Rugged Environment DC-DC Converters >100 Watt K Series
Edition 4/4.99
1/31
MELCHER
The Power Partners.
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
Table of Contents 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
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.
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.
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.
LED indicators display the status of the converter and allow
visual monitoring of the system at any time.
Full input to output, input to case, output to case and output
to output isolation is provided. The modules are designed
and built according to the international safety 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 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.
A temperature sensor generates an inhibit signal which
disables the outputs if the case temperature
T
C exceeds the
limit. The outputs are automatically re-enabled when the
temperature drops below the limit.
Various options are available to adapt the converters to in-
dividual applications.
The modules may either be plugged into 19" rack systems
according to DIN 41494, or be chassis mounted.
168
6.6"
80
3.2"
16 TE
111
4.4"
3 U
Safety according to IEC/EN 60950
LGA
C
Page
Electromagnetic Compatibility (EMC) ............................ 18
Immunity to Environmental Conditions........................... 20
Mechanical Data ............................................................ 21
Safety and Installation Instructions ................................ 22
Description of Options .................................................... 25
Accessories .................................................................... 31
K Series DC-DC Converters >100 Watt Rugged Environment
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MELCHER
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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
U
o nom
I
o nom
U
o nom
I
o nom
U
i min...
U
i max hmin
[V DC] [A] 2 [V DC] [A] 2 8...35 V DC [%]
5.1 20.0 - - AK 1001-7R 78 -9
12.0 10.0 - - AK 1301-7R 80 E 3
15.0 8.0 - - AK 1501-7R 80 D
24.0 5.0 - - AK 1601-7R 82 V 6
24.0 4 5.0 - - AK 2320-7R 78 P
30.0 4 4.0 - - AK 2540-7R 79 T
48.0 4 2.5 - - AK 2660-7R 79 B1
12.0 5.0 12.0 5 5.0 AK 2320-7R 78 B2
15.0 4.0 15.0 5 4.0 AK 2540-7R 79
24.0 2.5 24.0 5 2.5 AK 2660-7R 79
Table 1c: Type survey DK, EK
Output 1 Output 2 Input Voltage Range and Efficiency 1 Options
U
o nom
I
o nom
U
o nom
I
o nom
U
i min...
U
i max hmin
U
i min...
U
i max hmin
[V DC] [A] 2 [V DC] [A] 2 44...220 V DC [%] 67...385 V DC [%]
5.1 25.0 - - DK 1001-7R 79 - - -9
12.0 12.0 - - DK 1301-7R 83 EK 1301-7R 84 E 3
15.0 10.0 - - DK 1501-7R 86 EK 1501-7R 84 D
24.0 6.0 - - DK 1601-7R 87 EK 1601-7R 84 V 6
24.0 4 6.0 - - DK 2320-7R 81 EK 2320-7R 81 P
30.0 4 5.0 - - DK 2540-7R 82 EK 2540-7R 80 T
48.0 4 3.0 - - DK 2660-7R 85 EK 2660-7R 83 B1
12.0 6.0 12.0 5 6.0 DK 2320-7R 81 EK 2320-7R 81 B2
15.0 5.0 15.0 5 5.0 DK 2540-7R 82 EK 2540-7R 80
24.0 3.0 24.0 5 3.0 DK 2660-7R 85 EK 2660-7R 83
1Efficiency at
U
i nom and
I
o nom.
2If the output voltages are increased above
U
o nom via R-input control, option P setting, remote sensing or option T, the output currents
should be reduced accordingly so that
P
o nom is not exceeded.
3Option E only for CK, DK, EK types.
4Series connection of output 1 and 2.
5Second output semi-regulated.
6Option V for K 1001 types only.
Table 1b: Type survey BK, FK, CK
Output 1 Output 2 Input Voltage Range and Efficiency 1 Options
U
o nom
I
o nom
U
o nom
I
o nom
U
i min...
U
i max hmin
U
i min...
U
i max hmin
U
i min...
U
i max hmin
[V DC] [A] 2 [V DC] [A] 2 14...70 V DC [%] 20...100 V DC [%] 28...140 V DC [%]
5.1 25.0 - - BK 1001-7R 79 FK 1001-7R 80 CK 1001-7R 79 -9
12.0 12.0 - - BK 1301-7R 81 FK 1301-7R 82 CK 1301-7R 82 E 3
15.0 10.0 - - BK 1501-7R 82 FK 1501-7R 85 CK 1501-7R 84 D
24.0 6.0 - - BK 1601-7R 84 FK 1601-7R 86 CK 1601-7R 86 V 6
24.0 4 6.0 - - BK 2320-7R 80 FK 2320-7R 81 CK 2320-7R 80 P
30.0 4 5.0 - - BK 2540-7R 80 FK 2540-7R 83 CK 2540-7R 82 T
48.0 4 3.0 - - BK 2660-7R 80 FK 2660-7R 84 CK 2660-7R 84 B1
12.0 6.0 12.0 5 6.0 BK 2320-7R 80 FK 2320-7R 81 CK 2320-7R 80 B2
15.0 5.0 15.0 5 5.0 BK 2540-7R 80 FK 2540-7R 83 CK 2540-7R 82
24.0 3.0 24.0 5 3.0 BK 2660-7R 80 FK 2660-7R 84 CK 2660-7R 84
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Type Key
Type Key C K 2 5 40 -7 E R P D V T B1
Input voltage range
U
i:
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)
, U
o1 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,
U
o1/2 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
T
A:
–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
1External wiring of main and second output depending upon the desired output configuration (see:
R-Function for Different Output
Configurations
).
2Feature R excludes option P and vice versa.
3Option E available for CK, DK and EK types.
4Option D excludes option V and vice versa.
5Option V available for K 1001 type.
Example: CK 2540-7PD3: DC-DC converter, input voltage range 28...140 V, double output, each providing 15 V/5 A,
equipped with potentiometer and undervoltage monitoring option. Ambient temperature –25...71°C.
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Fig. 1
Block diagram of single output converters AK…EK 1000
Input filter
Control circuit
2
P
3
Forward converter
(approx. 120 kHz)
Y
16
18
20
22
12
4
6
8
10
14
Y
Output
filter
1
26
28
30
32
24
4
–+
Y
Y
Vi+
Vi–
R
i
D/V
T
03057
S+
Vo+
Vo–
S–
Functional Description
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
U
o1 and
generates, with respect to the maximum admissible output
currents, the control signal for the primary switching tran-
sistor.
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.
Fig. 2
Block diagram of symmetrical double output converters AK...EK 2000
1Transient suppressor (VDR) in CK, DK, EK, FK types
2Transient suppressor (diode) in AK, BK, CK, FK types
3Inrush current limiter in CK, DK, EK types (NTC or Opt. E), -9 versions exclude the NTC
4Input fuse
Input filter
Control circuit
1
2
P
3
Forward converter
(approx. 110 kHz)
16
18
20
22
12
14
4
6
8
10
Output 2
filter
Output 1
filter
26
28
30
32
24
4
–+
Y
YY
Y
Y
Y
R
i
D
T
Vi+
Vi–
03058
Vo1+
Vo1–
Vo2+
Vo2–
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Electrical Input Data
General Conditions
–
T
A = 25°C, unless
T
C is specified.
– Pin 18 connected to pin 14,
U
o adjusted to
U
o 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 typ max min typ max min typ max Unit
U
iOperating input voltage
I
o = 0…
I
o nom 8 35 14 70 20 100 V DC
U
i nom Nominal input voltage
T
C min…
T
C max 15 30 48
I
iInput current
U
i nom,
I
o nom 1 9.0 6.0 3.75 A
P
i0 No-load input power
U
i min…
U
i max 2.5 2.5 2.5 W
P
i inh Idle input power unit inhibited 1.5 1.5 1.5
R
iInput resistance
T
C = 25°C 65 100 70 mΩ
R
NTC NTC resistance 2 333
C
iInput capacitance 830 1250 300 450 1200 1800 µF
U
i RFI Conducted input RFI EN 55022 A B B
Radiated input RFI
U
i nom,
I
o nom AAB
U
i abs Input voltage limits 0 40 0 80 0 100 V DC
without damage
Table 2b:
Input data
Input CK DK EK
Characteristics Conditions min typ max min typ max min typ max
U
iOperating input voltage
I
o = 0…
I
o nom 28 140 44 220 67 385 V DC
U
i nom Nominal input voltage
T
C min…
T
C max 60 110 220
I
iInput current
U
i nom,
I
o nom 1 3.0 1.6 0.8 A
P
i0 No-load input power
U
i min…
U
i max 2.5 2.5 2.5 W
P
i inh Idle input power unit inhibited 1.5 1.5 1.5
R
iInput resistance
T
C = 25°C 150 170 180 mΩ
R
NTC NTC resistance 2 800 1600 3200
C
iInput capacitance 660 1000 260 400 210 400 µF
U
i RFI Conducted input RFI EN 55022 B B B
Radiated input RFI
U
i nom,
I
o nom BBB
U
i abs Input voltage limits 0 154 0 400 4 0 400 V DC
without damage
1With double output modules, both outputs loaded with
I
o nom.
2Valid 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.
