DK2540-7EPD5B2
更新时间:2024-09-19 01:17:02
品牌:BEL
描述:DC-DC Regulated Power Supply Module, 2 Output, 150W, Hybrid, METAL, CASE K02, MODULE
DK2540-7EPD5B2 概述
DC-DC Regulated Power Supply Module, 2 Output, 150W, Hybrid, METAL, CASE K02, MODULE
DK2540-7EPD5B2 数据手册
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DC-DC Converters >100Watt
K Series
150 Watt DC-DC Converters
K Series
Input to output isolation
Single output: AK...EK 1000
Double output: AK...EK 2000
• Extremely wide input voltage range
• Input over- and undervoltage lock-out
• Efficient input filter and built-in surge and transient
suppression circuitry
• 4 kVrms input to output electric strength test
• Fully isolated outputs
• Outputs open- and short-circuit proof
• No derating over entire operating temperature range
Safety according to IEC/EN 60950
LGA
C
111
4.4"
3 U
80
168
6.6"
3.2"
16 TE
Summary
The K 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, high reli-
ability, low output voltage noise and excellent dynamic re-
sponse to load/line changes.
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 standards
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 converter inputs are protected against surges and tran-
sients occuring at the source lines. An input over- and
undervoltage lock-out circuitry disables the outputs if the
input voltage is outside the specified range. Certain types
include an inrush current limitation preventing circuit break-
ers and fuses from being damaged at switch-on.
The case design allows operation at nominal load up to
71°C in a free air ambient temperature. If forced cooling is
provided, the ambient temperature may exceed 71°C but
the case temperature must remain below 95°C under all
conditions.
All outputs are open- and short-circuit proof and are pro-
tected against overvoltages by means of a built-in suppres-
sor diode. The outputs can be inhibited by a logic signal ap-
plied to the connector pin 18 (i). If the inhibit function is not
used pin 18 must be connected with pin 14 to enable the
outputs.
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 in-
dividual applications.
LED indicators display the status of the converter and allow
visual monitoring of the system at any time.
The modules may either be plugged into 19" rack systems
according to DIN 41494, or be chassis mounted.
Table of Contents
Page
Page
Summary.......................................................................... 1
Type Survey and Key Data .............................................. 2
Type Key .......................................................................... 3
Functional Description...................................................... 4
Electrical Input Data ......................................................... 5
Electrical Output Data ...................................................... 7
Auxiliary Functions ......................................................... 14
Electromagnetic Compatibility (EMC) ............................ 18
Immunity to Environmental Conditions........................... 20
Mechanical Data ............................................................ 21
Safety and Installation Instructions ................................ 22
Description of Options.................................................... 25
Accessories .................................................................... 31
Edition 4/4.99
1/31
MELCHER
The Power Partners.
K Series
DC-DC Converters >100Watt
Rugged Environment
Type Survey and Key Data
Non standard input configurations or special custom adaptions are available on request. See also: Commercial Informa-
tion: Inquiry Form for Customized Power Supply.
Table 1a: Type survey AK
Output 1
Output 2
Input Voltage
Options
Uo nom
[V DC]
Io nom
[A] 2
Uo nom
[V DC]
Io nom
[A] 2
Ui min...Ui max
8...35 V DC
hmin
[%]
5.1
20.0
10.0
8.0
-
-
-
-
-
-
-
-
AK 1001-7R
AK 1301-7R
AK 1501-7R
AK 1601-7R
78
80
80
82
-9
12.0
15.0
24.0
E 3
D
5.0
V 6
P
T
B1
B2
24.0 4
30.0 4
48.0 4
5.0
4.0
2.5
-
-
-
-
-
-
AK 2320-7R
AK 2540-7R
AK 2660-7R
78
79
79
12.0
15.0
24.0
5.0
4.0
2.5
12.0 5
15.0 5
24.0 5
5.0
4.0
2.5
AK 2320-7R
AK 2540-7R
AK 2660-7R
78
79
79
Table 1b: Type survey BK, FK, CK
Output 1
Output 2
Input Voltage Range and Efficiency 1
Options
Uo nom
[V DC]
Io nom
[A] 2
Uo nom
[V DC]
Io nom
[A] 2
Ui min...Ui max
14...70 V DC
hmin
[%]
Ui min...Ui max
20...100 V DC
hmin
[%]
Ui min...Ui max
28...140 V DC
hmin
[%]
5.1
25.0
12.0
10.0
6.0
-
-
-
-
-
-
-
-
BK 1001-7R
BK 1301-7R
BK 1501-7R
BK 1601-7R
79
81
82
84
FK 1001-7R
FK 1301-7R
FK 1501-7R
FK 1601-7R
80
82
85
86
CK 1001-7R
CK 1301-7R
CK 1501-7R
CK 1601-7R
79
82
84
86
-9
12.0
15.0
24.0
E 3
D
V 6
P
T
B1
B2
24.0 4
30.0 4
48.0 4
6.0
5.0
3.0
-
-
-
-
-
-
BK 2320-7R
BK 2540-7R
BK 2660-7R
80
80
80
FK 2320-7R
FK 2540-7R
FK 2660-7R
81
83
84
CK 2320-7R
CK 2540-7R
CK 2660-7R
80
82
84
12.0
15.0
24.0
6.0
5.0
3.0
12.0 5
15.0 5
24.0 5
6.0
5.0
3.0
BK 2320-7R
BK 2540-7R
BK 2660-7R
80
80
80
FK 2320-7R
FK 2540-7R
FK 2660-7R
81
83
84
CK 2320-7R
CK 2540-7R
CK 2660-7R
80
82
84
Table 1c: Type survey DK, EK
Output 1
Output 2
Input Voltage Range and Efficiency 1
Options
Uo nom
[V DC]
Io nom
[A] 2
Uo nom
[V DC]
Io nom
[A] 2
Ui min...Ui max
44...220 V DC
hmin
[%]
Ui min...Ui max
67...385 V DC
hmin
[%]
5.1
25.0
12.0
10.0
6.0
-
-
-
-
-
-
-
-
DK 1001-7R
DK 1301-7R
DK 1501-7R
DK 1601-7R
79
83
86
87
-
-
-9
12.0
15.0
24.0
EK 1301-7R
EK 1501-7R
EK 1601-7R
84
84
84
E 3
D
V 6
P
T
B1
B2
24.0 4
30.0 4
48.0 4
6.0
5.0
3.0
-
-
-
-
-
-
DK 2320-7R
DK 2540-7R
DK 2660-7R
81
82
85
EK 2320-7R
EK 2540-7R
EK 2660-7R
81
80
83
12.0
15.0
24.0
6.0
5.0
3.0
12.0 5
15.0 5
24.0 5
6.0
5.0
3.0
DK 2320-7R
DK 2540-7R
DK 2660-7R
81
82
85
EK 2320-7R
EK 2540-7R
EK 2660-7R
81
80
83
1 Efficiency at Ui nom and Io nom
.
2 If the output voltages are increased above Uo nom via R-input control, option P setting, remote sensing or option T, the output currents
should be reduced accordingly so that Po nom is not exceeded.
3 Option E only for CK, DK, EK types.
4 Series connection of output 1 and 2.
5 Second output semi-regulated.
6 Option V for K 1001 types only.
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DC-DC Converters >100Watt
K Series
Type Key
Type Key
C K 2 5 40 -7 E R P D V T B1
Input voltage range Ui:
8...35 V DC ............... A
14...70 V DC .............. B
20...100 V DC .............. F
28...140 V DC .............. C
44...220 V DC .............. D
67...385 V DC .............. E
Series ...............................................................................K
Number of outputs....................................................... 1...2
Single output units:
Nominal voltage output 1 (main output), Uo1 nom
5.1 V ....... 0, 1, 2
12 V ............... 3
15 V ........... 4, 5
24 V ............... 6
other voltages ........... 7, 8
Other specifications for
single output modules ...... 01...99
Symmetrical double output units:
Nominal voltage output 1/output 2, Uo1/2 nom
12 V/12 V 1 (24 V series connection) ............. 20
15 V/15 V 1 (30 V series connection) ............. 40
24 V/24 V 1 (48 V series connection) ............. 60
other symmetrical voltages ...... 70...99
Operational ambient temperature range TA:
–25…71°C .............. -7
–40…71°C .............. -9
customer specific ........ -0...-6
Auxiliary functions and options:
Inrush current limitation .................................................... E 3
Output voltage control input ............................................ R 2
Potentiometer (output voltage adjustment) ......................P 2
Save data signal (D0...DD, to be specified) .................... D 4
ACFAIL signal (V0, V2, V3, to be specified) .................... V 4, 5
Current sharing ................................................................ T
Cooling plate standard case ..........................................B1
Cooling plate for long case 220 mm .............................. B2
1 External wiring of main and second output depending upon the desired output configuration (see: R-Function for Different Output
Configurations).
2 Feature R excludes option P and vice versa.
3 Option E available for CK, DK and EK types.
4 Option D excludes option V and vice versa.
5 Option V available for K 1001 type.
Example:
CK 2540-7PD3: DC-DC converter, input voltage range 28...140 V, double output, each providing15 V/5 A,
equipped with potentiometer and undervoltage monitoring option. Ambient temperature –25...71°C.
Edition 4/4.99
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K Series
DC-DC Converters >100Watt
Rugged Environment
Functional Description
generates, with respect to the maximum admissible output
currents, the control signal for the primary switching tran-
sistor.
The input voltage is fed via an input fuse, an input filter, and
an inrush current limiter to the input capacitor. This capaci-
tor sources a single transistor forward converter. Each out-
put is powered by a separate secondary winding of the
main transformer. The resultant voltages are rectified and
their ripples smoothed by a power choke and output filter.
The control logic senses the main output voltage Uo1 and
The second output of double output units is controlled by
the main output but has independent current limiting. If the
main output is driven into current limitation, the second out-
put voltage will fall as well and vice versa.
P
03057
16
18
R
i
26
Vi+
Y
28
20 D/V
2
T
22
12
4
1
S+
Y
Y
Vo+
6
8
4
Vo–
10
3
30
Vi–
32
S–
14
Y
24
–
+
Fig. 1
Block diagram of single output converters AK…EK 1000
P
03058
16
R
26
18 i
20 D
Y
Vi+
28
2
T
22
1
Y
Y
12
Vo1+
14
4
Vo1–
4
Y
Vo2+
3
6
30
32
Vi–
8
Vo2–
Y
Y
10
24
–
+
Fig. 2
Block diagram of symmetrical double output converters AK...EK 2000
1 Transient suppressor (VDR) in CK, DK, EK, FK types
2 Transient suppressor (diode) in AK, BK, CK, FK types
3 Inrush current limiter in CK, DK, EK types (NTC or Opt. E), -9 versions exclude the NTC
4 Input fuse
Edition 4/4.99
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The Power Partners.
