H-Family AC-DC Converters <100 W 50 W AC-DC Converters Single output: Dual output: Triple output: Benign Environment H-Family series 110H/230H1000 series 110H/230H2000 series 110H/230H3000 * Two input voltage ranges suitable for most AC mains * Efficient input filter and built-in surge and transient suppression circuitry * 3 kVrms input to output electric strength test * Outputs individually isolated * Outputs fully protected against overload Safety according to IEC 950 LGA C Table of Contents ........................................... Page Description .............................................................. 10 - 62 Type Survey ............................................................ 10 - 63 Safety and Installation Instructions ......................... 10 - 63 Functional Description ............................................ 10 - 64 Electrical Input Data ................................................ 10 - 65 Electrical Output Data ............................................. 10 - 66 EMC and Immunity to Input Transients ................... 10 - 69 Supplementary Data ............................................... 10 - 70 Description of Options ............................................. 10 - 71 Immunity to Environmental Conditions .................... 10 - 75 Mechanical Data ..................................................... 10 - 76 Type Key and Product Marking ............................... 10 - 77 Description 10.3 The H-family of AC-DC converters represents a broad and flexible range of power supplies for use in advanced electronic systems. Features include high efficiency, reliability and low output voltage noise. The converter inputs are protected against surges and transients occuring at the source lines. An input over- and undervoltage cut-out circuitry disables the outputs if the input voltage is outside the specified range. The modules include an inrush current limitation preventing circuit breakers and fuses from being damaged at switch-on. All outputs are open- and short-circuit proof and are protected against overvoltages by means of built-in suppressor diodes. The outputs can be inhibited by a logic signal applied to the connector pin 2(i). If the inhibit function is not used pin 2 should be connected with pin 23 to enable the outputs. LED indicators display the status of the converter and allow visual monitoring of the system at any time. Full input to output, input to case, output to case and output to output isolation is provided. The modules are designed and built according to the international safety standard 10 - 62 IEC 950 and have been approved by the safety agencies LGA (Germany) and UL (USA). The UL Mark for Canada has been officially recognized be regulatory authorities in provinces across Canada. The case design allows operation at nominal load up to 50C in a free air ambient temperature. If forced cooling is provided, the ambient temperature may exceed 50 C but the case temperature should remain below 80C under all conditions. A temperature sensor generates an inhibit signal which disables the outputs if 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 modules may either be plugged into 19 inch rack systems according to DIN 41494, or be chassis mounted. Case: aluminium, black finish, self cooling. Dimensions: 38.7 x 111.2 x 168.5 mm. Weight: 770 g MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Benign Environment AC-DC Converters <100 W H-Family Type Survey Options see "Descriptions of Options" Table 1: Type survey 1 Output 1 Output 2 Output 3 Uo nom I o nom V DC A Uo nom Io nom V DC A Uo nom Io nom V DC A 5.1 12.0 15.0 24.0 48.0 8.0 4.0 3.4 2.0 1.0 12.0 15.0 2.0 1.7 12.0 15.0 2.0 1.7 5.1 5.1 5.0 5.0 12.0 15.0 0.7 0.6 12.0 15.0 0.7 0.6 Input Voltage Range and Efficiency 1 Option Ui min...Ui max 85...132 V AC 47...63 Hz min % Ui min...Ui max 187...255 V AC 47...63 Hz min % 110H1001-2R 110H1301-2R 110H1501-2R 110H1601-2R 110H1901-2R 74 81 83 83 85 230H1001-2R 230H1301-2R 230H1501-2R 230H1601-2R 230H1901-2R 74 81 82 82 85 110H2320-2 110H2540-2 81 82 230H2320-2 230H2540-2 81 82 110H3020-2 110H3040-2 79 79 230H3020-2 230H3040-2 78 79 V2, V3 D1...D8 Efficiency measured at Ui nom and I o nom Safety and Installation Instructions Safety If the output circuit of an AC-DC converter is operator-accessible according to the IEC 950 related safety standards, it shall be an SELV circuit (Safety Extra Low Voltage circuit, i.e. a circuit, separated from mains by at least basic insulation, that is so designed and protected such that under normal and single fault conditions, the voltage between any two conductors and between any conductor and earth does not