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benign environment dc-dc converters 100 watt h series edition 4/4.99 1/19 melcher the power partners. 50 watt dc-dc converters h series single output: series 12h/24h/48h1000 double output: series 12h/24h/48h2000 triple output: series 12h/24h/48h3000 ? wide input voltage range suitable for battery operation ? efficient input filter and built-in surge and transient suppression circuitry ?3 kv rms input to output electric strength test ? outputs individually isolated ? outputs fully protected against overload safety according to iec/en 60950 lga c summary the h series of dc-dc converters represents a broad and flexible range of power supplies for use in advanced elec- tronic systems. features include high efficiency, reliability and reasonable output voltage noise. the converter inputs are protected against surges and tran- sients occuring at the source lines. an input over- and undervoltage cut-out circuitry disables the outputs if the in- put voltage is outside the specified range. all outputs are open- and short-circuit proof and are pro- tected against overvoltages by means of built-in suppres- sor 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 to pin 23 to enable the out- puts. 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 iec/en 60950 and have been approved by the safety agencies lga (germany) and ul (usa). the ul mark for canada has been officially recognized by regulatory au- thorities in provinces across canada. the case design allows operation at nominal load up to 50 c 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 80 c under all conditions. a temperature sensor generates an inhibit signal which disables the outputs if the case temperature t c 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 in- dividual applications. the modules may either be plugged into 19 inch rack sys- tems according to din 41494, or be chassis mounted. 168 6.6" 39 1.54" 8te 111 4.37" 3u table of contents page summary .......................................................................... 1 type survey and key data .............................................. 2 type key .......................................................................... 2 functional description ...................................................... 3 electrical input data ......................................................... 4 electrical output data ...................................................... 5 auxiliary functions ........................................................... 8 page electromagnetic compatibility (emc) ............................ 10 mechanical data ............................................................ 11 immunity to environmental conditions ........................... 12 safety and installation instructions ................................ 12 description of options .................................................... 15 accessories .................................................................... 19
h series dc-dc converters 100 watt benign environment edition 4/4.99 2/19 melcher the power partners. type survey and key data table 1: type survey output 1 output 2 output 3 input voltage range and efficiency 1 option u o nom i o nom u o nom i o nom u o nom i o nom u i min ... u i max h min u i min ... u i max h min u i min ... u i max h min [v dc] [a] [v dc] [a] [v dc] [a] 8...15 v dc 2 [%] 14...30 v dc 2 [%] 28...60 v dc 2 [%] 5.1 8.0 - - - - 12h1001-2r 73 24h1001-2r 75 48h1001-2r 76 v2, v3 12.0 4.0 - - - - 12h1301-2r 79 24h1301-2r 82 48h1301-2r 82 d1...d8 15.0 3.4 - - - - 12h1501-2r 80 24h1501-2r 82 48h1501-2r 83 -7 24.0 2.0 - - - - 12h1601-2r 81 24h1601-2r 83 48h1601-2r 85 48.0 1.0 - - - - 12h1901-2r 2 83 24h1901-2r 2 85 48h1901-2r 2 86 12.0 2.0 12.0 2.0 - - 12h2320-2 79 24h2320-2 80 48h2320-2 82 15.0 1.7 15.0 1.7 - - 12h2540-2 80 24h2540-2 81 48h2540-2 83 5.1 5.0 12.0 0.7 12.0 0.7 12h3020-2 77 24h3020-2 78 48h3020-2 79 5.1 5.0 15.0 0.6 15.0 0.6 12h3040-2 77 24h3040-2 79 48h3040-2 80 1 efficiency measured at u i nom and i o nom 2 input voltage range 12h1901-2r: 9...15 v dc, 24h1901-2r: 18...30 v dc, 48h1901-2r: 36...60 v dc type key and product marking type key 48 h 2 5 40 -2 r d v input voltage range u i : 8...15 v dc ............. 12 14...30 v dc ............. 24 28...60 v dc ............. 48 series .............................................................................. h number of outputs ...................................................... 1...3 output 1, u o1 nom : 5.1 v ............... 0 12 v ............... 3 15 v ............... 5 24 v ............... 6 48 v ............... 9 single output modules ................................................... 01 output 2 and 3, u o2 nom , u o3 nom : 12 v ............. 20 15 v ............. 40 options and features: ambient temperature range t a C 10...50 c ..................... -2 extended temperature range t a C 25...71 c .................... -7 output voltage control input (single output modules only)r 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: 48h1501-2rd3: dc-dc converter, input voltage range 28...60 v, providing output with 15 v/3.4 a; equipped with an output voltage control input and undervoltage monitoring.
