HR2320-9RG [BEL]
DC-DC Regulated Power Supply Module,;
| 型号： | HR2320-9RG |
| 厂家： | 
BEL FUSE INC. |
| 描述： | DC-DC Regulated Power Supply Module, |
| 文件： | 总27页 (文件大小：5144K) |
| 中文： | 中文翻译 | 下载： | 下载PDF数据表文档文件 |
HR / ER Series
144 / 288 Watt 10:1 DC-DC Converters
The ER/HR Series of DC-DC converters represents versatile
power supplies ideally suitable for use in transportation and
other advanced electronic systems.
The HR Series converters include a very broad input voltage
range, very high efficiency, high reliability, low output voltage
noise, and excellent dynamic response to load/line changes.
HR converters can be connected to all conventional railway
batteries.
ER Series converters are optimized for connection to 110 V
railway batteries.
111
4.4ꢀ
3 U
Features
• Extremely wide input voltage range from 12 to 168 VDC
in the same converter (HR Series)
• RoHS-compliant for all 6 substances
• Class I equipment
60
2.4ꢀ
12 TE
168
6.6ꢀ
• Compliant with EN 50155, EN 50121, EN 45545
• Input over- and programmable undervoltage lockout
• Shutdown function
• Inrush current limitation
• Interruption time 10 ms
• Adjustable output voltages
• 2 isolated outputs: no load, overload, and short-circuit proof
• Rectangular current limiting characteristic
• Parallel operation with active current sharing
• Very high efficiency up to 94%
• Immunity according to IEC 61000-4-2, -3, -4, -5, -6, -8, -9
• All PCB boards protected by lacquer
• Very high reliability
111
4.4ꢀ
3 U
• 5 year warranty
80
3.2ꢀ
16 TE
168
6.6ꢀ
Safety-approved to the latest edition of IEC/EN 60950-1
and UL/CSA 60950-1
Table of Contents
Description........................................................................................1
Model Selection................................................................................2
Functional Description......................................................................5
Electrical Input Data .........................................................................7
Electrical Output Data.....................................................................10
Auxiliary Functions .........................................................................15
Electromagnetic Compatibility (EMC).............................................18
Immunity to Environmental Conditions...........................................20
Mechanical Data.............................................................................21
Safety and Installation Instructions.................................................24
Description of Options....................................................................25
Accessories....................................................................................26
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BCD.00185 Rev AH, 07-Jun-2018
ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Description
The converter inputs are protected against surges and transients. An input over- and undervoltage lockout circuitry disables
the outputs, when the input voltage is outside of the specified range. To avoid high input currents at operation with high-voltage
batteries, the inhibit input allows for adjusting the undervoltage lockout to a suitable level, thus allowing the use of an appropriate
external input fuse.
The converters exhibit an inrush current limiter, preventing external circuit breakers and fuses from tripping at switch-on.
The outputs are open- and short-circuit proof.
Full input-to-output, input-to-case, output-to-case, and output to output isolation is provided. The converters are particularly suitable
for railway applications. The HR converters can be supplied by all common railway batteries with 24 V, 36 V, 48 V, 72 V, 96 V, 110 V,
and 120 V nominal voltage. All PCB boards are coated with a protective lacquer.
The case design allows operation at nominal load up to 71 °C with natural cooling. If forced cooling is provided, the ambient
temperature may exceed 71 °C, but the case temperature must remain below 95 °C.
A temperature sensor disables the outputs when the case temperature TC exceeds the limit. The outputs are automatically re-
enabled, when the temperature drops below the limit.
LED indicators display the status of the converter and allow for visual monitoring of the system at any time.
The converters may either be plugged into a 19” rack system according to IEC 60297-3, or be chassis mounted. Two heat sinks
of different size and cooling plates for chassis mounting (option B, B1) are available.
Model Selection
Table 1a: Model Selection of HR models
Output 1
Output 2
Power
Input voltage
Efficiency
Model
Options
1
2
η24
η110
min typ
3
3
Vo nom
Io nom
Vo nom
Io nom
Po nom
Vi min
Vi cont
Vi max
min
[%]
typ
[V]
[A]
[V]
[A]
[W]
[V]
[V]
[V]
[%]
[%]
[%]
12
12
12
15
15
48
48
20
12
24
16
19.2
4
-
-
-
-
-
-
-
-
-
-
-
-
-
-
240
144
288
240
288
192
240
12
12
12
12
12
12
12
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
168
168
168
168
168
168
168
91
91
91
91
91
92.5
92.5
92.5
92.5
92.5
90.5
90.5
92
92
92
92
92
92
92
94
94
94
94
94
93
93
HR2320-9RG 4
HRL2320-9RG 4
HRP2320-9RG 4
HR2540-9RG 4
HRP2540-9RG 4
HR2880-9RG 4
HRP2880-9RG 4
B, B1
B, B1
B, B1
89.5
89.5
5
12
12
12
15
15
48
48
10
6
12
12
12
15
15
48
48
10
6
240
144
288
240
288
192
240
12
12
12
12
12
12
12
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
168
168
168
168
168
168
168
91
91
92.5
92.5
92.5
92.5
92.5
90.5
90.5
92
92
92
92
92
92
92
94
94
94
94
94
93
93
HR2320-9RG
HRL2320-9RG
HRP2320-9RG
HR2540-9RG
HRP2540-9RG
HR2880-9RG
HRP2880-9RG
12
8
12
8
91
91
9.6
2
9.6
2
90
89.5
89.5
2.5
2.5
24
24
24
30
30
96
96
10
6
-
-
-
-
-
-
-
-
-
-
-
-
-
-
240
144
288
240
288
192
240
12
12
12
12
12
12
12
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
168
168
168
168
168
168
168
91
91
92.5
92.5
92.5
92.5
92.5
90.5
90.5
92
92
92
92
92
92
92
94
94
94
94
94
93
93
HR2320-9RG 5
HRL2320-9RG 5
HRP2320-9RG 5
HR2540-9RG 5
HRP2540-9RG 5
HR2880-9RG 5
HRP2880-9RG 5
12
8
91
91
9.6
2
91
89.5
89.5
2.5
1
2
3
4
5
Efficiency at TA = 25 °C, Vi = 24 V, Io nom, Vo nom
Efficiency at TA = 25 °C, Vi = 110 V, Io nom, Vo nom
Short time; see table 2 for details
Both outputs connected in parallel
Both outputs connected in series
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Table 1b: Model Selection of ER models
Output 1
Output 2
Power
Input voltage
Efficiency
Model
Options
1
η110
2
2
Vo nom
Io nom
Vo nom
Io nom
Po nom
Vi min
Vi cont
Vi max
min
[%]
typ
[V]
[A]
[V]
[A]
[W]
[V]
[V]
[V]
[%]
12
12
12
15
15
48
48
20
12
24
16
19.2
4
-
-
-
-
-
-
-
-
-
-
-
-
-
-
240
144
288
240
288
192
240
66
66
66
66
66
66
66
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
168
168
168
168
168
168
168
93
94
ER2320-9RG 3
ERL2320-9RG 3
ERP2320-9RG 3
ER2540-9RG 3
ERP2540-9RG 3
ER2880-9RG 3
ERP2880-9RG 3
91
94
B, B1
B, B1
B, B1
90.5
92
5
12
12
12
15
15
48
48
10
6
12
12
12
15
15
48
48
10
6
240
144
288
240
288
192
240
66
66
66
66
66
66
66
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
168
168
168
168
168
168
168
93
91
94
94
ER2320-9RG
ERL2320-9RG
ERP2320-9RG
ER2540-9RG
ERP2540-9RG
ER2880-9RG
EHRP2880-9RG
12
8
12
8
9.6
2
9.6
2
90.5
92
2.5
2.5
24
24
24
30
30
96
96
10
6
-
-
-
-
-
-
-
-
-
-
-
-
-
-
240
144
288
240
288
192
240
66
66
66
66
66
66
66
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
168
168
168
168
168
168
168
93
91
94
94
ER2320-9RG 4
ERL2320-9RG 4
ERP2320-9RG 4
ER2540-9RG 4
ERP2540-9RG 4
ER2880-9RG 4
ERP2880-9RG 4
12
8
9.6
2
90.5
92
2.5
1
2
3
4
Efficiency at TA = 25 °C, Vi = 110 V, Io nom, Vo nom
Short time; see table 2 for details
Both outputs connected in parallel
Both outputs connected in series
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Part Number Description
HR 2 5 40 -9 R B1 G
Operating input voltage Vi cont (continuously):
16.8– 150 VDC .....................................HR, HRL, HRP
77– 150 VDC ..........................................ER, ERL, ERP
Number of outputs.......................................................... 2, 72
Nominal voltage of main output Vo1 nom
12 V .............................................................................3
15 V .............................................................................5
24 V .............................................................................6
36 V .............................................................................7
48 V .............................................................................8
Other voltages1 ...........................................................9
3
Nominal voltage of tracking output Vo2
12 V.............................................................................20
15 V.............................................................................40
24 V.............................................................................60
36 V.............................................................................70
48 V.............................................................................80
Other specifications or additional features1 ....... 21– 99
Operational temperature range: TA:
TA = –40 to 71 °C, TC ≤ 95 °C ......................................-9
Other1 ...............................................................-0, -5, -6
Auxiliary functions and options:
Output voltage control input ....................................... R
Cooling plate standard case...................................B, B1
Cooling plate for long case 220 mm2 .......................B22
RoHS-compliant for all 6 substances ......................... G4
1
Customer-specific models. No safety-relevant changes compared to the respective basic model, e.g. different mechanical details, special
markings, mounted front plates, reduced output voltage, etc.