exceed 60 V DC). In the following section an interpretation is provided of the IEC 950 safety standard with respect to the safety status of the output circuit. However, it is the sole responsibility of the installer or user to assure the compliance with the relevant and applicable safety standards: If the AC-DC converter is installed according to the relevant safety regulations its outputs are considered to be SELV circuits up to a nominal output voltage of 36 V. For safety reasons, the modules must be wired via the female connector H11 (according to DIN 41612 see section "Accessories") in order to meet national and international safety requirements! The connector protective earthing pin is leading. During the production process, all transformers and each of the fully assembled modules are individually tested for electric strength and earth continuity (see "Supplementary Data"). All electric strength tests are performed as factory tests. Installation Instruction Installation of the power supply must strictly follow the national safety regulations. To observe the safety requirements according to EN 60950/IEC 950, the module shall be connected via the female connector type H11 see section "Accessories". Other installation methods may not meet the safety requirements. The modules do not incorporate any fuse. At least one external fuse, installed in the wiring to the input is essential! See "Fuse types". Whenever the inhibit function is not required, pin 2 (i) should be connected to pin 23 to enable the output(s). Electric strength tests should not be repeated in the field. Improper test methods, for example overshooting or oscillating test voltages, voltage slopes exceeding 1 kV/s, internal Y-capacitors not carefully discharged, etc. can cause severe damage to switching devices and ICs. Melcher AG will not honour any guarantee/warranty claims resulting from high voltage field tests. Edition 2/96 - (c) Melcher AG MELCHER The Power Partners. 10 - 63 10.3 Important Advice H-Family AC-DC Converters <100 W Benign Environment Table 2: H11 connector pin allocation Electrical Determination H1000 Pin H2000 Ident Pin Inhibit control input Safe Data or ACFAIL 2 5 i D or V 2 5 Output voltage (positive) Output voltage (negative) 8 11 Vo1+ Vo1- 8 11 Control input + Control input - 14 17 R G Output voltage (positive) Output voltage (negative) 1 Output voltage (positive) Output voltage (negative) Protective earthing 1 20 23 AC input voltage AC input voltage 29 32 Vo1+ Vo1- 26 H3000 Ident Pin i D or V 2 5 i D or V 8 11 Vo3+ Vo3- 14 17 Vo2+ Vo2- 14 17 Vo2+ Vo2- 20 23 Vo1+ Vo1- 20 23 Vo1+ Vo1- N P 29 32 26 N P Ident 26 29 32 N P Leading pin (pregrounding) Degree of Protection Condition: Female connector fitted to the unit IP 40: All units, except those with options D or V incorporating potentiometer adjustment. IP 20: Type fitted with options D or V incorporating potentiometer. Functional Description The input voltage is fed via an input filter, an inrush current limiter and a bridge rectifier to the input capacitor. This capacitor sources a single transistor forward converter. Each output is powered by a separate secondary winding of the main transformer. The resultant voltages are rectified and their ripples smoothed by a power choke. The control logic senses the main output voltage Uo1 and generates, with respect to the maximum admissible output currents, the con- trol signal for the primary switching transistor. This signal is fed back via a coupling transformer. The auxiliary outputs Uo2 and Uo3 are unregulated. Each auxiliary output's current is sensed and transferred to the main control circuit using a current transformer. If one of the outputs is driven into current limit, the other outputs will reduce their output voltages as well because all output currents are controlled by the same control circuit. 2 5 1 Main control circuit 1 17 20 Y 29 Input filter Forward converter approx. 70 kHz 23 VDR 10.3 14 32 Y 14 Current limitation output 2 17 8 Current limitation output 3 11 26 Y 1 Fig. 1 AC-DC converter block diagram 10 - 64 Y Y Single output modules H1000 (R input) MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Benign Environment AC-DC Converters <100 W H-Family Electrical Input Data General conditions: - TA = 25C, unless TC is specified. - Connector pins 2 and 23 interconnected, R input not connected. Table 3: Input data Input 110H Conditions min Ui I o = 0...Io nom TC min...TC max 85 Ui nom Nominal input voltage Ii Input current U i nom, Io nom 1 Si 0 No-load apparent input power: Single output Double output Triple output Ui nom I o1,2,3 = 0 Idle apparent input power inhibit mode 2.5 2.5 Ui = Ui max RS = 0 4 TC = 25C 80 42 Si inh Input voltage range Iinr p 3 Peak inrush current tinr r Rise time tinr h Trailing edge half-life Ri Input resistance TC = 25 C typ 230H Characteristics max min 132 187 typ 110 230 0.78 0.44 1 7 7 1.5 9 9 1 7 7 max Unit 255 V AC Arms 1.5 9 9 200 300 1100 1600 VA A s 450 800 RNTC 2 NTC resistance 2000 8000 Ci 250 570 50 270 F 0 142 0 284 V AC Input capacitance U i abs Input voltage limits without any damage m 1 With multiple output modules, the same condition for each output applies. Initial switch-on cycle. Subsequent switch on/off cycles increase the inrush current peak value. 