3AK, BK and FK types have no NTC (inrush current limiter) fitted.
41 s max., duty cycle 1% max.
Input Transient Protection
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.
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-
tremely wide input range is required. The EK input range for
110 V batteries has been designed and tested to meet this
requirement.
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
.
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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!
Table 3:
Fuse Specification
Module Fuse type Fuse rating
AK 1 fast-blow Little fuse 314 30.0 A, 125 V
BK 1 fast-blow Little fuse 314 25.0 A, 125 V
CK 2 slow-blow SPT 12.5 A, 250 V
DK 2 slow-blow SPT 8 A, 250 V
EK 2 slow-blow SPT 4 A, 250 V
FK 2 slow-blow SPT 16 A, 250 V
1Fuse size 6.3 × 32 mm 2 Fuse size 5 × 20 mm
Input Under-/Overvoltage Lock-out
If the input voltage remains below approx. 0.8
U
i min or ex-
ceeds approx. 1.1
U
i max, an internally generated inhibit sig-
nal disables the output(s). When checking this function the
absolute maximum input voltage rating
U
i abs should be
considered! Between
U
i min and the undervoltage lock-out
level the output voltage may be below the value defined in
table:
Output data
(see:
Technical Information: Measuring
and Testing
).
Hold-up Time versus relative Input Voltage
Inrush Current Peak Value
The inrush current peak value (initial switch-on cycle) can
be determined by following calculation: (See also:
Input In-
rush Current Characteristic
)
U
i source
I
inr p = ––––––––––––––––
(
R
s ext +
R
i +
R
NTC)
R
s ext
R
i
R
NTC
I
inr p
U
i source
+C
i int
05109
Fig. 4
Equivalent circuit for input impedance
Reverse Polarity
The units are not protected against reverse polarity at the
input to avoid unwanted power losses and may be dam-
aged.
Input Inrush Current Characteristic
123 t [ms]
0
50
100
I
i inr
[A]
150
CK
EK
DK
05108
Fig. 5
Typical inrush current versus time at U
i max,
R
ext = 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.
234561
0.10
1.00
U
i
____
U
i min
t
h
(ms)
10.00
100.00
DK
CK/FK
EK
AK BK
04045
Fig. 6
Typical hold-up time t
h
versus relative input voltage
U
i
/U
imin
. The DC-DC converters require an external series
diode in the input path if other loads are connected to the
same input supply lines.
Static Input Current Characteristic
Fig. 3
Typical input current versus relative input voltage
2345
1
0.40
1.00
10.00
U
i
____
U
i min
I
i
(A)
20.00
04044
FK
CK
EK
DK
BK
AK
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Electrical Output Data
General Conditions
–
T
A = 25°C, unless
T
C is specified.
– Pin 18 (i) connected to pin 14 (S–/Vo1–),
U
o adjusted to
U
o 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 AK/BK 1301 AK/BK 1501 AK/BK 1601
5.1 V 12.0 V 15.0 V 24.0 V
Characteristics Conditions min typ max min typ max min typ max min typ max Unit
U
oOutput voltage
U
i nom,
I
o nom 5.07 5.13 11.93 12.07 14.91 15.09 23.86 24.14 V
U
o P Overvoltage protection 7.6 21 26.5 43.5
(suppressor diode)
I
o nom Output current 1
U
i min…
U
i max 20.0/25.0 10.0/12.0 8.0/10.0 5.0/6.0 A
T
C min…
T
C max
I
o L Output current limit 4
U
i min…
U
i max 21/26 10.2/12.2 8.2/10.2 5.2/6.2
u
o7Output Switching freq.
U
i nom,
I
o nom 10555mV
pp
voltage Total IEC/EN 61204 60 40 30 50
noise BW = 20 MHz
D
U
o u Static line regulation
U
i min...
U
i nom ±15 ±25 ±30 ±30 mV
U
i nom...
U
i max
I
o nom
D
U
o I Static load regulation
U
i nom,
I
o = 20253040
(0.1…1)
I
o nom
u
o d 5Dynamic Voltage
U
i nom,
I
o = ±220 ±110 ±150 ±130
load deviation
I
o nom ↔ 1/2
I
o nom
t
d 5regulation Recovery IEC/EN 61204 0.6 0.6 0.5 1 ms
time
aUo Temperature coefficient
T
C min…
T
C max –0.2 –1–1–1 mV/K
of output voltage 6 0...
I
o nom
1If the output voltages are increased above
U
o nom through R-input control, option P setting, remote sensing or option T, the output cur-
rent should be reduced accordingly so that
P
o nom is not exceeded.
4See:
Output voltage regulation of single output units
.
5See:
Dynamic load regulation of U
o1
.
6Negative temperature coefficient (0...–3 mV/cell and K) available on request
7Measured 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 AK/BK 2540 AK/BK 2660
(Outputs connected in Series) 24 V (2 × 12 V) 30 V (2 × 15 V) 48 V (2 × 24 V)
Characteristics Conditions min typ max min typ max min typ max Unit
U
oOutput voltage
U
i nom,
I
o nom 24.0 2 30.0 2 48.0 2 V
U
o P Overvoltage protection 38 48 74
(suppressor diode)
I
o nom Output current 1
U
i min…
U
i max 5.0/6.0 4.0/5.0 2.5/3.0 A
T
C min…
T
C max
I
o L Output current limit 4
U
i min…
U
i max 5.2/6.2 4.2/5.2 2.7/3.2
u
o7Output Switching freq.
U
i nom,
I
o nom 10 5 5 mVpp
voltage Total IEC/EN 61204 60 60 70
noise 3 BW = 20 MHz
D
U
o u Static line regulation
U
i min...
U
i nom ±15 ±15 ±20 mV
U
i nom...
U
i max
I
o nom
D
U
o I Static load regulation
U
i nom,
I
o =25 25 35
(0.1…1)
I
o nom
u
o d 5Dynamic Voltage
U
i nom,
I
o=±180 ±160 ±100
load deviation
I
o nom ↔ 1/2
I
o nom
t
d 5regulation Recovery IEC/EN 61204 0.3 0.2 0.2 ms
time
aUo Temperature coefficient
T
C min…
T
C max –2–2–2 mV/K
of output voltage 6 0...
I
o nom
1If the output voltages are increased above
U
o nom through R-input control, option P setting, remote sensing or option T, the output cur-
rent should be reduced accordingly so that
P
o nom is not exceeded.
2Series connection for
U
o nom = 24 V, 30 V or 48 V, see:
R-Function for Different Output Configurations
.
3Shortest possible wiring for series connection at the connector.
4See:
Output voltage regulation of single output units
.
5See:
Dynamic load regulation of U
o1
and U
o2.
6Negative temperature coefficient (0...–3 mV/cell and K) available on request.
7Measured 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 4d: Output data double output modules AK/BK
Output AK/BK 2660
(Outputs independently loaded) 1 24 V/24 V
Characteristics Conditions Output 1 Output 2
min typ max min typ max Unit
U
oOutput voltage
U
i nom,
I
o nom 2 23.86 24.14 23.64 24.36 V
U
o P Overvoltage protection 37 37
(suppressor diode)
I
o nom Output current 3
U
i min…
U
i max 2.5/3.0 2.5/3.0 A
T
C min…
T
C max
I
o L Output current limit 4
U
i min…
U
i max 2.7/3.2 2.7/3.2
u
o9Output Switching freq.
U
i nom,
I
o nom 55mV
pp
voltage Total IEC/EN 61204 60 30
noise BW = 20 MHz
D
U
o u Static line regulation
U
i min...
U
i nom ±40 ±40 mV
U
i nom...
U
i max
I
o nom
D
U
o I Static load regulation
U
i nom,
I
o =70
8
(0.1…1)
I
o nom 5
u
o d 6Dynamic Voltage
U
i nom,
I
o = ±50
load deviation
I
o nom ↔ 1/2
I
o nom
t
d 6regulation Recovery IEC/EN 61204 0.2 ms
time
aUo Temperature coefficient
T
C min…
T
C max –1 mV/K
of output voltage 7 0...
I
o nom
Table 4c: Output data double output modules AK/BK
Output AK/BK 2320 AK/BK 2540
(Outputs independently loaded) 1 12 V/12 V 15 V/15 V
Characteristics Conditions Output 1 Output 2 Output 1 Output 2
min typ max min typ max min typ max min typ max Unit
U
oOutput voltage
U
i nom,
I
o nom 2 11.93 12.07 11.82 12.18 14.91 15.09 14.78 15.23 V
U
o P Overvoltage protection 19 19 24 24
(suppressor diode)
I
o nom Output current 3
U
i min...
U
i max 5.0/6.0 5.0/6.0 4.0/5.0 4.0/5.0 A
T
C min...
T
C max
I
o L Output current limit 4
U
i min...
U
i max 5.2/6.2 5.2/6.2 4.2/5.2 4.2/5.2
u
o9Output Switching freq.
U
i nom,
I
o nom 10 10 10 10 mVpp
voltage Total IEC/EN 61204 50 20 50 20
noise BW = 20 MHz
D
U
o u Static line regulation
U
i min...
U
i nom ±30 ±30 ±30 ±30 mV
U
i nom...
