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rugged environment ac-dc converters >100 watt k series edition 4/4.99 1/28 melcher the power partners. 150 watt ac-dc converters with pfc k-series input to output isolation single output: lk 4000 5.1, 12, 15, 24 v double output: lk 5000 2 12, 2 15, 2 24 v universal input voltage range power factor > 0.95, harmonics < iec/en 61000-3-2 input over- and undervoltage lock-out ef?cient input ?lter and built-in surge and transient suppression circuitry 4 kv rms input to output electric strength test fully isolated outputs outputs overload, open- and short-circuit proof no derating over entire operating temperature range safety according to iec/en 60950 c table of contents page summary .......................................................................... 1 type survey and key data .............................................. 2 type key .......................................................................... 2 functional description ...................................................... 3 electrical input data ......................................................... 4 electrical output data ...................................................... 6 auxiliary functions ......................................................... 12 summary the k 4000/5000-series of ac-dc converters represents a ?exible range of power supplies for use in advanced elec- tronic systems. features include full power factor correc- tion, high ef?ciency, high reliability, low output voltage noise and excellent dynamic response to load/line changes. the converter inputs are protected against surges and tran- sients occurring at the source lines. an input over- and undervoltage lock-out circuitry disables the outputs if the input voltage is outside the speci?ed ranges. inrush current limitation is included preventing circuit breakers and fuses from being damaged at switch-on. all outputs are overload, open- and short-circuit proof and are protected against overvoltages by means of a built-in suppressor diode. the outputs can be inhibited by a logic signal applied to the connector pin 18 (i). if the inhibit func- tion is not used pin 18 must be connected with pin 14 to en- able 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 of?cially 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 inch rack sys- tems according to din 41494, or be chassis mounted. important: these products are intended to replace the lk 1000 and lk 2000 in order to comply with iec/en 61000-3-2. lga page electromagnetic compatibility (emc) ............................ 16 immunity to environmental conditions ........................... 17 mechanical data ............................................................ 18 safety and installation instructions ................................ 19 description of options .................................................... 22 accessories .................................................................... 28 168 6.6" 80 3.2" 16 te 111 4.4" 3 u
k series ac-dc converters >100 watt rugged environment edition 4/4.99 2/28 melcher the power partners. type survey and key data non standard input/output configurations or special custom adaptions are available on request. see also: commercial in- formation: inquiry form for customized power supply. table 1: type survey lk output 1 output 2 input voltage range and ef ciency 1 options u o nom i o nom u o nom i o nom u i min ... u i max h min [v dc] [a] 2 [v dc] [a] 2 85...255 v ac 7 [%] 5.1 25.0 - - lk 4003-6r 6 78 -9 12.0 12.0 - - lk 4301-7r 85 e 15.0 10.0 - - lk 4501-7r 85 d 24.0 6.0 - - lk 4601-7r 86 v 5 24.0 3 6.0 - - lk 5320-7r 83 p 30.0 3 5.0 - - lk 5540-7r 83 t 48.0 3 3.0 - - lk 5660-7r 84 b1 12.0 6.0 12.0 4 6.0 lk 5320-7r 83 b2 15.0 5.0 15.0 4 5.0 lk 5540-7r 83 24.0 3.0 24.0 4 3.0 lk 5660-7r 84 1 ef ? ciency at u i nom and i o nom . 2 if the output voltages are increased above u o nom via r-input control, op- tion p setting, remote sensing or op- tion t, the output currents must be reduced accordingly so that p o nom is not exceeded. 3 series connection of output 1 and 2 see: r-function for different output configurations. 4 second output semi-regulated. 5 option v for k 4003 types only. 6 lk 4003-6r types are speci ? ed for a max. ambient temperature t a = 60 c and a max. case temperature t c = 90 c. (see: output power derating ). 7 for dc-input please ask your local melcher partner. type key type key l k 5 5 40 -7 e r p d v t b1 input voltage range u i : 85 255 v ac ............................. l series ............................................................................... k number of outputs (4 for single, 5 for double outputs) 4...5 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 speci ? cations 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 : C 25 71 c .................................................. -7 C 40 71 c .................................................. -9 C 25 60 c .................................................. -6 customer speci ? c ................................... 0...-6 auxiliary functions and options: inrush current limitation ............................... e output voltage control input ........................ r 2 potentiometer (output voltage adjustment) .. p 2 save data signal (d0...dd, to be speci ? ed) d 3 acfail signal (v2, v3) ................................ v 3, 4 current sharing ............................................ t cooling plate standard case ...................... b1 cooling plate for long case 220 mm .......... b2 1 external wiring of main and second output depending upon the desired output con ? guration (see: r-function for different output con- figurations . 2 feature r excludes option p and vice versa. 3 option d excludes option v and vice versa. 4 option v for lk 4000 types with 5 v outputs. example: lk 5540-7pd3: power factor corrected ac-dc converter, input voltage range 85...255 v ac, double output, each providing 15 v/5 a, equipped with potentiometer and undervoltage monitoring option. ambient tempera- ture C 25...71 c.