benign environment dc-dc converters 100 watt h series edition 4/4.99 3/19 melcher the power partners. functional description the input voltage is fed via an input filter to the input capaci- tor. this capacitor sources a single transistor forward con- verter. 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 u o1 and gener- ates, with respect to the maximum admissible output cur- rents, the control signal for the primary switching transistor. this signal is fed back via a coupling transformer. the auxiliary outputs u o2 and u o3 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 re- duce their output voltages as well because all output cur- rents are controlled by the same control circuit. input filter current limitation output 3 main control circuit current limitation output 2 29 11 8 23 5 26 32 17 14 20 forward converter approx. 70 khz y 1 1 y y y y 17 14 2 vi+ vi C i d/v r g c mkt c mkt 03067 fig. 1 dc-dc converter block diagram 1 single output modules h1000 (r input)
h series dc-dc converters 100 watt benign environment edition 4/4.99 4/19 melcher the power partners. electrical input data general conditions: C t a = 25 c, unless t c is specified. C connector pins 2 and 23 interconnected, r input not connected. table 2: input data input 12h 24h 48h characteristics conditions min typ max min typ max min typ max unit u i operating input voltage i o = 0 i o nom 8 1514 3028 60v dc ..h1901-2r t c min t c max 9 1518 3036 60 u i nom nominal input voltage 12 24 48 i i input current u i nom , i o nom 1 5.0 2.5 1.3 a p i 0 no-load input power: u i nom single output i o1,2,3 = 0 1 1.5 1 1.5 1 1.5 w double output 4 6 4 6 4 6 triple output 4 6 4 6 4 6 p i inh idle input power inhibit mode 2 2 2 i inr p 3 peak inrush current u i = u i max 380 380 350 a t inr r rise time r s = 0 ? 2 60 50 20 s t inr h time to half value t c = 25 c 110 75 40 r i input resistance t c = 25 c 40 80 175 m ? c i input capacitance 2200 3300 750 1200 190 300 f u i abs input voltage limits 0 20 0 40 0 80 v dc without any damage 1 with multiple output modules, the same condition for each output applies. 2 r s = source resistance 3 i inr p = u i /( r s + r i ) input under-/overvoltage lock-out if the input voltage remains below 0.8 u i min or exceeds 1.1 u i max (approx. values), an internally generated inhibit signal disables the output(s). when checking this function the absolute maximum input voltage rating u i abs must be carefully considered (see table: electrical input data ). be- tween u i min and the undervoltage lock-out level the output voltage may be below the value defined in table: output data (see: technical information: measuring and testing ). reverse polarity the unit is not protected against reverse polarity at the in- put. (reverse polarity will cause the external fuse to blow.) input fuse the modules do not incorporate any fuse. external fuses installed in the wiring to the inputs are essential. table 3: recommended fuse types series schurter type part number 12h spt 10 a 250 v 0001.2514 24h spt 8 a 250 v 0001.2513 48h spt 3.15 a 250 v 0001.2509
benign environment dc-dc converters 100 watt h series edition 4/4.99 5/19 melcher the power partners. electrical output data general conditions C t a = 25 c, unless t c is specified. C connector pins 2 and 23 interconnected, r input not connected. table 4a: output data output 5.1 v 12 v 15 v characteristics conditions min typ max min typ max min typ max unit u o1 output voltage u i nom , i o nom 1 5.00 5.20 11.76 12.24 14.70 15.30 v u o2/3 - 11.10 12.90 13.90 16.10 u o2/3 0 u i min ... u i max - 13.80 17.25 i o2/3 = 0 u o1 p output overvoltage 7.5 21 25 u o2/3 p protection -2531 i o nom output current u i min ... u i max see: type survey and key data i o l output current t c min ... t c max see fig.: typical output voltage u o1 versus output currents i o limitation response u o1/2/3 output switch. freq. u i nom , i o nom 1 30 50 60 100 50 80 mv pp voltage total iec/en 61204 60 200 70 200 75 200 noise bw = 20 mhz d u o1 u static line regulation u i min ... u i nom 50 100 100 mv d u o2/3 u u i nom ... u i max - 150 150 i o nom 1 d u o1 i static load regulation u i nom 50 150 150 d u o2/3 i i o = i o nom ...0 2 - see: h2320/h3020 see: h2540/h3040 = d u o 2/3 vers . i o 2/3 = d u o 2/3 vers. i o 2/3 d u o1 ic static cross load u i nom 5 15 10 30 15 45 d u o2/3 ic regulation 3 i o = i o nom ...0 4 - see: h2320/h3020 see: h2540/h3040 = d u o 2/3 vers . i o 2/3 = d u o 2/3 vers . i o 2/3 table 4b: output data output 24 v 48 v characteristics conditions min typ max min typ max unit u o1 output voltage u i nom , i o1 nom 23.52 24.48 47.04 48.96 v u o p overvoltage prot. 41 85 i o1 nom output current u i min ... u i max see: type survey and key data i o1 l output current t c min ... t c max see: typical output voltage u o1 limitation response versus output currents i o u o1/2/3 output switch. freq. u i nom , i o nom 1 30 50 20 40 mv pp voltage total iec/en 61204 75 200 35 150 noise bw = 20 mhz d u o1 u static line regulation u i min ... u i nom 150 150 mv u i nom ... u i max i o1 nom d u o1 i static load regulation u i nom 150 150 i o1 = i o1 nom ...0 1 with multiple output modules, the same condition for each output applies. 2 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 o = i o nom . 4 multiple output modules.