U
i max
I
o nom
D
U
o I Static load regulation
U
i nom,
I
o =50
850 8
(0.1...1)
I
o nom 5
u
o d 6Dynamic Voltage
U
i nom,
I
o = ±80 ±80
load deviation
I
o nom ↔ 1/2
I
o nom
t
d 6regulation Recovery IEC/EN 61204 0.2 0.2 ms
time
aUo Temperature coefficient
T
C min...
T
C max –1–1 mV/K
of output voltage 7 0...
I
o nom
1Depending upon the desired out-
put configuration the wiring should
be made as shown in:
R-Function
for Different Output Configurations.
2Same conditions for both outputs.
3If the output voltages are in-
creased above
U
o nom via R-input
control, option P setting, remote
sensing or option T, the output cur-
rents should be reduced accord-
ingly so that
P
o nom is not ex-
ceeded.
4See:
Output voltage regulation of
single output units
.
5Condition for specified output.
Other output loaded with constant
current
I
o =
I
o nom
6See:
Dynamic load regulation of
U
o1
and U
o2
.
7Negative temperature coefficient
(0…–3 mV/cell and K) available on
request.
8See:
Output Voltage Regulation of
Double Output Modules
.
9Measured 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
)
K Series DC-DC Converters >100 Watt Rugged Environment
Edition 4/4.99
10/31
MELCHER
The Power Partners.
Table 4f: Output data double output modules
CK...EK
Output CK...EK 2320 CK...EK 2540 CK...EK 2660
(Outputs connected in Series) 24 V (2 × 12 V) 30 V (2 × 15 V) 48 V (2 × 24 V)
Characteristics Conditions min typ max min typ max min typ max Unit
U
oOutput voltage
U
i nom,
I
o nom 24.0 2 30.0 2 48.0 2 V
U
o P Overvoltage protection 38 48 74
(suppressor diode)
I
o nom Output current 1
U
i min...
U
i max 6.0 5.0 3.0 A
T
C min...
T
C max
I
o L Output current limit 4
U
i min...
U
i max 6.2 5.2 3.2
u
o7Output Switching freq.
U
i nom,
I
o nom 15 15 20 mVpp
voltage Total IEC/EN 61204 100 120 120
noise 3 BW = 20 MHz
D
U
o u Static line regulation
U
i min...
U
i nom ±40 ±30 ±50 mV
U
i nom...
U
i max
I
o nom
D
U
o I Static load regulation
U
i nom,
I
o =40 30 40
(0.1...1)
I
o nom
u
o d 5Dynamic Voltage
U
i nom,
I
o = ±100 ±100 ±100
load deviation
I
o nom ↔ 1/2
I
o nom
t
d 5regulation Recovery IEC/EN 61204 0.3 0.5 0.4 ms
time
aUo Temperature coefficient
T
C min...
T
C max –2.2 –2.2 –2.6 mV/K
of output voltage 6 0...
I
o nom
1If the output voltages are increased above
U
o nom through R-input control, option P setting, remote sensing or option T, the output cur-
rent should be reduced accordingly so that
P
o nom is not exceeded.
2Series connection for
U
o nom = 24 V, 30 V or 48 V, see:
R-Function for Different Output Configurations
.
3Shortest possible wiring for series connection at the connector.
4See:
Output voltage regulation of single output units
.
5See:
Dynamic load regulation of U
o1
and U
o2.
6Negative temperature coefficient (0...–3 mV/cell and K) available on request
7Measured 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.
)
Table 4e: Output data single output modules CK...EK
Output CK...DK 1001 CK...EK 1301 CK...EK 1501 CK...EK 1601
5.1 V 12.0 V 15.0 V 24.0 V
Characteristics Conditions min typ max min typ max min typ max min typ max Unit
U
oOutput voltage
U
i nom,
I
o nom 5.07 5.13 11.93 12.07 14.91 15.09 23.86 24.14 V
U
o P Overvoltage protection 7.6 21 26.5 43.5
(suppressor diode)
I
o nom Output current 1
U
i min...
U
i max 25.0 12.0 10.0 6.0 A
T
C min...
T
C max
I
o L Output current limit 4
U
i min...
U
i max 26 12.2 10.2 6.2
u
o7Output Switching freq.
U
i nom,
I
o nom 10555mV
pp
voltage Total IEC/EN 61204 50 40 30 50
noise BW = 20 MHz
D
U
o u Static line regulation
U
i min...
U
i nom ±15 ±25 ±30 ±30 mV
U
i nom...
U
i max
I
o nom
D
U
o I Static load regulation
U
i nom,
I
o = 202530 40
(0.1...1)
I
o nom
u
o d 5Dynamic Voltage
U
i nom,
I
o = ±100 ±100 ±100 ±80
load deviation
I
o nom ↔ 1/2
I
o nom
t
d 5regulation Recovery IEC/EN 61204 0.3 0.5 0.4 0.3 ms
time
aUo Temperature coefficient
T
C min...
T
C max –1–1–1–2 mV/K
of output voltage 6 0...
I
o nom
Rugged Environment DC-DC Converters >100 Watt K Series
Edition 4/4.99
11/31
MELCHER
The Power Partners.
Table 4h: Output data double output modules CK...EK
Output CK...EK 2660
(Outputs independently loaded) 1 24 V/24 V
Characteristics Conditions Output 1 Output 2
min typ max min typ max Unit
U
oOutput voltage
U
i nom,
I
o nom 2 23.86 24.14 23.64 24.36 V
U
o P Overvoltage protection 37 37
(suppressor diode)
I
o nom Output current 3
U
i min...
U
i max 3.0 3.0 A
T
C min...
T
C max
I
o L Output current limit 4
U
i min...
U
i max 3.2 3.2
u
o9Output Switching freq.
U
i nom,
I
o nom 55mV
pp
voltage Total IEC/EN 61204 100 25
noise BW = 20 MHz
D
U
o u Static line regulation
U
i min...
U
i nom,±30 ±50 mV
U
i nom...
U
i max,
I
o nom
D
U
o I Static load regulation
U
i nom,
I
o =50
8
(0.1...1)
I
o nom5
u
o d 6Dynamic Voltage
U
i nom,
I
o = ±50
load deviation
I
o nom ↔ 1/2
I
o nom
t
d 6regulation Recovery IEC/EN 61204 0.2 ms
time
aUo Temperature coefficient
T
C min...
T
C max –1.3 mV/K
of output voltage 7 0...
I
o nom
Table 4g: Output data double output modules CK...EK
Output CK...EK 2320 CK...EK 2540
(Outputs independendtly loaded) 1 12 V/12 V 15 V/15 V
Characteristics Conditions Output 1 Output 2 Output 1 Output 2
min typ max min typ max min typ max min typ max Unit
U
oOutput voltage
U
i nom,
I
o nom 2 11.93 12.07 11.82 12.18 14.91 15.09 14.78 15.22 V
U
o P Overvoltage protection Failure in 19 19 24 24
(suppressor diode) control circuit
I
o nom Output current 3
U
i min...
U
i max 6.0 6.0 5.0 5.0 A
T
C min...
T
C max
I
o L Output current limit 4
U
i min...
U
i max 6.2 6.2 5.2 5.2
u
o9Output Switching freq.
U
i nom,
I
o nom 5555mV
pp
voltage Total IEC/EN 61204 75 25 100 25
noise BW = 20 MHz
D
U
o u Static line regulation
U
i min...
U
i nom ±30 ±40 ±30 ±40 mV
U
i nom...
U
i max
I
o nom
D
U
o I Static load regulation
U
i nom,
I
o = 100 8100 8
(0.1...1)
I
o nom 5
u
o d 6Dynamic Voltage
U
i nom,
I
o = ±100 ±80
load deviation
I
o nom ↔ 1/2
I
o nom
t
d 6regulation Recovery IEC/EN 61204 0.3 0.2 ms
time
aUo Temperature coefficient
T
C min...
T
C max –1.1 –1.1 mV/K
of output voltage 7 0...
I
o nom
1Depending upon the desired out-
put configuration the wiring should
be made as shown in:
R-Function
for Different Output Configurations
.
2Same conditions for both outputs.
3If the output voltages are in-
creased above
U
o nom via R-input
control, option P setting, remote
sensing or option T, the output cur-
rents should be reduced accord-
ingly so that
P
o nom is not ex-
ceeded.
4See:
Output voltage regulation of
single output units
.
5Condition for specified output.
Other output loaded with constant
current
I
o =
I
o nom.
6See:
Dynamic load regulation of
U
o1
and U
o2
.
.
7Negative temperature coefficient
(0...–3 mV/cell and K) available on
request.
8See:
Output Voltage Regulation of
Double Output Modules
.
9Measured 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.
)
K Series DC-DC Converters >100 Watt Rugged Environment
Edition 4/4.99
12/31
MELCHER
The Power Partners.
Output Protection
Each output is protected against overvoltages which could
occur due to a failure of the internal control circuit. Voltage
suppressor diodes (which under worst case condition may
become a short circuit) provide the required protection. The
suppressor diodes are not designed to withstand externally
applied overvoltages. Overload at any of the outputs will
cause a shut-down of all outputs. 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.