rugged environment ac-dc converters >100 watt k series edition 4/4.99 3/28 melcher the power partners. functional description the input voltage is fed via an input fuse, an input ? lter, a recti ? er and an inrush current limiter to a single transistor boost converter. this converter provides a sinusoidal in- put current (iec/en 61000-3-2, class d equipment) and sources a capacitor with a voltage of 360-370 vdc. this capacitor sources a single transistor forward converter. each output is powered by a separate secondary winding on the main transformer. the resultant voltages are recti- ? ed and their ripples smoothed by a power choke and an output ? lter. the control logic senses the main output volt- age u o1 and generates, with respect to the maximum ad- missible output currents, the control signal for the primary switching transistor. 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. input filter control circuit p 2 y 16 18 20 22 12 4 6 8 10 14 y output filter 1 28 30 32 24 3 C + y y forward converter (approx. 80 khz) + boost converter (pfc) 360 v dc c i 4 03001 r i d/v t s+ vo+ vo C s C 26 n p~ fig. 1 block diagram of single output converters lk 4000 input filter control circuit 1 p 2 16 18 20 22 12 14 4 6 8 10 output 2 filter output 1 filter 26 28 30 32 24 3 C + y y y y y y forward converter (approx. 80 khz) boost converter (pfc) + 360 v dc c i 4 03002 n~ p~ r i d t vo1+ vo1 C vo2+ vo2 C fig. 2 block diagram of symmetrical double output converters lk 5000 1 transient suppressor (vdr). 2 inrush current limiter (ntc or option e), -9 versions exclude the ntc. 3 input fuse. 4 hold-up capacitor.
k series ac-dc converters >100 watt rugged environment edition 4/4.99 4/28 melcher the power partners. r s ext r i r ntc i inr p u i rms c i 04001 input under-/overvoltage lock-out if the input voltage remains below approx. 65 v ac or ex- ceeds approx. 280 v ac 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 ). input transient protection a vdr together with the input fuse and a symmetrical input ? lter form an effective protection against high input tran- sient voltages. input fuse a fuse mounted inside the converter protects the module against severe defects. (if operated from a dc-source this fuse may not fully protect the module when the input volt- age exceeds 200 v dc! in applications where the convert- ers operate at source voltages above 200 v dc an external fuse or a circuit breaker at system level should be in- stalled!) table 3: fuse speci ? cation module fuse type fuse rating lk4/5000 1 slow-blow sp t 4 a, 250 v 1 fuse size 5 20 mm fig. 3 equivalent circuit diagram for input impedance electrical input data general conditions C t a = 25 c, unless t c is speci ? ed. C pin 18 connected to pin 14, u o adjusted to u o nom (option p); r input not connected. C sense line pins s+ and s C connected to vo+ and vo C respectively. table 2: input data input lk characteristics conditions min typ max unit u i operating input voltage i o = 0 i o nom 85 255 v ac 3, 4 u i nom nominal input voltage t c min t c max 230 i i input current u i nom , i o nom 1 0.8 a rms p i o no-load input power u i min u i max 9.0 10 w p i inh idle input power unit inhibited 3.5 5 r i input resistance t c = 25 c 480 m ? r ntc ntc resistance 2 3200 4000 c i input capacitance 80 100 120 f u i rfi conducted input rfi en 55022 b radiated input rfi u i nom , i o nom b u i abs input voltage limits C 400 400 v dc (without damage) C 400 400 v p 1 with double output modules, both outputs loaded with i o nom . 2 valid for -7, -6, versions with ntc, (-9 versions exclude the ntc). initial switch-on cycle. subsequent switch-on/off cycles in crease the inrush current peak value. 