Converters with 220 mm case (customer-specific models). Add 5000 to the model number, e.g. HR2540-9RB1G → HR7540-9RB1G.
The nominal voltages of both outputs are always equal.
2
3
4
G is always placed at the end of the part number.
Note: The sequence of options must follow the order above.
Example: HR2540-9RB1G: DC-DC converter, operating input voltage range 16.8 – 150 VDC, 2 isolated outputs, each providing
15 V, 8 A, control input R to adjust the output voltages, cooling plate B1, and RoHS-compliant for all six substances.
Product Marking
Basic type designation, approval marks, CE mark, warnings, pin allocation, patents, MELCHER logo, specific type designation,
input voltage range, nominal output voltages and output currents, degree of protection, identification of LEDs, batch no., serial no.
and data code including production site, version, and production date.
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Functional Description
The input voltage is fed via an efficient filter to the interleaved switching boost converter (HR models), which provides the
intermediate circuit voltage on the bulk capacitor Cb. The inrush current is limited by the resistor Rinr, which is shorted by Vinr after
the bulk capacitor was charged.
The bulk capacitor sources a single-transistor forward converter with active clamp and provides the power during the interruption
time of 10 ms.
The main transformer exhibits two separate secondary windings for the two outputs. The resultant voltages are rectified by
synchronous rectifiers (not models with Vo = 2× 48 V) in order to provide the best efficiency. Their ripple voltages are smoothed by
a dual power choke and output filters. The control logic senses the main output voltage Vo1 and generates the control signal for the
forward converter, with respect to the max. output current transferred via magnetic feedback to the control circuit of the forward
converter, located on the primary side.
The second output voltage is tracking the main output, but has its own current limiting circuit. If the main output voltage drops due
to current limitation, the second output voltage will drop as well and vice versa.
The output voltages can be adjusted by external means. Parallel operation of several converters is possible by interconnecting
the T-pins to provide active current sharing. Both outputs can be connected in parallel or in series without any precaution. They
exhibit a rectangular current limitation characteristic. Switchable preloads VPL (Version V101 or later) ensure good regulation even
with no load at one output.
A control output (D) and two LEDs signal correct operation of the converter. In case of an output overvoltage, the converter is
disabled by a latch.
Input over- and undervoltage lockout is provided. The undervoltage trigger level can be adjusted by an external resistor connected
to PUL (pin 24) depending on the nominal voltage of the supplying battery.
Temperature sensors on the primary and secondary side prevent the converter from excessive warm-up.
A cooling plate for chassis-mounting is available (opt. B, B1).
ꢀM080c
16
R
Magnetic
feedback
Secondary
control
logic
18T 2
C
26
28
ꢁ
Vi+
20
D
Synchr.
rect. drive
S1+
12
4
1
Vo1+
C
C
ꢁ
C
x
C
i
C
V
+
+
b
+
ꢁ
Vo1–
8
14 S1–
Synchr.
rect. drive
V
PL
1
inr
Primary
control
Vo2+
Vo2–
6
C
C
ꢁ
+
30
32
Vi–
ꢁ
10
PUL 24
22
V
PL
C
ꢁ
1
Auxiliary
converter
(80 kHz)
2
models with 2x 48 V have rectifier diodes
T-pin is not connected for models HRL
Fig. 1
Block diagram of HR2320, version V101 (or later)
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
ꢀM157
16
R
Magnetic
feedback
Secondary
control
logic
18T 2
C
ꢁ
26
28
Vi+
20
D
Synchr.
rect. drive
S1+
12
4
1
Vo1+
C
C
ꢁ
C
x
C
V
+
b
+
ꢁ
Vo1–
8
14 S1–
Inrush
current
control
Synchr.
rect. drive
V
1
PL
inr
Vo2+
Vo2–
6
30
32
Vi–
C
C
ꢁ
+
ꢁ
PUL 24
22
10
C
ꢁ
Auxiliary
converter
(150 kHz)
V
PL
1
2
models with Vo = 2x 48 V have rectifier diodes
T-pin is not connected for models HRL
Fig. 2
Block diagram of ER2320
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Electrical Input Data
General conditions:
- TA = 25 °C, unless TC is specified.
- Pin 24 (PUL) left open-circuit
- Pin 16 (R) and 18 (D) left open-circuit.
Table 2a: Input data of HR models
Model
HR
HRL
HRP
Unit
Characteristics
Conditions
min
typ
max
min
typ
max
min
typ
max
16.8
12.0
24
150
168
120
176
16.8
12.0
24
150
168
120
176
9.31
16.8
12.0
24
150
168
120
176
Vi
Operating input voltage cont.
For ≤2 s without shutdown
Io = 0 – Io max
TC min – TC max
Vi 2s
V
(110)
(110)
(110)
Vi nom Nominal input voltage range
Vi abs Input voltage limits
HR2320
0
0
0
3 s, without damage
1.76
1.76
1.37
(2.36) 15.65
(2.36) 15.65
(1.86) 12.82
1.03
(1.38)
2.10
2.10
1.71
(2.83) 21.40
(2.83) 21.40
(2.33) 16.05
Ii
Input current:
HR2540
HR2880
Vi max ..(110 V) Vi min, Io nom
A
..