With option T (current sharing), all units share the current
approximately equally.
Single output units and/or main and second outputs of dou-
ble output units can be connected in series with any other
(similar) output.
Note:
–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.
–Series connection of second outputs without involving
their main outputs should be avoided as regulation may
be poor.
–The maximum output current is limited by the output with
the lowest current limitation if several outputs are con-
nected in series.
Thermal Considerations
If a converter is located in free, quasi-stationary air (con-
vection cooling) at the indicated maximum ambient tem-
perature
T
A max (see table:
Temperature specifications)
and
is operated at its nominal input voltage and output power,
the temperature measured at the
Measuring point of case
temperature T
C
(see:
Mechanical Data
) will approach the
indicated value
T
C max after the warm-up phase. However,
the relationship between
T
A and
T
C depends heavily on the
conditions of operation and integration into a system. The
thermal conditions are influenced by input voltage, output
current, airflow and temperature of surrounding compo-
nents and surfaces.
T
A max is therefore, contrary to
T
C max,
an indicative value only.
Caution: The installer must ensure that under all operat-
ing conditions
T
C remains within the limits stated in the
table
Temperature specifications.
Notes: Sufficient forced cooling or an additional heat sink
allows
T
A to be higher than 71°C (e.g. 85°C) if
T
C max is not
exceeded.
For -7 or -9 units at an ambient temperature
T
A of 85°C with
only convection cooling, the maximum permissible current
for each output is approx. 40% of its nominal value as per
figure.
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
50 60 70 80 90 100
I
o
/I
o nom
T
A
[°C]
0.9
1.0
Forced cooling
05089
T
A min
T
C max
Convection cooling
Fig. 7
Output current derating versus temperature for -7 and -9
units.
Thermal Protection
A temperature sensor generates an internal inhibit signal
which disables the outputs if the case temperature exceeds
T
C max. The outputs are automatically re-enabled if the tem-
perature drops below this limit.
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.
Uo1d
Uo1d
tdtd
UrUr
t
t
t
Uo2d
<10 µs<10 µs
Uo1
Uo2
Io1/Io1 nom
0
0.5
1
Io2/Io2 nom
05072
Fig. 8
Typical dynamic load regulation of
Uo1 and Uo2
Rugged Environment DC-DC Converters >100 Watt K Series
Edition 4/4.99
13/31
MELCHER
The Power Partners.
Output Voltage Regulation of Double Output Modules
Output 1 is under normal conditions regulated to
U
o1 nom,
independent of the output currents.
U
o2 is dependent upon the load distribution. If both outputs
are loaded with more than 10% of
I
o nom, the deviation of
U
o2 remains within ±5% of the value of
U
o1. The following 3
figures show the regulation with varying load distribution. If
I
o1 =
I
o2 or the two outputs are connected in series, the de-
viation of
U
o2 remains within ±1% of the value of
U
o1 pro-
vided that a total load of more than 10% of
I
o 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.
Fig. 10
AK...EK 2320:
D
U
o2
(typ.) vs. I
o2
with different I
01
0123456
Io nom
78
Io2
[A]
11.2
11.4
11.6
11.8
12.0
12.2
12.4
12.6
[V] Uo2
Io1 = 6.0 A
Io1 = 4.5 A
Io1 = 3.0 A
Io1 = 1.5 A
Io1 = 0.6 A
05105
0123456
I
o nom
7
I
o2
[A]
14.00
14.25
14.50
14.75
15.00
15.25
15.50
15.75
[V] U
o2
I
o1
= 5.00 A
I
o1
= 3.75 A
I
o1
= 2.50 A
I
o1
= 1.25 A
I
o1
= 0.50 A
05106
Fig. 11
AK...EK 2540:
D
U
o2
(typ.) vs. I
o2
with different I
01
[V] U
o2
I
o2
[A]
0 0.5 1 1.5 2 2.5 3
I
o nom
3.5 4
23.0
23.5
24.0
24.5
25.0
25.5
26.0 I
o1
= 3.0 A
I
o1
= 2.0 A
I
o1
= 1.0 A
I
o1
= 0.5 A
I
o1
= 0.3 A
05107
Fig. 12
AK...EK 2660:
D
U
o2
(typ.) vs. I
o2
with different I
01
Output Voltage Regulation of Single or Double Output
Modules with Outputs 1 and 2 Connected in Series
Fig. 9
U
o1
vs. I
o1
(typ.) of single output units AK...EK
Uo
Uo nom
0.98
0.5
00.5 1.0
Io1
IoL
Io
Io nom
05098
K Series DC-DC Converters >100 Watt Rugged Environment
Edition 4/4.99
14/31
MELCHER
The Power Partners.
Fig. 15
Typical output response as a function of inhibit control
Table 5: Inhibit characteristics
Characteristic Conditions min typ max Unit
U
inh Inhibit
U
o = on
U
i min…
U
i max –50 0.8 V
voltage
U
o = off 2.4 50
I
inh Inhibit current
U
inh = 0 –400 µA
t
rRise time 30 ms
t
fFall time depending on
I
o
0t
t
0
Inhibit
1
0.1
1
Uo/Uo nom
trtf
06001
Sense Lines
(Only for single output units 5.1 V, 12 V, 15 V, 24 V)
This feature enables for compensation of voltage drops
across the connector contacts and if necessary, across the
load lines. If the sense lines are connected at the load
rather than directly at the connector, the user should ensure
that
U
o max (between Vo1+ and Vo1–) is not exceeded. We
recommend connecting the sense lines directly at the fe-
male connector.
For further information, please refer to:
Application Notes
.
To ensure correct operation, both sense lines (S+ and S–)
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:
Table 6: Maximum voltage compensation allowed using
sense lines
Output Total voltage difference Voltage difference
voltage between sense lines and between
their respective outputs Vo– and S–
5.1 V < 0.5 V < 0.25 V
12 V, 15 V < 1.0 V < 0.25 V
If the output voltages are increased above
U
o nom via R-in-
put control, option P setting, remote sensing or option T, the
output currents must be reduced accordingly so that
P
o nom is not exceeded.
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.
Auxiliary Functions
i Inhibit for Remote On and Off
Note: With open i input: Output is disabled (
U
o = off).
The outputs of the module may be enabled or disabled by
means of a logic signal (TTL, CMOS, etc.) applied between
the inhibit input i and the negative pin of output 1 (Vo1–). In
systems with several units, this feature can be used, for ex-
ample, to control the activation sequence of the converters.
If the inhibit function is not required, connect the inhibit pin
18 to pin 14 to enable the outputs (active low logic, fail
safe). For output response refer to:
Hold-up Time and Out-
put Response
.
Vi+
Vi–Vo–
i
Vo+
I
inh
U
inh
06031
1.6
0.8
0
–0.8
–50 U
inh
[V]
I
inh
[mA]
–30 0–10 10 30 50
2.0
1.2
0.4
–0.4
U
inh
= 0.8 V
U
o
= on U
o
= off
U
inh
= 2.4 V
06032
Fig. 13
Definition of U
inh
and I
inh
.
Fig. 14
Typical inhibit current I
inh
versus inhibit voltage U
inh
Rugged Environment DC-DC Converters >100 Watt K Series
Edition 4/4.99
15/31
MELCHER
The Power Partners.
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
U
ext or a resistor
R
ext to adjust the desired output voltage.
When not connected, the control input automatically sets
the output voltage to
U
o nom.
a) Adjustment by means of an external control voltage
U
ext
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%
U
o nom.
U
o
U
ext = –––––– • 2.5 V (approximate formula)
U
o nom
b) Adjustment by means of an external resistor:
Depending upon the value of the required output voltage
the resistor shall be connected
Either: Between pin 16 and pin 14 (
U
o <
U
o nom) to
achieve an output voltage adjustment range of approxi-
mately 0...100%
U
o nom
or: Between pin 16 and pin 12 (
U
o >
U
o nom) to achieve an
output voltage adjustment range of approximately
100...110%
U
o nom.
Warning:
–
U
ext shall never exceed 2.75 V DC.
–The value of
R'
ext shall never be less than the lowest
value as indicated in table R'ext for (
U
o >
U
o nom) to
avoid damage to the unit!
Remarks:
–The R-Function excludes option P (output voltage adjust-
ment by potentiometer).
–If the output voltages are increased above
U
o nom via R-
input control, option P setting, remote sensing or option
T, the output current(s) should be reduced accordingly so
that
P
o nom is not exceeded.
–The R-input (as well as option P) is related to the main
output.
–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%.