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DC-DC Converters >100Watt
K Series
Electrical Input Data
General Conditions
– TA = 25°C, unless TC is specified.
– Pin 18 connected to pin 14, Uo adjusted to Uo nom (option P); R input not connected.
– Sense line pins S+ and S– connected to Vo+ and Vo– respectively.
Table 2a: Input data
Input
AK
BK
FK
Characteristics
Conditions
min
8
typ
max
35
min
14
typ
max
70
min
20
typ
max
Unit
Ui
Operating input voltage
Io = 0…Io nom
TC min…TC max
100
V DC
Ui nom Nominal input voltage
15
30
48
1
Ii
Input current
Ui nom, Io nom
9.0
6.0
3.75
A
Pi0
No-load input power
Idle input power
Input resistance
NTC resistance 2
Input capacitance
Conducted input RFI
Radiated input RFI
Ui min…Ui max
unit inhibited
TC = 25°C
2.5
1.5
2.5
1.5
2.5
1.5
W
Pi inh
Ri
65
100
300
70
mΩ
µF
3
3
3
RNTC
Ci
830
1250
40
450
80
1200
1800
100
Ui RFI
EN 55022
Ui nom, Io nom
A
A
B
A
B
B
Ui abs
Input voltage limits
without damage
0
0
0
V DC
Table 2b: Input data
Input
CK
DK
EK
Characteristics
Conditions
min
28
typ
max
140
min
44
typ
max
220
min
67
typ
max
385
Ui
Operating input voltage
Io = 0…Io nom
TC min…TC max
V DC
Ui nom Nominal input voltage
60
110
1.6
220
0.8
1
Ii
Input current
Ui nom, Io nom
3.0
A
Pi0
No-load input power
Idle input power
Input resistance
NTC resistance 2
Input capacitance
Conducted input RFI
Radiated input RFI
Ui min…Ui max
unit inhibited
TC = 25°C
2.5
1.5
2.5
1.5
2.5
1.5
W
Pi inh
Ri
150
800
660
170
1600
260
180
3200
210
mΩ
µF
RNTC
Ci
1000
154
400
400
400
Ui RFI
EN 55022
Ui nom, Io nom
B
B
B
B
B
B
Ui abs
Input voltage limits
without damage
0
0
400 4
0
V DC
1 With double output modules, both outputs loaded with Io nom
.
2 Valid for -7 versions with NTC, (-9 versions exclude the NTC). Initial switch-on cycle. Subsequent switch-on/off cycles increase the in-
rush current peak value.
3 AK, BK and FK types have no NTC (inrush current limiter) fitted.
4 1 s max., duty cycle 1% max.
Input Transient Protection
tremely wide input range is required. The EK input range for
110 V batteries has been designed and tested to meet this
requirement.
A suppressor diode or a VDR (depending upon the input
voltage range) together with the input fuse and a symmetri-
cal input filter form an effective protection against high input
transient voltages which typically occur in most installa-
tions, but especially in battery driven mobile applications.
Inrush Current Limitation
The CK, DK, EK modules incorporate an NTC resistor in
the input circuitry which - at initial turn on - reduces the peak
inrush current value by a factor of 5...10 to protect connec-
tors and switching devices from damage. Subsequent
switch-on cycles within short periods will cause an increase
of the peak inrush current value due to the warming-up of
the NTC resistor. See also: E option.
Nominal battery voltages in use are: 12, 24, 36, 48, 60, 72,
110 and 220 V. In most cases each nominal value is speci-
fied in a tolerance of –30%...+25%.
In certain applications, surges according to RIA 12 are
specified in addition to those defined in IEC 571-1. The
power supply must not switch off during these surges and
since their energy can practically not be absorbed an ex-
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K Series
DC-DC Converters >100Watt
Rugged Environment
Input Inrush Current Characteristic
Ii inr [A]
150
Input Fuse
A fuse mounted inside the converter protects the module
against severe defects. This fuse may not fully protect the
module when the input voltage exceeds 200 V DC! In appli-
cations where the converters operate at source voltages
above 200 V DC an external fuse or a circuit breaker at sys-
tem level should be installed!
05108
Table 3: Fuse Specification
100
Module
Fuse type
Fuse rating
AK 1
BK 1
CK 2
DK 2
EK 2
FK 2
fast-blow
fast-blow
slow-blow
slow-blow
slow-blow
slow-blow
Little fuse 314 30.0 A, 125 V
Little fuse 314 25.0 A, 125 V
CK
EK
DK
SPT
SPT
SPT
SPT
12.5 A, 250 V
8 A, 250 V
4 A, 250 V
16 A, 250 V
50
0
1 Fuse size 6.3 × 32 mm
2 Fuse size 5 × 20 mm
Static Input Current Characteristic
Ii (A)
04044
20.00
2
3
t [ms]
1
Fig. 5
Typical inrush current versus time at Ui max, Rext = 0.
For AK, BK and FK as well as for application related val-
ues use the formula given in Inrush Current Peak Value to
get realistic results.
10.00
AK
Input Under-/Overvoltage Lock-out
If the input voltage remains below approx. 0.8 Ui min or ex-
ceeds approx. 1.1 Ui max, an internally generated inhibit sig-
nal disables the output(s). When checking this function the
absolute maximum input voltage rating Ui abs should be
considered! Between Ui 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).
BK
FK
CK
1.00
0.40
DK
EK
Ui
____
Hold-up Time versus relative Input Voltage
Ui min
1
2
3
4
5
Fig. 3
th (ms)
Typical input current versus relative input voltage
04045
EK
Inrush Current Peak Value
100.00
The inrush current peak value (initial switch-on cycle) can
be determined by following calculation: (See also: Input In-
rush Current Characteristic)
CK/FK
DK
Ui source
Iinr p = ––––––––––––––––
10.00
(Rs ext + Ri + RNTC
)
AK
BK
05109
Rs ext
Iinr p
Ri
RNTC
1.00
+
Ci int
Ui source
Ui
____
0.10
Fig. 4
1
2
3
4
5
6
Ui min
Equivalent circuit for input impedance
Fig. 6
Reverse Polarity
Typical hold-up time th versus relative input voltage
Ui/Ui min. The DC-DC converters require an external series
diode in the input path if other loads are connected to the
same input supply lines.
The units are not protected against reverse polarity at the
input to avoid unwanted power losses and may be dam-
aged.
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DC-DC Converters >100Watt
K Series
Electrical Output Data
General Conditions
– TA = 25°C, unless TC is specified.
– Pin 18 (i) connected to pin 14 (S–/Vo1–), Uo adjusted to Uo nom (option P), R input not connected.
– Sense line pins 12 (S+) and 14 (S–) connected to Vo1+ and Vo1– respectively.
Table 4a: Output data single output modules AK/BK
Output
AK/BK 1001
5.1 V
AK/BK 1301
12.0 V
AK/BK 1501
15.0 V
AK/BK 1601
24.0 V
Characteristics
Conditions
min typ max
min typ max
min typ max
min typ max
Unit
V
Uo
Output voltage
Ui nom, Io nom
5.07
5.13 11.93
12.07 14.91
15.09 23.86
24.14
Uo P Overvoltage protection
(suppressor diode)
7.6
20.0/25.0
21/26
21
26.5
43.5
5.0/6.0
5.2/6.2
Io nom Output current 1
Ui min…Ui max
TC min…TC max
10.0/12.0
8.0/10.0
A
Io L
Output current limit 4
Ui min…Ui max
10.2/12.2
8.2/10.2
7
uo
Output Switching freq. Ui nom, Io nom
10
60
5
5
5
mVpp
mV
voltage
noise
IEC/EN 61204
BW = 20 MHz
Total
40
30
50
DUo u Static line regulation
Ui min...Ui nom
Ui nom...Ui max
Io nom
±15
±25
±30
±30
DUo I Static load regulation
Ui nom, Io =
(0.1…1) Io nom
20
25
30
±150
0.5
40
5
uo d
Dynamic
load
Voltage
deviation
Ui nom, Io =
±220
0.6
±110
0.6
±130
1
1
I
o nom ↔ /
2
Io nom
regulation
IEC/EN 61204
5
td
Recovery
time
ms
aUo
Temperature coefficient TC min…TC max
of output voltage 6
0...I o nom
–0.2
–1
–1
–1
mV/K
1 If the output voltages are increased above Uo nom through R-input control, option P setting, remote sensing or option T, the output cur-
rent should be reduced accordingly so that Po nom is not exceeded.
4 See: Output voltage regulation of single output units.
5 See: Dynamic load regulation of Uo1
.
6 Negative temperature coefficient (0...–3 mV/cell and K) available on request
7 Measured according to IEC/EN 61204 sub clause 3.10 with a probe acc. to annex A of the same standards. (see: Technical Informa-
tion: Measuring and Testing)
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Table 4b: Output data double output modules AK/BK
Output
AK/BK 2320
24 V (2 × 12 V)
AK/BK 2540
30 V (2 × 15 V)
AK/BK 2660
48 V (2 × 24 V)
(Outputs connected in Series)
Characteristics
Conditions
min
typ
24.0 2
38
max
min
typ
30.0 2
48
max
min
typ
48.0 2
74
max
Unit
V
Uo
Output voltage
Ui nom, Io nom
Uo P Overvoltage protection
(suppressor diode)
Io nom Output current 1
Ui min…Ui max
TC min…TC max
5.0/6.0
4.0/5.0
2.5/3.0
A
Io L
Output current limit 4
Ui min…Ui max
5.2/6.2
4.2/5.2
2.7/3.2
7
uo
Output Switching freq. Ui nom, Io nom
10
60
5
5
mVpp
mV
voltage
noise 3
IEC/EN 61204
BW = 20 MHz
Total
60
70
DUo u Static line regulation
Ui min...Ui nom
Ui nom...Ui max
Io nom
±15
±15
±20
DUo I Static load regulation
Ui nom, Io =
(0.1…1) Io nom
25
±180
0.3
25
±160
0.2
35
±100
0.2
5
uo d
Dynamic
load
Voltage
deviation
Ui nom, Io=
Io nom ↔ 1/
2
Io nom
regulation
IEC/EN 61204
5
td
Recovery
time
ms
aUo
Temperature coefficient TC min…TC max
of output voltage 6
0...I o nom
–2
–2
–2
mV/K
1 If the output voltages are increased above Uo nom through R-input control, option P setting, remote sensing or option T, the output cur-
rent should be reduced accordingly so that Po nom is not exceeded.
2 Series connection for Uo nom = 24 V, 30 V or 48 V, see: R-Function for Different Output Configurations.
3 Shortest possible wiring for series connection at the connector.
4 See: Output voltage regulation of single output units.
5 See: Dynamic load regulation of Uo1 and Uo2
.