11
11
11
Pi 0
No-load input power
Vi min – Vi max, Io = 0
W
2.5
2.5
2.5
Pi inh Idle input power
Vi min – Vi max, VPUL = 0 V
8.6
10
8.6
10
8.6
10
Cx
Ri
Input capacitance 1
µF
mΩ
A
Input resistance
30
30
30
Iinr p
tinr r
ton
Peak inrush current 2
Time constant of Iinr
Start-up time
Vi = 150 V Io nom
,
10
10
10
400
400
400
0→ Vi min, Io nom
ms
Vi ≥ 16.8 V Io nom,
,
40
40
40
tr
Rise time after inhibit
VPUL = 0→ 5 V
Table 2b: Input data of ER models
Model
ER
ERL
ERP
Unit
Characteristics
Conditions
min
typ
max
min
typ
max
min
typ
max
77
66
150
168
120
176
77
66
150
168
120
176
77
66
150
168
120
176
Vi
Operating input voltage
Io = 0 – Io max
TC min – TC max
Vi 2s
For ≤2 s without shutdown
V
110
110
110
Vi nom Nominal input voltage range
Vi abs Input voltage limits
ER2320
0
0
0
3 s, without damage
1.76
1.76
1.37
(2.36)
(2.36)
(1.86)
1.03
(1.38)
2.10
2.10
1.71
(2.83)
(2.83)
(2.33)
Vi max ..(110 V) Vi min, Io nom
..
Ii
Input current:
ER2540
ER2880
A
10
10
10
Pi 0
No-load input power
Vi min – Vi max, Io = 0
W
2.5
2.5
2.5
Pi inh Idle input power
Vi min – Vi max, VPUL = 0 V
Cx
Ri
Input capacitance 1
µF
mΩ
A
10
10
10
Input resistance
Iinr p
tinr r
ton
Peak inrush current 2
Time constant of Iinr
Start-up time
Vi = 150 V Io nom
,
400
40
400
40
400
40
0→ Vi min, Io nom
ms
Vi ≥ 77 V Io nom,
,
tr
Rise time after inhibit
VPUL = 0→ 5 V
1
2
Not smoothed by the inrush current limiter
According to ETS 300132-2
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
PUL Function and Fuse
No fuse is incorporated in the converters. Consequently, an external fuse or a circuit breaker must be installed at system level to
protect against severe defects.
HR converters are designed for an extremely wide input voltage range, allowing for connection to all common railway batteries.
However, the programmable input undervoltage lockout (PUL, pin 24) should be adjusted adequately, in order to limit the input
current at low input voltage.
Table 3 specifies the values of the resistor RPUL, connected between PUL and Vi–, versus the resultant minimum input voltage and
the recommended external input fuse.
Fig. 3 shows more values of RPUL versus start-up voltage. For stationary batteries, a higher start-up voltage might be advantageous.
Vi min ꢀVꢁ
ꢂM101a
80
60
40
20
0
RPUL
2
4
6
8
10
12
16
14
kΩ
Fig. 3
RPUL versus switch-on voltage (HR models)
ER models are designed for the input voltage range of a 110 V railway battery. The input undervoltage lockout (PUL, pin 24) may
be adjusted if requested. The PUL resistors are specified in table 4.
Table 3: PULSpecification (typ.)and recommended external fuses
Table 4: PULspecification (typ.)and recommended external fuses
forHR/HRP models.Smallerfuses are possible forHRL models.
forER/ERP models. Smallerfuses are possible forERL models.
Battery
24 V
RPUL
∞
Vi min (on/off) Fuse recommended
Battery
110 V
110 V
110 V
110 V
120 V
RPUL
Vi min (on/off)
64.5 V 60.5 V 6.3 A slow, BEL fuse MRT 2
74.5 V 69 V
6.3 A slow, BEL fuse MRT 2
87.4 V 81.6 V 6.3 A slow, BEL fuse MRT 2
Fuse recommended
15 V
20 V
26 V
38 V
62 V
90 V
12 V3 25 A fast, Littlefuse 314 1
18 V 16 A fast, Schurter / SP 2
20 V 12.5 A fast, Schurter / SP 2
32 V 8 A fast, Schurter / SP 2
57 V 6.3 A slow, BEL fuse MRT 2
84 V 5.0 A slow, BEL fuse MRT 2
5.0 kΩ
4.0 kΩ
3.0 kΩ
2.5 kΩ
36 V
16.9 kΩ
13.7 kΩ
9.5 kΩ
5.2 kΩ
2.9 kΩ
< 100 Ω
48 V
72 V
96 V
90 V
96 V
6.3 A slow, BEL fuse MRT 2
5.0 A slow, BEL fuse MRT 2
96 V
2.2 kΩ 101.7 V
110 V
-
< 100 Ω
Converter disabled
1
2
fuse size 6.3 × 32 mm
fuse size 5 × 20 mm
all
Converter disabled
1
2
3
fuse size 6.3 × 32 mm
fuse size 5 × 20 mm
for ≤ 2 s
Note: If PUL (pin 24) is connected to Vi– (pin 30/32), the converter is disabled; see Inhibit Function.
Fig. 4 and 5 show the input current versus the input voltage.
Ii ꢀAꢁ
Ii ꢀAꢁ
ꢂM087
ꢂM167
5
25
20
15
4
3
2
1
10
5
0
0
Vi ꢀVꢁ
0
80
100
120
140 Vi ꢀVꢁ
20
40
60
80
100
120
140 160
Fig. 4
Fig. 5
Typ. input current vs input voltage at nominal load (HR2320)
Typ. input current vs input voltage at nominal load (ER2320)
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Reverse Polarity and Input Transient Protection
Reverse polarity protection of all models is provided by an antiparallel diode across the input, causing the external input fuse or
circuit breaker to trip. ER models exhibit an additional serial diode on the input.
The double stage symmetrical input filter together with a VDR (voltage depending resistor) form an effective protection against
high input transient voltages, which typically occur in battery-driven mobile applications.
At very high input voltage, the overvoltage lockout disables the converter in order to protect it from damage.
Inrush Current Limitation
The converters exhibit an electronic inrush current limiting circuit. This circuit is also functional, when the input voltage is removed
and immediately reapplied.
However, several capacitors are directly connected to the input pins. Consequently, a short current peak is present, when applying
the input voltage.
The inrush current peak value can be determined by following calculation; see also fig. 6:
Vi source
–––––––––
=
Iinr p
(Rext + Ri )
I
inr ꢀAꢁ
50
ꢂM086
ꢀM001c
40
30
Converter
Lext
Rext
Vi+
Vo+
Vo–
+
Ri
Ci
20
10
0
Vi–
0.1
100
200
300
400 ms
Fig. 6
Equivalent input ciruit
Fig. 7
Inrush current at Vi = 150 V, Io nom (HR2320, ER2320)
Efficiency
η ꢂꢃꢄ
ꢁM100
100
V = 110 V
i
ꢀ0
80
70
V = 150 V
i
V = 15.4 V
i
60
0.2
0.6
0.8
0
0.4
Io / Io nom
Fig. 8
Efficiency versus Vi and Io (HR2320, both outputs connected in series)
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Electrical Output Data
General Conditions: – TA = 25 °C, unless TC is specified; Pin 24 (PUL) ≥ 5 V
Table 5a: Output data of HR/ER2320 and HRL/ERL2320
Model
HR2320 / ER2320
2 × 12 V
HRL2320 / ERL2320
2 × 12 V
Unit
Nom. output voltage
Output 1
typ
Output 2
max min typ max min
Output 1
typ
Output 2
typ max
Characteristics
Conditions
min
max
min
11.93 12.0 12.07
12.0
11.93 12.0 12.07
12.0
Vo
Vo BR
Io
Output voltage
Vi nom, 0.5 Io nom
V
A
Output protection
(suppressor diode)
-
14.4
15.9
-
14.4
15.9
Output 2
10
10.5
10
6.0
6.0
Output current nom.