h series dc-dc converters 100 watt benign environment edition 4/4.99 6/19 melcher the power partners. 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. 1.0 0 0.5 u o1 0.5 u o1 nom i o i o nom 1.0 1.2 i o nom i o1 i o2 , i o3 i ol1 i ol2 , i ol3 .95 05022 fig. 2 typical output voltage u o1 versus output currents i o u o2/3 [v] 13 12 11 0 0.25 0.5 0.75 1.0 u o2/3 0 i o2/3 i o2/3 nom i o1 nom 0.5 ? i o1 nom i o1 = 0 a 05119 u o2/3 [v] 16 15 14 0 0.25 0.5 0.75 1.0 u o2/3 0 i o2/3 i o2/3 nom i o1 nom 0.5 ? i o1 nom i o1 = 0 a 05120 fig. 3 h2320/h3020: d u o2/3 (typ.) versus i o2/3 with different i o1 fig. 4 h2540/h3040: d u o2/3 (typ.) versus i o2/3 with different i o1 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 cur- rent of 0.1 a to enable correct operation of its own auxiliary outputs. outputs one and two of a double output unit may be con- nected in 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 main outputs may operate continuously in current limitation which will cause an increase in case temperature. consequently, a reduc- tion of the max. ambient temperature by 10 k is recom- mended. 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 possi- ble. if output terminals are connected together in order to estab- lish 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 exces- sive output ripple voltages.
benign environment dc-dc converters 100 watt h series edition 4/4.99 7/19 melcher the power partners. thermal protection a temperature sensor generates an internal inhibit signal which disables the outputs if the case temperature exceeds t c max . the outputs are automatically re-enabled if the tem- perature drops below this limit. thermal considerations if a converter is located in free, quasi-stationary air (con- vection cooling) at the indicated maximum ambient tem- perature t a 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 t c (see: mechanical data ) will approach the indicated value t c max after the warm-up phase. however, the relationship between t a and t c depends heavily on the conditions of operation and integration into a system. the thermal conditions are influenced by input voltage, output current, airflow and temperature of surrounding compo- nents and surfaces. t a max is therefore, contrary to t c max , an indicative value only. caution: the installer must ensure that under all operat- ing conditions t c remains within the limits stated in the table: temperature specifications. notes: sufficient forced cooling or an additional heat sink allows t a to be higher than 50 c (e.g. 65 c) if t c max is not exceeded. for -2 units at an ambient temperature t a of 65 c with only convection cooling, the maximum permissible current for each output is approx. 50% of its nominal value as per fig- ure. output response the reaction of the outputs is similar whether the input volt- age is applied or the inhibit is switched low. an output voltage overshoot will not occur when the module is turned on or off. 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 40 60 70 80 i o / i o nom t a [ c] 0.9 1.0 forced cooling 05032 t c max 50 convection cooling t a min fig. 5 output current derating versus temperature for -2 units. 0 t r t f t t 0 inhibit 1 output 0.1 u o nom t 0 1 0.95 u o nom t h u i 05025 table 5: output response time t r and t f type of converter t r at p o = 0 and t f at p o = p o nom t r and t f at p o = 3 / 4 p o nom t r at p o = p o nom unit typ max typ max typ max h1001-2r 3 7 3 7 5 15 ms h1301-2r 5 15 8 20 10 30 h1501-2r 3 7 5 15 15 40 h1601-2r 8 20 15 35 20 60 h1901-2r 35 90 50 140 85 220 h2320-2 10 30 15 40 25 70 h2540-2 8 20 10 30 20 50 h3020-2 30 75 45 120 75 200 h3040-2 20 60 30 80 50 140 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 u i min ... u i max does not influence the values. fig. 6 output response as a function of input voltage (on/off switching) or inhibit control
h series dc-dc converters 100 watt benign environment edition 4/4.99 8/19 melcher the power partners. table 6: inhibit data characteristics conditions min typ max unit u inh inhibit input voltage to keep u o = on u i min ... u i max C 50 0.8 v dc output voltage u o = off t c min ... t c max 2.4 50 i inh inhibit current u inh = 0 C 60 C 100 C 220 a auxiliary functions i inhibit for remote on and off note: with open i input: output is disabled ( u o = off). the outputs of the module may be enabled or disabled by means of a logic signal (ttl, cmos, etc.) applied between the inhibit input i and the negative pin of output 1 (vo1 C ). in systems with several units, this feature can be used, for ex- ample, to control the activation sequence of the converters. if the inhibit function is not required, connect the inhibit pin 2 to pin 23 to enable the outputs (active low logic, fail safe). for output response refer to: output response . vi+ vi C vo C i vo+ i inh u inh 06031 1.6 0.8 0 C 0.8 C 50 u inh [v] i inh [ma] C 30 0 C 10 10 30 50 2.0 1.2 0.4 C 0.4 u inh = 0.8 v u o = on u o = off u inh = 2.4 v 06032 fig. 7 definition of u inh and i inh . fig. 8 typical inhibit current i inh versus inhibit voltage u inh r-control for output voltage adjustment note: with open r input, u o u o nom . as a standard feature, single output modules offer an adjustable output voltage identified by letter r in the type designation. the output voltage u o1 can either be adjusted with an exter- nal voltage ( u ext ) or with an external resistor ( r 1 or r 2 ). the adjustment range is approximative 0...110% of u o nom . for output voltages u o > u o nom , the minimum input voltage ac- cording to electrical input data increases proportionally to u o / u o nom . fig. 9 voltage adjustment with external voltage u ext a) u o 0...110% u o nom , using u ext between r (14) and g (17): u o u ext u ext 2.5 v ? CCCCC u o u o nom ? CCCCC u o nom 2.5 v fig. 10 voltage adjustment with external resistor r 1 or r 2 b) u o 0...100% u o nom , using r 1 between r (14) and g (17): r 1 4000 ? ? u o u o u o nom ? CCCCCCCCCCC r 1 CCCCCCCCCC r 1 + 4000 ? u o nom - u o c) u o u o nom ... u o max , using r 2 between r (14) and vo1+ (20): u o max = u o nom + 10% 4000 ? ? u o ? ( u o nom C 2.5 v) r 2 CCCCCCCCCCCCCCCCCCCCCCCC 2.5 v ? ( u o C u o nom ) u o nom ? 2.5 v ? r 2 u o CCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCC 2.5 v ? ( r 2 + 4000 ? ) C u o nom ? 4000 ? vo1+ r + 4000 ? g u ref u ext C + 06087 caution: to prevent damage, u ext should not exceed 8 v, nor be negative. vo1+ r C + g 4000 ? u ref r 1 r 2 06088 caution: to prevent damage, r 2 should never be less than 47 k ? . note: r inputs of n units with paralleled outputs may be paralleled, too, but if only one external resistor is to be used, its value should be r 1 /n, or r 2 /n respectively.