6 Negative temperature coefficient (0...–3 mV/cell and K) available on request.
7 Measured according to IEC/EN 61204 sub clause 3.10 with a probe acc. to annex A of the same standards. (See: Technical Informa-
tion: Measuring and Testing.)
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DC-DC Converters >100Watt
K Series
Table 4c: Output data double output modules AK/BK
Output
AK/BK 2320
12 V/12 V
AK/BK 2540
15 V/15 V
(Outputs independently loaded) 1
Characteristics
Conditions
Output 1
min typ max
11.93
Output 2
Output 1
Output 2
min typ max Unit
min typ max
min typ max
2
Uo
Output voltage
Ui nom, Io nom
12.07 11.82
12.18 14.91
15.09 14.78
15.23
V
Uo P Overvoltage protection
(suppressor diode)
19
5.0/6.0
5.2/6.2
19
24
24
Io nom Output current 3
Ui min...Ui max
TC min...TC max
5.0/6.0
4.0/5.0
4.0/5.0
A
Io L
Output current limit 4
Ui min...Ui max
5.2/6.2
4.2/5.2
4.2/5.2
9
uo
Output Switching freq. Ui nom, Io nom
10
50
10
20
10
50
10
20
mV
pp
voltage
noise
IEC/EN 61204
BW = 20 MHz
Total
DUo u Static line regulation
Ui min...Ui nom
Ui nom...Ui max
Io nom
±30
±30
±30
±30
mV
8
8
DUo I Static load regulation
Ui nom, Io =
(0.1...1) Io nom
50
50
5
6
uo d
Dynamic
load
regulation
Voltage
deviation
Ui nom, Io =
±80
0.2
–1
±80
0.2
–1
Io nom ↔ 1/
2
Io nom
IEC/EN 61204
6
td
Recovery
time
ms
aUo
Temperature coefficient TC min...TC max
of output voltage 7
0...I o nom
mV/K
Table 4d: Output data double output modules AK/BK
Output
AK/BK 2660
24 V/24 V
(Outputs independently loaded) 1
1 Depending upon the desired out-
put configuration the wiring should
be made as shown in: R-Function
for Different Output Configurations.
2 Same conditions for both outputs.
3 If the output voltages are in-
creased above Uo nom via R-input
control, option P setting, remote
sensing or option T, the output cur-
rents should be reduced accord-
ingly so that Po nom is not ex-
ceeded.
Characteristics
Conditions
Output 1
Output 2
min typ max min typ max Unit
2
Uo
Output voltage
Ui nom, Io nom
23.86
24.14 23.64
24.36
V
A
Uo P Overvoltage protection
(suppressor diode)
37
2.5/3.0
2.7/3.2
37
Io nom Output current 3
Ui min…Ui max
TC min…TC max
2.5/3.0
Io L
Output current limit 4
Ui min…Ui max
2.7/3.2
9
4 See: Output voltage regulation of
single output units.
uo
Output Switching freq. Ui nom, Io nom
5
5
mVpp
mV
voltage
noise
IEC/EN 61204
BW = 20 MHz
Total
60
30
5 Condition for specified output.
Other output loaded with constant
current Io = Io nom
DUo u Static line regulation
Ui min...Ui nom
Ui nom...Ui max
Io nom
±40
±40
6 See: Dynamic load regulation of
Uo1 and Uo2
.
8
7 Negative temperature coefficient
(0…–3 mV/cell and K) available on
request.
DUo I Static load regulation
Ui nom, Io =
(0.1…1)Io nom
70
5
6
uo d
Dynamic
load
Voltage
deviation
Ui nom, Io =
Io nom ↔ 1/
IEC/EN 61204
±50
0.2
–1
8 See: Output Voltage Regulation of
Double Output Modules.
2
Io nom
regulation
9 Measured according to IEC/EN
61204 sub clause 3.10 with a
probe acc. to annex A of the same
standards. (see: Technical Infor-
mation: Measuring and Testing)
6
td
Recovery
time
ms
aUo
Temperature coefficient TC min…TC max
of output voltage 7
mV/K
0...I o nom
Edition 4/4.99
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MELCHER
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K Series
DC-DC Converters >100Watt
Rugged Environment
Table 4e: Output data single output modules CK...EK
Output
CK...DK 1001
5.1 V
CK...EK 1301
12.0 V
CK...EK 1501
15.0 V
CK...EK 1601
24.0 V
Characteristics
Conditions
min typ max min typ max min typ max min typ max Unit
Uo
Output voltage
Ui nom, Io nom
5.07
26
5.13 11.93
12.07 14.91
15.09 23.86
24.14
V
Uo P Overvoltage protection
(suppressor diode)
7.6
21
26.5
10.0
43.5
6.0
Io nom Output current 1
Ui min...Ui max
TC min...TC max
25.0
12.0
A
Io L
Output current limit 4
Ui min...Ui max
12.2
10.2
6.2
7
uo
Output Switching freq. Ui nom, Io nom
10
50
5
5
5
mV
pp
voltage
noise
IEC/EN 61204
BW = 20 MHz
Total
40
30
50
DUo u Static line regulation
Ui min...Ui nom
Ui nom...Ui max
Io nom
±15
±25
±30
±30 mV
DUo I Static load regulation
Ui nom, Io =
(0.1...1) Io nom
20
25
30
40
5
uo d
Dynamic
load
regulation
Voltage
deviation
Ui nom, Io =
±100
0.3
±100
0.5
±100
0.4
±80
0.3
–2
Io nom ↔ 1/
2
Io nom
IEC/EN 61204
5
td
Recovery
time
ms
aUo
Temperature coefficient TC min...TC max
of output voltage 6
0...Io nom
–1
–1
–1
mV/K
Table 4f: Output data double output modules CK...EK
Output
CK...EK 2320
24 V (2 × 12 V)
CK...EK 2540
30 V (2 × 15 V)
CK...EK 2660
48 V (2 × 24 V)
(Outputs connected in Series)
Characteristics
Conditions
min
typ
24.0 2
38
max
min
typ
30.0 2
48
max
min
typ
48.0 2
74
max
Unit
V
Uo
Output voltage
Ui nom, Io nom
Uo P Overvoltage protection
(suppressor diode)
Io nom Output current 1
Ui min...Ui max
TC min...TC max
6.0
5.0
3.0
A
Io L
Output current limit 4
Ui min...Ui max
6.2
5.2
3.2
7
uo
Output Switching freq. Ui nom, Io nom
15
15
20
mVpp
mV
voltage
noise 3
IEC/EN 61204
BW = 20 MHz
Total
100
120
120
DUo u Static line regulation
Ui min...Ui nom
Ui nom...Ui max
Io nom
±40
±30
±50
DUo I Static load regulation
Ui nom, Io =
(0.1...1) Io nom
40
±100
0.3
30
±100
0.5
40
±100
0.4
5
uo d
Dynamic
load
Voltage
deviation
Ui nom, Io =
Io nom ↔ 1/
IEC/EN 61204
2
Io nom
regulation
5
td
Recovery
time
ms
aUo
Temperature coefficient TC min...TC max
of output voltage 6
0...Io nom
–2.2
–2.2
–2.6
mV/K
1 If the output voltages are increased above Uo nom through R-input control, option P setting, remote sensing or option T, the output cur-
rent should be reduced accordingly so that Po nom is not exceeded.
2 Series connection for Uo nom = 24 V, 30 V or 48 V, see: R-Function for Different Output Configurations.
3 Shortest possible wiring for series connection at the connector.
4 See: Output voltage regulation of single output units.
5 See: Dynamic load regulation of Uo1 and Uo2
.
6 Negative temperature coefficient (0...–3 mV/cell and K) available on request
7 Measured according to IEC/EN 61204 sub clause 3.10 with a probe acc. to annex A of the same standards. (See Technical Informa-
tion: Measuring and Testing.)
Edition 4/4.99
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DC-DC Converters >100Watt
K Series
Table 4g: Output data double output modules CK...EK
Output
CK...EK 2320
12 V/12 V
CK...EK 2540
15 V/15 V
(Outputs independendtly loaded) 1
Characteristics
Conditions
Output 1
Output 2
Output 1
Output 2
min typ max min typ max min typ max min typ max Unit
2
Uo
Output voltage
Ui nom, Io nom
11.93
12.07 11.82
12.18 14.91
15.09 14.78
15.22
V
A
Uo P Overvoltage protection Failure in
19
19
24
24
(suppressor diode)
control circuit
Io nom Output current 3
Ui min...Ui max
TC min...TC max
6.0
6.0
5.0
5.0
Io L
Output current limit 4
Ui min...Ui max
6.2
6.2
5.2
5.2
9
uo
Output Switching freq. Ui nom, Io nom
5
5
5
5
mVpp
voltage
noise
IEC/EN 61204
BW = 20 MHz
Total
75
25
100
25
DUo u Static line regulation
Ui min...Ui nom
Ui nom...Ui max
Io nom
±30
±40
±30
±40 mV
8
8
DUo I Static load regulation
Ui nom, Io =
(0.1...1) Io nom
100
100
5
6
uo d
Dynamic
load
regulation
Voltage
Ui nom, Io =
±100
0.3
±80
0.2
deviation Io nom ↔ 1/
2
Io nom
IEC/EN 61204
6
td
Recovery
time
ms
aUo
Temperature coefficient TC min...TC max
of output voltage 7
0...Io nom
–1.1
–1.1
mV/K
Table 4h: Output data double output modules CK...EK
Output
CK...EK 2660
24 V/24 V
(Outputs independently loaded) 1
1 Depending upon the desired out-
put configuration the wiring should
be made as shown in: R-Function
for Different Output Configurations.
2 Same conditions for both outputs.
3 If the output voltages are in-
creased above Uo nom via R-input
control, option P setting, remote
sensing or option T, the output cur-
rents should be reduced accord-
ingly so that Po nom is not ex-
ceeded.
Characteristics
Conditions
Output 1
Output 2
min typ max min typ max Unit
2
Uo
Output voltage
Ui nom, Io nom
23.86
24.14 23.64
24.36
V
A
Uo P Overvoltage protection
(suppressor diode)
37
37
Io nom Output current 3
Ui min...Ui max
TC min...TC max
3.0
3.0
Io L
Output current limit 4
Ui min...Ui max
3.2
3.2
9
4 See: Output voltage regulation of
single output units.
uo
Output Switching freq. Ui nom, Io nom
5
5
mV
pp
voltage
noise
IEC/EN 61204
BW = 20 MHz
Total
100
25
5 Condition for specified output.
Other output loaded with constant
DUo u Static line regulation
Ui min...Ui nom
Ui nom...Ui max
Io nom
,
,
±30
±50
mV
current Io = Io nom
.