Vi min – V
i max
Io1L, Io2L Output current limit 1
10.5
-
6.5
13
6.5
-
TC min – TC max
212
Io12L
Output current limit 1, 2
Output noise incl. spikes
Adjustment by R-input 4
Vi nom, Io nom
60
60
60
60
mVpp
V
Vo
BW = 20 MHz
3
3
3
3
4.8
13.81
±120
4.8
13.81
±120
Vo adj
∆Vo u
Vi min – V
i max
Static line/load regulation
(total deviation of Vo)
(0.1 – 1)Io nom
mV
Voltage
deviation
V
i nom, 0.5 Io2 nom
Dynamic
load
±200
1
±200
±150
1
±150
Vo d
to d
5
Io1 nom ↔ 0.5 Io1 nom
5
3
3
regulation Recovery time
and after turn on
ms
Io nom,
Temperature coefficient of
output voltage
±0.01 ±0.02
-
±0.01 ±0.02
-
%/K
α v o
TC min – TC max
Table 5b: Output data of HRP/ERP2320 models
Model
HRP2320 / ERP2320
2 × 12 V
Unit
Nom. output voltage
Output 1
Output 2
max min typ max
Characteristics
Conditions
min
typ
11.93 12.0 12.07
12.0
Vo
Output voltage
Vi nom, 0.5 Io nom
V
A
Output protection
(suppressor diode)
-
14.4
15.9
Vo BR
Io
Output 2
12
12.3
12
Output current nom.
Vi min – V
i max
Io1L, Io2L Output current limit 1
12.3
-
TC min – TC max
24.6 2
Io12L
Output current limit 1 2
Output noise incl. spikes
Adjustment by R-input 4
Vi nom, Io nom
60
60
mVpp
V
Vo
BW = 20 MHz
3
3
4.8
13.8 1
±120
Vo adj
∆Vo u
Vi min – V
i max
Static line/load regulation
(total deviation of Vo)
(0.1 – 1)Io nom
mV
Voltage
deviation
Vi nom, 0.5 Io2 nom
Dynamic
load
±250
1
±250
Vo d
to d
5
Io1 nom ↔ 0.5 Io1 nom
and after turn on
5
3
regulation Recovery time
ms
Io nom,
Temperature coefficient of
output voltage
±0.01 ±0.02
-
%/K
α v o
TC min – TC max
1
If Vo is increased above Vo nom through R-, sense, or T-input, the output currents should be reduced so that Po nom is not exceeded.
Both outputs connected in parallel
See Output voltage regulation
For battery charger application, a defined negative temp. coefficient can be provided by using a temp. sensor (see Accessories)
See Dynamic load regulation
Measured with a ceramic cap of 1 µF across each output.
2
3
4
5
6
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Table 5c: Output data of HR/ER2540 and HRP/ERP2540. General conditions as per table 5a
Model
HR2540 / ER2540
2 × 15 V
HRP2540 / ERP2540
2 × 15 V
Unit
Nom. output voltage
Output 1
typ
Output 2
min typ max min
Output 1
typ
Output 2
typ max
Characteristics
Conditions
min
max
max
min
14.91 15.0
15.09
15.0
14.91 15.0
15.09
15.0
Vo
Vo BR
Io
Output voltage
Vi nom, 0.5 Io nom
V
A
Output protection
(suppressor diode)
-
20.9
23.1
-
20.9
23.1
Output 2
8
8
9.6
10.1
9.6
Output current nom.
Vi min – V
i max
Io1L, Io2L Output current limit 1
8.4
8.4
-
10.1
-
TC min – TC max
16.8 2
19.7 2
Io12L
Output current limit 1, 2
Output noise incl. spikes
Adjustment by R-input 4
Vi nom, Io nom
75
75
75
75
mVpp
V
Vo
BW = 20 MHz
3
3
3
3
6.0
17.25 1
±150
6.0
17.25 1
±150
Vo adj
∆Vo u
Vi min – V
i max
Static line/load regulation
(total deviation of Vo)
(0.1 – 1)Io nom
mV
Voltage
deviation
V
i nom, 0.5 Io2 nom
Dynamic
load
±300
1
±300
±350
1
±350
Vo d
to d
5
Io1 nom ↔ 0.5 Io1 nom
5
3
3
regulation Recovery time
and after turn on
ms
Io nom,
Temperature coefficient of
output voltage
±0.01 ±0.02
-
±0.01 ±0.02
-
%/K
α v o
TC min – TC max
Table 5d: Output data of HR/ER2880 and HRP/ERP2880. General conditions as per table 5a
Model
HR2880 / ER2880
2 × 48 V
HRP2880 / ERP2880
2 × 48 V
Unit
Nom. output voltage
Output 1
typ
Output 2
max min typ max min
Output 1
Output 2
Characteristics
Conditions
min
typ
max
min
typ max
47.7 48.0
-
48.3
48.0
47.7
48.0
48.3
48.0
Vo
Vo BR
Io
Output voltage
Vi nom, 0.5 Io nom
V
A
Output protection
(suppressor diode)
56.7
62.7
-
56.7
62.7
2.5
Output 2
2
2
2.5
Output current nom.
Vi min – V
i max
Io1L, Io2L Output current limit 1
2.1
2.1
-
2.625
5.25 2
2.625
-
TC min – TC max
4.2 2
Io12L
Output current limit 1, 2
Output noise incl. spikes
Adjustment by R-input 4
Vi nom, Io nom
240
55.2 1
±0.5
240
240
55.2 1
±0.5
240 mVpp
V
Vo
BW = 20 MHz
3
3
3
3
19.2
19.2
Vo adj
∆Vo u
Vi min – V
i max
Static line/load regulation
(total deviation of Vo)
(0.1 – 1)Io nom
mV
Voltage
deviation
Vi nom, 0.5 Io2 nom
Dynamic
load
±0.8
1
±0.8
±1.0
1
±1.0
Vo d
to d
5
Io1 nom ↔ 0.5 Io1 nom
and after turn on
5
3
3
regulation Recovery time
ms
Io nom,
Temperature coefficient of
output voltage
±0.01 ±0.02
-
±0.01 ±0.02
-
%/K
α v o
TC min – TC max
1
If the output voltages are increased above Vo nom through R-input control, remote sensing, or option T, the output currents should be
reduced accordingly so that Po nom is not exceeded.
Both outputs connected in parallel
See Output voltage regulation
For battery charger applications, a defined negative temperature coefficient can be provided by using a temperature sensor (see Accessories)
See Dynamic load regulation
Measured with a ceramic cap of 1 µF across each output.
2
3
4
5
6
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Thermal Considerations
If a converter is located in free, quasi-stationary air (convection cooling) at the indicated maximum ambient temperature TA max
(see table Temperature specifications) and is operated within the specified input voltage range and nominal load, 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 upon the conditions of operation and integration
into a system. The thermal conditions are influenced by input voltage, output current, airflow, and temperature of surrounding
components and surfaces. TA max is therefore, contrary to TC max, an indicative value only; see also fig. 9.
Po ꢁWꢂ
HRP2320
HR2320
300
Convection
cooling
240
180
120
60
HRL2320
TC max
ꢃM23ꢀ
0
TA ꢁ°Cꢂ
50
60
70
80
ꢀ0
100
Fig. 9
Power derating for HRP/HR/HRL2320
Caution: The installer must ensure that under all operating conditions TC remains within the limits stated in the table Temperature specifications.
Notes: Sufficient forced cooling or enhanced cooling with the help of cooling plates (options B, B1) allows for TA to be higher than 71 °C
(e.g. 85 °C), as long as TC max is not exceeded.
Thermal Protection
Two temperature sensors generate an internal inhibit signal, which disables the converter in the case of overtemperature.
The outputs automatically recover when the temperature drops below the limit.
Interruption Time
The integrated storage capacitor (Cb) is loaded to the boost voltage and ensures full output voltage with nominal load during an
interruption time (or ride-through time) of at least 10 ms, provided that Vi was ≥ 20 V before the interruption. This complies with
EN 50155:2017 class S2.