Fig. 16
Output voltage control for single output units AK...EK 1000
by means of the R input
Table 7a: R
ext
for U
o
<
U
o nom
; approximative values (U
i nom,
I
o nom
, series E 96 resistors); R'
ext
=
∞
U
o nom = 5.1 V
U
o nom = 12 V
U
o nom = 15 V
U
o nom = 24 V
U
o (V)
R
ext [kΩ]
U
o [V] 1
R
ext [kΩ]
U
o [V] 1
R
ext [kΩ]
U
o [V] 1
R
ext [kΩ]
0.5 0.422 2 4 0.825 2 4 0.56 4 8 0.825
1.0 1.0 3 6 1.3 4 8 1.47 6 12 1.33
1.5 1.62 4 8 1.96 6 12 2.61 8 16 1.96
2.0 2.16 5 10 2.87 8 16 4.64 10 20 2.87
2.5 3.83 6 12 3.83 9 18 6.19 12 24 3.83
3.0 5.61 7 14 5.62 10 20 8.25 14 28 5.61
3.5 9.09 8 16 8.28 11 22 11.0 16 32 8.25
4.0 14.7 9 18 12.1 12 24 16.2 18 36 12.1
4.5 28.7 10 20 19.6 13 26 26.1 20 40 19.6
5.0 196 11 22 42.2 14 28 56.2 22 44 46.4
Table 7b:
R’
ext
for U
o
>
U
o nom
; approximative values (U
i nom
, I
o nom
, series E 96 resistors); R
ext
=
∞
U
o nom = 5.1 V
U
o nom = 12 V
U
o nom = 15 V
U
o nom = 24 V
U
o [V]
R'
ext [kΩ]
U
o [V] 1
R'
ext [kΩ]
U
o [V] 1
R'
ext [kΩ]
U
o [V] 1
R'
ext [kΩ]
5.15 422 12.1 24.2 1780 15.2 30.4 1470 24.25 48.5 3160
5.2 215 12.2 24.4 909 15.4 30.8 750 24.5 49.0 1620
5.25 147 12.3 24.6 623 15.6 31.2 511 24.75 49.5 1100
5.3 110 12.4 24.8 464 15.8 31.6 383 25.0 50.0 825
5.35 90.9 12.5 25.0 383 16.0 32.0 316 25.25 50.5 681
5.4 75 12.6 25.2 316 16.2 32.4 261 25.5 51.0 562
5.45 61.9 12.7 25.4 286 16.4 32.8 237 25.75 51.5 511
5.5 56.2 12.8 25.6 234 16.5 33.0 215 26.0 52.0 464
13.0 26.0 196 26.25 52.5 422
13.2 26.4 162 26.4 52.8 383
1First column: single output units or double output units with separated outputs, second column: outputs in series connection
R
Vo1+
Vo1–
S–
U
ext
Vi+
Vi–
R
ext
R'
ext
14
16
16
14
+
S+
Vo1+
Vo1–
S–
Vi+
Vi–
R
12
05074
K Series DC-DC Converters >100 Watt Rugged Environment
Edition 4/4.99
16/31
MELCHER
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R-Function for Different Output Configurations
Fig. 17a
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.
Fig. 17b
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.
Fig. 17c
AK...EK 2000 with H15 connector. R-input for output volt-
age control. Wiring of main and second output for two
symmetrical output voltages U
o1
and U
o2
:
±
12 V or
±
15 V
or
±
24 V.
R'ext
Rext
14
16
Vo1–
Vo1+
R
Vo2–
Vo2–
Vo2+
Vo2+
12
10
8
6
4
+
–
Uo1
12 V
15 V
24 V
1
06005
R'
ext
R
ext
14
16
Vo1–
Vo1+
R
Vo2–
Vo2–
Vo2+
Vo2+
12
10
8
6
4
U
o2
0 V
–12/–15/–24 V
+12/+15/+24 V
U
o1
1
1
+
–
06006
R'
ext
R
ext
14
16
Vo1–
Vo1+
R
Vo2–
Vo2–
Vo2+
Vo2+
12
10
8
6
4
U
o1
+24/+30/+48 V
+12/+15/+24 V
0 V
U
o2
1
1
2
+
+
06007
R'ext
Rext
14
16
Vo1–
Vo1+
R
Vo2–
Vo2–
Vo2+
Vo2+
12
10
8
6
4
+
–
Uo1
24 V
30 V
48 V
1
2
06004
Fig. 17d
AK...EK 2000 with H15 connector. R-input for output volt-
age control. Wiring of main and second output for two
output voltages U
o1
and U
o2
: +12 V
and +24 V or +15 V
and +30 V or +24 V and +48 V.
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 U
o1
and U
o2:
12 V/12 V or 15 V/15 V or
24 V/24 V, the outputs are galvanically isolated.
R'ext
Rext
14
16
Vo1–
Vo1+
R
Vo2–
Vo2–
Vo2+
Vo2+
12
10
8
6
4+
–
Uo2
12 V
15 V
24 V –
+
12 V
15 V
24 V
Uo1 1
1
06008
Remarks:
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.
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.
Please note:
U
o2 varies depending upon its own load and
the load on output 1.
1A ceramic multilayer capacitor connected across the output
lines reduces ripple and spikes.
2Shortest possible wiring for series connection at the female con-
nector
Rugged Environment DC-DC Converters >100 Watt K Series
Edition 4/4.99
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MELCHER
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Display Status of LEDs
Uo1 > 0.95...0.98Uo1 adj
Ui max Ui ov
Ui min
Ui uv
Ui
Ui abs
OK
i
Uo1 > 0.95...0.98Uo1 adj
Io nom IoL
Io
OK
Io L
Uo1 < 0.95...0.98Uo1 adj
TC
i
TC max TPTC threshold
Ui inh
i
+50 V
+0.8 V +2.4 V
-50 V
Uinh threshold
Io L
LED off LED on
LED Status undefined
06002
Fig. 18
LEDs
"
OK
"
,
"
i
"
and
"
I
o L"
status versus input voltage
Conditions: I
o £
I
o nom
, T
C £
T
C max
, U
inh £
0.8 V
U
i uv
= undervoltage lock-out, U
i ov
= overvoltage lock-out
LEDs
"
OK
"
and
"
I
o L"
status versus output current
Conditions: U
i min...
U
i max
, T
C £
T
C max
, U
inh £
0.8 V
LED
"
i
"
versus case temperature
Conditions: U
i min...
U
i max
, I
o £
I
o nom
, U
inh £
0.8 V
LED
"
i
"
versus U
inh
Conditions: U
i min...
U
i max
, I
o £
I
o nom
, T
C £
T
C max
Test Sockets (Main output only)
Test sockets for measuring the output voltage
U
o1 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
U
o = 24 V, 30 V or 48 V the monitored output voltage
is 12 V, 15 V or 24 V respectively.
K Series DC-DC Converters >100 Watt Rugged Environment
Edition 4/4.99
18/31
MELCHER
The Power Partners.
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 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
Electromagnetic Immunity
Table 8: Immunity type tests
Phenomenon Standard 1 Level Coupling Value Waveform Source Test In Per-
mode 2 applied imped. procedure oper. form. 3
Voltage surge IEC 60571-1 i/c, +i/–i 800 Vp100 µs 100 Ω1 pos. and 1 neg. yes A
1500 Vp50 µsvoltage surge per
3000 Vp5 µscoupling mode
4000 Vp1 µs
7000 Vp100 ns
Supply related RIA 12 A 4 +i/–i 3.5 •
U
batt 2/20/2 ms 0.2 Ω1 positive yes A
surge B 1.5 •
U
batt 0.1/1/0.1 s surge
Direct transient C +i/c, –i/c 960 Vp10/100 µs5 Ω5 pos. and 5 neg. yes B
D 1800 Vp5/50 µsimpulses
E 3600 Vp0.5/5 µs 100 Ω
F 4800 Vp0.1/1 µs
G 8400 Vp0.05/0.1 µs
Indirect coupled H +o/c, –o/c, 1800 Vp5/50 µs5
transient J 3600 Vp0.5/5 µs
K 4800 Vp0.1/1 µs
L 8400 Vp0.05/0.1 µs
Electrostatic IEC/EN 4 contact discharge 8000 Vp1/50 ns 330 Ω10 positive and yes A
discharge 61000-4-2 air discharge 15000 Vp10 negative
(to case) discharges
Electromagnetic IEC/EN 3 antenna 10 V/m AM 80% n.a. 26…1000 MHz yes A
field 61000-4-3 1 kHz
Electromagnetic ENV 50204 50% duty cycle, 900 ±5 MHz yes A
field, 200 Hz repetition
pulse modulated frequency
Electrical fast IEC/EN 4 capacitive, o/c 2000 Vpbursts of 5/50 ns 50 Ω1 min positive yes A
transient/burst 61000-4-4 i/o, +i/–i 4000 Vp2.5/5 kHz over 1 min negative
direct 15 ms; burst transients per
period: 300 ms coupling mode
Surge IEC/EN 3 i/c 2000 Vp1.2/50 µs 12 Ω5 pos. and 5 neg. yes A
61000-4-5 4 +i/–i2 Ωsurges per
coupling mode
Conducted IEC/EN 3 i, o, signal wires 10 Vrms AM 80% 150 Ω0.15...80 MHz yes A
disturbances 61000-4-6 (140 dBµV) 1 kHz
1Related and previous standards are referenced in:
Technical Information: Standards
.
2i = input, o = output, c = case.
3A = Normal operation, no deviation from specifications, B = Normal operation, temporary deviation from specs possible.
4Only 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.
5Test in progress, please consult factory.
Note: Previous standards are referenced in:
Technical Information: Standards
.