6 See: Dynamic load regulation of
Uo1 and Uo2.
.
8
7 Negative temperature coefficient
(0...–3 mV/cell and K) available on
request.
DUo I Static load regulation
Ui nom, Io =
(0.1...1) Io nom
50
5
6
uo d
Dynamic
load
Voltage
deviation
Ui nom, Io =
±50
0.2
8 See: Output Voltage Regulation of
Double Output Modules.
Io nom ↔ 1/
2
Io nom
regulation
IEC/EN 61204
6
td
Recovery
time
ms
9 Measured according to IEC/EN
61204 sub clause 3.10 with a
probe acc. to annex A of the same
standards. (Se:e Technical Infor-
mation: Measuring and Testing.)
aUo
Temperature coefficient TC min...TC max
of output voltage 7
–1.3
mV/K
0...Io nom
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K Series
DC-DC Converters >100Watt
Rugged Environment
Thermal Considerations
Output Protection
If a converter is located in free, quasi-stationary air (con-
vection cooling) at the indicated maximum ambient tem-
perature TA max (see table: Temperature specifications) and
is operated at its nominal input voltage and output power,
the temperature measured at the Measuring point of case
temperature TC (see: Mechanical Data) will approach the
indicated value TC max after the warm-up phase. However,
the relationship between TA and TC depends heavily 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-
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. A red LED indicates the
overload condition.
Parallel or Series Connection of Units
Single or double output units with equal nominal output
voltage can be connected in parallel without any precau-
tions using option T.
nents and surfaces. TA max is therefore, contrary to TC max
,
an indicative value only.
With option T (current sharing), all units share the current
approximately equally.
Caution: The installer must ensure that under all operat-
ing conditions TC remains within the limits stated in the
table Temperature specifications.
Single output units and/or main and second outputs of dou-
ble output units can be connected in series with any other
(similar) output.
Notes: Sufficient forced cooling or an additional heat sink
allows TA to be higher than 71°C (e.g. 85°C) if TC max is not
exceeded.
Note:
For -7 or -9 units at an ambient temperature TA of 85°C with
only convection cooling, the maximum permissible current
for each output is approx. 40% of its nominal value as per
figure.
– Parallel connection of double output units should always
include both, main and second output to maintain good
regulation of both outputs.
– Not more than 5 units should be connected in parallel.
Io/Io nom
– Series connection of second outputs without involving
their main outputs should be avoided as regulation may
be poor.
Forced cooling
1.0
0.9
0.8
0.7
– The maximum output current is limited by the output with
the lowest current limitation if several outputs are con-
nected in series.
Convection cooling
0.6
05072
Uo1
TC max
0.5
Uo1d
Ur
Ur
0.4
0.3
0.2
0.1
Uo1d
td
td
0
T [°C]
A
T
50
60
70
80
90
100
t
t
A min
Uo2
Fig. 7
Output current derating versus temperature for -7 and -9
units.
Uo2d
Thermal Protection
Io1/Io1 nom
Io2/Io2 nom
A temperature sensor generates an internal inhibit signal
which disables the outputs if the case temperature exceeds
TC max. The outputs are automatically re-enabled if the tem-
perature drops below this limit.
1
0.5
0
<10 µs
<10 µs
t
It is recommended that continuous operation under simul-
taneous extreme worst case conditions of the following
three parameters be avoided: Minimum input voltage,
maximum output power and maximum temperature.
Fig. 8
Typical dynamic load regulation of Uo1 and Uo2
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DC-DC Converters >100Watt
K Series
Output Voltage Regulation of Single or Double Output
Modules with Outputs 1 and 2 Connected in Series
[V] Uo2
15.75
05106
Io1 = 5.00 A
Io1 = 3.75 A
Io1 = 2.50 A
Io1 = 1.25 A
Io1 = 0.50 A
Uo
Uo nom
05098
15.50
15.25
15.00
14.75
14.50
14.25
14.00
0.98
0.5
Io1
IoL
Io
Io nom
Io2
[A]
0
0.5
1.0
0
1
2
3
4
5
6
7
Io nom
Fig. 9
o1 vs. Io1 (typ.) of single output units AK...EK
Fig. 11
U
AK...EK 2540: DUo2 (typ.) vs. Io2 with different I01
Output Voltage Regulation of Double Output Modules
[V] Uo2
Output 1 is under normal conditions regulated to Uo1 nom
,
independent of the output currents.
05107
26.0
25.5
25.0
24.5
24.0
23.5
23.0
Io1 = 3.0 A
Io1 = 2.0 A
Io1 = 1.0 A
Io1 = 0.5 A
Io1 = 0.3 A
Uo2 is dependent upon the load distribution. If both outputs
are loaded with more than 10% of Io nom, the deviation of
Uo2 remains within ±5% of the value of Uo1. The following 3
figures show the regulation with varying load distribution. If
Io1 = Io2 or the two outputs are connected in series, the de-
viation of Uo2 remains within ±1% of the value of Uo1 pro-
vided that a total load of more than 10% of Io nom is applied.
Two outputs of a single K 2000 module connected in paral-
lel will behave like the output of a K 1000 module; the paral-
leled output is fully regulated. No precautions are neces-
sary in using the R-input and the test sockets.
[V] Uo2
Io2
[A]
05105
12.6
0
0.5
1
1.5
2
2.5
3
3.5
4
Io1 = 6.0 A
Io1 = 4.5 A
Io1 = 3.0 A
Io1 = 1.5 A
Io nom
12.4
Fig. 12
AK...EK 2660: DUo2 (typ.) vs. Io2 with different I01
12.2
12.0
11.8
11.6
11.4
11.2
Io1 = 0.6 A
Io2
0
1
2
3
4
5
6
7
8
[A]
Io nom
Fig. 10
AK...EK 2320: DUo2 (typ.) vs. Io2 with different I01
Edition 4/4.99
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K Series
DC-DC Converters >100Watt
Rugged Environment
Auxiliary Functions
i Inhibit for Remote On and Off
Sense Lines
Note: With open i input: Output is disabled (Uo = off).
(Only for single output units 5.1 V, 12 V, 15 V, 24 V)
The outputs of the module may be enabled or disabled by This feature enables for compensation of voltage drops
means of a logic signal (TTL, CMOS, etc.) applied between across the connector contacts and if necessary, across the
the inhibit input i and the negative pin of output 1 (Vo1–). In load lines. If the sense lines are connected at the load
systems with several units, this feature can be used, for ex- rather than directly at the connector, the user should ensure
ample, to control the activation sequence of the converters. that Uo max (between Vo1+ and Vo1–) is not exceeded. We
If the inhibit function is not required, connect the inhibit pin recommend connecting the sense lines directly at the fe-
18 to pin 14 to enable the outputs (active low logic, fail male connector.
safe). For output response refer to: Hold-up Time and Out-
put Response.
For further information, please refer to: Application Notes.
To ensure correct operation, both sense lines (S+ and S–)
06031
should be connected to their respective power outputs
(Vo1+ and Vo1–) and the voltage difference between any
sense line and its respective power output pin (as meas-
ured on the connector) should not exceed the following val-
ues:
Vo+
i
Vi+
Iinh
Uinh
Table 6: Maximum voltage compensation allowed using
sense lines
Vo–
Vi–
Output
voltage
Total voltage difference Voltage difference
Fig. 13
Definition of Uinh and Iinh
between sense lines and
their respective outputs
between
Vo– and S–
.
5.1 V
< 0.5 V
< 1.0 V
< 0.25 V
< 0.25 V
Table 5: Inhibit characteristics
12 V, 15 V
Characteristic
Conditions min typ max Unit
Uinh Inhibit Uo = on Ui min…Ui max –50
0.8
50
V
If the output voltages are increased above Uo nom via R-in-
put control, option P setting, remote sensing or option T, the
output currents must be reduced accordingly so that
Po nom is not exceeded.
voltage
Uo = off
2.4
Iinh Inhibit current
Uinh = 0
–400 µA
tr
tf
Rise time
Fall time
30
ms
Note: The output terminals Vo1+ and Vo1– must always be
connected to the load before connecting the sense lines S+
and S–, otherwise the unit will be damaged.
depending on Io
Iinh [mA]
Uinh = 2.4 V
Uinh = 0.8 V
2.0
1.6
1.2
0.8
0.4
Uo = on
Uo = off
0
–0.4
–0.8
Uinh [V]
–50
–30
–10
0
10
30
50
Fig. 14
Typical inhibit current Iinh versus inhibit voltage Uinh
06001
Uo/Uo nom
1
0.1
0
t
tf
tr
Inhibit
1
t
0
Fig. 15
Typical output response as a function of inhibit control
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DC-DC Converters >100Watt
K Series
Programmable Output Voltage (R-Function)
As a standard feature, the modules offer an adjustable out-
put voltage, identified by letter R in the type designation.
The control input R (pin 16) accepts either a control voltage
Uext or a resistor Rext to adjust the desired output voltage.
When not connected, the control input automatically sets
– If the output voltages are increased above Uo nom via R-
input control, option P setting, remote sensing or option
T, the output current(s) should be reduced accordingly so
that Po nom is not exceeded.
– The R-input (as well as option P) is related to the main
output.
the output voltage to Uo nom
.
– With double output units the second output follows the
value of the controlled main output. Resistor values as
indicated for the single output units should be used.
– For correct output voltage adjustment of double output
units the external wiring of the outputs should be accord-
ing to: R-Function for Different Output Configurations,
depending upon the desired output configuration.
– In case of parallel connection the output voltages should
be individually set within a tolerance of 1 - 2%.
05074
a) Adjustment by means of an external control voltage Uext
between pin 16 (R) and pin 14:
The control voltage range is 0...2.75 V DC and allows an
output voltage adjustment in the range of approximately
0...110% Uo nom
U
.
Uext = –––o––– • 2.5 V (approximate formula)
Uo nom
b) Adjustment by means of an external resistor:
Depending upon the value of the required output voltage
the resistor shall be connected
Vo1+
Vi+
R
+
Either: Between pin 16 and pin 14 (Uo < Uo nom) to
achieve an output voltage adjustment range of approxi-
mately 0...100% Uo nom
16
14
Uext
S–
or: Between pin 16 and pin 12 (Uo > Uo nom) to achieve an
output voltage adjustment range of approximately
Vo1–
Vi–
100...110% Uo nom
.
Vo1+
Vi+
Warning:
– Uext shall never exceed 2.75 V DC.
S+
R
12
R'ext
Rext
– The value of R'ext shall never be less than the lowest
value as indicated in table R'ext for (Uo > Uo nom) to
avoid damage to the unit!