Output Protection
The 2nd output of double-output models is protected by a suppressor diode against overvoltage, which could occur due to a failure
of the internal control circuit. This suppressor diode was not designed to withstand externally applied overvoltages. Overload at
any of the outputs will cause both outputs to shut down.
Note: Vo BR of the suppressor diode is specified in Electrical Output Data. If this voltage is exceeded, the suppressor diode generates losses
and may become a short circuit.
Note: The output voltage of the first output is monitored. If it exceeds typ. 140% of Vo nom for 10 ms, the converter is inhibited. To reactivate,
Vi must be removed or an inhibit signal must be applied to PUL (pin 24).
Each output has its own current limiting circuit, providing a rectangular output characteristic and protecting against short circuit.
There is no limitation for the capacitive load, and battery charging is possible as well.
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Series and Parallel Connection
Both outputs of the same converter can be series-connected or parallel-connected in order to double the output current or the
output voltage respectively.
Outputs of different converters may be series-connected.
In parallel connection of several converters, the T-pins should be interconnected so that all converters share the output current
equally; see fig. 10. HRL and ERL models have no T-pins and should not be operated in parallel connection.
If both outputs of each converter are connected in series, Vo1– of both converters should be connected together and the T-pins
as well. See fig. 11.
ꢀM088a
ꢁM084a
6 Vo2+
Vo2+
Vo2–
6
10
4
Vo1+
1
2
4
12 S1+
Vo1+
S1+
T
Converter
1
18 T
Converter
ꢁ1
12
18
14
8
ꢀ1
14 S1–
S1–
Vo1–
Vo2–
10
Vo1–
8
Load
Load
Vo2+
6
Vo2+
Vo2–
2
4Vo1+
12 S1+
18 T
6
10
Vo1+
S1+
T
1
1
4
12
18
14
8
Converter
ꢁ2
Converter
ꢀ2
S1–
14
Vo2–
10
S1–
Vo1–
8
Vo1–
1
2
Lead lines with equal length
and cross section
Diodes for redundant operation only
Max. 5 converters
in parallel connection
Max. 5 converters
–
+
T
in parallel connection
Power bus
Fig. 10
Fig. 11
Parallel connection with OR-ing diodes and sense lines
connected at the load
Parallel connection of double-output models with the ouputs
of each converter connected in series, using option T.
The signal at the T pins are referenced to Vo1–.
Notes:
– Not more than 5 converters should be connected in parallel.
– If several outputs are connected in series, the resulting voltage can exceed the SELV level.
– The PUL-pins (pin 24) should exhibit an individual PUL resistor for each converter. If the shutdown function is used, each PUL-pin must be
controlled individually.
– The R-pins should be left open-circuit. If not, the output voltages must individually be adjusted prior to paralleling within 1 to 2% or the R-pins
should be connected together.
– Series connection of second outputs without involving their main outputs should be avoided, as regulation may be poor.
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Output Voltage Regulation
If both outputs are connected in parallel or in series, the converter exhibits a rectangular output characteristic; see fig. 12.
The typ. dynamic load regulation illustrates fig. 13.
Vo/Vo nom
Vo
Vod
0.ꢀ8
0.5
Vo ±1ꢀ
Vod
Vo ±1ꢀ
td
td
t
Io/Io nom
Io1
IoL
1
0.5
0
≥ 10 µs
≥ 10 µs
050ꢀ8a
t
05102c
0
Io/Io nom
0.5
1.0
Fig. 12
Fig. 13
Output characteristic Vo versus Io
(both outputs connected in parallel or in series)
Typical dynamic load regulation of Vo.
Output 1 is under normal conditions regulated to Vo nom, irrespective of the output currents.
However, Vo2 depends upon the load distribution; see fig. 14 a and fig.14b. Converters with version V101 (or later) have incorporated
switchable preloads and do not need a minimum load.
Note: If output 2 is not used, connect it with output 1 ! This ensures good voltage regulation and efficiency.
V
ꢁVꢂ
V
ꢁVꢂ
o2
o2
ꢃM168
ꢃM08ꢀc
50
12.3
12.2
12.1
12.0
11.ꢀ
11.8
11.7
11.6
I
I
I
I
I
= 2 A
= 1.5 A
= 1 A
= 0.5 A
= 0.2 A
I
I
I
I
I
I
= 10 A
= 7.5 A
= 5.0 A
= 2.5 A
= 1.0 A
= 0.1 A
o1
o1
o1
o1
o1
o1
o1
o1
o1
o1
o1
4ꢀ.5
4ꢀ
48.5
48
47.5
47
46.5
I
o2
I
o2
0
0.4
0.8
1.2
1.6
2
2.4
A
0
2
4
6
8
10
12
A
Fig. 14a
Models HR/ER2320:Vo2 versus Io2 with various Io1
Fig. 14b
Models HR/ER2880:Vo2 versus Io2 with various Io1
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Auxiliary Functions
Inhibit Function
The PUL input (pin 24) can also be used as inhibit (for the PUL function see table 3 and 4). The response time ton and the rise time tr
are specified in table 2.
The current coming out from pin 24 (PUL) is typ. 1.5 mA (<2 mA). If pin 24 is left open-circuit, the voltage is typ. 5 V. The converter
is disabled when VPUL is ≤ 500 mV.
ꢀM127
ꢀM13ꢁc
28
tr
Vo/Vo nom
thu
Vi+
tf
1
IPUL
td on
ton
24
PUL
0.1
0
toff
30
32
PUL
1
Vi–
PE
t
0
22
Fig. 15
Fig. 16
Circuit for the inhibit function
Typical output response to the PUL-signal (inhibit)
Current Share Function
If the pins 18 (T) of parallel-connected converters are connected together, the converters share the output current evenly. Refer
to section Parallel and Series Connection. Not for HRL and ERL models.
Sense Lines
This feature allows for compensation of voltage drops across the connector contacts and if necessary, across the load lines. We
recommend connecting the sense lines directly at the female connector.
To ensure correct operation, both sense lines (S1+, S1–) should be connected to their respective power outputs (Vo1+ and Vo1–),
and the voltage difference between any sense line and its respective power output (as measured on the connector) should not
exceed the values specified in table 6.
Table 6: Maximum voltage compensation allowed using sense lines
Output
voltage
Total voltage difference
between sense lines and
their respective outputs
Voltage difference
between Vo1– and S1–
12 V
15 V
48 V
< 1.00 V
< 1.25 V
< 2.00 V
< 0.5 V
< 0.6 V
< 1.0 V
Important: Sense lines should be connected ! Incorrectly connected sense lines may activate the overvoltage protection resulting in a
permanent short-circuit of the output. Open sense lines are allowed, but result in inaccurate output voltages.
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Output Voltage Adjust
As a standard feature, the converters offer an adjustable output voltage. The control input R (pin 16) accepts either a control
voltage Vext or a resistor Rext to adjust the output voltage. When input R is not connected, the output voltage is set to Vo nom
.
a) Adjustment by means of an external control voltage Vext between pin 16 (R) and pin 14 (S1–):
The control voltage range is 1.0 – 2.875 V and allows for an adjustment in the range of approx. 40 – 115% of Vo nom
.
V • 2.5 V
__o_______
Vext
≈
Vo nom
Caution: Applying an external control voltage >2.875V may damage the converter.
b) Adjustment by means of an external resistor:
Depending on the value of the required output voltage, the resistor shall be connected
either: between pin 16 (R) and pin 14 (S1–) to adjust the output voltage in the range of approx. 40 –100% of Vo nom
.
Vo
___________
Rext1 ≈ 4 kΩ •
Vo nom – Vo
or: between pin 16 (R) and pin 12 (S1+) to adjust the output voltage in the range of 100 – 115% of Vo nom
(Vo – 2.5 V)
.