benign environment dc-dc converters 100 watt h series edition 4/4.99 9/19 melcher the power partners. table 7b: r 2 for u o > u o nom (conditions: u i nom , i o nom , rounded up to resistor values e 96); r 1 = u o nom = 5.1 v u o nom = 12 v u o nom = 15 v u o nom = 24 v u o nom = 48 v u o [v] r 2 [k ? ] u o [v] r 2 [k ? ] u o [v] r 2 [k ? ] u o [v] r 2 [k ? ] u o [v] r 2 [k ?] 5.15 464 12.1 1780 15.2 1470 24.25 3160 48.5 6810 5.20 215 12.2 909 15.4 750 24.50 1620 49.0 3480 5.25 147 12.3 619 15.6 511 24.75 1100 49.5 2370 5.30 110 12.4 464 15.8 383 25.00 825 50.0 1780 5.35 90.9 12.5 383 16.0 332 25.25 715 50.5 1470 5.40 78.7 12.6 316 16.2 274 25.50 590 51.0 1270 5.45 68.1 12.7 274 16.4 237 25.75 511 51.5 1100 5.50 61.9 12.8 249 16.5 226 26.00 453 52.0 953 13.0 200 26.25 402 52.5 845 13.2 169 26.40 383 52.8 806 table 7a: r 1 for u o < u o nom (conditions: u i nom , i o nom , rounded up to resistor values e 96); r 2 = u o nom = 5.1 v u o nom = 12 v u o nom = 15 v u o nom = 24 v u o nom = 48 v u o [v] r 1 [k ? ] u o [v] r 1 [k ? ] u o [v] r 1 [k ? ] u o [v] r 1 [k ? ] u o [v] r 1 [k ?] 0.5 0.432 2.0 0.806 2.0 0.619 4.0 0.806 8.0 0.806 1.0 0.976 3.0 1.33 4.0 1.47 6.0 1.33 12.0 1.33 1.5 1.65 4.0 2.0 6.0 2.67 8.0 2.0 16.0 2.0 2.0 2.61 5.0 2.87 8.0 4.53 10.0 2.87 20.0 2.87 2.5 3.83 6.0 4.02 9.0 6.04 12.0 4.02 24.0 4.02 3.0 5.76 7.0 5.62 10.0 8.06 14.0 5.62 28.0 5.62 3.5 8.66 8.0 8.06 11.0 11.0 16.0 8.06 32.0 8.06 4.0 14.7 9.0 12.1 12.0 16.2 18.0 12.1 36.0 12.1 4.5 30.1 10.0 20.0 13.0 26.1 20.0 20.0 40.0 20.0 5.0 200.0 11.0 44.2 14.0 56.2 22.0 44.2 44.0 44.2 display status of leds u o1 > 0.95 0.98 u o1 adj u i max u i ov u i min u i uv u i u i abs ok i u o1 > 0.95 0.98 u o1 adj i o nom i ol i o ok u o1 < 0.95 0.98 u o1 adj t c i t c max t ptc threshold u i inh i +50 v +0.8 v +2.4 v -50 v u inh threshold led off led on led status undefined 06090 fig. 11 leds "ok" and "i" status versus input voltage conditions: i o i o nom , t c t c max , u inh 0.8 v u i uv = undervoltage lock-out, u i ov = overvoltage lock-out led "ok" status versus output current conditions: u i min ... u i max , t c t c max , u inh 0.8 v led "i" versus case temperature conditions: u i min ... u i max , i o i o nom , u inh 0.8 v led "i" versus u inh conditions: u i min ... u i max , i o i o nom , t c t c max
h series dc-dc converters 100 watt benign environment edition 4/4.99 10/19 melcher the power partners. driven mobile applications. the h series has been success- fully tested to the following specifications: electromagnetic compatibility (emc) a suppressor diode together with an input filter form an ef- fective protection against input transient voltages which typically occur in most installations, but especially in battery electromagnetic immunity table 8: immunity type tests phenomenon standard 1 level coupling value waveform source test in per- mode 2 applied imped. procedure oper. form. 3 electrostatic iec/en 2 contact discharge 4000 v p 1/50 ns 330 ? 10 positive and yes a discharge 61000-4-2 10 negative (to case) discharges electromagnetic iec/en x antenna 20 v/m am 80% n.a. 26 1000 mhz yes a field 61000-4-3 1 khz electrical fast iec/en 1 direct, i/c, +i/ C i 500 v p bursts of 5/50 ns 50 ? 1 min positive yes transient/burst 61000-4-4 2.5 / 5 khz over 1 min negative 15 ms; burst transients per period: 300 ms coupling mode surge iec/en 1 i/c 500 v p 1.2/50 s 12 ? 5 pos. and 5 neg. yes a 61000-4-5 +i/ C i2 ? surges per 1 related and previous standards are referenced in: technical information: standards . 2 i = input, o = output, c = case. 3 a = normal operation, no deviation from specifications, b = normal operation,temporary deviation from specs possible. electromagnetic emissions table 9: emissions at u i nom and i o nom series standard cispr 11/en 55011, 1991 cispr 22/en 55022, 1987 30 mhz 30 mhz 12h benign environment dc-dc converters 100 watt h series edition 4/4.99 11/19 melcher the power partners. mechanical data dimensions in mm. tolerances 0.3 mm unless otherwise indicated. 111.2 0.8 3u 88 (11.6) 168.5 0.5 127 173.7 0.5 20 100 0.6 1.6 6te 2 5 8 11 14 17 20 23 26 29 32 male connector h 11 according to din 41 612 38.7 95 0.5 measurement point for case temperature t c m 3; depth = 4 mm (chassis mount) 22 68 159.4 mounting plane of connector h11 25.40 30.48 2te 7.09 17.25 mounting holes for retaining clips v 12.17 103 3.27 20.5 12.1 94.5 0.1 0 31.5 0.1 0 ? 3.5 ? 4.0 ok (led green) inhibit i (led red) potentiometer (option d or v) front plate main face rear face back plate 09050 european projection fig. 12 dc-dc converter in case h02, weight 770 g (approx.) case aluminium, black finish and self cooling.