3 I inr p = U i/(R s + Ri + RNTC) 4 R = source resistance. S 2 Input Under-/Overvoltage Cut-out Input fuse The modules do not incorporate any fuse. External fuses installed in the wiring to the input are essential. Table 4: Recommended fuse types (slow-blow) Series Schurter type Part number 110H SPT 2.5 A 250 V 0001.2508 230H SPT 2.5 A 250 V 0001.2508 10.3 If the input voltage remains below 0.6 Ui min or exceeds 1.1 Ui max (approx. values), an internally generated inhibit signal disables the output(s). When checking this function the absolute maximum input voltage rating Ui abs must be carefully considered (see table above). Edition 2/96 - (c) Melcher AG MELCHER The Power Partners. 10 - 65 H-Family AC-DC Converters <100 W Benign Environment Electrical Output Data General conditions - TA = 25C, unless TC is specified. - Connector pins 2 and 23 interconnected, R input not connected. Table 5a: Output data Uo nom Output Characteristics Uo1 Output voltage Conditions U i nom, I o nom 5.1 V min 1 5.00 Uo2/3 Overvoltage prot. Uo2/3 L Unit 12.24 12.90 14.70 15.30 V 13.90 16.10 21 25 31 13.80 U i min... Ui max TC min...TC max 17.25 see table 1 see fig. 2 U i min... U i nom 20 U i nom...U i max I o nom 1 - Static load regulation U i nom I o = I o nom ...0 2 15 Uo2/3 I 50 120 150 mVrms 200 360 450 mVpp mV 50 50 Static cross load regulation 3 max 25 Output voltage noise U i nom, I o nom 1 BW = 20 MHz Uo2/3 Ic 11.76 11.10 typ - u o1/2/3 Uo1 Ic min 7.5 Output current limitation response Static line regulation max Failure in control circuit Output current Uo2/3 U typ - Io L Uo1 I 5.20 min 15 V Ui min...Ui max Io2/3 = 0 I o nom Uo1 U max - Uo2/3 0 Uo1 L typ 12 V 5 U i nom I o = I o nom ...0 4 25 120 30 150 80 240 100 300 35 120 45 150 see fig. 3 15 10 - see fig. 4 30 15 see fig. 3 45 see fig. 4 Table 5b: Output data Uo nom 10.3 Output Characteristics Conditions Uo1 Output voltage U i nom, I o1 nom Uo L Overvoltage prot. I o1 nom I o1 nom Output current Uo1 L Output current limitation response U i min... Ui max TC min...TC max u o1 Output voltage noise U i nom, I o1 nom BW = 20 MHz Uo1 U Static line regulation Uo1 I Static load regulation U i nom I o1 = I o1 nom...0 U i min... Ui nom U i nom...U i max I o1 nom 24 V min typ 23.52 48 V max min max Unit 24.48 47.04 48.96 V 240 480 mVrms 720 1440 mVpp mV 41 typ 85 see table 1 see fig. 2 30 240 30 480 70 240 150 480 1 With multiple output modules, the same condition for each output applies. Condition for specified output. With multiple output modules, other output(s) loaded with constant current I o = I o nom. 3 Condition for non-specified output, individually tested, other output(s) loaded with constant current I = I o o nom. 4 Multiple output modules. 2 10 - 66 MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Benign Environment AC-DC Converters <100 W 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 applied overvoltages. Overload at any of the outputs will cause a shut-down of all outputs. H-Family Uo Uo nom Io nom IoL1 1.0 0.95 IoL2,IoL3 0.5 Io2,Io3 Io1 0 0.5 1.0 1.2 Io Io nom Fig. 2 Typical output voltage Uo versus output currents Io Uo2/3 [V] Uo2/3 0 Uo2/3 [V] Uo2/3 0 16 13 Io1 nom Io1 nom 0.5 * Io1 nom 0.5 * Io1 nom Io1 = 0 A Io1 = 0 A 15 12 14 11 Io2/3 0.5 0.75 1.0 Io2/3 nom Fig. 3 H2320/3020: Uo2/3 (typ.) versus Io2/3 with different Io1 0.5 0.75 Io2/3 Io2/3 nom 1.0 Fig. 4 H2540/3040: Uo2/3 (typ.) versus Io2/3 with different Io1 Parallel and Series Connection Main outputs of equal nominal voltage can be connected in parallel. It is important to assure that the main output of a multiple output module is forced to supply a minimum current of 0.1 A to enable correct operation of its own auxiliary outputs. Outputs one and two of a dual output unit may be connected parallel without a minimum current requirement at the main output. Outputs two and three of a triple output unit can be connected in parallel. In parallel operation, one or more of the outputs may operate continuously in current limit which will cause an increase in case temperature. Consequently, a