___________________
Rext2 ≈ 4 kΩ •
2.5 V • (Vo/Vo nom – 1)
Caution: To prevent the converter from damage, the value of R’ext shall never be less than the value for increasing Vo1 to 115% !
ꢀM0ꢁ1a
Vi+
S1+
12
16
Rext2
4 kΩ
V
ref = 2.5 V
R
+
+
–
Control
logic
Vext
Rext1
S1–
Vi–
14
Fig. 17
Output voltage adjustment
Notes:
– If the output voltages are increased above Vo nom via R-input control, sense lines, or option T, the output currents should be reduced, so that
Po nom is not exceeded.
– The second output of double-output models follows the voltage of the controlled main output.
Output Voltage Monitor
The output voltage monitor generates a logic “low” signal (NPN open-collector output) at the D-output (pin 20), when Vo1 ≥ 0.96 Vo nom
.
For converters with version V101 (or later), the voltage at S1+ (corresponding to Vo1) must be ≥ 0.96 Vo nom and ≤1.04 Vo nom (typ.
values). Then, a green LED (Out OK) at the frontplate is illuminated. If the output voltage is adjusted by the R-input, the trigger
levels are corrected accordingly.
At low D-output, the current is limited by a 10 Ω protective resistor; for converters with Version V102 (or later) ID should be ≤100 mA.
If the D-output is high (open collector), VD should be ≤ 75 V. For previous converters: ≤50 mA and 50 V.
Note: Output overvoltage activates a latch;see Output Protection.
ꢀM0ꢁ0
S1+
12
R
p
I
D
NPN open
collector
D
20
14
10 Ω
V
D
S1–
Fig. 18
Output voltage monitor
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Indicators
Two green LED indicators are visible at the front plate:
- Out OK; see Output Voltage Monitor
- In OK. This signal is activated when Vi is below 158 V and greater than Vi min, whereas Vi min is defined by the adjust resistor
connected to the PUL input (pin 24).
Battery Charging /Temperature Sensor
All converters with an R-input are suitable for battery charger application. For optimal battery charging and life expectancy of the
battery an external temperature sensor can be connected to the R-input. The sensor is mounted as close as possible to the battery
and adjusts the output voltage according to the battery temperature.
Depending upon cell voltage and the temperature coefficient of the battery, different sensor types are available; see Accessories.
Cell voltage ꢀVꢁ
0613ꢂb
2.45
030ꢀꢀd
2.40
Vo+
Vo–
Power
supply
Load
Input
2.35
R
2.30
2.25
2.20
2.15
2.10
–
+
+
Vo safe
Battery
Temperature sensor
–20
–10
0
10
20
30
40
50 °C
VC = 2.27 V, –3 mV/ꢃ
VC = 2.23 V, –3 mV/ꢃ
VC = 2.27 V, –3.5 mV/ꢃ
VC = 2.23 V, –3.5 mV/ꢃ
Fig. 19
Fig. 20
Connection of a temperature sensor
Trickle charge voltage versus temperature for defined temp.
coefficient. Vo nom is the output voltage with open R-input.
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Electromagnetic Compatibility (EMC)
A metal oxide VDR together and an efficient input filter form an effective protection against high input transient voltages, which
typically occur in most installations. The converters have been successfully tested to the following specifications:
Electromagnetic Immunity
Table 7: Electromagnetic immunity (type tests)
Phenomenon
Standard Level Coupling mode 1 Value
applied
Waveform
Source Test procedure
imped.
In
Perf.
oper. crit.2
Electrostatic
discharge (to case) 61000-4-2
IEC/EN
contact discharge 8000 Vp
10 pos. & 10 neg.
discharges
330 Ω
150 pF
4 3
x 4
1/50 ns
yes
yes
A
A
air discharge
antenna
15000 Vp
20 V/m
20 V/m
10 V/m
5 V/m
Electromagnetic
field
IEC/EN
61000-4-3
AM 80% / 1 kHz
N/A
80 – 1000 MHz
800 – 1000 MHz
1400 – 2000 MHz
2000 – 2500 MHz
5100 – 6000 MHz
5
antenna
antenna
AM 80% / 1 kHz
N/A
yes
A
3 V/m
10 V/m
50% duty cycle,
200 Hz rep. rate
900 ±5 MHz
pulse modul.
3
N/A
yes
yes
A
A
Electrical fast
transients / burst
IEC/EN
61000-4-4
3 6
capacitive, o/c 1 ±2000 Vp
60 s positive
60 s negative
transients per
coupling mode
burstsof 5/50ns;
2.5 / 5 kHz over 15 ms;
burst period: 300 ms
i/c, +i/–i 1
±4000 Vp
direct
50 Ω
4
i/c 1
±2000 Vp
±1000 Vp
42 Ω
Surges
IEC/EN
61000-4-5
5 pos. & 5 neg.
surges per
coupling mode
3 7
1.2 / 50 µs
yes
A
+i/–i 1
0.5 μF
Conducted
disturbances
IEC/EN
61000-4-6
10 VAC
(140 dBµV)
3 8
3 9
-
i, o, signal wires
AM 80% / 1 kHz
150 Ω 0.15 – 80 MHz
yes
yes
yes
A
A
A
Power frequency
magnetic field
IEC/EN
61000-4-8
-
-
300 A/m
60 s in all 3 axes
Pulse magnetic
field
IEC/EN
61000-4-9
5 pulses per axis
repetit. rate 10 s
±300 A/m
1
i = input, o = output, c = case
2
3
4
5
6
7
8
9
A = normal operation, no deviation from specs.; B = normal operation, temporary loss of function or deviation from specs possible
Exceeds EN 50121-3-2:2016 table 5.3 and EN 50121-4:2016 table 2.4.
Corresponds to EN 50121-3-2:2016 table 5.1 and exceeds EN 50121-4:2016 table 2.1.
Corresponds to EN 50121-3-2:2016 table 5.2 and EN 50121-4:2016 table 2.2 (compliance with digital communication devices).
Corresponds/exceeds EN 50121-3-2:2016 table 3.2 and EN 50121-4:2016 table 4.2.
Covers EN 50121-3-2:2016 table 5.3 and EN 50121-4:2016 table 4.3.
Corresponds to EN 50121-3-2:2016 table 3.1 and EN 50121-4:2016 table 4.1 (radio frequency common mode).
Corresponds to EN 50121-4:2016 table 2.3.
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Electromagnetic Emissions
All conducted emissions (fig. 21 and 22) have been tested according to EN 55011, group 1, class A. These limits are much
stronger than requested in EN 50121-3-2:2016, table 2.1, and coincide with EN 50121-4:2016, table 1.1. The limits in fig. 21 and
22 apply to quasipeak values, which are always lower then peak values.
In addition, the values for average must hold a limit 10 dBµV below the limits in fig. 21 and 22 (not shown).
Radiated emissions have been tested according to EN 55011, group 1, class A . These limits are similar to the requirements of
EN 50121-3-2:2016 and EN 50121-4:2016, both calling up EN 61000-6-4+A1:2011, table 1. The tests were executed with hori-
zontal and vertical polarization. The worse result is shown in fig. 22 and 23.
VUS EMC Labatory, Vin = 110 VDC, Iout = 2x 10 A, C115.
Testdistance 10 m, Class A, HR2320-9RG, B01932739, U00004, 26.07.2012
dBµV
VUS EMC Labatory, Vin
Testdistance 10 m, Class A, HR2320-ꢁRꢂ, B01ꢁ3273ꢁ, U00004, 26.07.2012
=
24 VDC, Iout
=
2x 10 A, C115.
dBµV
80
80
60
40
EN 55011 A qp
EN 55011 A av
EN 55011 A qp
EN 55011 A av
60
40
20
0
20
0
0.2
0.5
1
2
5
10
20 MHz
0.2
0.5
1
2
5
10
20 MHz
Fig. 21
Fig. 22
Typ. conducted emissions (peak/quasipeak and average) at
the input, measured at Vi = 24 V and Io nom (HR2320-9RG).