16
14
S–
Vo1–
Vi–
Remarks:
– The R-Function excludes option P (output voltage adjust-
ment by potentiometer).
Fig. 16
Output voltage control for single output units AK...EK 1000
by means of the R input
Table 7a: Rext for Uo < Uo nom; approximative values (Ui nom, Io nom, series E 96 resistors); R'ext = ∞
Uo nom = 5.1 V
Uo (V) Rext [kΩ]
Uo nom = 12 V
Uo [V] 1
Uo nom = 15 V
Uo [V] 1
Uo nom = 24 V
Uo [V] 1
Rext [kΩ]
Rext [kΩ]
Rext [kΩ]
0.825
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
0.422
1.0
2
3
4
5
6
7
8
9
10
11
4
6
8
10
12
14
16
18
20
22
0.825
1.3
2
4
6
8
9
10
11
12
13
14
4
8
0.56
1.47
2.61
4.64
6.19
8.25
11.0
16.2
26.1
56.2
4
6
8
10
12
14
16
18
20
22
8
12
16
20
24
28
32
36
40
44
1.33
1.96
2.87
3.83
5.61
8.25
12.1
19.6
46.4
1.62
2.16
3.83
5.61
9.09
14.7
28.7
196
1.96
2.87
3.83
5.62
8.28
12.1
19.6
42.2
12
16
18
20
22
24
26
28
Table 7b: R’ext for Uo > Uo nom; approximative values (Ui nom, Io nom, series E 96 resistors); Rext = ∞
Uo nom = 5.1 V
Uo [V] R'ext [kΩ]
5.15 422
Uo nom = 12 V
Uo [V] 1
Uo nom = 15 V
Uo [V] 1
Uo nom = 24 V
R'ext [kΩ]
R'ext [kΩ]
Uo [V] 1
R'ext [kΩ]
12.1
12.2
12.3
12.4
12.5
12.6
12.7
12.8
13.0
13.2
24.2
24.4
24.6
24.8
25.0
25.2
25.4
25.6
26.0
26.4
1780
909
623
464
383
316
286
234
196
162
15.2
15.4
15.6
15.8
16.0
16.2
16.4
16.5
30.4
30.8
31.2
31.6
32.0
32.4
32.8
33.0
1470
750
511
383
316
261
237
215
24.25
24.5
24.75
25.0
25.25
25.5
25.75
26.0
48.5
49.0
49.5
50.0
50.5
51.0
51.5
52.0
52.5
52.8
3160
1620
1100
825
681
562
511
464
422
383
5.2
5.25
5.3
215
147
110
5.35
5.4
90.9
75
5.45
5.5
61.9
56.2
26.25
26.4
1 First column: single output units or double output units with separated outputs, second column: outputs in series connection
Edition 4/4.99
MELCHER
15/31
The Power Partners.
K Series
DC-DC Converters >100Watt
Rugged Environment
R-Function for Different Output Configurations
06004
06005
+
+
Vo2+
Vo2+
Vo2–
Vo2–
Vo1+
Vo1–
Vo2+
Vo2+
Vo2–
Vo2–
Vo1+
Vo1–
4
6
4
6
12 V
15 V
24 V
1
Uo1
24 V
30 V
48 V
8
8
1
Uo1
–
10
12
14
10
12
2
–
14
16
Rext R'ext
Rext R'ext
16
R
R
Fig. 17a
Fig. 17b
AK...EK 2000 with H15 connector. R-input for output volt-
age control. Wiring for output voltage 24 V or 30 V or 48 V
with main and second output connected in series.
AK...EK 2000 with H15 connector. R-input for output volt-
age control. Wiring for output voltage 12 V or 15 V or
24 V with main and second output connected in parallel.
06006
06007
+24/+30/+48 V
0 V
Vo2+
Vo2+
Vo2–
Vo2–
Vo1+
Vo1–
Vo2+
Vo2+
Vo2–
Vo2–
Vo1+
Vo1–
4
6
4
6
+
1
1
Uo2
–12/–15/–24 V
–
8
8
Uo2
+12/+15/+24 V
0 V
Uo1
10
12
+
10
12
2
1
1
Uo1
+12/+15/+24 V
+
14
16
14
16
Rext R'ext
Rext R'ext
R
R
Fig. 17c
Fig. 17d
AK...EK 2000 with H15 connector. R-input for output volt-
age control. Wiring of main and second output for two
symmetrical output voltages Uo1 and Uo2: ±12 V or ±15 V
or ±24 V.
AK...EK 2000 with H15 connector. R-input for output volt-
age control. Wiring of main and second output for two
output voltages Uo1 and Uo2: +12 V and +24 V or +15 V
and +30 V or +24 V and +48 V.
1 A ceramic multilayer capacitor connected across the output
lines reduces ripple and spikes.
06008
+
Vo2+
Vo2+
Vo2–
Vo2–
Vo1+
Vo1–
4
6
2 Shortest possible wiring for series connection at the female con-
nector
12 V
15 V
24 V
1
1
Uo2
–
8
+
10
12
12 V
15 V
24 V
Uo1
–
Remarks:
14
16
Rext R'ext
Double output units fitted with H-15 connectors have the
output pins of the second output, pins 4/6 and 8/10, inter-
nally paralleled.
R
It is recommended that pins 4/6 and 8/10 be directly paral-
leled at the female connector as well to reduce the voltage
drop across the connector.
Fig. 17e
AK...EK 2000 with H15 connector. R-input for output volt-
age control. Wiring of main and second output for two out-
put voltages Uo1 and Uo2: 12 V/12 V or 15 V/15 V or
24 V/24 V, the outputs are galvanically isolated.
Please note: Uo2 varies depending upon its own load and
the load on output 1.
Edition 4/4.99
16/31
MELCHER
The Power Partners.
Rugged Environment
DC-DC Converters >100Watt
K Series
Display Status of LEDs
06002
Uo1 > 0.95...0.98Uo1 adj
Fig. 18
OK
i
Io L
LEDs "OK", "i" and "Io L"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
Ui
Ui uv Ui min
Ui max Ui ov Ui abs
Uo1 > 0.95...0.98Uo1 adj
Uo1 < 0.95...0.98Uo1 adj
OK
LEDs "OK" and "Io L"status versus output current
Conditions: Ui min...Ui max, TC £ TC max, Uinh £ 0.8 V
Io L
Io
Io nom
IoL
i
i
LED "i"versus case temperature
Conditions: Ui min...Ui max, Io £ Io nom, Uinh £ 0.8 V
TC
TC max
TPTC threshold
Uinh threshold
LED "i"versus Uinh
Ui inh
Conditions: Ui min...Ui max, Io £ Io nom, TC £ TC max
+0.8 V
+2.4 V
+50 V
-50 V
LED off
LED Status undefined
LED on
Test Sockets (Main output only)
Test sockets for measuring the output voltage Uo1 are lo-
cated at the front of the module. The positive test socket is
protected by a series resistor (see: Functional Description,
block diagrams). The voltage measured at the test sockets
is approximetly 30 mV lower than the value measured at
the output terminals.
In case of double output units externally connected in se-
ries for Uo = 24 V, 30 V or 48 V the monitored output voltage
is 12 V, 15 V or 24 V respectively.
Edition 4/4.99
17/31
MELCHER
The Power Partners.
K Series
DC-DC Converters >100Watt
Rugged Environment
Electromagnetic Compatibility (EMC)
A suppressor diode or a metal oxide VDR (depending upon
the type) together with an input fuse and an input filter form
an effective protection against high input transient voltages
which typically occur in most installations, but especially in
battery driven mobile applications. The K series has been
successfully tested to the following specifications:
Electromagnetic Immunity
Table 8: Immunity type tests
Phenomenon
Standard 1
Level
Coupling
mode 2
Value
applied
Waveform
Source
imped.
Test
procedure
In
Per-
oper. form. 3
Voltage surge
IEC 60571-1
i/c, +i/–i
800 Vp
1500 Vp
3000 Vp
4000 Vp
7000 Vp
3.5 • Ubatt
1.5 • Ubatt
960 Vp
100 µs
50 µs
100 Ω
1 pos. and 1 neg.
voltage surge per
coupling mode
yes
A
5 µs
1 µs
100 ns
Supply related
surge
RIA 12
A 4
B
C
D
E
F
+i/–i
2/20/2 ms
0.1/1/0.1 s
10/100 µs
5/50 µs
0.5/5 µs
0.1/1 µs
0.05/0.1 µs
5/50 µs
0.5/5 µs
0.1/1 µs
0.05/0.1 µs
1/50 ns
0.2 Ω
5 Ω
1 positive
surge
yes
yes
A
B
Direct transient
+i/c, –i/c
5 pos. and 5 neg.
impulses
1800 Vp
3600 Vp
4800 Vp
8400 Vp
1800 Vp
3600 Vp
4800 Vp
8400 Vp
100 Ω
G
H
J
5
Indirect coupled
transient
+o/c, –o/c,
K
L
Electrostatic
discharge
(to case)
IEC/EN
61000-4-2
4
contact discharge 8000 Vp
330 Ω
10 positive and
10 negative
discharges
yes
A
air discharge
15000 Vp
Electromagnetic IEC/EN
3
4
antenna
10 V/m
AM 80%
1 kHz
n.a.
26…1000 MHz
yes
yes
A
A
field
61000-4-3
Electromagnetic ENV 50204
field,
pulse modulated
50% duty cycle,
200 Hz repetition
frequency
900 ±5 MHz
Electrical fast
transient/burst
IEC/EN
61000-4-4
capacitive, o/c
2000 Vp bursts of 5/50 ns 50 Ω
1 min positive
1 min negative
transients per
coupling mode
yes
A
2.5/5 kHz over
15 ms; burst
period: 300 ms
i/o, +i/–i
direct
4000 Vp
Surge
IEC/EN
61000-4-5
3
4
i/c
2000 Vp
1.2/50 µs
12 Ω
2 Ω
5 pos. and 5 neg.
surges per
coupling mode
yes
yes
A
A
+i/–i
Conducted
disturbances
IEC/EN
61000-4-6
3
i, o, signal wires
10 Vrms
(140 dBµV)
AM 80%
1 kHz
150 Ω
0.15...80 MHz
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.
4 Only met with extended input voltage range of CK (48 V battery) and EK (110 V battery) types. These units are available on custom-
er's request. Standard DK units (110 V battery) will not be damaged, but overvoltage lock-out will occur during the surge. Under nor-
mal operation temporary deviation from specifications possible.
5 Test in progress, please consult factory.
Note: Previous standards are referenced in: Technical Information: Standards.
Edition 4/4.99
MELCHER
18/31
The Power Partners.
