melcher. the power of comprehensive data sheets are available from either source: C internet: www.melcher.ch C melcher cd-rom C melcher databook C nearest sales office by fax or mail. edition 6/3.99 melcher the power partners. power output [v dc] no. of input [v dc] series [w] 3 5 15 24 36 48 outputs 3 10 20 60 80 180 print mountable 1 ????????????????????? 1, 2 ??? dsp 1...12 ???????????????????????? 1, 2, 3 ??????????????????????? imp 2.4 ? ? ? ? 1 ?????? chs 3 ???????????????????????? 1,2 ?????????????????????? ixp 3...15 ???????????????????????? 1, 2, 3 ?????????????????????? imr 4 ??????????????????????????????????? 1, 2 ???????????????????????????????? imx 4 6 ??????????? 1, 2 ????????????????????? imo 6...20 ??????????? 1, 2 ????????????????????? dfa 6...30 ??????????? 1, 2, 3 ????????????????????? dfc 7 ????????????????????????????????? 1, 2 ??????????????????? ims 7 7 ????????????????????????????????? 1, 2 ?????????????????????????????? imx 7 10 ??????????????????? 1, 2 ?????????????????? iml 10...30 ??????????????????? 1, 2, 3 ???????????????????????? dgp 15 ?????????????????????????????? 1, 2 ??????????????????? ims 15 15 ?????????????????????????????? 1, 2 ??????????????????????????????? imx 15, imy 15 25 ???????? 1, 2 ????????????????????? obs, obd 25/40 ?????????????????????? 1, 2, 3 ?????????????????????? imr 25, imr 40 cassette style 20 ??????????????????? 1 ??????????????????????????? sr 50 ????????????????????????????????? 1, 2, 3 ?????????????????? h 50 ????????????????????????????????? 1, 2, 3 ???????????????????????????????????????? m 100...150 ????????????????????????????????? 1, 2 ?????????????????????????? q 100 ????????????????????????????????? 1, 2 ???????????????????????????????????????? s 150 ????????????????????????????????? 1, 2 ???????????????????????????????????????? k open frame 150 ??????????? 3, 4 ??????????? mdu bricks 15...60 ??????????????? 1 ????????????????? has 25...150 ???????? 1 ??????????? hes 33...100 ????????????? 1 ????????????????? hbs 38...66 ??? 1 ????????????????? qes 38...150 ??????????????? 1 ????????????????? qbs 50...60 ??????????????????????????????????? 1 ??????????? qas 100...190 ???????????????????? 1 ????????????????? xws 100...300 ???????? 1 ???????????? fes 100...300 ?????????????????????????????? 1 ???????????????? vws 113...225 ???????? 1 ???????????????? tes dc-dc converters
industrial environment dc-dc converters >100 watt p series edition 4/6.99 1/8 melcher the power partners. preliminary 120/180 watt dc-dc converters p series input to output isolation single output: 3.3, 5.1 v dc double output: 3.3/5.1, 2 5.1, 2 12, 2 15, 2 24 v triple output: 5.1/ 2 12, 5.1/ 2 15 v dc quadruple output: 5.1/3.3 with 2 12, 2 24 with 2 24 v dc extremely high efficiency flex power: flexible load distribution excellent surge and transient protection 4242 v dc input to output electric strength test redundant operation (n+1), current sharing option extremely low inrush current, hot plug-in externally adjustable output voltage inhibit primary or secondary referenced very compact and fully functional unit (20 mm wide) telecoms compatible input voltage range of dp units according to prets 300132-2 (40...101 v dc) safety according to iec/en 60950, ul 1950 lga c summary these extremely compact dc-dc converters incorporate all necessary input and output filtering, signalling and pro- tection features which according to the latest industry standards are required in the majority of applications. the converters provide important advantages such as flexible output power through primary current limitation, extremely high efficiency, excellent reliability, very low ripple and rfi noise levels, full input to output isolation, negligible inrush current, soft start, overtemperature protection and input over-/undervoltage lock-out. the converter inputs are pro- tected against surges and transients occurring on the source lines, covering a total input voltage range from 16 v dc up to 150 v dc with five different types. the outputs are continuously open- and short-circuit proof. leds at the front panel and an isolated output power good option indicate the status of the power supply modules. voltage suppressor diodes protect the outputs against an internally generated overvoltage. full system flexibility and n +1 redundant operating mode are possible due to virtually unrestricted series or parallel connection capabilities of all outputs. in parallel connection