Typ. conducted emissions (peak/quasipeak and average) at
the input, measured at Vi = 110 V and Io nom (HR2320-9RG,
ER2320-9RG).
VUS EMC Labatory, Vin
Testdistance 10 m, Class A, HR2320-ꢀRꢁ, B01ꢀ3273ꢀ, U00004, 26.07.2012
= 110 VDC, Iout=2x10A, C115.
VUS EMC Labatory, Vin
Testdistance 10 m, Class A, HR2320-ꢀRꢁ, B01ꢀ3273ꢀ, U00004, 26.07.2012
= 24 VDC, Iout=2x10A, C115.
dBµV/m
60
dBµV/m
60
EN 5501A
EN 55011 A
EN 55011 A
50
40
30
20
50
40
30
20
10
10
0
30
0
30
50
100
200
500
1000 MHz
50
100
200
500
1000 MHz
Fig. 23
Fig. 24
Typ.radiated emissions in 10 m distance, measured at Vi = 24 V
Typ.radiated emissions in10m distance,measured at Vi = 110V
and Io nom (HR2320-9RG).
and Io nom (HR2320-9RG, ER2320-9RG).
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Immunity to Environmental Conditions
Table 8: Mechanical and climatic stress
Test method
Standard
Test Conditions
Temperature:
Status
Cab Damp heat
steady state
IEC/EN 60068-2-78
MIL-STD-810D section 507.2
40±2 °C
Converter
not operating
Relative humidity:
Duration:
93+2/-3
%
56 days
55°C and 25°C
2
Db 2 Cyclic damp heat
test
EN 50155:2017, clause 13.4.7
IEC/EN 60068-2-30
Temperature:
Converter
not operating
Cycles (respiration effect)
Duration:
2x 24 h
70°C
Be
Ad
Ka
Dry heat test
steady state
EN 50155:2017, clause 13.4.5
IEC/EN 60068-2-2
Temperature:
Converter
operating
Duration:
6 h
Low temperature
start-up test
EN 50155:2017, clause 13.4.4
IEC/EN 60068-2-1
Temperature, duration:
Performance test:
-40 °C, 2 h
+25 °C
35 ±2 °C
48 h
Converter
not operating
Salt mist test
EN 50155:2017, clause 13.4.10 Temperature:
Duration:
Converter
not operating
sodium chloride
(NaCl) solution
Fc
Fh
Vibration
(sinusoidal)
IEC/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)
10 – 2000 Hz
Converter
operating
Frequency (1 Oct/min):
Test duration:
7.5 h (2.5 h in each axis)
Random vibration
broad band (digital
control) & guidance
IEC/EN 60068-2-64
Acceleration spectral density: 0.05 gn2/Hz
Frequency band:
8 – 500 Hz
Converter
operating
Acceleration magnitude:
Test duration:
4.9 gn
rms
1.5 h (0.5 h in each axis)
50 gn = 490 m/s2
11 ms
Ea
Shock
(half-sinusoidal)
IEC/EN 60068-2-27
MIL-STD-810D section 516.3
Acceleration amplitude:
Bump duration:
Converter
operating
Number of bumps:
Acceleration amplitude:
Bump duration:
18 (3 in each direction)
5.1 gn
-
-
Shock
EN 50155:2017 clause 13.4.11,
EN 61373:2010 sect. 10,
class B, body mounted 1
Converter
operating
crit. A
30 ms
Number of bumps:
18 (3 in each direction)
2
Simulated long life
testing at increased
random vibration
levels
EN 50155:2017 clause 13.4.11.2, Acceleration spectral density: 0.02 gn /Hz
EN 61373:2010 sect. 8 and 9,
Converter
operating
crit. A
Frequency band:
Acceleration magnitude:
Test duration:
5 – 150 Hz
class B, body mounted 1
0.8 gn rms
15 h (5 h in each axis)
1
Body mounted = chassis of a railway coach
Temperatures
Table 9: Temperature specifications, valid for an air pressure of 800 – 1200 hPa (800 – 1200 mbar)
Model
-9
Unit
Characteristics
Conditions
min
- 40
- 40
- 55
typ
max
TA
TC
TS
Ambient temperature
Converter operating
71 1
2
Case temperature
95 1
° C
Storage temperature
Not operational
85
1
2
See Thermal Considerations.
Overtemperature lockout at TC >95 °C (An NTC resistor on primary and secondary heatsink).
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Reliability
Table 10: MTBF and device hours
Ratings at specified
case temperature
Bellcore SR332
Model
Ground benign
40 °C
Ground fixed
Ground mobile Life test 1 Device hours 2
Unit
40 °C
176 000
70 °C
50 °C
25 °C
HR2320
352 000
49 000
38 000
500 000
h
1
Life test with 32 converters during 26 days, cycling at 60 °C; confidence level 60%.
Statistical values, based on an average of 4300 working hours per year and in general field use over 5 years; upgrades and customer-
2
induced errors are excluded.
Mechanical Data
Dimensions in mm. The converters are designed to be inserted into a 19” rack, 160 mm long, according to IEC 60297-3.
7 TE
30.3
5 TE
3.27
(171.0 to 171.ꢁ)
50
M4
ꢂM0ꢁ2
Out Oꢀ
In Oꢀ
Measuring point of
case temperature TC
d
8
152
8
27.38
60
Front plate
Back plate
Main face
168.5
Ø5 x ꢁ0°
Ø2.8
Screw holes of the
frontplate
European
Projection
Fig. 25
Case S03 for HR / ER and HRL / ERL models with heat sink;
Aluminum, black finish (EP powder coated);
weight approx. 1.5 kg
Notes:
– d ≥ 15 mm, recommended minimum distance to next part in order to ensure proper air circulation at full output power.
– free air location: the converter should be mounted with fins in a vertical position to achieve maximum airflow through the heat sink.
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Dimensions in mm. The converters are designed to be inserted into a 19” rack, 160 mm long, according to IEC 60297-3.
7 TE
30.3
ꢀ TE
3.27
15ꢀ
4.5
ꢁM0ꢀ3
Out Oꢂ
In Oꢂ
d
Measuring point of
case temperature TC
50
27.38
(171.0 .... 171.ꢀ)
80
Front plate
Back plate
Main face
168.5
Ø5 x ꢀ0°
Ø2.8
Screw holes of the
frontplate
European
Projection
Mounting slots for chassis or wall mounting
Fig. 26
Case K03 for HRP and ERP models with heat sink;
Aluminum, black finish (EP powder coated);
weight approx. 1.8 kg
Notes:
– d ≥ 15 mm, recommended minimum distance to next part in order to ensure proper air circulation at full output power.
– free air location: the converter should be mounted with fins in a vertical position to achieve maximum airflow through the heat sink.
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
5
47.2
38.5
6.5
11027
11.8
±0.2
17.3
133.4
168
30
Fig. 27
Option B: Aluminum case S03 with large cooling plate; black finish (EP powder coated).
Suitable for front mounting.
Total weight approx. 1.5 kg
Note: Long case with option B2, elongated by 60 mm for 220 mm rack depth, is available on request. (No LEDs)
7 TE
3.27
4 TE
50
38.5
5
158
11.8
ꢁM0ꢀ4
M 4
Out Oꢂ
In Oꢂ
Measuring point of
case temperature TC
5
47.2
17.3
133.4
168
(171.0 ... 171.ꢀ)
Fig. 28
Option B1: Aluminum case S03 with small cooling plate; black finish (EP powder coated).
Suitable for mounting with access from the backside.
Total weight approx. 1.4 kg.