Rugged Environment
DC-DC Converters >100Watt
K Series
Electromagnetic Emission
u [dBµV]
07037
90
[dBµV/m]
07077
50
A
80
70
60
50
40
30
20
10
0
A
B
40
B
30
20
10
[MHz]
0
f
[MHz]
Fig. 19
Fig. 20
Typical disturbance voltage (quasi-peak) at the input ac-
cording to CISPR 11/22 and EN 55011/22, measured at
Typical radiated electromagnetic field strength (quasi-
peak) according to CISPR 11/22 and EN 55011/22, nor-
malized to a distance of 10 m, measured at Ui nom and
Ui nom and Io nom.
Io nom
.
Edition 4/4.99
19/31
MELCHER
The Power Partners.
K Series
DC-DC Converters >100Watt
Rugged Environment
Immunity to Environmental Conditions
Table 9: Mechanical stress
Test method
Standard
Test conditions
Status
Ca
Ea
Eb
Fc
Damp heat
steady state
IEC/DIN IEC 60068-2-3
MIL-STD-810D section 507.2 Relative humidity:
Duration:
Temperature:
40 ±2 °C
%
56 days
Unit not
operating
93 +2/-3
Shock
(half-sinusoidal)
IEC/EN/DIN EN 60068-2-27
MIL-STD-810D section 516.3 Bump duration:
Number of bumps:
Acceleration amplitude:
100 gn = 981 m/s2
6 ms
18 (3 each direction)
Unit
operating
Bump
(half-sinusoidal)
IEC/EN/DIN EN 60068-2-29
MIL-STD-810D section 516.3 Bump duration:
Number of bumps:
Acceleration amplitude:
40 gn = 392 m/s2
6 ms
6000 (1000 each direction)
Unit
operating
Vibration
(sinusoidal)
IEC/EN/DIN EN 60068-2-6
MIL-STD-810D section 514.3
Acceleration amplitude:
0.35 mm (10...60 Hz)
5 gn = 49 m/s2 (60...2000 Hz) operating
10...2000 Hz
Unit
Frequency (1 Oct/min):
Test duration:
7.5 h (2.5 h each axis)
Fda Random vibration IEC 60068-2-35
Acceleration spectral density: 0.05 gn2/Hz
Unit
wide band
Reproducibility
high
DIN 40046 part 23
Frequency band:
Acceleration magnitude:
Test duration:
20...500 Hz
4.9 gn rms
3 h (1 h each axis)
operating
Kb
Salt mist, cyclic
(sodium chloride
NaCl solution)
IEC/EN/DIN IEC 60068-2-52 Concentration:
5% (30°C)
Unit not
operating
Duration:
Storage:
Storage duration:
Number of cycles:
2 h per cycle
40°C, 93% rel. humidity
22 h per cycle
3
Table 10: Temperature specifications, valid for an air pressure of 800...1200 hPa (800...1200 mbar)
Temperature
Standard -7
Option -9
Characteristics
Conditions
Operational 2
min
max
71
min
–40
–40
–55
max
71
Unit
TA
TC
TS
Ambient temperature 1
Case temperature 3
Storage temperature 1
–25
–25
–40
°C
95
95
Non operational
100
100
1 MIL-STD-810D section 501.2 and 502.2.
2 See: Thermal Considerations.
3 Overtemperature lock-out at TC >95°C (PTC).
Table 11: MTBF
Values at specified
case temperature
Module types
Ground benign
Ground fixed
Ground mobile Unit
40°C
40°C
70°C
50°C
MTBF 1
AK...EK
500'000
150'000
80'000
50'000
h
Device hours 2
500'000
1 Calculated in accordance with MIL-HDBK-217F.
2 Statistical values, based on an average of 4300 working hours per year and in general field use, over 3 years.
Edition 4/4.99
MELCHER
20/31
The Power Partners.
Rugged Environment
DC-DC Converters >100Watt
K Series
7 TE
9 TE
3.27
Mechanical Data
Dimensions in mm. Tolerances ±0.3 mm unless otherwise indicated.
159
4.5
Test jacks (+/–)
Option P (Uo)
Option D (Uto)
Option D (Uti)
LED i (red)
LED OK (green)
LED IoL (red)
Measuring point of
case temperature TC
= Ø 3.5
= Ø 4.1
50
42
171.93 (DIN 41494)
Main face
80
d
Front plate
Back plate
168.5 ±0.5
European
Projection
Note:
– d ≥15 mm, recommended minimum distance to
next part to ensure proper air circulation at full
output power.
Fig. 21
– free air locations: the module should be moun-
ted with fins in vertical position to achieve a
maximum air flow through the heat sink.
Case K02 with heatsink, case aluminium, black finish and
self cooling, weight: Approx. 1.55 kg
7 TE
3.27
4 TE
50
5
158
M 4
Measuring point of
case temperature TC
5
47.2
17.3
133.4
168 ±0.5
171.93 (DIN 41494)
Note: Long case with S-type heatsink
or cooling plate B2, elongated by 60 mm
for 220 mm rack depth, is available on
request. (No LED's and no test jacks.)
Fig. 22
Case K02 with option B1 (cooling plate),case aluminium,
black finish and self cooling, weight: Approx. 1.15 kg
Edition 4/4.99
21/31
MELCHER
The Power Partners.
K Series
DC-DC Converters >100Watt
Rugged Environment
Safety and Installation Instructions
Connector Pin Allocation
The connector pin allocation table defines the electrical
potentials and the physical pin positions on the H15/H15 S4
connector. Pin no. 24, the protective earth pin present on all
AK...FK DC-DC converters is leading, ensuring that it
makes contact with the female connector first.
10010
10010
Fixtures for connector
retention clips V
Fixtures for connector
retention clips V
(see Accessory Products)
(see Accessory Products)
32
4
30/32
4/6
Type H15 S4
Type H15
Fig. 23
View of module's male connectors
Table 12: H15 and H15 S4 connector pin allocation
Pin
No.
4
Connector type H15 S4
Connector type H 15
AK 1000 (all), BK...EK 1001
AK 2000
BK…EK 1301/1501/1601
BK…EK 2000
Vo1+
Vo2+
Vo1+
Output 1
Output 1
Vo2+
Output 2
Output 2
Output 1
Vo1+
Output 2
6
Vo2+
Vo2–
Vo2–
Vo1+
Vo1–
R 1
8
Vo1–
Vo1–
Vo2–
Output 1
Vo1–
Output 2
10
12
14
16
18
20
S+
S–
R 1
i
Sense
Vo1+
Vo1–
R 1
i
Output 1
Output 1
Control of Uo1
Inhibit
S+
S–
R 1
i
Sense
Output 1
Output 1
Control of Uo1
Inhibit
Sense
Sense
Control of Uo1
Inhibit
Control of Uo1
Inhibit
i
D 3
V 3
T
Save data
ACFAIL
D
Safe data
D
Save data
D
Save data
22
24 2
26
28
30
32
Current sharing
Protective earth
T
Current sharing
Protective earth
T
Current sharing
Protective earth
T
Current sharing
Protective earth
Vi+
Vi+
Vi–
Vi–
Vi+
Vi+
Vi–
Vi–
Vi+
Input
Vi+
Input
Input
Input or Neutral
Vi–
Input
Vi–
Input
Input
Input or Phase
2
3
1 Feature R excludes option P and vice versa; Leading pin (pregrounding); Option D excludes option V and vice versa.
Installation Instructions
An input fuse is built-in in the connection from pins no. 30
and 32 (Vi-) of the unit. Since this fuse is designed to pro-
tect the unit in case of an overcurrent and does not neces-
sarily cover all customer needs, an external fuse suitable
for the application and in compliance with the local require-
ments might be necessary in the wiring to one or both input
potentials, pins nos. 26 and 28 and/or nos. 30 and 32.
The K series DC-DC converters are components, intended
exclusively for inclusion within other equipment by an in-
dustrial assembly operation or by professional installers. In-
stallation must strictly follow the national safety regulations
in compliance with the enclosure, mounting, creepage,
clearance, casualty, markings and segregation require-
ments of the end-use application.
Connection to the system shall be made via the female con-
nector H15 (see: Accessories). Other installation methods
may not meet the safety requirements.
Important: Whenever the inhibit function is not in use,
pin no. 18 (i) should be connected to pin no. 14 (S–/
Vo1–) to enable the output(s).
The DC-DC converters are provided with pin no. 24 ( ),
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 unless specified in: Safety of op-
erator accessible output circuit.
Do not open the modules, or guarantee will be invali-
dated.
Edition 4/4.99
22/31
MELCHER
The Power Partners.
Rugged Environment
DC-DC Converters >100Watt
K Series
Due to high current values, all AK...FK units provide two in-
ternally parallel connected contacts for certain paths (pins
4/6, 8/10, 26/28 and 30/32 respectively). It is recommended
to connect load and supply to both female connector pins of
each path in order to keep the voltage drop across the con-
nector pins to an absolute minimum and to not overstress
the connector contacts if currents are higher than approx. 8
A. The connector contacts are rated 8 A over the whole
temperature range.
Standards and approvals
All DC-DC converters correspond to class I equipment.
They are UL recognized according to UL 1950, UL recog-
nized 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,
•
Basic insulation between input and case and double or
reinforced insulation between input and output, based
on 150 V AC/DC (AK and BK) or 250 VAC and 400 V DC
(CK, DK, EK, FK),
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 TC max shall not be exceeded. See also Thermal
Considerations.
•
•
The use in a pollution degree 2 environment,
Connecting the input to a primary or secondary circuit
which is subject to a maximum transient rating of
2500 V.
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.
The DC-DC converters are subject to manufacturing sur-
veillance in accordance with the above mentioned UL,
CSA, EN and with ISO 9001 standards.Cleaning Agents
Check for hazardous voltages before altering any connec-
tions.
In order to avoid possible damage, any penetration of
cleaning fluids is to be prevented, since the power supplies
are not hermetically sealed.
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.
Protection Degree
Condition: Female connector fitted to the unit.
Cleaning Agents
IP 30: All units except those with option P, and except
those with option D or V with potentiometer.
In order to avoid possible damage, any penetration of
cleaning fluids is to be prevented, since the power supplies
are not hermetically sealed.
IP 20: All units fitted with option P, or with option D or V with
potentiometer.
Isolation
The electric strength test is performed as factory test in ac-
cordance with IEC/EN 60950 and UL 1950 and should not
be repeated in the field. Melcher will not honour any guar-
antee claims resulting from electric strength field tests.