Rugged Environment DC-DC Converters >100 Watt K Series
Edition 4/4.99
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MELCHER
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Fig. 19
Typical disturbance voltage (quasi-peak) at the input ac-
cording to CISPR 11/22 and EN 55011/22, measured at
U
i nom
and I
o nom.
90
80
70
60
50
40
30
20
10
0
0.01
0.05
0.1
0.5
1
2
5
10
20
30
u
[dBµV]
[MHz]
0.02
07037
A
B
f
50
40
30
20
10
0
30
50
100
200
500
1000
[dBµV/m]
[MHz]
A
B
07077
Fig. 20
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 U
i nom
and
I
o nom.
Electromagnetic Emission
K Series DC-DC Converters >100 Watt Rugged Environment
Edition 4/4.99
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Immunity to Environmental Conditions
Table 9: Mechanical stress
Test method Standard Test conditions Status
Ca Damp heat IEC/DIN IEC 60068-2-3 Temperature: 40 ±2 °C Unit not
steady state MIL-STD-810D section 507.2 Relative humidity: 93 +2/-3 % operating
Duration: 56 days
Ea Shock IEC/EN/DIN EN 60068-2-27 Acceleration amplitude: 100 gn = 981 m/s2Unit
(half-sinusoidal) MIL-STD-810D section 516.3 Bump duration: 6 ms operating
Number of bumps: 18 (3 each direction)
Eb Bump IEC/EN/DIN EN 60068-2-29 Acceleration amplitude: 40 gn = 392 m/s2Unit
(half-sinusoidal) MIL-STD-810D section 516.3 Bump duration: 6 ms operating
Number of bumps: 6000 (1000 each direction)
Fc Vibration IEC/EN/DIN EN 60068-2-6 Acceleration amplitude: 0.35 mm (10...60 Hz) Unit
(sinusoidal) MIL-STD-810D section 514.3 5 gn = 49 m/s2 (60...2000 Hz) operating
Frequency (1 Oct/min): 10...2000 Hz
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 DIN 40046 part 23 Frequency band: 20...500 Hz operating
Reproducibility Acceleration magnitude: 4.9 gn rms
high Test duration: 3 h (1 h each axis)
Kb Salt mist, cyclic IEC/EN/DIN IEC 60068-2-52 Concentration: 5% (30°C) Unit not
(sodium chloride Duration: 2 h per cycle operating
NaCl solution) Storage: 40°C, 93% rel. humidity
Storage duration: 22 h per cycle
Number of cycles: 3
Table 10: Temperature specifications, valid for an air pressure of 800...1200 hPa (800...1200 mbar)
Temperature Standard -7 Option -9
Characteristics Conditions min max min max Unit
T
AAmbient temperature 1 Operational 2 –25 71 –40 71 °C
T
CCase temperature 3 –25 95 –40 95
T
SStorage temperature 1 Non operational –40 100 –55 100
1MIL-STD-810D section 501.2 and 502.2.
2See:
Thermal Considerations
.
3Overtemperature lock-out at
T
C >95°C (PTC).
Table 11: MTBF
Values at specified Module types Ground benign Ground fixed Ground mobile Unit
case temperature 40°C40°C70°C50°C
MTBF 1 AK...EK 500'000 150'000 80'000 50'000 h
Device hours 2 500'000
1Calculated in accordance with MIL-HDBK-217F.
2Statistical values, based on an average of 4300 working hours per year and in general field use, over 3 years.
Rugged Environment DC-DC Converters >100 Watt K Series
Edition 4/4.99
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Fig. 21
Case K02 with heatsink, case aluminium, black finish and
self cooling, weight: Approx. 1.55 kg
Note:
–d ≥15 mm, recommended minimum distance to
next part to ensure proper air circulation at full
output power.
–free air locations: the module should be moun-
ted with fins in vertical position to achieve a
maximum air flow through the heat sink.
Fig. 22
Case K02 with option B1 (cooling plate),case aluminium,
black finish and self cooling, weight: Approx. 1.15 kg
Mechanical Data
Dimensions in mm. Tolerances ±0.3 mm unless otherwise indicated.
European
Projection
159 4.5
89
111 (3U)
168.5
±0.5
d
80
4.5
19.7
9.5
29.9
6.5
51.5
30.3
20.3
12.1
10.3
7.0
3.27
7 TE 9 TE
Test jacks (+/–)
Option P (U
o
)
Option D (U
ti
)
LED OK (green)
LED i (red)
LED I
oL
(red)
Option D (U
to
)
25.9 11.8
Front plate Main face Back plate
Measuring point of
case temperature T
C
171.93 (DIN 41494)
50
= Ø 3.5
= Ø 4.1
09002
42
Gravitational
axis
111 (3U)
17.3 133.4
168
±0.5
101
5
47.2
158
5
M 4
5
Measuring point of
case temperature T
C
50
171.93 (DIN 41494)
3.27
7 TE 4 TE
09003
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.)
K Series DC-DC Converters >100 Watt Rugged Environment
Edition 4/4.99
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The Power Partners.
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
Installation Instructions
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.
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
.
Table 12: H15 and H15 S4 connector pin allocation
Pin Connector type H15 S4 Connector type H 15
No. AK 1000 (all), BK...EK 1001 AK 2000 BK…EK 1301/1501/1601 BK…EK 2000
4Vo1+ Output 1 Vo2+ Output 2 Vo1+ Output 1 Vo2+ Output 2
6 Vo1+ Vo2+
8Vo1–Output 1 Vo2–Output 2 Vo1–Output 1 Vo2–Output 2
10 Vo1–Vo2–
12 S+ Sense Vo1+ Output 1 S+ Sense Vo1+ Output 1
14 S–Sense Vo1–Output 1 S–Sense Vo1–Output 1
16 R 1 Control of
U
o1 R 1 Control of
U
o1 R 1 Control of
U
o1 R 1 Control of
U
o1
18 i Inhibit i Inhibit i Inhibit i Inhibit
20 D 3 Save data D Safe data D Save data D Save data
V 3 ACFAIL
22 T Current sharing T Current sharing T Current sharing T Current sharing
24 2Protective earth Protective earth Protective earth Protective earth
26 Vi+ Input Vi+ Input Vi+ Input Vi+ Input or Neutral
28 Vi+ Vi+
30 Vi–Input Vi–Input Vi–Input Vi–Input or Phase
32 Vi–Vi–
1Feature R excludes option P and vice versa; 2 Leading pin (pregrounding); 3 Option D excludes option V and vice versa.
Fig. 23
View of module's male connectors
4/630/32
Type H15 S4
Fixtures for connector
retention clips V
(see Accessory Products)
10010
432
Type H15
Fixtures for connector
retention clips V
(see Accessory Products)
10010
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.
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).
Do not open the modules, or guarantee will be invali-
dated.
AK...FK DC-DC converters is leading, ensuring that it
makes contact with the female connector first.
Rugged Environment DC-DC Converters >100 Watt K Series
Edition 4/4.99
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MELCHER
The Power Partners.
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.
Make sure that there is sufficient air flow possible for con-
vection cooling. This should be verified by measuring the
case temperature when the unit is installed and operated in
the end-use application. The maximum specified case tem-
perature
T
C max shall not be exceeded. See also
Thermal
Considerations.
If the end-product is to be UL certified, the temperature of
the main isolation transformer should be evaluated as part
of the end-product investigation.
Check for hazardous voltages before altering any connec-
tions.
Ensure that a unit failure (e.g. by an internal short-circuit)
does not result in a hazardous condition. See also:
Safety
of operator accessible output circuit.
Cleaning Agents
In order to avoid possible damage, any penetration of
cleaning fluids is to be prevented, since the power supplies
are not hermetically sealed.
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 Input to Output to Output to Unit
case output case output
Electric Required according to AK, BK 1.0 2.0 1 0.5 - kVrms
strength IEC/EN 60950 1.4 2.8 1 0.7 - kV DC
test voltage CK, DK 1.5 3.0 1 0.5 - kVrms
EK, FK 2.1 4.2 1 0.7 - kV DC
Actual factory test 1 s AK, BK 2.8 5.6 1 1.4 0.14
AC test voltage equivalent CK, DK 2.0 4.0 1 1.0 0.1 kVrms
to actual factory test EK, FK
Insulation resistance at 500 V DC >300 >300 >300 >100 2 MΩ
1In accordance with IEC/EN 60950 only subassemblies are tested in factory with this voltage.
2Tested at 150 V DC.
For creepage distances and clearances refer to:
Technical
Information: Safety.
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 V AC and 400 V DC
(CK, DK, EK, FK),
•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.
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
In order to avoid possible damage, any penetration of
cleaning fluids is to be prevented, since the power supplies
are not hermetically sealed.
Protection Degree
Condition: Female connector fitted to the unit.
IP 30: All units except those with option P, and except
those with option D or V with potentiometer.
IP 20: All units fitted with option P, or with option D or V with
potentiometer.
K Series DC-DC Converters >100 Watt Rugged Environment
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The Power Partners.