of several units, current sharing option is provided by a sin- gle wire interconnection. as a modular power supply or as part of a distributed power supply system, the low profile design significantly reduces the necessary power supply volume without sacrificing high reliability. the units are designed as forward converters using planar magnetics and control circuits in hybrid technology. the switching frequency is fix at 307 khz under normal operat- ing conditions. triple and quadruple output modules have their voltage regulation of output 3 and 4 relying on the close magnetic coupling of transformer and output conduc- tor together with the circuit symmetry of their main outputs 2, respectively 1. outputs with an equal output voltage can either be series or parallel connected. the fully enclosed, black coated aluminium case acts as heat sink and rfi shield. it is particularly suitable for 19" rack systems occupying 3u/4te only, but can also be chassis-mounted by means of four m3 screws. connector type is h15 and for single output modules h15 s2. 164 6.5" 20 0.8" 4 te 111 4.4" 3 u table of contents page summary .......................................................................... 1 type survey and key data .............................................. 2 type key and product marking ........................................ 4 page mechanical data .............................................................. 5 safety and installation instructions .................................. 6 safety approvals in progress
p series dc-dc converters >100 watt industrial environment edition 4/6.99 2/8 melcher the power partners. preliminary type survey and key data table 1a: type survey bp, cp output 1, 4 3 output 2, 3 3 input voltage range and efficiency 2 options u o nom t a = 50 c t a = 71 c u o nom t a = 50 c t a = 71 c h min u i min ... u i max 4 h min u i min ... u i max 4 [v dc] p o max [w] p o nom [w] [v dc] p o max [w] p o nom [w] [%] 16...36 v dc [%] 33.6...75 v dc 3.3 125 106 - - - bp 1101-7r cp 1101-7r -9 5.1 152 122 - - - bp 1001-7r cp 1001-7r d 3.3 62 53 5.1 76 61 bp 2101-7r cp 2101-7r v 6 5.1 76 61 5.1 76 61 bp 2001-7r cp 2001-7r g 12 90 72 12 90 72 bp 2320-7r cp 2320-7r t 6 15 82 60 15 82 60 bp 2540-7r cp 2540-7r i 24 84 60 24 84 60 bp 2660-7r cp 2660-7r w 5.1 76 61 12, 12 72 1 60 1 bp 3020-7r cp 3020-7r 5.1 76 61 15, 15 75 1 60 1 bp 3040-7r cp 3040-7r 5.1, 3.3 5 50 1 40 1 12, 12 72 1 60 1 bp 4720-7r cp 4720-7r 24, 24 84 1 60 1 24, 24 84 1 60 1 bp 4660-7r cp 4660-7r table 1b: type survey dp, ep output 1, 4 3 output 2, 3 3 input voltage range and efficiency 2 options u o nom t a = 50 c t a = 71 c u o nom t a = 50 c t a = 71 c h min u i min ... u i max 4 h min u i min ... u i max 4 [v dc] p o max [w] p o nom [w] [v dc] p o max [w] p o nom [w] [%] 40...101 v dc [%] 66...150 v dc 3.3 125 106 - - - dp 1101-7r ep 1101-7r -9 5.1 152 122 - - - dp 1001-7r ep 1001-7r d 3.3 62 53 5.1 76 61 dp 2101-7r ep 2101-7r v 6 5.1 76 61 5.1 76 61 dp 2001-7r ep 2001-7r g 12 90 72 12 90 72 dp 2320-7r ep 2320-7r t 6 15 82 60 15 82 60 dp 2540-7r ep 2540-7r i 24 84 60 24 84 60 dp 2660-7r ep 2660-7r w 5.1 76 61 12, 12 72 1 60 1 dp 3020-7r ep 3020-7r 5.1 76 61 15, 15 75 1 60 1 dp 3040-7r ep 3040-7r 5.1, 3.3 5 50 1 40 1 12, 12 72 1 60 1 dp 4720-7r ep 4720-7r 24, 24 84 1 60 1 24, 24 84 1 60 1 dp 4660-7r ep 4660-7r table 1c: type survey gp output 1, 4 3 output 2, 3 3 input voltage range and efficiency 2 options u o nom t a = 50 c t a = 71 c u o nom t a = 50 c t a = 71 c h min u i min ... u i max [v dc] p o max [w] p o nom [w] [v dc] p o max [w] p o nom [w] [%] 19.2...57.6 v dc 3.3 100 80 - - - gp 1101-7r -9 5.1 120 92 - - - gp 1001-7r d 3.3 50 40 5.1 60 46 gp 2101-7r v 6 5.1 60 46 5.1 60 46 gp 2001-7r g 12 72 54 12 72 54 gp 2320-7r t 6 15 68 50 15 68 50 gp 2540-7r i 24 70 48 24 70 48 gp 2660-7r w 5.1 60 46 12, 12 66 1 48 1 gp 3020-7r 5.1 60 46 15, 15 68 1 50 1 gp 3040-7r 5.1, 3.3 5 40 1 30 1 12, 12 66 1 48 1 gp 4720-7r 24, 24 70 1 48 1 24, 24 70 1 48 1 gp 4660-7r 1 the cumulated power of both outputs may not exceed the total power for the specified ambient temperature. 2 minimum efficiency at u i nom , p o nom and t a = 25 c 3 output configuration with second output semi-regulated ( 5% u o nom if each output is loaded with 5% p o nom ). parallel or series con- figuration possible. 4 short deviations of u i min / u i max according to en 50155 possible. 5 internal common ground. 6 not available for all types.