h series dc-dc converters 100 watt benign environment edition 4/4.99 12/19 melcher the power partners. table 11: temperature specifications, values given are for an air pressure of 800...1200 hpa (800...1200 mbar) temperature standard -2 option -7 characteristics conditions min max min max unit t a ambient temperature 1 operational 2 C 10 50 C 25 71 c t c case temperature 3 C 10 80 C 25 95 t s storage temperature 1 not operational C 25 100 C 40 100 1 mil std 810d section 501.2 and 502.2. 2 see: thermal considerations. 3 overtemperature lock-out at t c >95 c (ptc). table 12: mtbf values at specified module types ground benign unit case temperature 40 c mtbf 1 h1000 384'000 h h2000 306'000 h3000 270'000 immunity to environmental conditions table 10: mechanical stress test method standard test conditions status ca damp heat iec/din iec 60068-2-3 temperature: 40 2 c unit not steady state mil-std-810d section 507.2 relative humidity: 93 +2/-3 % operating duration: 21 days ea shock iec/en/din en 60068-2-27 acceleration amplitude: 15 g n = 147 m/s 2 unit (half-sinusoidal) mil-std-810d section 516.3 bump duration: 11 ms operating number of bumps: 18 (3 each direction) eb bump iec/en/din en 60068-2-29 acceleration amplitude: 10 g n = 98 m/s 2 (half-sinusoidal) mil-std-810d section 516.3 bump duration: 16 ms number of bumps: 6000 (1000 each direction) fc vibration iec/en/din en 60068-2-6 acceleration amplitude: 0.15 mm (10...60 hz) (sinusoidal) mil-std-810d section 514.3 2 g n = 20 m/s 2 (60...150 hz) frequency (1 oct/min): 10...150 hz test duration: 3.75 h (1.25 h each axis) safety and installation instructions connector pin allocation the connector pin allocation table defines the electrical potentials and the physical pin positions on the h11 con- nector. pin no. 26, the protective earth pin present on all 12h 48h dc-dc converters is leading, ensuring that it makes contact with the female connector first. 32 29 26 23 20 17 14 11 852 10028 fig. 13 view of male h11 connector. table 13: h11 connector pin allocation and designation electrical determination h1000 h2000 h3000 pin ident pin ident pin ident inhibit control input 2 i 2 i 2 i safe data or acfail 5 d or v 5 d or v 5 d or v output voltage (positive) 8 vo1+ 8 8 vo3+ output voltage (negative) 11 vo1 C 11 11 vo3 C control input + 14 r control input C 17 g output voltage (positive) 14 vo2+ 14 vo2+ output voltage (negative) 17 vo2 C 17 vo2 C output voltage (positive) 20 vo1+ 20 vo1+ 20 vo1+ output voltage (negative) 23 vo1 C 23 vo1 C 23 vo1 C protective earthing 1 26 26 26 dc input voltage 29 vi+ 29 vi+ 29 vi+ dc input voltage 32 vi C 32 vi C 32 vi C 1 leading pin (pregrounding) 1 calculated in accordance with mil-hdbk-217e (calculation ac- cording to edition f would show even better results)
benign environment dc-dc converters 100 watt h series edition 4/4.99 13/19 melcher the power partners. table 14: isolation characteristic input to input to output output unit case output to case to output electric required according to 1.5 3.0 1 0.5 - kv rms strength iec/en 60950 2.1 4.2 1 0.7 - kv dc test voltage actual factory test 1 s 2.8 5.6 1 1.4 0.3 ac test voltage equivalent 2.0 4.0 1 1.0 0.2 kv rms to actual factory test insulation resistance at 500 v dc >300 >300 >300 >100 2 m ? 1 in accordance with iec/en 60950 only subassemblies are tested in factory with this voltage. 2 tested at 300 v dc. for creepage distances and clearances refer to: technical information: safety. cleaning agents in order to avoid possible damage, any penetration of liq- uids (e.g. cleaning fluids) is to be prevented, since the power supplies are not hermetically sealed. standards and approvals 12h 48h dc-dc converters correspond to class i equip- ment. all types are ul recognized according to ul 1950, ul recognized for canada to can/csa c22.2 no. 950-95 and lga approved to iec/en 60950 standards. the units have been evaluated for: ? building in ? supplementary insulation between input and case and double or reinforced insulation between input and out- put, based on 250 v ac and 400 v dc ? operational insulation between output(s) and case ? operational insulation between the outputs ? the use in a pollution degree 2 environment ? connecting the input to a primary or secondary circuit with a maximum transient rating of 2500 v. the dc-dc converters are subject to manufacturing sur- veillance in accordance with the above mentioned ul, csa, en and with iso 9001 standards. protection degree condition: female connector fitted to the unit. ip 40: all units, except those with option d or v with potentiometer. ip 20: all units fitted with option d or v with potentiometer. isolation the electric strength test is performed as a factory test in accordance with iec/en 60950 and ul 1950 and should not be repeated in the field. melcher will not honour any guarantee/warranty claims resulting from electric strength field tests. installation instructions the h series dc-dc converters are components, intended exclusively for inclusion within other equipment by an in- dustrial assembly operation or by professional installers. installation must strictly follow the national safety regula- tions in compliance with the enclosure, mounting, creep- age, clearance, casualty, markings and segregation re- quirements of the end-use application. see also: technical information: installation and application. connection to the system shall be made via the female con- nector h11 (see: accessories ) . other