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
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. The
protective earth is connected by a leading pin (no. 22), ensuring that it makes contact with the female connector first.
S10002b
30 26 22 18 14 10
32 28 24 20 16 12
6
8
4
Fixtures for retention clips
Fig. 29
View of module’s male connectors
Table 11: Pin allocation
Pin
4
Name
Vo1+
Vo2+
Vo1-
Vo2-
S1+
S1-
R
Function
Output 1 positive
Output 2 positive
Output 1 negative
Output 2 negative
Sense line positive
Sense line negative
6
8
10
12
14
16
18 2
20
Output voltage adjust
Current share
Out OK
T
D
22 1
PE
Protection earth
24
PUL
Vi+
Vi-
Programmable undervoltage lockout
Input positive
26 + 28
30 + 32
Input negative
1
2
Leading pin (pre-connecting)
Not connected for HRL models
Installation Instructions
The converters are components, intended exclusively for inclusion within other equipment by an industrial assembly operation
or by professional installers. Installation must strictly follow the national safety regulations in compliance with the enclosure,
mounting, creepage, clearance, casualty, markings, and segregation requirements of the end-use application.
Connection to the system shall be made via the female connector H15; see Accessories. Other installation methods may not meet
the safety requirements.
Pin no. 22 ( ) is connected with the case. For safety reasons it is essential to connect this pin reliably to protective earth.
Notes:
– The PUL function (pin 24) must be programmed to enable the outputs. PUL should be connected to Vi– (pins 30 + 32) by a resistor to adjust
the start-up voltage; see table 3. Otherwise, the input current may become too high at low input voltage.
– Do not open the converter, or warranty will be invalidated.
– If the second output is not used, connect it in parallel with the main output.
Make sure that there is sufficient airflow available for convection cooling and verify it by measuring the case temperature TC, when
the converter is installed and operated in the end-use application; see Thermal Considerations.
Ensure that a converter failure (e.g. an internal short-circuit) does not result in a hazardous condition.
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Standards and Approvals
The converters are safety-approved to UL/CSA 60950-1 2nd Ed. and IEC/EN 60950-1 2nd Ed.
The converters correspond to Class I equipment (with case connected to ground). They have been evaluated for:
• Building-in
• Basic insulation between input and case based on 250 VA. Double or reinforced insulation between input and outputs
• Functional insulation between outputs
• Overvoltage category II
• Pollution degree 2 environment
• Max. altitude: 2000 m
• The converters fulfill the requirements of a fire enclosure.
The output voltage is considered as SELV, except HR/HRP/ER/ERP2880 with both outputs in series connection.
The converters are subject to manufacturing surveillance in accordance with the above mentioned standards and ISO 9001:2015.
CB-scheme is available on request.
Protection Degree and Cleaning Liquids
The protection degree is IP 40, provided that the female connector is fitted to the converter.
In order to avoid possible damage, any penetration of cleaning fluids has to be prevented, since the power supplies are not
hermetically sealed.
Railway Application and Fire Protection
The converters have been designed by observing the railway standards EN 50155, EN 50121-3-2, and EN 50121-4. All boards
are coated with a protective lacquer.
The converters comply with NF-F16 (I2/F1). They also comply with EN 45545-1, EN 45545-2, if installed in a technical compartment
or cabinet.
Isolation and Protective Earth
The electric strength test is performed in the factory as routine test according to EN 50514 and IEC/EN 60950 and should not be
repeated in the field. The Company will not honor warranty claims resulting from incorrectly executed electric strength tests. The
resistance case to the earth pin (<0.1 Ω) is tested with 25 A for 1 s.
Table 12: Isolation
Characteristics
Input to
Case + Outputs
Output(s)
to Case
Output 1 to
Output 2
Unit
Electric strength test
Factory test 10 s
2.8 1
1.4
1.0
0.3
0.21
>100 2
-
kVDC
kVAC
MΩ
AC test voltage equivalent to factory test
2.0
Insulation resistance
>300
≥ 3.5 3
>300
≥ 2.5
Creepage distances
mm
1
According to EN 50514 and IEC/EN 60950, subassemblies connecting input to output are pre-tested with 5.6 kVDC or 4 kVAC.
Tested at 150 VDC
Input to outputs: 6.4 mm
2
3
Description of Options
B, B1 Cooling Plates
Where a cooling surface is available, we recommend the use of a cooling plate instead of the standard heat sink. The mounting
system should ensure that the maximum case temperature TC max is not exceeded. The cooling capacity is calculated by (η see
Model Selection):
(100% – η)
PLoss
=
–––––––––– • Vo • Io
η
For the dimensions of the cooling plates; see Mechanical Data.
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Accessories
A variety of electrical and mechanical accessories are available including:
– Front panels for 19” DIN-rack: Schroff or Intermas, 12 or 16TE /3U; see fig. 30 and the data sheet BCD.00495.
– Mating H15 connectors with screw, solder, faston, or press-fit terminals; see fig. 31
– Coding clips for connector coding HZZ00202
– Pair of connector retention clips HZZ01209-G; see fig. 32
– Connector retention brackets HZZ01216-G; see fig. 33
– Cage clamp adapter HZZ00144-G; see fig. 34
– Cable hood for H15 connectors (fig 35):
- HZZ00141-G, screw version
- HZZ00142-G, use with retention brackets HZZ01218-G
- HZZ00143-G, metallic version providing fire protection
– Wall-mounting plate K02 (HZZ01213-G) for models with option B1; see fig. 36
– DIN-rail mounting assembly HZZ0615-G (DMB-K/S); see fig. 37
– Additional external input and output filters
– Different battery sensors S-KSMH... for using the converter as a battery charger. Different cell characteristics can be selected;
see fig. 38, table 13, and Battery Charging/Temperature Sensors.
For additional accessory product information, see the accessory data sheets listed with each product series or individual
model at our web site belfuse.com/power-solutions.
Fig. 31
Different mating connectors
Fig. 30
Fig.32
Different front panels
Connector retention clips to fasten the H15 connector to the
rear plate; see fig.29. HZZ01209-G consists of 2 clips.
20 to 30 Ncm
Fig. 33
Fig. 34
Connector retention brackets HZZ01216-G
Cage clamp adapter HZZ00144-G
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Fig. 35
Fig. 36
Different cable hoods
Chassis- or wall-mounting plate HZZ01213-G (Mounting
plate K02)
European
Projection
26 (1.02")
09125a
L
56 (2.2")
adhesive tape
L = 2 m (standard length)
other cable lengths on request
Fig. 37
Fig. 38
Battery temperature sensor
DIN-rail mounting assembly HZZ00615-G (DMB-K/S)
Table 13: Battery temperature sensors
Battery
voltage nom.
[V]
Sensor type
Cell
Cell temp. Cable
voltage coefficient length
[V]
[mV/K]
–3.0
–3.5
–3.0
–3.5
–3.5
–3.5
–3.5
–3.0
–3.5
[m]
2
12
12
24
24
24
24
24
48
48
S-KSMH12-2.27-30-2
S-KSMH12-2.27-35-2
S-KSMH24-2.27-30-2
S-KSMH24-2.27-35-2
S-KSMH24-2.31-35-0
S-KSMH24-2.31-35-2
S-KSMH24-2.35-35-2
S-KSMH48-2.27-30-2
S-KSMH48-2-27-35-2
2.27
2.27
2.27
2.27
2.31
2.31
2.35
2.27
2.27
2
2
2
4.5
2
2
2
2
NUCLEAR AND MEDICAL APPLICATIONS - These products are not designed or intended for use as critical components in life support systems,
equipment used in hazardous environments, or nuclear control systems.
TECHNICAL REVISIONS - The appearance of products, including safety agency certifications pictured on labels, may change depending on the
date manufactured. Specifications are subject to change without notice.
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