industrial environment dc-dc converters >100 watt p series edition 4/6.99 3/8 melcher the power partners. preliminary output configuration the p unit design allows high flexibility in output configura- tion to cover almost every individual requirement, by simply wiring the separated outputs in parallel, series or independ- ent configurations as per following figures. parallel and se- ries operation of several modules with equal output voltage is possible also. load 1 vo2+ vo1 vo3+ s1 s1+ vo1+ triple output vi vi+ i 28 30 32 4 12 14 8 6 18 01009 load 2 vo2 vo3 10 20 fig. 4 parallel configurration of output 2 and 3 fig. 2 series output configuration s1 s1+ vo1 vo1+ vo2 vo2+ double output vi vi+ i load 1 28 30 32 6 10 4 12 14 8 01007 18 20 s2+ s2 fig. 6 common ground configuration of output 1 with 4 and in- dependent configuration of output 2 and 3 load 1 load 2 vo2+ vo4+ vo2 vo4 vo1 vo1+ quadruple output vi vi+ i 28 30 32 4 8 14 12 6 10 01011 load 3 vo3+ vo3 18 20 load 4 load 1 vo2+ vo1 vo2 s1 s1+ vo1+ triple output vi vi+ i 28 30 32 4 12 14 8 6 10 01010 load 2 vo3+ vo3 18 20 fig. 5 series configurration of output 2 and 3 fig. 1 parallel output configuration load 1 vo2 vo1 s1 vo1+ vo2+ s1+ double output vi vi+ i 28 30 32 6 4 12 14 8 10 01006 18 20 s2 s2+ load 1 load 2 vo2+ vo1 vo2 s1 s1+ vo1+ triple output vi vi+ i 28 30 32 4 12 14 8 6 10 01008 load 3 vo3+ vo3 18 20 fig. 3 independent output configuration (all outputs) load 2 load 1 vo2+ vo1 vo2 vo4 vo4+ vo1+ quadruple output vi vi+ i 28 30 32 4 12 14 8 6 10 01012 vo3+ vo3 18 20 fig. 7 parallel configuration of output 1 with 4 and series con- figuration of output 2 with 3
p series dc-dc converters >100 watt industrial environment edition 4/6.99 4/8 melcher the power partners. preliminary type key and product marking type key c p 2 5 40 -7 r d v g t i w input voltage range u i : 16...36 v dc ................................................. b 33.6...75 v dc .............................................. c 40...101 v dc ............................................... d 66...150 v dc ................................................ e 19.2...57.6 v dc .......................................... g series ............................................................................... p number of outputs: single output ................................................. 1 double output ................................................ 2 triple output .................................................. 3 quadruple output ........................................... 4 nominal voltage output 1/output 4 , u o1/4 nom : 5.1 v .............................................................. 0 3.3 v .............................................................. 1 12 v ............................................................... 3 15 v ........................................................... 4, 5 24 v ............................................................... 6 5.1/3.3 v ........................................................ 7 other voltages ............................................ 2, 8 other specifications for main output ........................ 01...99 nominal voltage output 2/output 3, u o2/3 nom 5.1 v ............................................................ 01 12 v ............................................................. 20 15 v ............................................................. 40 24 v ............................................................. 60 other voltages ....................................... 70...99 operational ambient temperature range t a : 25 71 c ................................................... -7 40...71 c (option) ....................................... -9 customer specific .................................... -0...-6 output voltage control input (auxiliary function) .............. r options: out ok output .............................................. d vme compatible monitoring circuit ................ v second control loop (ovp) ........................... g current sharing .............................................. t isolated inhibit on secondary side .................. i synchronisation of switching frequency ....... w example: cp 2540-7r: dc-dc converter, input voltage range 33.6...75 v, each providing 15 v, equipped with r-control for output 1 and operating ambient temperature of 25...71 c. note: all units feature the following auxiliary functions which are not shown in the type designation: input and output filter, inhibit (primary referenced), sense lines (single, double and triple output modules only) and led indicators. product marking basic type designation, applicable safety approval and recognition marks, ce mark, warnings, pin allocation of input, out- put and auxiliary functions, melcher patents and company logo. label with specific type designation, input voltage range, nominal output voltage and output current, degree of protection, batch no., serial no. and data code including production site, modification status and date of production. confirmation of success fully passed final test. identification of led's.