Table 14: Safety concept leading to an SELV output circuit
Conditions Front end DC-DC converter Result
Nominal Minimum required grade Nominal DC Minimum required Types Measures to achieve the Safety status
supply of isolation, to be provided output voltage safety status of the specified safety status of of the DC-DC
voltage by the AC-DC front end, from the front end front end output the output circuit converter
including mains supplied circuit output circuit
battery charger
Mains Operational (i.e. there is ≤100 V (The Primary circuit AK Double or reinforced SELV circuit
≤150 V AC no need for electrical nominal voltage BK insulation, based on
isolation between the between any input the mains voltage and 2
mains supply voltage pin and earth can (provided by the DC-DC
and the DC-DC converter be up to 150 V AC converter) and earthed
input voltage) or DC) case 3
Mains ≤400 V (The CK
≤250 V AC nominal voltage DK
between any input EK
pin and earth can FK
be up to 250 V AC
or 400 V DC)
Basic ≤400 V Unearthed AK Supplementary insulation,
hazardous voltage BK based on 250 V AC and
secodary circuit CK double or reinforced
DK insulation 2 (provided by
EK DC-DC converter) and
FK earthed case 3.
Earthed Double or reinforced
hazardous voltage insulation 2 (provided by
secondary circuit 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
1The front end output voltage should match the specified input voltage range of the DC-DC converter.
2Based on the maximum nominal output voltage from the front end.
3The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC/EN 60950.
4Earthing of the case is recommended, but not mandatory.
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
.
AC-DC
front
end
DC-DC
con-
verter
Mains Battery SELV
Earth connection
+
–
~
~
10044
Max. 150 V AC or DC for AK, BK
Max. 250 V AC or 400 V DC for CK, DK, EK, FK
Fuse
Fuse
Max. 150 V AC or DC for AK, BK
Max. 250 V AC or 400 V DC for CK, DK, EK, FK
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.
The following table shows some possible installation con-
figurations, compliance with which causes the output circuit
of the DC-DC converter to be an SELV circuit according to
IEC/EN 60950 up to a configured output voltage (sum of
nominal voltages if in series or +/– configuration) of 35 V.
However, it is the sole responsibility of the installer to as-
sure the compliance with the relevant and applicable safety
regulations. More information is given in:
Technical Infor-
mation: Safety
.
Rugged Environment DC-DC Converters >100 Watt K Series
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MELCHER
The Power Partners.
R
V
: Current limiting resistance = R
S
+ R
I = 15 Ω
Î [A]
U
i
/R
V
<30
t [ms]
CapacitorC
i
fully charged
Normal operation
(current limiting
circuit is fully
conducting)
0
0
I
i
= P
i
/U
i
11039
Fig. 26
Inrush current with option E
Table 16: Inrush current characteristics with option E
Characteristics CK DK EK Unit
U
i nom,
I
o nom Input voltage 60 110 220 V
I
inr p Peak inrush 6.8 7.4 14.6 A
current
t
inr Inrush current 18 14 16 ms
duration
U
i max,
I
o nom Input voltage 140 220 380 V
I
inr p Peak inrush 9.3 14.5 25.3 A
current
t
inr Inrush current 20 14 12 ms
duration
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 (
T
C=95°C) max. 1
cycle every 8 sec.
Input Filter
Control
Converter
FET
C
i
R
I
R
S
10017
Fig. 25
Option E block diagram
P Potentiometer
The potentiometer provides an output voltage adjustment
range of +10/–60% of
U
o 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.
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).
If the output voltages are increased above
U
o nom via R-in-
put control, option P setting, remote sensing or option T, the
output current(s) should be reduced accordingly so that
P
o nom is not exceeded.
Description of Options
Table 15: Survey of options
Option Function of Option Characteristics
-9 Extended operational ambient temperature range
T
A = –40°C...71°C
E Electronic inrush current limitation circuitry Active inrush current limitation for CK, DK, EK
P 1 Potentiometer for fine adjustment of output voltage Adjustment range +10/–60% of
U
o nom excludes R input
D 2 Input and/or output undervoltage monitoring circuitry Safe data signal output (Versions D0...DD)
V 2 3 Input (and output) undervoltage monitoring circuitry ACFAIL signal according to VME specs (Versions V0, V2, V3)
T Current sharing Interconnect T-pins if paralleling outputs (5 units max.)
B1/B2 Cooling plate Replaces standard heat sink, allowing direct chassis-mounting
1Function R excludes option P and vice versa.
2Option D excludes Option V and vice versa .
3Only available if main output voltage
U
o1 = 5.1.
-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.
E Inrush Current Limitation
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).
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.
K Series DC-DC Converters >100 Watt Rugged Environment
Edition 4/4.99
26/31
MELCHER
The Power Partners.
Vo+
Vo–
Vo+
Vo–
Load
Vo+
Vo–
11003
Fig. 27
An example of poor wiring for connection in parallel
T Current Sharing
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.
Fig. 28
Paralleling of single output units using option T with the
sense lines connected at the load
1Leads should have equal length and cross sections and should
run in the same cable loom.
2Diodes recommended in redundant operation only
3DC common point
Load
1
1
1
2
2
3
3
S+
Vo+
Vo–
S–
Vi+
Vi–
T
Vi+
Vi–
S+
Vo+
Vo–
S–
T
1
max. 5 units in parallel connection
11036
Load
max. 5 units in parallel connection
+–
Power bus
Module
Vo2–
Vo2+
Vo1–
Vo1+
T
Module
Vo2–
Vo2+
Vo1–
Vo1+
T
11037
Fig. 29
Paralleling of double output units using option T with
Power Bus
Rugged Environment DC-DC Converters >100 Watt K Series
Edition 4/4.99
27/31
MELCHER
The Power Partners.
Fig. 30
Option D1...D0: JFET output, I
D £
2.5 mA
NPN output (D5...DD):
Connector pin D is internally connected via the collector-
emitter path of a NPN transistor to the negative potential of
output 1.
U
D < 0.4 V (logic low) corresponds to a monitored
voltage level (
U
i and/or
U
o1) >
U
t +
U
h. The current
I
D
through the open collector should not exceed 20 mA. The
NPN output is not protected against external overvoltages.
U
D should not exceed 40 V.
U
i,
U
o1 status D output,
U
D
U
i or
U
o1 <
U
thigh, H,
I
D ≤ 25 µA at
U
D = 40 V
U
i and
U
o1 >
U
t +
U
hlow, L,
U
D ≤ 0.4 V at
I
D = 20 mA
Table 18: D-output logic signals
Version of D
U
i <
U
t resp.
U
o <
U
t
U
i >
U
t +
U
h resp.
U
o >
U
tConfiguration
D1, D2, D3, D4, D0 low high JFET
D5, D6, D7, D8, D9, DD high low NPN
JFET output (D0…D4):
Connector pin D is internally connected via the drain-
source path of a JFET (self-conducting type) to the nega-
tive potential of output 1.
U
D ≤ 0.4 V (logic low) corresponds
to a monitored voltage level (
U
i and/or
U
o1) <
U
t. The cur-
rent
I
D through the JFET should not exceed 2.5 mA. The
JFET is protected by a 0.5 W Zener diode of 8.2 V against
external overvoltages.
U
i,
U
o1 status D output,
U
D
U
i or
U
o1 <
U
tlow, L,
U
D ≤ 0.4 V at
I
D = 2.5 mA
U
i and
U
o1 >
U
t +
U
hhigh, H,
I
D ≤ 25 µA at
U
D = 5.25 V
Vo1+
Vo1–
D
U
D
I
D
R
p
Input
11007
Vo1+
Vo1–
D
U
D
I
D
R
p
Input
11006
Fig. 31
Option D5...DD: NPN output, U
o1 £
40 V, I
D £
20 mA
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
U
t. The return for this signal is Vo1–. The D output recovers
when the monitored voltage(s) exceed(s)
U
t +
U
h. The
threshold levels
U
ti and
U
to 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 Typical hysteresis
U
h [% of
U
t]
JFET NPN
U
i
U
o1 of threshold level
U
tfor
U
t min...
U
t max
U
ti
U
to
U
hi
U
ho
D1 D5 no yes - 3.5...40 V 1 - 2.5...0.6
D2 D6 yes no
U
i min...
U
i max 1 - 3.4...0.4 -
D3 D7 yes yes
U
i min...
U
i max 1 (0.95...0.985
U
o1) 2 3.4...0.4 "0"
D4 D8 no yes - (0.95...0.985
U
o1) 2 - "0"
D0 D9 no yes - 3.5...40 V 3 - 2.5...0.6
yes no
U
i min...
U
i max 3 4 - 3.4...0.4 -
yes yes
U
i min...
U
i max 3 4 3.5...40 V 3 3.4...0.4 2.5...0.6
yes yes
U
i min...
U
i max 3 4 (0.95...0.985
U
o1) 2 3.4...0.4 "0"
- DD yes yes
U
i min...
U
i max 1 3.5...40 V 1 3.4...0.4 2.5...0.6
1Threshold level adjustable by potentiometer
2Fixed value tracking if
U
o1 is adjusted via R-input, option P or sense lines.
3The 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)!
4Adjusted at
I
o nom
K Series DC-DC Converters >100 Watt Rugged Environment
Edition 4/4.99
28/31
MELCHER
The Power Partners.
