Accessories Mounti ng Supports Description Special mounting supports have been designed for the integration of power supplies into switch boards, control panels, printed circuit boards, etc., using adapters for chassis-, DIN-rail, or PCB mounting. The 19-inch cassette style DC-DC and AC-DC converters can also be chassis-mounted with frontal access by means of a special Chassis Mounting Plate, attached to the converters. The Universal Mounting Bracket also fits to most of these cassette type converters, allowing for either vertical-chassis or DIN-rail mounting. Table of Contents A Bracket Kit, consisting of a PCB with screw-terminal connectors and a brackets suitable for either chassis or DINrail mounting, is available either for PCB mountable PSR and PSA Switching Regulators with option "Y" pins or for small DC-DC converters up to 15 Watt. For isolation of the PCB-mountable converters from a double- sided PCB, the use of Isolation Pads is recommended, as described below. RoHS-compliant products are available on request. Note: All dimensions are in mm, unless otherwise specified. Page Page Description ............................................................................ 1 Chassis and Wall Mounting Plates ..................................... 2 Universal Mounting Brackets ................................................ 4 Supports for 7 W Converters ................................................ 8 Series H, M, Q, P, HP, PSL ......................................................... 4 Series W and X ......................................................................... 4 DIN-Rail Mounting Brackets DMB .............................................. 5 Chassis Mounting Brackets CMB .............................................. 5 CMB3W and DMB3W ............................................................ 8 DIN-Rail- and Chassis-Mounting Supports ........................ 6 Basic Kit CMBIMX15 ................................................................ 10 Basic Kit DMBIMX15 ................................................................ 10 Application-Specific Circuitry .................................................. 11 CMB: Chassis Mounting Support .............................................. 7 DMB: DIN-Rail Mounting Support ............................................... 7 Electrical Description CMBA01, DMBA01 ................................. 7 Basic Kit CMBIMX/S7 ................................................................. 8 Basic Kit DMBIMS/X7 ................................................................. 8 Mounting Instructions for Basic Kit ........................................... 8 Application-Specific Circuitry .................................................... 9 Supports for 15 W Converters ............................................ 10 Copyright (c) 2015, Bel Power Solutions Inc. All rights reserved. MELCHER BCD.20007 Rev AD, 01-Dec-2015 The Power Partners. Page 1 of 2 Accessories Mounti ng Supports Chassis and Wall Mounting Plates For chassis mounting of 19" cassette-style converters, where only frontal access to the mounting screws is given, special chassis mounting plate adapters are available according to the following table and figures 1 to 3. Table 1: Mounting Plate survey Ca se Converter size s e r i e s Part number Description Delivery content Fig. M02 M 1 H02 H HZZ01210-G Mounting plate XMK085-G Mounting plate M 4 countersunk screws M3x 6 4 serrated sunk washers Q01 Q Q04 P HZZ01215-G Mounting plate with brackets Mounting plate Q 4 countersunk screws M3x 6 2 3 Q05 HP Q01 Q Q04 P Q05 HP K02 K1, PSK 1, RP1 HZZ01213-G Mounting plate XMK074 Mounting Plate K 4 countersunk screws M4 x10 1 1 1 S , PSS , R S02 1 Fig. 1a Mounting plate M (HZ Z 01210-G), connector with faston terminals (HZ Z 00101-G), secured with retention clips (HZ Z 01209-G) with Option B1 133 16.3 115 25.5 6.5 4.5 M3x 6 Washer 103.5 XMK085-G M3x 6 Washer 18.5 128 4.5 / 9 x 90 140 European Projection 12020a 11.2 6 Note: The mounting plate K fits to K, S, PSK, PSS, RP, R converters with opt. B1. However, it is possible to order these converters directly with option B. Such converters exhibit the same mounting plate as shown in fig. 1. 