industrial environment dc-dc converters >100 watt p series edition 4/6.99 5/8 melcher the power partners. preliminary mechanical data dimensions in mm. tolerances 0.3 mm unless otherwise indicated. european projection note: long cases, elogated by 60 mm for 220 mm rack depth is available on request. 104 0.15 70 111 20 100 127 0.15 164 0.5 8 0.5 19.8 m3; through measuring point of case temperature t c 20.32 (4 te) 13.43 100 95 5.5 led "out ok" green led "in ok" green 171.93 (din 41494) 09099 front plate main face rear face back plate fig. 8 case p01, weight 480 g aluminium, fully enclosed, black finish and self cooling
p series dc-dc converters >100 watt industrial environment edition 4/6.99 6/8 melcher the power partners. preliminary fig. 9 view of male h15 connector 32 28 24 20 16 12 8 4 30 26 22 18 14 10 6 10025 fig. 10 view of male h15 s2 connector for p 1000 32 28 24 20 16 12 4/6 30 26 22 18 14 8/10 10051 safety and installation instructions connector pin allocation the connector pin allocation table defines the electrical potentials and the physical pin positions on the h15 connector. pin no. 26, the protective earth pin present on all bp gp dc-dc converters is leading, ensuring that it makes contact with the female connector first. table 2: pin allocation of the h15 s2 and h 15 connector pin p 1000 p 2000 p 3000 p 4000 4 vo1+ 1 output 1 vo1+ output 1 vo1+ output 1 vo1+ output 1 6 vo2+ output 2 vo2+ output 2 vo2+ output 2 8vo1 1 output 1 vo1 output 1 vo1 output 1 vo1 output 1 10 vo2 output 2 vo2 output 2 vo2 output 2 12 s+ 2 sense s1+ 2 sense 1 s1+ 2 sense 1 vo4+ output 4 14 s 2 sense s1 2 sense 1 s1 2 sense 1 vo4 output 4 16 3 r control of u o r1 control of u o1 r1 control of u o1 r1/4 control of u o1/4 t1 current sharing t1 current sharing 18 3 t current sharing t1 current sharing vo3+ output 3 vo3+ output 3 s2+ sense 2 20 3 n.c. not connected s2 sense 2 vo3 output 3 vo3 output 3 pd in power down pd in power down 22 3 out ok+ output good out ok+ output good out ok+ output good out ok+ output good i+ inhibit secondary i+ inhibit secondary i+ inhibit secondary i+ inhibit secondary d save data d save data 24 3 out ok output good out ok output good out ok output good out ok output good i inhibit secondary i inhibit secondary i inhibit secondary i inhibit secondary rst reset rst reset 26 2 prot. ground prot. ground prot. ground prot. ground 28 3 i inhibit i inhibit i inhibit i inhibit w synchronisat. w synchronisat. w synchronisat. w synchronisat. 30 vi+ input vi+ input vi+ input vi+ input 32 vi input vi input vi input vi input 1 h15 s2 connector with two high current contacts. 2 leading pin (pre-connecting). 3 one function/option per pin possible only.