Table 13: Isolation
Characteristic
Input to
case
Input to
output
Output to
case
Output to
output
Unit
Electric
strength
test voltage
Required according to
IEC/EN 60950
AK, BK
1.0
1.4
1.5
2.1
2.8
2.0
2.0 1
2.8 1
3.0 1
4.2 1
5.6 1
4.0 1
0.5
0.7
0.5
0.7
1.4
1.0
-
kVrms
kV DC
kVrms
-
-
CK, DK
EK, FK
-
kV DC
Actual factory test 1 s
AK, BK
CK, DK
EK, FK
0.14
0.1
AC test voltage equivalent
to actual factory test
kVrms
Insulation resistance at 500 V DC
>300
>300
>300
>100 2
MΩ
1 In accordance with IEC/EN 60950 only subassemblies are tested in factory with this voltage.
2 Tested at 150 V DC.
For creepage distances and clearances refer to: Technical
Information: Safety.
Edition 4/4.99
MELCHER
23/31
The Power Partners.
K Series
DC-DC Converters >100Watt
Rugged Environment
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.
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 is given in: Technical Infor-
mation: Safety.
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
Table 14: Safety concept leading to an SELV output circuit
Conditions Front end
DC-DC converter
Result
Nominal
supply
Minimum required grade
of isolation, to be provided output voltage
Nominal DC
Minimum required Types
safety status of the
Measures to achieve the Safety status
specified safety status of of the DC-DC
voltage
by the AC-DC front end,
including mains supplied
battery charger
from the front end front end output
the output circuit
converter
output circuit
circuit
Mains
Operational (i.e. there is
≤100 V (The
Primary circuit
AK
BK
Double or reinforced
insulation, based on
the mains voltage and 2
(provided by the DC-DC
converter) and earthed
case 3
SELV circuit
≤150 V AC no need for electrical
isolation between the
nominal voltage
between any input
pin and earth can
mains supply voltage
and the DC-DC converter be up to 150 V AC
input voltage)
or DC)
Mains
≤250 V AC
≤400 V (The
CK
DK
EK
FK
nominal voltage
between any input
pin and earth can
be up to 250 V AC
or 400 V DC)
Basic
≤400 V
Unearthed
hazardous voltage BK
secodary circuit
AK
Supplementary insulation,
based on 250 V AC and
double or reinforced
insulation 2 (provided by
DC-DC converter) and
earthed case 3.
CK
DK
EK
FK
Earthed
hazardous voltage
secondary circuit
Double or reinforced
insulation 2 (provided by
the DC-DC converter)
earthed case 3
Double or reinforced
≤60 V
SELV circuit
Operational insulation
(provided by the DC-DC
converter) 4
≤120 V
TNV-3 circuit
Basic insulation (provided
by the DC-DC converter) 4
1 The front end output voltage should match the specified input voltage range of the DC-DC converter.
2 Based on the maximum nominal output voltage from the front end.
3 The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC/EN 60950.
4 Earthing of the case is recommended, but not mandatory.
Max. 150 V AC or DC for AK, BK
Max. 250 V AC or 400 V DC for CK, DK, EK, FK
10044
+
~
Mains
AC-DC
front
end
DC-DC
con-
verter
Fuse
Fuse
Battery
SELV
–
~
Max. 150 V AC or DC for AK, BK
Max. 250 V AC or 400 V DC for CK, DK, EK, FK
Earth connection
Fig. 24
Schematic safety concept.
Use earth connection as per table: Safety concept leading
to an SELV output circuit. Use fuse if required by the appli-
cation. See also: Installation Instructions.
Edition 4/4.99
24/31
MELCHER
The Power Partners.
Rugged Environment
DC-DC Converters >100Watt
K Series
Description of Options
Table 15: Survey of options
Option
-9
Function of Option
Characteristics
Extended operational ambient temperature range
Electronic inrush current limitation circuitry
Potentiometer for fine adjustment of output voltage
Input and/or output undervoltage monitoring circuitry
Input (and output) undervoltage monitoring circuitry
Current sharing
TA = –40°C...71°C
E
Active inrush current limitation for CK, DK, EK
P 1
Adjustment range +10/–60% of Uo nom excludes R input
Safe data signal output (Versions D0...DD)
D 2
V 2 3
T
ACFAIL signal according to VME specs (Versions V0, V2, V3)
Interconnect T-pins if paralleling outputs (5 units max.)
Replaces standard heat sink, allowing direct chassis-mounting
B1/B2
Cooling plate
1 Function R excludes option P and vice versa.
2 Option D excludes Option V and vice versa .
3 Only available if main output voltage U o1 = 5.1.
10017
-9 Extended Temperature Range
Option -9 extends the operational ambient temperature
range from –25...71°C (standard) to –40...71°C. The power
supplies provide full nominal output power with convection
cooling. Option -9 excludes inrush current limitation by
NTC.
Control
FET
E Inrush Current Limitation
RS
Ci
RI
CK/DK/EK types may be supplemented by an electronic
circuit (option E, replacing the standard built-in NTC) to
achieve an enhanced inrush current limiting function (not
available with AK/BK/FK types).
Fig. 25
Option E block diagram
If fitted with option E (inrush current limitation) together with
option D6, input voltage monitoring, the CK units meet the
CEPT/ETSI standards for 48 V DC supply voltages accord-
ing to prETS 300132-2, version 4.2, date 9312. Option D6,
externally adjustable via potentiometer, is necessary to dis-
able the converter at input voltages below actual service
voltage ranges, avoiding an excessive input current
when the input voltage is raised slowly according to
prETS 300132-2. Option D6 threshold level should be ad-
justed to 36.0...40.5 V for 48 V nominal supply systems or
44.0...50.0 V for 60 V nominal supply systems (refer also to
description of option D). The D output should be connected
to the inhibit input. Please contact Melcher if applications
do not permit potentiometer setting.
11039
CapacitorCi
fully charged
Normal operation
(current limiting
circuit is fully
Î [A]
Ui/RV
conducting)
Ii = Pi/Ui
t [ms]
0
0
<30
RV: Current limiting resistance = RS + RI = 15 Ω
Fig. 26
Inrush current with option E
Table 16: Inrush current characteristics with option E
Characteristics
CK
60
DK
110
7.4
EK
220
14.6
Unit
V
P Potentiometer
Ui nom, Io nom Input voltage
The potentiometer provides an output voltage adjustment
range of +10/–60% of Uo nom and is accessible through a
hole in the front cover. This feature enables compensation
of voltage drops across the connector and wiring. Option P
is not recommended if units are connected in parallel.
Iinr p
Peak inrush
current
6.8
A
tinr
Inrush current
duration
18
14
16
ms
Ui max, Io nom Input voltage
140
9.3
220
380
V
A
Option P excludes the R-function. With double output units
both outputs are affected by the potentiometer setting (dou-
bling the voltage setting if the outputs are in series).
Iinr p
Peak inrush
current
14.5
25.3
tinr
Inrush current
duration
20
14
12
ms
If the output voltages are increased above Uo nom via R-in-
put control, option P setting, remote sensing or option T, the
output current(s) should be reduced accordingly so that
Po nom is not exceeded.
Precaution: Subsequent switch-on cycles at start-up
are limited to max. 10 cycles during the first 20 seconds
(cold unit) and at continuing on/off (TC = 95°C) max. 1
cycle every 8 sec.
Edition 4/4.99
25/31
MELCHER
The Power Partners.
K Series
DC-DC Converters >100Watt
Rugged Environment
T Current Sharing
11003
This option ensures that the output currents are approxi-
mately shared between all paralleled modules hence in-
creasing system reliability. To use this facility, simply inter-
connect the T pins of all modules and make sure, that pins
14, the S– pins (K 1000) or the Vo1– pins (K 2000) are also
connected together. The load leads should have equal
length and cross section to ensure equal voltage drops. Not
more than 5 units should be connected in parallel. If output
voltage adjustment is requested we strongly recommend to
use the R-input instead of option P, as with option P the re-
quired setting accuracy is difficult to achieve. The output
voltages must be individually set prior to paralleling to
within a tolerance of 1...2% or the R pins should be con-
nected together.
Vo+
Load
Vo–
Vo+
Vo–
Vo+
Vo–
Fig. 27
An example of poor wiring for connection in parallel
Power bus
+
–
Vo+
Vo2+
Vi+
2
11036
1
S+
T
Vo2–
T
11037
1
Module
3
S–
Vo1+
Vo–
Vo1–
Vi–
Load
Load
2
Vo+
Vo2+
Vi+
S+
T
Vo2–
T
1
1
Module
3
S–
Vo1+
Vo–
Vo1–
Vi–
max. 5 units in parallel connection
Fig. 29
Paralleling of double output units using option T with
Power Bus
max. 5 units in parallel connection
1 Leads should have equal length and cross sections and should
run in the same cable loom.
2 Diodes recommended in redundant operation only
3 DC common point
Fig. 28
Paralleling of single output units using option T with the
sense lines connected at the load
Edition 4/4.99
26/31
MELCHER
The Power Partners.
Rugged Environment
DC-DC Converters >100Watt
K Series
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 20 as soon as one of the moni-
tored voltages drops below the preselected threshold level
Ut. The return for this signal is Vo1–. The D output recovers
when the monitored voltage(s) exceed(s) Ut + Uh. The
threshold levels Uti and Uto are either adjustable by a
potentiometer, accessible through a hole in the front cover,
or factory adjusted to a fixed value specified by the cus-
tomer.
Option D exists in various versions D0...DD as shown in the
following table.
Table 17: Undervoltage monitor functions
Output type
Monitoring
Minimum adjustment range
of threshold level Ut
Uti Uto
Typical hysteresis Uh [% of Ut]
for Ut min...U t max
JFET
NPN
U i
Uo1
Uhi
Uho
2.5...0.6
-
D1
D2
D3
D4
D0
D5
D6
D7
D8
D9
no
yes
yes
no
yes
no
-
3.5...40 V 1
-
-
1
1
Ui min...Ui max
Ui min...Ui max
-
3.4...0.4
3.4...0.4
-
2
2
yes
yes
yes
no
(0.95...0.985 Uo1
(0.95...0.985 Uo1
3.5...40 V 3
-
)
)
"0"
"0"
no
-
-
2.5...0.6
-
3 4
3 4
3 4
1
yes
yes
yes
yes
Ui min...Ui max
Ui min...Ui max
Ui min...Ui max
Ui min...Ui max
3.4...0.4
3.4...0.4
3.4...0.4
3.4...0.4
yes
yes
yes
3.5...40 V 3
(0.95...0.985 Uo1
3.5...40 V 1
2.5...0.6
"0"
2
)
-
DD
2.5...0.6
1 Threshold level adjustable by potentiometer
2 Fixed value tracking if Uo1 is adjusted via R-input, option P or sense lines.
3 The threshold level permanently adjusted according to customer specification ±2% at 25°C. Any value within the specified range is
basically possible but causes a special type designation in addition to the standard option designations (D0/D9 respectively)!