reduction of the max. ambient temperature by 10 K is recommended. Main or auxiliary outputs can be connected in series with any other output of the same or another module. In series connection, the maximum output current is limited by the lowest current limit. Output ripple and regulation values are added. Connection wiring should be kept as short as possible. If output terminals are connected together in order to establish multi-voltage configurations, e.g. +5.1 V, 12 V etc. the common ground connecting point should be as close as possible to the connector of the converter to avoid excessive output ripple voltages. Inhibit (i Input) The outputs of the module may be enabled or disabled by means of a logic signal (TTL, CMOS, etc.) applied to the inhibit input. If the inhibit function is not required, connect the inhibit pin 2 to pin 23 to enable the outputs (active low logic, fail safe). I inh [mA] 2.0 U inh= 0.8 V U inh= 2.4 V 1.6 1.2 The reference for the inhibit signal is the negative pin of output 1. N 0.25 0 10.3 0.25 0 0.8 Uo = on 0.4 Vo+ Uo = off 0 i I inh -0.4 -0.8 -50 U inh P Vo- Fig. 5 Definition of inhibit voltage and current Edition 2/96 - (c) Melcher AG -40 -30 -20 -10 0 10 20 30 40 50 U inh [V] Fig. 6 Typical inhibit current I inh versus inhibit voltage U inh MELCHER The Power Partners. 10 - 67 H-Family AC-DC Converters <100 W Benign Environment Table 6: Inhibit data Characteristics Conditions U inh Inhibit input voltage causing output voltage being... I inh Inhibit current switched on min U i min...U i max - 50 Uinh = 0 -60 switched off typ 2.4 max Unit 0.8 V DC 50 -100 A -220 Output Output Response The reaction of the outputs is similar whether the input voltage is applied or the inhibit is switched low. An output voltage overshoot will not occur when the module is turned on or off. Uo nom 0.1 0 tr t tf Ui 1 t 0 Inhibit Fig. 7 Output response as a function of input voltage (on/off switching) or inhibit control 1 t 0 Table 7: Output response time Type of Converter t r and t f at Po = 3 / 4 Po nom typ max t r at Po = 0 and t f at Po = Po nom typ max t r at Po = Po nom typ max H1001-2R H1301-2R H1501-2R H1601-2R H1901-2R 3 5 3 8 35 17 25 17 30 100 3 8 5 15 50 17 30 25 45 150 5 10 15 20 85 25 40 50 70 230 H2320-2 H2540-2 10 8 40 30 15 10 50 40 25 20 80 60 H3020-2 H3040-2 30 20 85 70 45 30 130 90 75 50 210 150 Unit ms Conditions: R input not used. For multiple output modules the figures indicated in the table above relate to the output which reacts slowest. All outputs are resistively loaded. Variation of the input voltage within Ui min...Ui max does not influence the values. Programmable Voltage (R Input) 10.3 As a standard feature single output modules offer an adjustable output voltage identified by letter R in the type designation. The control input R (pin 14) accepts either a control voltage Uext or a resistor Rext to adjust the desired output voltage. When not connected, the control input automatically sets the output voltage to Uo nom. The control input is protected against external overvoltage up to 8 V max. a) Adjustment by means of an external control voltage Uext between pin 14 (R) and pin 17 (G): The control voltage range is 0...2.75 V and allows an adjustment in the range of approximately Uo = 0...110 % Uo nom. Uo Uext ------- * 2.5 V Uo nom or: Between pin 14 and pin 20 (Uo > Uo nom) to achieve an output voltage adjustment range of approximately Uo = 100...110 % of Uo nom (U o - 2.5 V) R 'ext 4 k * ---------------- 2.5 V* (U o / Uo nom - 1) For output voltages Uo > Uo nom, the minimum input voltage according to "Electrical Input Data" increases proportionally to Uo /Uo nom. Warning The value of R'ext should never be less than 47 k to avoid damage to the unit! R inputs may be parallel connected, but 1/Rtot = 1/R1 + 1/R2 +.... should be considered. Vi+ 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 14 and pin 17 (Uo < Uo nom) to achieve an output voltage adjustment range of approx. Uo = 0...100% Uo nom Uo R ext 4 k * -------- Uo nom - U o 10 - 68 Vo1+ 29 20 2.5 V 4 k 14 control circuit 32 Vo1+ 23 20 29 2.5 V 4 k R + G - Vo1- 14 control circuit Uext 17 Vi- Vi+ Rext 17 Vi- 32 R'ext R 23 G Vo1- Fig. 8 Output voltage control by means of the R input MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Benign Environment AC-DC Converters <100 W H-Family Table 8a: Rext for Uo < Uo nom (conditions: Ui nom, Io nom, rounded up to resistor values E 96); R'ext = Uo nom = 5.1 V Uo [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 30.1 200.0 Uo nom = 12 V Uo [V] Rext [k] Uo nom = 15 V Uo [V] Rext [k] Uo nom = 24 V Uo [V] Rext [k] Uo nom = 48 V Uo [V] Rext [k] 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 2.0 4.0 6.