installation methods may not meet the safety requirements. all dc-dc converters are provided with pin no. 26 ( ), which is reliably connected with their case. for safety rea- sons it is essential to connect this pin with the protective earth of the supply system if required in: safety of operator accessible output circuit . ensure that a unit failure (e.g. by an internal short-circuit) does not result in a hazardous condition. see also: safety of operator accessible output circuit. to prevent excessive current flowing into the unit (e.g. by an internal short-circuit), an external fuse suitable for the application and in compliance with the local requirements should be installed in the wiring to one or both input pins (no. 29 and/or no. 32). see also: input fuse . important: whenever the inhibit function is not in use, pin no. 2 (i) should be connected to pin no. 23 (vo1 C ) to enable the output(s). do not open the modules, or guarantee will be invali- dated. make sure that there is sufficient air flow possible for con- vection cooling. this should be verified by measuring the case temperature when the unit is installed and operated in the end-use application. the maximum specified case tem- perature t c max shall not be exceeded. see also: thermal considerations. if the end-product is to be ul certified, the temperature of the main isolation transformer should be evaluated as part of the end-product investigation.
h series dc-dc converters 100 watt benign environment edition 4/4.99 14/19 melcher the power partners. table 15: safety concept leading to an selv output circuit conditions front end dc-dc converter result nominal minimum required grade nominal dc output minimum required measures to achieve the safety status supply of isolation, to be provided voltage from the safety status of the specified safety status of of the dc-dc voltage by the ac-dc front end, front end front end output the output circuit converter including mains supplied circuit output circuit battery charger mains operational (i.e. there is 400 v 1 (the primary circuit double or reinforced insulation, selv circuit 250 v ac no need for electrical rated voltage based on 250 v ac and 400 v dc isolation between the between any input (provided by the dc-dc converter) mains supply voltage and pin and earth can and earthed case 2 thedc-dc converter be up to 250 v ac input voltage) or 400 v dc) 400 v unearthed supplementary insulation, based hazardous voltage on 250 v ac and 400 v dc and secondary circuit double or reinforced insulation, based on the maximum nominal output voltage from the front end (both provided by the dc-dc con- verter) and earthed case 3 1 the front end output voltage should match the specified operating input voltage range of the dc-dc converter. 2 the earth connection has to be provided by the installer according to the relevant safety standard, e.g. iec/en 60950. 3 the earth connection has to be provided by the installer according to the relevant safety standard, e.g. iec/en 60950. if the c onverter case shall not be connected with earth, the front end output circuit has to be insulated from earth according to the relevant s afety standard by at least basic insulation, based on the maximum nominal output voltage from the front end, and insulated from the c on- verter case by at least supplementary insulation, based on the maximum nominal mains voltage. the converter case is then consid - ered to be a double insulated accessible part fig. 14 schematic safety concept. use earth connection as per table: safety concept leading to an selv output circuit . use fuse according to: installa- tion instructions. ac-dc front end dc-dc con- verter mains selv earth connection + C ~ ~ 10024 battery max. 250 v ac or 400 v dc max. 250 v ac or 400 v dc fuse fuse safety of operator accessible output circuit if the output circuit of a dc-dc converter is operator acces- sible, it shall be an selv circuit according to the iec/en 60950 related safety standards. since the h series dc-dc converters provide double or re- inforced insulation between input and output, based on a rated primary input voltage of 250 v ac and 400 v dc only operational insulation is needed between the ac mains and the input of the dc-dc converter. this means that there is no need for an electrical isolation between the ac mains circuit and the dc-dc converter input circuit to cause the output of an h series dc-dc converter to be an selv cir- cuit. only voltage adaption and rectification to the specified input voltage range of the dc-dc converter is needed. the following table shows some possible installation con- figurations, compliance with which causes the output circuit of the dc-dc converter to be an selv circuit according to iec/en 60950 up to a configured output voltage (sum of nominal voltages if in series or +/ C configuration) of 36 v. however, it is the sole responsibility of the installer to as- sure the compliance with the relevant and applicable safety regulations. more information is given in: technical infor- mation: safety .