industrial environment dc-dc converters >100 watt p series edition 4/6.99 7/8 melcher the power partners. preliminary isolation the electric strength test is performed as 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 claims resulting from electric strength field tests. table 3: isolation characteristic input to input to output to output to auxiliary 1 auxiliary 1 auxiliary 1 unit case output(s) case output(s) to input to case to output electric required according to 1.5 3.0 2 0.5 - 3.0 2 0.5 0.5 kv rms strength iec/en 60950 2.1 4.2 2 0.7 - 4.2 2 0.7 0.7 kv dc test voltage actual factory test 1 s 2.1 4.2 2 1.5 0.5 4.2 2 1.5 0.5 ac test voltage equivalent 1.5 3.0 2 1.1 0.35 3.0 2 1.1 0.35 kv rms to actual factory test insulation resistance at 500 v dc > 300 > 300 > 300 > 100 > 300 > 100 > 100 m ? 1 insulated auxiliary circuits, e.g. out ok output circuit (option d), inhibit on output side (option i). 2 in accordance with iec/en 60950 only subassemblies are tested in factory with this voltage. installation instruction the p 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 connector h15 or h15 s2 (see: accessories ) according to connector pin allocation. other installation methods may not meet the safety requirements. check for hazardous voltages before altering any connec- tions. the dc-dc converters are provided with pin no. 26 ( ), which is reliably connected to the case. for safety reasons it is essential to connect these pins to the protective earth of the supply system if required in: safety of operator accessi- ble output circuit . the vi input (pin no. 32) is internally fused. this fuse is de- signed to protect the unit in case of overcurrent and may not be able to satisfy all customer requirements. external fuses in the wiring to one or both input pins (no. 30 and/or no. 32) may therefore be necessary to ensure compliance with local requirements. important: whenever the inhibit function is not in use, pin 28 (i) should be connected to pin 32 (vi ) to enable the output(s). do not open the modules, or guarantee will be invalidated. make sure that there is sufficient air flow available 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 must not be overridden. 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 . cleaning agents in order to avoid possible damage, any penetration of cleaning fluids is to be prevented, since the power supplies are not hermetically sealed. standards and approvals all p series dc-dc converters correspond to class i equip- ment. they are pending to be 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 and have been designed in accordance with these standards for: building in basic insulation between input and case, based on 250 v ac or 240 v dc double or reinforced insulation between input and out- put, based on 250 v ac or 240 v dc operational insulation between output(s) and case operational insulation between the outputs operational insulation between option d or i and out- put(s) operational insulation between option d or i and case the use in a pollution degree 2 environment connecting the input to a primary circuit with a maximum transient rating of 2500 v (overvoltage class iii based on a 110 v primary circuit, overvoltage class ii based on a 230 v primary circuit). after approvals, the ac-dc converters are subject to manufacturing surveillance in accordance with the above mentioned ul, csa, en and with iso 9001 standards. protection degree condition: female connector fitted to the unit. the protection degree of the dc-dc converters is ip 40.
p series dc-dc converters >100 watt industrial environment edition 4/6.99 8/8 melcher the power partners. preliminary table 4: safety concept leading to an selv output circuit conditions front end dc-dc converter result nominal minimum required grade maximum dc minimum required safety measures to achieve the safety status supply of insolation, to be pro- output voltage status of the front end output specified safety status of the of the dc-dc voltage vided by the ac-dc front from the front circuit output circuit converter end, including mains end 1 output circuit supplied battery charger mains operational (i.e. there is 168 v primary circuit (the nominal double or reinforced insula- selv circuit 250 v ac no need for electrical iso- voltage between any input tion, based on 250 v ac and lation between the mains pin and earth can be up to 240 v dc (provided by the supply circuit and the 250 v ac or 240 v dc.) dc-dc converter) and dc-dc converter input earthed case 3 circuit) basic earth related hazardous double or reinforced insula- voltage secondary circuit 2 tion, based on the maximum (the nominal voltage nominal output voltage from between any input pin and the front end (both provided earth can be up to 250 v ac by the dc-dc converter) and or 240 v dc.) earthed 2 case unearded hazardous voltage supplementary insulation, secondary circuit based on 250 v ac and dc and double or reinforced insulation, based on the maximum nominal output voltage from the front end (both providedby the dc-dc converter) andearthed 3 case supplementary unearded hazardous voltage basic insulation, based on secondary circuit 3 250 v ac and dc (provided by thedc-dc converter) 1 the front end output voltage should match the specified input voltage range of the dc-dc converter. 2 the maximum rated input voltage of the eq units according to iec/en 60950/ul 1950 is 150 v. 3 has to be insulated from earth by at least supplementary insulation (by the installer) according to the relevant safety standar ds, e.g. iec/en 60950, based on the maximum nominal output voltage from the front end. if the converter case is accessible, it has to be earthed or the front end output circuit has to be insulated from the converter case by at least basic insulation, based on the maximum nominal mains supply voltage. safety of operator accessible output circuit if the output circuit of an dc-dc converter is operator ac- cessible, it shall be an selv circuit according to iec/en 60950 related safety standards 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 +/ configuration) of 35 v. however, it is the sole responsibility of the installer to as- sure the compliance with the relevant and applicable safety regulations. more information about this subject and about output circuits at hazardous voltages are given in: techni- cal information: safety . ac-dc front end dc-dc con- verter mains selv earth connection + ~ ~ 10052 battery max. 250 v ac or 240 v dc max. 250 v ac or 240 v dc fuse fuse fig. 11 schematic safety concept use fuse, suppressor diode and earth connections as per table: safety concept leading to an selv output circuit . use fuse(s) also if required by the application. see: instal- lation instructions .
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