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 4.0 6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0 22.0 8.0 12.0 16.0 20.0 24.0 28.0 32.0 36.0 40.0 44.0 0.806 1.33 2.0 2.87 4.02 5.62 8.06 12.1 20.0 44.2 0.619 1.47 2.67 4.53 6.04 8.06 11.0 16.2 26.1 56.2 0.806 1.33 2.0 2.87 4.02 5.62 8.06 12.1 20.0 44.2 0.806 1.33 2.0 2.87 4.02 5.62 8.06 12.1 20.0 44.2 Table 8b: R'ext for Uo > Uo nom (conditions: Ui nom, Io nom, rounded up to resistor values E 96); Rext = Uo nom = 5.1 V Uo [V] R'ext [k] 5.15 5.20 5.25 5.30 5.35 5.40 5.45 5.50 Uo nom = 12 V Uo [V] R'ext [k] 464 215 147 110 90.9 78.7 68.1 61.9 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 13.0 13.2 1780 909 619 464 383 316 274 249 200 169 Uo nom = 15 V Uo [V] R'ext [k] 15.2 15.4 15.6 15.8 16.0 16.2 16.4 16.5 Uo nom = 24 V Uo [V] R'ext [k] 1470 750 511 383 332 274 237 226 24.25 24.50 24.75 25.00 25.25 25.50 25.75 26.00 26.25 26.40 3160 1620 1100 825 715 590 511 453 402 383 Uo nom = 48 V Uo [V] R'ext [k] 48.5 49.0 49.5 50.0 50.5 51.0 51.5 52.0 52.5 52.8 6810 3480 2370 1780 1470 1270 1100 953 845 806 EMC and Immunity to Input Transients A metal oxide VDR together with an input filter form an effective protection against input transient voltages which typically occur in most installations. The H-Family has been successfully tested to the following specifications: Electromagnetic Immunity Source impedance Test procedure 1/50 ns 330 10 positive and 10 negative 2 contact discharge to case, Electric field IEC 801-3 (1984) 2 antenna in 1m distance Fast transient/ burst IEC 801-4 (1988) 1 i/c, +i/-i Transient IEC 801-5 (Draft 1993-01) 1 i/c 500 Vp +i/-i 500 Vp 3 V/m yes 2 26...1000 MHz yes 2 50 1 min positive 1 min negative bursts per coupling mode yes 2 12 5 pos. and 5 neg. impulses per coupling mode yes 1 sine wave modulated w. 1 kHz 500 Vp bursts of 5/50 ns 5 kHz rep. rate transients with 15 ms burst duration and a 300 ms period 1.2/50 s 2 10.3 IEC 801-2 (1991-04) Performance Waveform 4000 Vp Electrostatic discharge In operation Value applied Coupling mode 3 Level Standard Phenomenon Table 9: Immunity type tests 1 Normal operation, no deviation from specifications Normal operation, temporary deviation from specs possible 3 i = input, o = output, c = case 2 Edition 2/96 - (c) Melcher AG MELCHER The Power Partners. 10 - 69 H-Family AC-DC Converters <100 W Benign Environment Electromagnetic Emissions Table 10: Emissions at Ui nom and Io nom Series Standard EN 55011, 1991 1 EN 55022, 1987 2 30 MHz 30 MHz 110H <B <B 230H <B <B 1 2 Identical with CISPR 11 (1990-09) and VDE 0875 part 11 (1992-07) Identical with CISPR 22 (1985) and FCC Part 15, VDE 0878 part 3 (1989-11) Supplementary Data Isolation Input to output electric strength tests, in accordance with the safety standards IEC 950, EN 60950, VDE 0805 and EN 41003 are performed as factory tests and should not be repeated in the field. Important Advice Testing by applying AC voltages will result in high and dangerous leakage currents through the Y-capacitors (see fig. 1). Melcher will not honour any guarantee/warranty claims resulting from high voltage field tests. Reference is also made to chapter: "Safety and Installation Instructions". Table 11: Electric strength test voltage, insulation resistance, clearance and creepage distances Characteristic Values according to IEC 950 Electric strength test voltage DC: 1 s Insulation resistance at 500 V DC Input to output Input to case Output to case Output to output Unit 4243 1 2122 707 300 V 1 AC: 50 Hz, 1 min 3000 Clearance and creepage distances 1 1500 500 200 300 300 100 - M 4.0 2.0 1.0 0.9 mm Only subassemblies performance in accordance with IEC 950 Display Status of LEDs Uo1 > 0.95...0.98Uo1 adj OK i Ui Ui uv Ui min Ui max Uo1 > 0.95...0.98Uo1 adj Ui ov Ui abs Uo1 < 0.95...0.98Uo1 adj OK Io L Io nom Io LED "OK" status versus output current Conditions: U i min...U i max, TC TC max, U inh 0.8 V TC LED "i"versus case temperature Conditions: U i min...U i max, I o I o nom, U inh 0.8 V IoL i 10.3 Fig. 9 LEDs "OK" and "i" status versus input voltage Conditions: Io Io nom, TC TC max , Uinh 0.8 V Ui uv = undervoltage lock-out, Ui ov = overvoltage lock-out TC max TPTC threshold Uinh threshold i Ui inh -50 V LED off 10 - 70 +0.8 V +2.4 V LED Status undefined LED "i"versus U inh Conditions: U i min...U i max, I o I o nom, TC TC max +50 V LED on MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Benign Environment AC-DC Converters <100 W H-Family Description of Options Table 12: Survey of options Option 1 2 Function of Option Characteristic D1 Input and/or output undervoltage monitoring