benign environment dc-dc converters 100 watt h series edition 4/4.99 15/19 melcher the power partners. description of options table 16: survey of options option function of option characteristic -7 extended operational ambient temperature range t a = C 25...71 c d 1 input and/or output undervoltage monitoring circuitry safe data signal output (d1...d8) v 1 2 input and output undervoltage monitoring circuitry acfail signal according to vme specifications ( v2, v3) 1 option d excludes option v and vice versa 2 only available with main output voltage u o1 = 5.1 v -7 extended temperature range option -7 extends the operational ambient temperature range from C 10...50 c (standard) to C 25...71 c. the power supplies provide full nominal output power with convection cooling. d undervoltage monitor the input and/or output undervoltage monitoring circuit op- erates independently of the built-in input undervoltage lock- out circuit. a logic "low" (jfet output) or "high" signal (npn output) is generated at pin 5 as soon as one of the moni- tored voltages drops below the preselected threshold level u t . the return for this signal is vo1 C (pin 23). the d output recovers when the monitored voltage(s) exceed(s) u t + u h . the threshold level u t is adjustable by a potentiometer, ac- cessible through a hole in the front cover. option d exists in various versions d1...d8 as shown in the following table. table 17: undervoltage monitor functions output type monitoring minimum adjustment range typical hysteresis u h [% of u t ] jfet npn u i u o1 of threshold level u t for u t min ... u t max u ti u to u hi u ho d1 d5 no yes C 3.5 v...48 v 1 C 2.3...1 d2 d6 yes no u i min ... u i max 1 C 3.0...0.5 C d3 d7 yes yes u i min ... u i max 1 0.95...0.98 u o1 2 3.0...0.5 "0" d4 d8 no yes C 0.95...0.98 u o1 2 C "0" 1 threshold level adjustable by potentiometer (not recommended for mobile applications) 2 fixed value between 95% and 98% of u o1 (tracking) jfet output (d1 d4): connector pin d is internally connected via the drain- source path of a jfet (self-conducting type) to the nega- tive potential of output 1. u d 0.4 v (logic low) corresponds to a monitored voltage level ( u i and/or u o1 ) < u t . the cur- rent 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. u i , u o1 status d output, u d u i 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+ vo1 C d u d i d r p input 11006 fig. 15 options d1...d4, jfet output npn output (d5...d8): connector pin d is internally connected via the collector- emitter path of a npn transistor to the negative potential of output 1. u d 0.4 v (logic low) corresponds to a monitored voltage level ( u i and/or u o1 ) > u t + u h . the current i d through the open collector should not exceed 20 ma. the npn output is not protected against external overvoltages. u d 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 fig. 16 options d5...d8, npn output vo1+ vo1 C d u d i d r p input 11007
h series dc-dc converters 100 watt benign environment edition 4/4.99 16/19 melcher the power partners. 0 1 0.95 0 u i [v dc] 0 t t t t low min 4 t low min 4 t high min t h 1 u ti + u hi u ti input voltage failure switch-on cycle input voltage sag switch-on cycle and subsequent input voltage failure u d high u d low u d 0 jfet npn t u o1 u o1 nom u d high u d low u d t low min 4 t h 1 0 0 u d high u d low u d 0 jfet npn u o1 u d high u d low u d t low min 4 u to 3 output voltage failure 0 i d high i d low i d t 0 i d high i d low i d t t t t 3 2 33 33 u o1 nom u to + u ho input voltage monitoring output voltage monitoring 11008 threshold tolerances and hysteresis: if u i 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 ? u t i across the input filter. the value of ? u ti depends upon the input voltage range, threshold level u t , temperature and in- put current. the input current is a function of the input volt- age and the output power. fig. 18 relationship between u i , u o1 , u d , i d and u o1 /u o nom versus time. d u ti u hi u d low u d u d high u i p o = p o nom p o = 0 p o = 0 u ti p o = p o nom 11021 fig. 17 definition of u ti , ? u ti and u hi (jfet output) 1 n.a. 2 with output voltage monitoring the hold-up time t h = 0 3 the d signal remains high if the d output is connected to an external source. 4 t low min = 40...200 ms, typically 80 ms