4 Adjusted at Io nom
JFET output (D0…D4):
11006
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. UD ≤ 0.4 V (logic low) corresponds
to a monitored voltage level (Ui and/or Uo1) < Ut. The cur-
rent 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.
Vo1+
R
p
I
D
D
U
D
Ui, Uo1 status
Ui or Uo1 < Ut
D output, UD
low, L, UD ≤ 0.4 V at ID = 2.5 mA
high, H, ID ≤ 25 µA at UD = 5.25 V
Vo1–
Ui and Uo1 > Ut + Uh
Fig. 30
Option D1...D0: JFET output, ID £ 2.5 mA
11007
NPN output (D5...DD):
Vo1+
Connector pin D is internally connected via the collector-
emitter 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.
R
p
I
D
D
U
D
Ui, Uo1 status
Ui or Uo1 < Ut
D output, UD
Vo1–
high, H, ID ≤ 25 µA at UD = 40 V
low, L, UD ≤ 0.4 V at ID = 20 mA
Fig. 31
Option D5...DD: NPN output, Uo1 £ 40 V, ID £ 20 mA
Ui and Uo1 > Ut + Uh
Table 18: D-output logic signals
Version of D
Ui < Ut resp. Uo < Ut
Ui > Ut + Uh resp. Uo > Ut
Configuration
JFET
D1, D2, D3, D4, D0
D5, D6, D7, D8, D9, DD
low
high
low
high
NPN
Edition 4/4.99
27/31
MELCHER
The Power Partners.
K Series
DC-DC Converters >100Watt
Rugged Environment
11021
Threshold tolerances and hysteresis:
UD
DUti
Uhi
If Ui 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 DUti
across the input filter. The threshold levels of the D0 and D9
options are factory adjusted at nominal output current Io nom
and at TA = 25°C. The value of DUti depends upon the input
voltage range (CK, DK, ..), threshold level Ut, temperature
and input current. The input current is a function of the input
voltage and the output power.
UD high
P
P
P
P
P
P
UD low
Ui
Uti
Fig. 32
Definition of Uti, ∆Ut i and ∆Uhi (JFET output)
D-signal with respect to input and output voltage versus time:
Input voltage monitoring
NPN
UD
11008
UD high
3
3
3
3
UD low
0
t
t
ID
ID high
ID low
0
JFET UD
UD high
UD low
0
t
t
1
4
4
4
th
tlow min
tlow min
tlow min
thigh min
Uo1
Uo1 nom
1
th
1
0.95
0
Ui [V DC]
Uti +Uhi
Uti
t
0
Input voltage failure
Switch-on cycle
Input voltage sag
Switch-on cycle and subsequent
input voltage failure
Output voltage monitoring
NPN UD
2
UD high
3
3
UD low
0
t
t
ID
ID high
ID low
0
UD
JFET
UD high
UD low
0
t
t
4
tlow min
Uo1
Uo1 nom
Uto +Uho
Uto
1 Hold-up time see section Electrical Input Data
2 With output voltage monitoring, hold-up time th = 0.
0
3 The signal will remain high if the D output is connected to
an external source.
Output voltage failure
Fig. 33
4 tlow min = 100...170 ms, typically 130 ms.
Relationship between Ui, Uo1, UD, Uo1/Uo nom versus time
Edition 4/4.99
28/31
MELCHER
The Power Partners.
Rugged Environment
DC-DC Converters >100Watt
K Series
V ACFAIL signal (VME)
Formula for the external input capacitor:
Available for units with Uo1 = 5.1 V.
This option defines an undervoltage monitoring circuit for
the input or input and main output voltage (Uo1 nom = 5.1 V
only) equivalent to option D and generates an ACFAIL sig-
nal (V signal) which conforms to the VME standard.
2 • Po • (th + 0.3 ms) • 100
Ci ext = –––––––––––––––––––––– – Ci min
2
h • (Uti 2 – Ui min
)
where as:
Ci min = internal input capacitance [mF]
Ci ext = external input capacitance [mF]
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 out-
put of a NPN transistor). The pull-up resistor feeding the
open-collector output should be placed on the VME back
plane.
Po
h
= output power [W]
= efficiency [%]
= hold-up time [ms]
th
Ui min = minimum input voltage [V] 1
Uti = threshold level [V]
After the ACFAIL signal has gone low, the VME standard
requires a hold-up time th of at least 4 ms before the 5.1 V
output drops to 4.875 V when the output is fully loaded.
This hold-up time th is provided by the internal input capaci-
tance. Consequently the working input voltage and the
threshold level Uti should be adequately above the mini-
mum input voltage Ui min of the converter so that enough
energy is remaining in the input capacitance. If the input
voltage is below the required level, an external hold-up ca-
pacitor (Ci ext) should be added.
1 Min. input voltage according to Electrical Input Data. For output
voltages Uo > Uo nom, the minimum input voltage increases pro-
portionally to Uo/Uo nom
.
Remarks:
Option V2 and V3 can be adjusted by potentiometer to a
threshold level between Ui min and Ui max. A decoupling di-
ode should be connected in series with the input of AK...FK
converters to avoid the input capacitance discharging
through other loads connected to the same source voltage.
Formula for threshold level for desired value of th:
2 • Po • (th + 0.3 ms) • 100
2
Uti = ––––––––––––––––––––– + Ui min
Ci min • h
Table 19: Available internal input capacitance and factory potentiometer setting of Uti with resulting hold-up time
Types
Ci min
Ut i
AK
0.83
9.5
BK
0.3
FK
1.2
39
CK
0.66
39
DK
0.26
61
EK
0.21
97
Unit
mF
19.5
0.1
V DC
ms
th
0.1
3.4
1.1
1.1
2.7
voltage(s) exceed(s) Ut + Uh. The threshold level Uti is ei-
ther adjustable by potentiometer, accessible through a hole
in the front cover, or adjusted during manufacture to a de-
termined customer specified value.
Option V operates independently of the built-in input under-
voltage lock-out circuit. A logic "low" signal is generated at
pin 20 as soon as one of the monitored voltages drops be-
low the preselected threshold level Ut. The return for this
signal is Vo1–. The V output recovers when the monitored
Versions V0, V2 and V3 are available as shown below.
Table 20: Undervoltage monitor functions
V output
(VME compatible)
Monitoring
Minimum adjustment range
of threshold level Ut
Uti Uto
Typical hysteresis Uh [% of Ut]
for Ut min…Ut max
Ui
Uo1
no
Uhi
Uho
–
1
–
V2
V3
V0
yes
yes
yes
yes
Ui min...Ui max
Ui min...Ui max
3.4...0.4
3.4...0.4
3.4...0.4
3.4...0.4
1
2
2
yes
no
0.95...0.985 Uo1
–
"0"
–
3 4
Ui min...Ui max
Ui min...Ui max
3 4
yes
0.95...0.985 Uo1
"0"
1 Threshold level adjustable by potentiometer. 2 Fixed value between 95% and 98.5% of Uo1 (tracking). 3 Adjusted at Io nom
.
4 Fixed value, resistor-adjusted (±2% at 25°C) acc. to customer's specifications; individual type number is determined by Melcher.
11009
V output (V0, V2, V3):
Vo1+
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. UV ≤ 0.6 V (logic low) corre-
sponds to a monitored voltage level (Ui and/or Uo1) <Ut.
The current IV through the open collector should not exceed
50 mA. The NPN output is not protected against external
overvoltages. UV should not exceed 60 V.
R
p
I
V
V
U
V
Ui, Uo1 status
V output, UV
Vo1–
Ui or Uo1 < Ut
low, L, UV ≤ 0.6 V at IV = 50 mA
high, H, IV ≤ 25 µA at UV = 5.1 V
Fig. 34
Output configuration of options V0, V2 and V3
Ui and Uo1 > Ut + Uh
Edition 4/4.99
29/31
MELCHER
The Power Partners.
K Series
DC-DC Converters >100Watt
Rugged Environment
11023
Threshold tolerances and hysteresis:
UV
DUti
Uhi
If Ui 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 DUti
across the input filter. The threshold level of option V0 is ad-
justed during manufacture at Io nom and TA = 25°C. The
value of DUti depends upon the input voltage range (AK,
BK, ...), threshold level Ut, temperature and input current.
The input current is a function of input voltage and output
power.
UV high
P
P
P
P
P
P
UV low
Ui
Fig. 35
Uti
Definition of Uti, ∆Uti and Uhi
Input voltage monitoring
2
2
2
tlow min
tlow min
tlow min
V2
UV high
UV
3
3
3
11010
4
2
4
2
UV low
0
t
t
tlow min
tlow min
V3
UV high
UV
3
3
3
UV low
0
1
1
th
th
Uo1
5.1 V
4.875 V
2.0 V
0
t
Ui [V DC]
Uti + Uhi
Uti
t
0
Input voltage failure
Switch-on cycle
Input voltage sag
Switch-on cycle and subsequent
input voltage failure
Output voltage monitoring
V2 UV
UV high
1 VME request: minimum 4 ms
2 tlow min = 40...200 ms, typically 80 ms
4
4
UV low
3 UV level not defined at Uo1 < 2.0 V
t
t
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.
0
2
tlow min
V3 UV
UV high
3
3
4
UV low
0
Uo1
5.1 V
4.875 V
2.0 V
0
t
Ui
Uti + Uhi
Uti
t
0
Output voltage failure
Fig. 36
Relationship between Ui, Uo1, UV, IV and Uo1/Uo nom ver-
sus time.
Edition 4/4.99
30/31
MELCHER
The Power Partners.
Rugged Environment
DC-DC Converters >100Watt
K Series
B1/B2 Cooling Plate (see: Mechanical Data)
Where a cooling surface is available, we recommend the
use of a cooling plate (option B1) instead of the standard
heatsink. The mounting system should ensure sufficient
cooling capacity to guarantee that the maximum case tem-
perature TC max is not exceeded. The cooling capacity is cal-
culated by:
(100% – h)
PLoss = –––––––––– (Uo • Io)
h
Efficiency h see Type survey
Elongated case for 220 mm rack depth: Option B2
Accessories
A variety of electrical and mechanical accessories are
available including:
– Front panels for 19" rack mounting, Schroff and Intermas
systems.
– Mating H15/H15 S4 connectors with screw, solder, fast-
on or press-fit terminals.
– Connector retention facilities.
– Code key system for connector coding.
– Chassis mounting plates for mounting the 19" cassette to
a chassis/wall where only frontal access is given.
– Universal mounting bracket for DIN-rail or chassis moun-
ting.
For more detailed information please refer to: Accessory
Products.
Front panels
H15 female connector,
code key system
Mounting plate (option B1 essential),
connector retention clips
Universal mounting bracket for DIN-rail mounting.
Edition 4/4.99
31/31
MELCHER
The Power Partners.
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