circuitry Safe data signal output (D1...D8) V12 Input and output undervoltage monitoring circuitry ACFAIL signal according to VME specifications ( V2, V3) Option D excludes option V and vice versa Only available with main output voltage Uo1 = 5.1 V Option D Undervoltage monitor The input and/or output undervoltage monitoring circuit operates independently of the built-in input undervoltage lockout circuit. A logic "low" (JFET output) or "high" signal (NPN output) is generated at pin 5 as soon as one of the monitored voltages drops below the preselected threshold level Ut. The return for this signal is Vo1- (pin 23). The D output recovers when the monitored voltage(s) exceed(s) Ut+Uh. The threshold level Ut is either adjustable by a potentiometer, accessible through a hole in the front cover, or is factory adjusted to a fixed value specified by the customer. Option D exists in various versions D1...D8 as shown in the following table. Table 13: Undervoltage monitor functions Output type JFET NPN 2 Typical hysteresis U h [% of Ut ] for U t min... Ut max U hi U ho Minimum adjustment range of threshold level U t Uti Uto D1 D5 no yes - 3.5 V...48 V 1 - 2.3...1 D2 D6 yes no Ui min... Ui max 1 - 3.0...0.5 - 1 D3 D7 yes yes Ui min... Ui max D4 D8 no yes - 0.95...0.98 Uo1 2 0.95...0.98 Uo1 2 3.0...0.5 "0" - "0" Threshold level adjustable by potentiometer (not recommended for mobile applications) Fixed value between 95% and 98% of Uo1 (tracking) JFET output (D1...D4): N Connector pin D is internally connected via the drainsource path of a JFET (self-conducting type) to the negative potential of output 1. UD 0.4 V (logic low) corresponds to a monitored voltage level (Ui and/or Uo1) < Ut. The current ID 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. D output, U D Ui or U o1 < U t low, L, U D 0.4 V at I D = 2.5 mA U i and U o1 > U t + U h high, H, I D 25 A at U D = 5.25 V Vo1+ Rp 5 D UD 6 V 32 23 Vo1- NPN output (D5...D8): Connector pin D is internally connected via the collectoremitter path of a NPN transistor to the negative potential of output 1. UD < 0.4 V (logic low) corresponds to a monitored voltage level (Ui and/or Uo1) > Ut + Uh. The current ID through the open collector should not exceed 20 mA. The NPN output is not protected against external overvoltages. UD should not exceed 40 V. U i , U o1 status D output, U D U i or U o1 < U t high, H, I D 25 A at U D = 40 V U i and U o1 > U t + U h low, L, U D 0.4 V at I D = 20 mA Edition 2/96 - (c) Melcher AG 20 ID P U i , U o1 status 29 Fig. 10 Options D1...D4, JFET output N 29 20 Vo1+ Rp ID 5 D UD P 32 23 Vo1- Fig. 11 Options D5...D8, NPN output MELCHER The Power Partners. 10 - 71 10.3 1 Monitoring Ui Uo1 AC-DC Converters <100 W Uti UD Threshold tolerances and hysteresis: If Ui is monitored, the internal input voltage after the input filter and rectifier is measured. Consequently this voltage differs from the voltage at the connector pins by the voltage drop Uti across the input filter. The value of Uti depends upon the input voltage range, threshold level Ut, temperature and input current. The input current is a function of the input voltage and the output power. Benign Environment Uhi Po = 0 Po = 0 Po = Po nom UD high Po = Po nom H-Family UD low Ui Uti Fig. 12 Definition of Uti, Uti and Uhi (JFET output) Input voltage monitoring NPN UD UD high 3 3 3 3 UD low t 0 ID ID high ID low 0 t JFET UD UD high UD low 0 t th1 tlow min4 tlow min4 Uo1 Uo1 nom 1 0.95 tlow min4 thigh min th1 t 0 Ui [V DC] Uti +Uhi Uti t 0 Input voltage failure Input voltage sag Switch-on cycle Output voltage monitoring NPN UD UD high Switch-on cycle and subsequent input voltage failure 2 UD low t 0 ID ID high 10.3 ID low 0 t JFET UD UD high UD low 0 t tlow min4 Uo1 Uo1 nom Uto +Uho Uto 1 2 3 t 0 With output voltage monitoring the hold-up time t h = 0 The D signal remains high if the D output is connected to an external source. t low min = 40...200 ms, typically 80 ms Output voltage failure Fig. 13 Relationship between Ui, Uo1, UD, ID and Uo1/Uo nom versus time. 10 - 72 MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Benign Environment AC-DC Converters <100 W Option V ACFAIL signal (VME) This option defines an undervoltage monitoring circuit for the input or the input and main output voltage (Uo1 nom = 5.1 V only) equivalent to option D and generates the 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 IV = 48 mA to UV 0.6 V (open-collector output of a NPN transistor). The pull-up resistor feeding the open-collector output should be placed on the VME backplane. 