benign environment dc-dc converters 100 watt h series edition 4/4.99 17/19 melcher the power partners. formula for additional external input capacitor 2 ? p o ? ( t h + 0.3 ms) ? 100 c i ext = CCCCCCCCCCCCCCCCCCCCC - c i min ? ( u ti 2 C u i min 2 ) where as: c i min = minimum internal capacitance [mf], according to the table below c i ext = external input capacitance [mf] p o = output power [w] = efficiency [%] t h = hold-up time [ms] u i min = minimum input voltage [v] u ti = threshold level [v] remarks: the threshold level u ti 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. v acfail signal (vme) available for units with u o1 = 5.1 v. this option defines an undervoltage monitoring circuit for the input or the input and main output voltage 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 i v = 48 ma to u v 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 should be provided by an exter- nal input capacitance. consequently the working input volt- age and the threshold level u ti should be adequately above the minimum input voltage u i min of the converter so that enough energy is remaining in this capacitance. if the input voltage is below the required level, an external hold-up capacitor (c i ext ) should be added. voltage(s) exceed(s) u t + u h . the threshold level u t is ad- justable by a potentiometer accessible through a hole in the front cover. versions v2 and v3 are available as shown below. option v operates independently of the built-in input under- voltage 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 u t . the return for this signal is vo1 C (pin 23). the v output recovers when the monitored table 18: available internal input capacitance and factory potentiometer setting of u ti with resulting hold-up time. types 12h 24h 48h unit c i min 2.2 0.75 0.19 mf u t i 9.5 19.5 39 v dc t h 0.19 0.87 0.89 ms table 19: undervoltage monitor functions v output monitoring minimum adjustment range typical hysteresis u h [% of u t ] (vme compatible) of threshold level u t for u t min ... u t max u i u o1 u ti u to u hi u ho v2 yes no u i min ... u i max 1 C 3.0...0.5 C v3 yes yes u i min ... u i max 1 0.95...0.98 u o1 2 3.0...0.5 "0" 1 threshold level adjustable by potentiometer (not recommended for mobile applications) 2 fixed value between 95% and 98% of u o1 (tracking), output undervoltage monitoring is not a requirement of vme standard v output (v2, v3): connector pin v is internally connected to the open collec- tor of a npn transistor. the emitter is connected to the negative potential of output 1. u v 0.6 v (logic low) corre- sponds to a monitored voltage level ( u i and/or u o1 ) < 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. u i , u o1 status v output, u v u i or u o1 < u t low, l, u v 0.6 v at i v = 50 ma u i and u o1 > u t + u h high, h, i v 25 a at u v = 5.1 v fig. 19 output configuration of options v2 and v3 vo1+ vo1 C v u v i v r p input 11009 formula for threshold level for desired value of t h : 2 ? p o ? ( t h + 0.3 ms) ? 100 u ti = CCCCCCCCCCCCCCCCCCCCCC + u i min 2 c i min ?
h series dc-dc converters 100 watt benign environment edition 4/4.99 18/19 melcher the power partners. 3 5.1 v 4.875 v 0 u i [v dc] 0 t t u ti + u hi u ti input voltage failure switch-on cycle input voltage sag switch-on cycle and subsequent input voltage failure u v high u v low u v 0 v2 t u o1 0 u v high u v low u v 0 v2 u i u ti 4 output voltage failure 0 u v high u v low u v 3 u ti + u hi t low min 2 t low min 2 t low min 2 3 3 4 4 u v high u v low u v 0 v3 t 3 t low min 2 t low min 2 3 3 t h 1 2.0 v t h 1 4 3 4 t low min 2 v3 5.1 v 4.875 v 0 u o1 2.0 v input voltage monitoring output voltage monitoring 11010 t t t t fig. 21 relationship between u i , u o1 , u v , i v and u o1 /u o nom versus time. 1 vme request: minimum 4 ms 2 t low min = 40...200 ms, typically 80 ms 3 u v level not defined at u o1 < 2.0 v 4 the v signal drops simultaneously with the output voltage, if the pull-up resistor r p is connected to vo1+. the v signal remains high if r p is connected to an external source. d u ti u hi u v low u v u v high u i p o = p o nom p o = 0 p o = 0 u ti p o = p o nom 11023 fig. 20 definition of u ti , ? u ti and u hi threshold tolerances and hysteresis: if u i is monitored, the internal input voltage is measured af- ter the input filter. 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 , tempera- ture and input current. the input current is a function of in- put voltage and output power.
benign environment dc-dc converters 100 watt h series edition 4/4.99 19/19 melcher the power partners. accessories a variety of electrical and mechanical accessories are available including: C front panels for 19" rack mounting, schroff and intermas systems. C mating h11 connectors with screw, solder, fast-on or press-fit terminals. C connector retention facilities. C code key system for connector coding. C flexible h11 pcb for mounting of the unit onto a pcb. C chassis mounting plates for mounting the 19" cassette to a chassis/wall where only frontal access is given. C universal mounting bracket for din-rail or chassis moun- ting. for more detailed information please refer to accessory products . h11 female connector, code key system front panels flexible h11 pcb mounting plate, connector retention clips universal mounting bracket for din-rail mounting.

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