Threshold tolerances and hysteresis:
If
U
i is monitored, the internal input voltage after the input
filter is measured. Consequently this voltage differs from
the voltage at the connector pins by the voltage drop D
U
ti
across the input filter. The threshold levels of the D0 and D9
options are factory adjusted at nominal output current
I
o nom
and at
T
A = 25°C. The value of D
U
ti depends upon the input
voltage range (CK, DK, ..), threshold level
U
t, temperature
and input current. The input current is a function of the input
voltage and the output power.
Fig. 32
Definition of U
ti, ∆
U
t i
and
∆
U
hi
(JFET output)
D
U
ti
U
hi
U
D low
U
D
U
D high
U
i
P
o =
P
o nom
P
o
= 0
P
o = 0
U
ti
P
o
=
P
o nom
11021
D-signal with respect to input and output voltage versus time:
Fig. 33
Relationship between U
i
, U
o1
, U
D
, U
o1
/U
o nom
versus time
0
1
0.95
0
U
i
[V DC]
0
t
t
t
t
low min4
t
low min4
t
high min
t
h1
U
ti
+
U
hi
U
ti
Input voltage failure Switch-on cycle Input voltage sag Switch-on cycle and subsequent
input voltage failure
U
D high
U
D low
U
D
0
JFET
NPN
t
U
o1
U
o1 nom
U
D high
U
D low
U
D
t
low min4
t
h1
0
0
U
D high
U
D low
U
D
0
JFET
NPN
U
o1
U
D high
U
D low
U
D
t
low min4
U
to
3
Output voltage failure
0
I
D high
I
D low
I
D
t
0
I
D high
I
D low
I
D
t
t
t
t
3
2
33 33
U
o1 nom
U
to
+
U
ho
Input voltage monitoring
Output voltage monitoring
11008
1Hold-up time see section Electrical Input Data
2With output voltage monitoring, hold-up time
t
h = 0.
3The signal will remain high if the D output is connected to
an external source.
4
t
low min = 100...170 ms, typically 130 ms.
Rugged Environment DC-DC Converters >100 Watt K Series
Edition 4/4.99
29/31
MELCHER
The Power Partners.
V output (V0, V2, V3):
Connector pin V is internally connected to the open collec-
tor of a NPN transistor. The emitter is connected to the
negative potential of output 1.
U
V ≤ 0.6 V (logic low) corre-
sponds to a monitored voltage level (
U
i and/or
U
o1) <
U
t.
The current
I
V through the open collector should not exceed
50 mA. The NPN output is not protected against external
overvoltages.
U
V should not exceed 60 V.
U
i,
U
o1 status V output,
U
V
U
i or
U
o1 <
U
tlow, L,
U
V ≤ 0.6 V at
I
V = 50 mA
U
i and
U
o1 >
U
t +
U
hhigh, H,
I
V ≤ 25 µA at
U
V = 5.1 V
Fig. 34
Output configuration of options V0, V2 and V3
Vo1+
Vo1–
V
U
V
I
V
R
p
Input
11009
Formula for the external input capacitor:
2 •
P
o • (
t
h + 0.3 ms) • 100
C
i ext = –––––––––––––––––––––– –
C
i min
h • (
U
ti 2 –
U
i min2)
where as:
C
i min = internal input capacitance [mF]
C
i ext = external input capacitance [mF]
P
o= output power [W]
h= efficiency [%]
t
h= hold-up time [ms]
U
i min = minimum input voltage [V] 1
U
ti = threshold level [V]
1Min. input voltage according to
Electrical Input Data
. For output
voltages
U
o >
U
o nom, the minimum input voltage increases pro-
portionally to
U
o/
U
o nom.
Remarks:
Option V2 and V3 can be adjusted by potentiometer to a
threshold level between
U
i min and
U
i 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.
V ACFAIL signal (VME)
Available for units with
U
o1 = 5.1 V.
This option defines an undervoltage monitoring circuit for
the input or input and main output voltage (
U
o1 nom = 5.1 V
only) equivalent to option D and generates an ACFAIL sig-
nal (V signal) which conforms to the VME standard.
The low state level of the ACFAIL signal is specified at a
sink current of
I
V ≤ 48 mA to
U
V ≤ 0.6 V (open-collector out-
put of a NPN transistor). The pull-up resistor feeding the
open-collector output should be placed on the VME back
plane.
After the ACFAIL signal has gone low, the VME standard
requires a hold-up time
t
h of at least 4 ms before the 5.1 V
output drops to 4.875 V when the output is fully loaded.
This hold-up time
t
h is provided by the internal input capaci-
tance. Consequently the working input voltage and the
threshold level
U
ti should be adequately above the mini-
mum input voltage
U
i 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 (
C
i ext) should be added.
Formula for threshold level for desired value of
t
h:
2 •
P
o • (
t
h + 0.3 ms) • 100
U
ti = ––––––––––––––––––––– +
U
i min2
C
i min • h
Table 20: Undervoltage monitor functions
V output Monitoring Minimum adjustment range Typical hysteresis
U
h [% of
U
t]
(VME compatible) of threshold level
U
tfor
U
t min…
U
t max
U
i
U
o1
U
ti
U
to
U
hi
U
ho
V2 yes no
U
i min...
U
i max 1 –3.4...0.4 –
V3 yes yes
U
i min...
U
i max 1 0.95...0.985
U
o1 2 3.4...0.4 "0"
V0 yes no
U
i min...
U
i max 3 4 –3.4...0.4 –
yes yes
U
i min...
U
i max 3 4 0.95...0.985
U
o1 2 3.4...0.4 "0"
1Threshold level adjustable by potentiometer. 2 Fixed value between 95% and 98.5% of
U
o1 (tracking). 3 Adjusted at
I
o nom.
4Fixed value, resistor-adjusted (±2% at 25°C) acc. to customer's specifications; individual type number is determined by Melcher.
voltage(s) exceed(s)
U
t +
U
h. The threshold level
U
ti 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.
Versions V0, V2 and V3 are available as shown below.
Option V operates independently of the built-in input under-
voltage lock-out circuit. A logic "low" signal is generated at
pin 20 as soon as one of the monitored voltages drops be-
low the preselected threshold level
U
t. The return for this
signal is Vo1–. The V output recovers when the monitored
Table 19: Available internal input capacitance and factory potentiometer setting of U
ti
with resulting hold-up time
Types AK BK FK CK DK EK Unit
C
i min 0.83 0.3 1.2 0.66 0.26 0.21 mF
U
t i 9.5 19.5 39 39 61 97 V DC
t
h0.1 0.1 3.4 1.1 1.1 2.7 ms
K Series DC-DC Converters >100 Watt Rugged Environment
Edition 4/4.99
30/31
MELCHER
The Power Partners.
Threshold tolerances and hysteresis:
If
U
i is monitored, the internal input voltage is measured af-
ter the input filter. Consequently this voltage differs from the
voltage at the connector pins by the voltage drop D
U
ti
across the input filter. The threshold level of option V0 is ad-
justed during manufacture at
I
o nom and
T
A = 25°C. The
value of D
U
ti depends upon the input voltage range (AK,
BK, ...), threshold level
U
t, temperature and input current.
The input current is a function of input voltage and output
power.
D
U
ti
U
hi
U
V low
U
V
U
V high
U
i
P
o
=
P
o nom
P
o
= 0
P
o
= 0
U
ti
P
o
=
P
o nom
11023
Fig. 35
Definition of U
ti
,
∆
U
ti
and U
hi
3
5.1 V
4.875 V
0
U
i
[V DC]
0
t
t
U
ti
+
U
hi
U
ti
Input voltage failure Switch-on cycle Input voltage sag Switch-on cycle and subsequent
input voltage failure
U
V high
U
V low
U
V
0
V2
t
U
o1
0
U
V high
U
V low
U
V
0
V2
U
i
U
ti
4
Output voltage failure
0
U
V high
U
V low
U
V
3
U
ti
+
U
hi
t
low min 2
t
low min 2
t
low min 2
33
4
4
U
V high
U
V low
U
V
0
V3
t
3
t
low min 2
t
low min 2
33
t
h 1
2.0 V
t
h 1
4
3
4
t
low min 2
V3
5.1 V
4.875 V
0
U
o1
2.0 V
Input voltage monitoring
Output voltage monitoring
11010
t
t
t
t
Fig. 36
Relationship between U
i
, U
o1
, U
V
, I
V
and U
o1
/U
o nom
ver-
sus time.
1VME request: minimum 4 ms
2
t
low min = 40...200 ms, typically 80 ms
3
U
V level not defined at
U
o1 < 2.0 V
4The V signal drops simultaneously with the output voltage. If the
pull-up resistor
R
P is connected to Vo1+. The V signal remains
high if
R
P is connected to an external source.
Rugged Environment DC-DC Converters >100 Watt K Series
Edition 4/4.99
31/31
MELCHER
The Power Partners.
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
.
H15 female connector,
code key system
Front panels
Mounting plate (option B1 essential),
connector retention clips
Universal mounting bracket for DIN-rail mounting.
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
T
C max is not exceeded. The cooling capacity is cal-
culated by:
(100% –
h)
P
Loss = –––––––––– (
U
o •
I
o)
h
Efficiency h
see Type survey
Elongated case for 220 mm rack depth: Option B2