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 5.1 V output is fully loaded. This hold-up time t h is provided by the internal input capacitance. Consequently the working input voltage and the threshold level U ti should be adequately above the minimum input voltage Ui min of the converter so that enough energy is remaining in the input capacitance. Table 14: Factory potentiometer setting of Uti Types 110H 230H Unit Ci min 0.25 0.05 mF Uti 94 200 V DC th 5 5 ms Option V operates independently of the built-in input undervoltage lock-out circuit. A logic "low" signal is generated at pin 5 as soon as one of the monitored voltages drops below the preselected threshold level Ut. The return for this signal is Vo1- (pin 23). The V output recovers when the monitored H-Family Formula for threshold level for desired value of th : Uti 2 * Po * (th + 0.3 ms) * 100 --------------------- + Ui min2 Ci min * = where as: Ci min = minimum internal input capacitance [mF], according to table below Po = output power [W] h = efficiency [%] th = hold-up time [ms] Ui min = minimum input voltage [V] Uti = threshold level [V] Remarks: The threshold level Uti of option V2 and V3 is adjusted during manufacture to a value according to table "Undervoltage monitor functions", section "Option D"). A decoupling diode should be connected in series with the input to avoid the input capacitance discharging through other loads connected to the same source voltage. voltage(s) exceed(s) Ut + Uh. The threshold level Ut is adjustable by a potentiometer accessible through a hole in the front cover. Versions V2 and V3 are available as shown below. Table 15: Undervoltage monitor functions V output (VME compatible) V2 V3 1 2 Monitoring Ui U o1 yes yes no yes Typical hysteresis U h [ % of U t ] for U t min...U t max U hi U ho Minimum adjustment range of threshold level U t U ti U to U i min... Ui max 1 U i min... Ui max 1 - 0.95...0.98 U o1 2 3.0...0.5 - 3.0...0.5 "0" Threshold level adjustable by potentiometer (not recommended for mobile applications) Fixed value between 95% and 98% of Uo1 (tracking), output undervoltage monitoring is not a requirement of VME standard V output (V2, V3): Ui, Uo1 status U i or U o1 < U t U i and U o1 > U t + U h Edition 2/96 - (c) Melcher AG V output, UV N 20 Vo1+ Rp IV 5 V UV P low, L, U V 0.6 V at I V = 50 mA high, H, I V 25 A at UV = 5.1 V 29 32 23 Vo1- Fig. 14 Output configuration of options V2 and V3 MELCHER The Power Partners. 10 - 73 10.3 Connector pin V is internally connected to the open collector of a NPN transistor. The emitter is connected to the negative potential of output 1. U V 0.6 V (logic low) corresponds to a monitored voltage level (U i and/or Uo1) < U t. The current I V through the open collector should not exceed 50 mA. The NPN output is not protected against external overvoltages. U V should not exceed 80 V. AC-DC Converters <100 W Threshold tolerances and hysteresis: If Ui is monitored, the internal input voltage is measured after the input filter and rectifier. Consequently this voltage differs from the voltage at the connector pins by the voltage drop U ti across input filter and rectifier. The value of U ti depends upon the input voltage range, threshold level U t, temperature and input current. The input current is a function of input voltage and output power. UV Benign Environment Uti Uhi Po = 0 Po = 0 Po = Po nom UV high Po = Po nom H-Family UV low Fig. 15 Definition of Uti, Uti and Uhi Input voltage monitoring V2 UV UV high t low min 2 t low min 2 t low min 2 3 Ui Uti 3 3 4 4 2 2 UV low t 0 t low min V3 UV UV high 3 t low min 3 3 UV low t 0 th 1 th 1 Uo1 5.1 V 4.875 V 2.0 V 0 t Ui [V DC] Uti + Uhi Uti t 0 Input voltage failure Input voltage sag Switch-on cycle Switch-on cycle and subsequent input voltage failure Output voltage monitoring V2 UV UV high 4 UV low 4 0 V3 UV UV high t low min 2 3 3 4 10.3 UV low 0 Uo1 5.1 V 4.875 V 2.0 V 0 1 VME request: minimum 4 ms t low min = 40...200 ms, typically 80 ms 3 U level not defined at U V o1 < 2.0 V 4 The V signal drops simultaneously with the output voltage, if the pull-up resistor RP is connected to Vo1+. The V signal remains high if RP is connected to an external source. Ui 2 Uti + Uhi Uti 0 Output voltage failure Fig. 16 Relationship between U i, Uo1, U V, I V and Uo1 / Uo nom versus time. 10 - 74 MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Benign Environment AC-DC Converters <100 W H-Family Immunity to Environmental Conditions Table 16: Mechanical stress Test Method Standard Test Conditions Ca Damp heat steady state DIN 40046 part 5 IEC 68-2-3 Temperature: Relative humidity: Duration: 40 2 C 93 +2/-3 % 21 days Unit not operating Ea Shock (half-sinusoidal) DIN 40046 part 7 IEC 68-2-27 MIL-STD-810D section 516.3 Acceleration