-up time [ms] minimum input voltage [V] 1 threshold level [V] V i min see Electrical Input Data. For output voltages Vo > Vo nom, V i min increases proportionally to Vo /Vo nom. V output, VV V i or V o1 < V t low, L, V V 0.6 V at I V = 50 mA V i and V o1 > V t + V h high, H, I V 25 A at V V = 5.1 V voltage at the connector pins by the voltage drop V ti across the input filter. The threshold level of option V0 is adjusted in the factury at Io nom and TA = 25 C. The value of V ti depends upon the input voltage range (AK, BK, etc.), threshold level V t , temperature, and input current. The input current is a function of input voltage and output power. Table 25: Undervoltage monitor functions Option Monitoring 4 Typical hysteresis Vh [% of V t] for V t min - V t max V hi V ho Vi V o1 V2 yes no V i min - V i max 1 -- 3.4 - 0.4 -- V3 yes yes V i min - V i max 1 0.95 - 0.985 V o1 2 3.4 - 0.4 "0" V0 yes no V i min - V i max 3 4 -- 3.4 - 0.4 -- 3.4 - 0.4 "0" yes 1 Minimum adjustment range of threshold level V t V ti V to yes V i min - V i max 34 0.95 - 0.985 V o1 2 Threshold level adjustable by potentiometer. 2 Fixed value between 95% and 98.5% of Vo1 (tracking). 3 Adjusted at Io nom. Fixed value, resistor-adjusted (2% at 25C) accord. to customer's specification; individual type number is determined by Power-One. MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 28 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters Vhi VV high 11023a Po = 0 V VV VV low S- Fig. 40 Output configuration of options V0, V2 and V3 Input voltage monitoring Fig. 41 Definition of Vti, Vti and Vhi VV high 3 Vi Vti tlow min 2 tlow min 2 tlow min 2 VV Po = Po nom 20 NPN open collector 14 V2 Vti Po = Po nom Rp IV Input VV 11009a Po = 0 Vo+ 3 3 11010a 4 4 VV low t 0 V3 tlow min VV VV high 3 tlow min 2 2 3 3 VV low t 0 th 1 th 1 Vo 5.1 V 4.875 V 2.0 V 0 t Vi [VDC] Vti + Vhi Vti t 0 Input voltage failure Input voltage sag Switch-on cycle Switch-on cycle and subsequent input voltage failure Output voltage monitoring V2 VV VV high 4 VV low 4 t 0 V3 VV VV high tlow min 2 3 3 1 4 2 VV low 0 t 3 4 Vo 5.1 V 4.875 V 2.0 V 0 VME request: minimum 4 ms t low min = 40 - 200 ms, typ 80 ms VV level not defined at Vo < 2.0 V The V signal drops simultaneously with Vo, if the pull-up resistor R P is connected to Vo+; the V signal remains high if R P is connected to an external source. t Vi Vti + Vhi Vti t 0 Fig. 39 Relationship between Vb, Vo, VD, Vo /Vo nom versus time Output voltage failure MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 29 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters B, B1, B2 Cooling Plate Where a cooling surface is available, we recommend the use of a cooling plate instead of the standard heat sink. The mounting system should ensure that the maximum case temperature TC max is not exceeded. The cooling capacity is calculated by ( see Model Selection): Option B2 is for customer-specific models with elongated case (for 220 mm DIN-rack depth). G RoHS RoHS-compliant for all six substances. (100% - ) P Loss = ---------- * Vo * Io For the dimensions of the cooling plates, see Mechanical Data. Accessories A variety of electrical and mechanical accessories are available including: - Front panels for 19" DIN-rack: Schroff or Intermas, 12 TE / 3U; see fig. 40. - Mating H15 connectors with screw, solder, faston, or pressfit terminals, code key system and coding wedges HZZ00202-G; see fig. 41. Fig. 42 Connector retention clips to fasten the H15 connector to the rear plate; see fig. 24. HZZ01209-G consists of 2 clips. - Pair of connector retention clips HZZ01209-G; see fig. 42 - Connector retention brackets HZZ01216-G; see fig. 43 - Cage clamp adapter HZZ00144-G; see fig. 44 20 to 30 Ncm Fig. 43 Connector retention brackets HZZ01216-G (CRB-HKMS) Fig. 40 Different front panels Fig. 41 Different mating connectors Fig. 44 Cage clamp adapter HZZ00144-G MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 30 of 31 S Series Data Sheet 100 Watt DC-DC and AC-DC Converters - Different cable hoods for H15 connectors (fig. 45): - HZZ00141-G, screw version - HZZ00142-G, use with retention brackets HZZ01218-G - HZZ00143-G, metallic version providing fire protection - Chassis or wall-mounting plate K02 (HZZ01213-G) for models with option B1. Mating connector (HZZ00107-G) with screw terminals; see fig. 46 - DIN-rail mounting assembly HZZ0615-G (DMB-K/S); see fig. 47 - Additional external input and output filters - Different battery sensors S-KSMH... for using the converter as a battery charger. Different cell characteristics can be selected; see fig. 48, table 27, and Battery Charging / Temperature Sensors. Fig. 47 DIN-rail mounting assembly HZZ00615-G (DMB-K/S) For additional accessory product information, see the accessory data sheets listed with each product series or individual model at our web site: European Projection www.belpowersolutions.com/power 9.8 (0.4") 26 (1.02") 09125a L 56 (2.2") adhesive tape L = 2 m (standard length) other cable lengths on request Fig. 48 Battery temperature sensor Fig. 45 Different cable hoods Table 27: Battery temperature sensors Battery voltage nom.[V] Sensor type Cell voltage [V] 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 Fig. 46 Chassis- or wall-mounting plate HZZ01213-G (Mounting plate K02) Cell temp. Cable coefficient length [mV/K] [m] Note: Other temperature coefficients and cable lengths are available on request. 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. Copyright (c) 2015, Bel Power Solutions Inc. All rights reserved. www.belpowersolutions.com/power MELCHER BCD20004-G Rev AC, 29-Apr-2015 The Power Partners. Page 31 of 31