127 166 19.5 3 Fig. 1b HZZ001210 (mounting plate M) Aluminum, black anodized MELCHER BCD.20007 Rev AD, 01-Dec-2015 The Power Partners. Page 2 of 2 Accessories Mounti ng Supports 168 4.5 4.5 European Projection 12022c M3 x 6 104 0.1 128 140 3.2 / 6.3 x 90 M3 x 6 6 18 XMK162-G 115 12701 115 26 20 16.8 Fig. 2b HZZ01229-G Retention clip Q 3 14 Converter 14 12021c M4 x 10 19.5 7.5 6.5 11.2 Fig. 2a HZZ01215-G (mounting plate Q) with integrated connector retention facility using HZZ01229-G (the retention clip Q), Aluminum, black anodized 4.8 / 9 x 90 13 (140) 125 XMK074-G 17.3 133.35 168 30 Converter S, K, PSK, PSS, or R with option B1 5 Fig. 3 HZZ01213-G (mounting plate K) Aluminum, black anodized MELCHER BCD.20007 Rev AD, 01-Dec-2015 The Power Partners. Page 3 of 2 Accessories Mounti ng Supports Universal Mounting Brackets (DIN-Rail and Chassis Mounting) Series H, M, Q, P, HP, PSL A special universal mounting bracket has been designed for vertical or upright chassis- and DIN-rail mounting of the 19" cassette style converters; see table 2. 49 12031 4 7.5 European Projection 168 84 20.5 127 158 20.5 5 4 20 14 29 5 14 Fig. 4 DIN-rail clamp XMM162-G, steel, galvanized M4 3 M4 (3) 10068a 4.5 5.5 10 5 12032a Fig. 5 Universal mounting bracket XKM159-G, Aluminum, untreated Series W and X Chassis mounting brackets UMB-W are available; see table 2 and fig. 6. DIN-rail mounting is possible with the built-in snap fit devices. For heavy-duty railway applications, 2 or better all 4 fixing brackets DMB-EWG should be fitted; see fig. 8. Fig. 7 W unit with chassis-mounting brackets 3 4.2 Left bracket 12055b Right bracket JM 18 09 5 5 33 0.5 49 Fig. 6 Universal mounting bracket XMK038-G Fig. 8 Additional fixing brackets for railway application Table 2: Universal mounting bracket survey Case size Converter series Description Part number Delivery content L04 H02, M02 Q01, Q03, Q04 PSL H, M Q, P, HP UMB-LHMQ HZZ00610-G Alu-profile (fig. 5), DIN-rail clamp (fig. 4), screws and washers W01, X01 W, X UMB-W HZZ00618-G 2 clamps (fig. 6), 4 counter sunk screws M4 x 16, 4 washers, and 4 spring washers DMB-EWG HZZ00624-G DIN-rail clamp left and right (fig. 9), 2 screws M4 x 12, 2 washers, 2 ribbed-lock washers MELCHER BCD.20007 Rev AD, 01-Dec-2015 The Power Partners. Page 4 of 2 Accessories Mounti ng Supports DIN-Rail Mounting Brackets DMB By means of the mounting kits listed in table 3, converters can be fastened onto a DIN-rail. The kit consists of two aluminum brakets to be mounted on each side of the converter, including a clamp. The kit HZ Z00615-G contains two different sets of screws for the adaption of the brackets to all listed converter series. The design of the kit is made such that the fixture is very tight. As a result the assembly can be used for mobile applications. Table 3: Mounting bracket survey Case Converter Part number size series Description S01 S02 K01 K02 PSS HZZ00615-G S, HR, HRL DMB-K/S PSK K, HRP M02 H02 Q01 Q04 Q05 M H Q1 P1 HP1 1 HZZ00619-G DMB-MHQ Not together with screw-style connectors HZZ00107-G Fig. 9 Schematic view: Assembly of DMB-K/S Chassis Mounting Brackets CMB Series S, HR, HRL, PSS This mounting kit allows for chassis mounting of the converters listed in table 4, if access is only possible from the front of the chassis. Note: If space conditions are very tight, option B1 or B can be used instead of the heat sink. Refer to the data sheets of the respective converters. This kit uses parts of the DMB-K/S kit, since it consists of the same two brakets but without the clamps and fitted the other way round on the heat sink. Table 4: Mounting bracket survey Case Converter Part number size s e r i e s Description S01 S02 PSS S, R HZZ00616-G CMB-S MELCHER BCD.20007 Rev AD, 01-Dec-2015 The Power Partners. Page 5 of 2 Accessories Mounti ng Supports DIN-Rail- and