amplitude: Bump duration: Number of bumps: 15 gn = 147 m/s2 11 ms 18 (3 each direction) Unit operating Eb Continuous shock (half-sinusoidal) DIN 40046 part 26 IEC 68-2-29 MIL-STD-810D section 516.3 Acceleration amplitude: Bump duration: Number of bumps: 10 gn = 98 m/s2 16 ms 6000 (1000 each direction) Unit operating Fc Vibration (sinusoidal) DIN 40046 part 8 IEC 68-2-6 MIL-STD-810D section 514.3 Frequency (1 Oct/min): Acceleration amplitude: Test duration: 10...150 Hz 2 gn = 20 m/s2 3.75 h (1.25 h each axis) Unit operating Thermal considerations Table 17: Temperature specifications, values given are for an air pressure of 800...1200 hPa (800...1200 mbar) Characteristic min max Unit C TA Standard operational ambient temperature range -2 -10 50 TC Standard operational case temperature range -2, overtemp. lock-out (PTC) above TC max -10 80 TS Storage temperature range -2 -25 100 Basically the available output power is limited by thermal characteristics. Operation at higher temperatures with nominal output currents is also possible if forced cooling can be provided (heat sink, fan, etc.). Example: Sufficient forced cooling allowsTA max = 65 C. A simple check of the case temperature TC ( TC 80 C) at full load ensures correct operation of the system (temperature measurement point on the case see "Mechanical Data"). In general: For an ambient temperature of 65 C with only convection cooling, the maximum permissible current for each output is approx. 50% of it's nominal value. 110 Io nom (forced cooling) 100 90 Io nom each output (convection cooling) 80 70 60 TC max 50 40 30 20 Table 18: MTBF 10 Module Types Ground Benign Unit 40C MTBF Edition 2/96 - (c) Melcher AG H1000 H2000 H3000 384'000 306'000 270'000 h 0 TA min 40 50 60 70 80 TA [C] Fig. 17 Output derating versus ambient temperature under convection and forced cooling conditions MELCHER The Power Partners. 10 - 75 10.3 Values at specified Case Temperature Io nom [%] H-Family AC-DC Converters <100 W Benign Environment Mechanical Data European Projection 12.1 0.5 32 29 26 23 20 17 14 8 11 2 6TE 5 Dimensions in mm. Tolerances 0.3 mm unless otherwise indicated. 20.5 3.27 Mounting holes for retaining clips V 1.6 2TE Male connector H 11 according to DIN 41 612 100 0.6 Front plate 20 103 M 3; depth = 4 mm (chassis mount) Rear face Measurement point for case temperatureTC 68 22 171.9 (DIN 41494) 127 159.4 168.5 0.5 Main face Mounting plane of connector H11 (11.6) 88 111.2 0.8 38.7 Back plate o 4.0 0 o 3.5 17.25 12.17 7.09 31.5 0.1 10.3 30.48 25.40 94.5 0.1 95 0.5 0 OK (LED green) Inhibit i (LED red) Potentiometer (option D or V) Fig. 18 Case H02, weight 770 g (approx.) 10 - 76 MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Benign Environment AC-DC Converters <100 W H-Family Type Key and Product Marking Type Key 230 H 2 5 40 -2 R D V Input voltage range Ui: 85...132 V AC ........... 110 187...255 V AC ........... 230 Family ............................................................................. H Number of outputs ...................................................... 1...3 Output 1, Uo1 nom: 5.1 V 12 V 15 V 24 V 48 V Single output modules Output 2 and 3, Uo2 nom, Uo3 nom: ............. 01 12 V ............. 20 15 V ............. 40 Ambient temperature range TA: (operational) ............... 0 ............... 3 ............... 5 ............... 6 ............... 9 -10...50 C .............. -2 Output voltage control input (single output modules only) R Options: Save data signal (D1...D8, to be specified) ..................... D 1 ACFAIL signal (V2, V3, to be specified) ........................... V 1 1 Option D excludes option V and vice versa Example: 230H1501-2RD3: AC-DC converter, input voltage range 187...255 V AC, providing output with 15 V/3.4 A; equipped with an output voltage control input and undervoltage monitoring. Accessories: Front panels, female connectors, mounting facilities, etc. please refer to section "Accessories". 10.3 Product Marking (refer also to "Mechanical Data") Main face: Basic type designation, applicable safety approval and recognition marks, warnings, pin allocation, Melcher patents and company logo. Front plate: Identification of LEDs and potentiometer. Back plate: Specific type designation, input voltage range, nominal output voltage(s) and current(s), pin allocation of options and auxiliary functions, external fuse specification and degree of protection. Rear face: Label with batch no., serial no. and data code comprising production site, modification status of the main PCB, date of production. Confirmation of successfully passed final test. Edition 2/96 - (c) Melcher AG MELCHER The Power Partners. 10 - 77