Chassis-Mounting Supports PCB mounting as well as cassette style converters can be chassis- or DIN-Rail mounted by means of mounting bracket adapters. For selection and part numbers refer to table 5 ! Note: Customized adapters for other case sizes are available upon request. Each part number gives a direct indication of the kind of mounting, the type of converter, i.e. the case size, or the output power as well as the possible pin-out and the options according to the relevant converter data. The adaptors are divided into two mechanical types: CMB and DMB. Note: Application-specific assemblies are available on request: MK001-xxx and MK002-xxx. Table 5: Mounting support survey A1 [mm] A2 [mm] 95.0 90.0 Converter Converter case size s e r i e s A01 Delivery content PSR, PSA (Vi max = 40, 60, 80 V) CMBA01-iRY/80 HZZ00607 DMBA01-iRY/80 HZZ00606 PSA (Vi max = 144 V) CMBA01-iRY/144 HZZ00609 DMBA01-iRY/144 HZZ00608 PCB, screw teminal blocks, 4 diodes, capacitor C1 and C- or D-bracket with screws 50.0 45.0 DIL 24 IMX4 with Option K IMS6 with Option K CMB3W-123 HZZ00604 DMB3W -123 HZZ00602 PCB, screw teminal blocks, C- or D-bracket with screws 72.5 67.5 1" x 2" IMX7, IMS7 IML10 1 CMBIMS/X7 HZZ00617 DMBIMS/X7 HZZ00613 See Basic Kit C/DMBIMS/X7 IMX15, IMS15 CMBIMX15 HZZ00626 DMBIMX15 HZZ00625 See Basic Kit C/DMBIMX15 1.6" x 2" 1 Chassis-mounting DIN-mounting Part number Part number Obsolete model 12023 A1 4 4 3.2 60 83 85 11.5 12024 13.3 38 A2 12 Fig. 10 Dimensions of CMB chassis mounting support: Bracket: Aluminum, black finish Fig. 11 Dimensions of DMB DIN-rail support Bracket: Polycarbonate, black MELCHER BCD.20007 Rev AD, 01-Dec-2015 The Power Partners. Page 6 of 2 Accessories Mounti ng Supports CMB: Chassis Mounting Support The kit consists of a PCB for the converter, a set of screw terminals allowing for easy electrical connection and two aluminium profiles, attached to the PCB by means of four screws, which serve as the chassis mounting bracket. Fife different versions according to table 5 are available. Details on the layout of the PCBs and diagrams are given in the description below. DMB: DIN-Rail Mounting Support The DMB kit differs from the CMB version by a bracket suited for DIN-rail mounting. The black plastic body of the bracket holds the PCB by means of a snap-in device. Fife different versions according to table 5 are available. Details on the layout of the PCBs and diagrams are given in the description below. 12026a Electrical Description CMBA01, DMBA01 Exception: Input voltage for PSA55 is 20 VAC. D1 X2 X1 1 1 Vi Gi Note: PSA55 and PSR362 require an additional capacitor (C2) of at least 470 F. X1 - 1 Input - AC-input: The recommended transformer secondary voltage is 48 VAC for PSR/PSA (with Vi max = 80 V) and 72 VAC for PSA (with Vi max = 144 V) i + C2 + C1 D3 D4 D1 D2 G R Go Vo Output - DC-input: Consider the forward voltage drop across the rectifier diodes (also providing reverse polarity protection). Capacitor C1 compensates for the negative input impedance of the converter in case of long connection wires. PSR01/PSA-...iRY CMB/DMBA01 This bracket is designed for non-isolated switching regulators of the PSR and PSA Series in the A01 case size, equipped with option Y. Technical details and further information, e.g. max. input voltage etc., are described in the PSR/PSA data sheet. The use of the optional inhibit - and Rfunction (external output voltage adjustment with R1) is possible, and the device can be driven either from a DCsource or from a transformer secondary voltage. R1 Fig. 13 C/DMBA01- .. PCB layout 12025a D3 Gi- Vo+ Go- X2 - 3 X2 - 2 D2 D4 C2 + C1 X1 - 4 PSR/PSA A01-iRY + Vi+ R1 R i X2 - 1 X1 - 3 X1 - 2 Fig. 12 C/DMBA01-... circuit diagram MELCHER BCD.20007 Rev AD, 01-Dec-2015 The Power Partners. Page 7 of 2 Accessories Mounti ng Supports CMB3W and DMB3W This support is designed for galvanically isolated DC-DC converters of the IMX4 and IMS6 Series (both with option K) in 12028b 23 24 15 16 X2 - 3 12030 MB 3W-123 11 Go2 10 9 Vo-1 12 Vi- X1 - 1 Vo+2 X2 - 4 Vi+ IMX4...K IMS6...K D1 Vo+ Vo-2 Depending on the application input transient protection may be incorporated (e.g. an appropriate Transzorb diode D1) . X2 - 2 Input Output 1 2 X2 - 1 4 C2 D1 C1 C3 X2 X1 - 2 X1 - 4 13 1 X1 20 1 2 DIL 24 cases with one or two output voltages. The pin configuration of the converter groups single, double, and dual, and all technical converter details are described in the data sheets. 3 3 2 1 C1 4 1 C2 C3 1 2 Single-output models Double-output models Fig. 14 Circuit diagram of CMB3W and DMB3W Supports for 7 W Converters Basic Kit CMBIMX/S7 For use with 1" x 2" DC-DC converter types: IMX7, IMS7, IML10. Part no. HZZ00617 The basic kit contains the following: - Two mounting rails, 83 mm - Four screws M 2.5 x 6 - Four nuts M 2.5 - PCB - Three 2-pole terminal blocks (2 x for X1 terminal, 1 x for X3 terminal) - One 3-pole terminal block for X2 terminal - Three wire jumpers 5.08 mm (positions B1, B4, B5) - One wire jumper 10.16 mm (position D1) - Six wire jumpers 6.8 mm (positions L2, L4, L6) - Circuit diagram no. YSK25300 S3 01 Basic Kit DM BIMS/X7 For use with 1"2" DC-DC converter types: IMS7, IMX7, IML10 The basic kit contains the following: - DIN-mounting support for 35 mm DIN-rail systems - PCB - Three 2-pole terminal blocks (2 x for X1 terminal, 1x for X3 terminal) - One 3-pole terminal block for X2 terminal Fig. 15 Print layout of CMB3W and DMB3W - - - - Three wire jumpers 5.08 mm (positions B1, B4, B5) One wire jumper 10.16 mm (position D1) Six wire jumpers 6.8 mm (positions L2, L4, L6) Circuit diagram no. YSK25300 S3 01 Mounting Instructions for Basic Kit Single-output models IMX7, IMS7, IML10: - Solder the wire jumpers into positions as below: 1. D1 (10.16 mm) 2. B1 (5.08 mm), inhibit. Note: This jumper should be fitted, if the inhibit is not actively used. An open inhibit disables the converter. 3. L2-A and L2-B, L6-A and L6-B (6.8 mm) 4. L4-A and L4-B (6.8 mm), only necessary, if the R-input is used. - Solder terminal blocks 5. X1: Position Vi+/ Vi-, 2-pole terminal block 6. X1: Position i/n.c., 2-pole terminal block (only necessary in the case of remote inhibit) 7. X3: Position Vo+/ Vo-, 2-pole terminal block 8. X2: Position n.c., R, Vo-, 3-pole terminal block only necessary in the case of Vo adjustment by e.g. an external voltage source) - Solder the selected DC-DC converter - Mount PCB onto rails by using the 4 screws and nuts or snap PCB onto the DIN mounting support. - Perform function test MELCHER BCD.20007 Rev AD, 01-Dec-2015 The Power Partners. Page 8 of 2 Accessories Mounti ng Supports - Improved input transient protection according to IEC/EN 61000-4-5, level 2, by chokes L1 or L2-A, L2-B (EMC version) and capacitor C1. Double-output models IMX7, IMS7, IML10: - Solder the wire jumpers into positions as below: 1. D1 (10.16 mm) 2. B1 (5.08 mm), inhibit - Remote inhibit. Note: If the inhibit is not actively used the inhibit has to be connected to Vi- by jumper B1. Note: This jumper should be fitted, if the inhibit is not actively used. An open inhibit disables the converter. - External output voltage trimming/adjustment 3. L2-A and L2-B, L6-A and L6-B, L4-A and L4-B (all 6.8 mm) Single-output models: - For applications with both outputs in parallel: 4. Place/solder jumpers B4 and B5, (5.08 mm) a) Vo - adjustment in the range of 70/75 - 100% of Vo nom by resistors RX3 or RX4 or combinations of RX3/RX4. - Solder terminal blocks 5. X1: Position Vi+/ Vi-, 2-pole terminal block 6. X1: Position i/R (Trim), 2-pole terminal block (only necessary in the case of remote inhibit or output voltage trimming by an external voltage source) 7. X3: Position Vo1+/ Vo1-, 2-pole terminal block 8. X2: Position n.c/Vo2+/Vo2-, 3-pole terminal block b) Vo - adjustment in the range of 100 - 105% of Vo nom by resistors RX1 or RX2 or combinations of RX1/RX2. Double-output models: a) Vo - trimming by resistor R2 in the range of 100 - 105% of Vo nom b) Vo - trimming in the range of 70/75 - 100% of Vo nom by a current diode together with a Zener diode D2 applicable for 24/48 IMS7 and 20/40IMX7 types. - Solder the selected DC-DC converter - Mount PCB onto rails by using the 4 screws and nuts or snap PCB onto the DIN mounting support. - Reduced output ripple (by approx. factor 5) by using chokes L3/L5 together with electrolytic capacitors C8/C9. - Perform function test - Improved electromagnetic emission EN 55022, class B, lead length to load 1 m (class A for 110IMX7 types). Application-Specific Circuitry The assembly C/DMBIMX/S7 offers a variety of additional external circuitries which may be implemented onto the PCB. See circuit diagram and consult the IMS/X7 data sheet. This requires all capacitors and output chokes as per circuit diagram fig. 16, whereby the coupling capacitor C10 connected to Vi- via jumper B2 is foreseen for 24/ 48IMS/L types and 20/40/70IMX7 models. Depending upon the application the following pheripheral additions can be made: For 110IMX7 types the coupling capacitor C11 or C12 should be used connected to Vo+ via jumper B3. - Reverse polarity protection by a series diode D1. IMX7, IMS7, IML10 X2 14 D1 BYV27-200 L1 + L2 - A 12036b n.c. X1 1 + Vi + L3 Vi C11 B1 R1 X1 Vi- B5 Vo2+ 12 [Vo-] i X1 R2 R B2 B3 D2 ZPD 16 V 4 C6 1 63 V B4 Vo1- 10 [Vo-] X2 L5 X3 Vo1+ 11 [Vo+] R [n.c.] + + C8 180 Vo2 50 V - L4 - B C4 1 63 V 3 i C3 470 n 63 V L4 - A C5 470 n 63 V RX4 + D3 E - 2025N L2 - B RX3 2 - X2 RX2 100 100 V Vo2+ 13 [R] RX1 X1 C2 150 n 250 V L6 - A + + C9 180 Vo1 50 V L6 - B X3 C7 470 n 63 V - 1 for 70IMX7 use 160 V, for 110IMX7 use 200 V C10 Ker Y2, 4.7 n, 250 V [ ] = single-output models C11, Y2, 47 n, 250 V C12, Y2, 60 n, 250 V Fig. 16 C/DMB circuit diagram with IMX7, IMS7, IML10 MELCHER BCD.20007 Rev AD, 01-Dec-2015 The Power Partners. Page 9 of 2 Accessories Mounti ng Supports Notes: - Wire jumpers B2 and B3 should not be mounted together onto the PCB as this would cause a short circuit. - For single-output models or double-output models with both outputs in parallel, one filter set (L5 or L6-A/L6-B) together with C7 and C9 is sufficient. - The coupling capacitors C10 or C11/12 should be Y2 ceramic types to maintain the outputs being SELV. 12037 Input IMS/X 7 C12 C11 B3 B1 R2 D2 D3 R1 C3 B2 Output B4 C10 C9 x X3 Vo1- (Vo-) R (n.c.) C7 i Fig. 17 C/DMB arrangement of the terminals on the PCB for IMX7, IMS7, IML10. Pin designations for singleoutput models are shown in brackets. Supports for 15 W Converters Basic Kit CMBIMX15 For use with 1.6" x 2" DC-DC converter types: IMS15, IMX15, IMY15. L5 L6 Vo1+ (Vo+) X1 Vo2- (Vo-) Vi- C6 C4 Vo2+ (R) Vi+ C5 C2 L2 L1 x C2 RX4 RX3 RX2 RX1 B5 L3 L4 n.c. X2 C8 x - Four 2-pole terminal blocks (2 x for X1 terminal, 2 x for X2 terminal) - Five wire jumpers 6.35 mm (could be fitted on positions L2-A, L2-B, B1...B6 depending on required configuration) - Circuit diagram no. ZGN.00262.0SD Part no. CMBIMX15 (HZZ00626) Basic Kit DMBIMX15 The basic kit contains the following: For use with 1.6" x 2" DC-DC converter types: IMX15, IMY15, IMS15. - - - - Two mounting rails, 83 mm Four screws M 2.5 x 6 Four nuts M 2.5 PCB Part no. DMBIMX15 (HZZ00625) Fig. 18 C/DMB circuit diagram with IMS15, IMX15, IMY15 MELCHER BCD.20007 Rev AD, 01-Dec-2015 The Power Partners. Page 10 of 2 Accessories Mounti ng Supports The basic kit contains the following: - DIN-mounting support for 35 mm DIN-rail systems - PCB - Four 2-pole terminal blocks (2 x for X1 terminal, 2 x for X2 terminal) - Five wire jumpers 6.35 mm (could be fitted on positions L2-A, L2-B, B1...B6 depending on required configuration) - Circuit diagram no. ZGN.00262.0SD Application-Specific Circuitry The assemblies CMBIMX15 and DMBIMX15 offer a variety of external circuitries which may be implemented onto the PCB. See circuit diagram and consult the IMX15 data sheet on the Power-One web site. Fig. 19 C/DMB arrangement of the terminals on the PCB for IMX15, IMY15, IMS15 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 MELCHER BCD.20007 Rev AD, 01-Dec-2015 The Power Partners. Page 11 of 2