3 ac frequency range 47...63 hz. 4 for dc-input please ask your local melcher partner reverse polarity protection should the input voltage to the unit be supplied from a dc source the built-in bridge recti ? er provides reverse polarity protection. inrush current limitation the modules of the versions -7, -6, incorporate an ntc re- sistor in the input circuitry which - at initial turn on - reduces the peak inrush current value by a factor of 5...10 to protect connectors and switching devices from damage. subse- quent switch-on cycles within short periods will cause an increase of the peak inrush current value due to the warm- ing-up of the ntc resistor. see also: e option . inrush current peak value the inrush current peak value (initial switch-on cycle) can be determined by following calculation: u i rms ? 2 i inr p = CCCCCCCCCCCCCCCC ( r s ext + r i + r ntc )
rugged environment ac-dc converters >100 watt k series edition 4/4.99 5/28 melcher the power partners. 100 150 200 250 300 50 1 3 0.5 1.5 2 2.5 l i [a rms ] u i [v ac] 04002 0.2 0.4 0.6 0.8 1 0 1 0.7 0.75 0.8 0.85 0.9 0.95 power factor i o / i o nom u i = 230 v ac u i = 85 v ac 04004 3 5 7 9 11 13 17 19 15 harm. 3.0 2.5 2.0 1.5 1.0 0.5 0 i i [ma/w] 3.5 04042 limit class d according to iec/en 61000-3-2 fig. 6 input current versus input voltage at i o nom fig. 5 harmonic currents at the input, iec/en 61000-3-2, class d. u i = u i nom , i o = i o nom . fig. 7 power factor versus output power at u i 230 v ac and 85 v ac. static input current characteristic harmonic currents the harmonic distortion is well below the limits specified in iec/en 61000-3-2, class d. 1 23 t [ms] 1 50 100 i inr [a] 130 0 u i = 255 v rms u i = 115 v rms 04006 input inrush current characteristic fig. 4 theoretical input inrush current versus time at u i 255 v rms and 115 v rms , r ext = 0 power factor, harmonics power factor correction is achieved by controlling the input current waveform synchronously with the input voltage waveform. the power factor control is active under all oper- ating conditions.
k series ac-dc converters >100 watt rugged environment edition 4/4.99 6/28 melcher the power partners. electrical output data general conditions C t a = 25 c, unless t c is speci ? ed. C pin 18 (i) connected to pin 14 (s C /vo1 C ), u o adjusted to u o nom (option p), r input not connected. C sense line pins 12 (s+) and 14 (s C ) connected to 4 (vo1+) and 8 (vo1 C ) respectively. table 4a: output data single output modules output lk 4003-6 lk 4301 lk 4501 lk 4601 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 o output 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 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 ol output current limit 4 u i min ... u i max 26 12.2 10.2 6.2 u o 7 output low frequency u i nom , i o nom 2222mv pp voltage switching freq. iec/en 6120 15555 noise total bw = 20 mhz 50 40 40 50 d u o u static line regulation u i min ... u i nom , 5 12 15 24 mv u i nom ... u i max i o nom d u o i static load regulation u i nom , i o = 202430 48 (0.1...1) i o nom u o d 5 dynamic voltage u i nom 170 150 150 100 load deviation i o nom ? 1 / 2 i o nom t d 5 regulation recovery iec/en 61204 0.3 0.4 0.4 0.3 ms time a uo temperature coef ? cient t c min ... t c max C 0.5 C 1.5 C 1.5 C 1.5 mv/k of output voltage 6 0... i o nom 1 if the output voltages are increased above u o nom through r-input control, option p setting, remote sensing or option t, the output cur- rents should be reduced accordingly so that p o nom is not exceeded. 4 see: typical output voltage regulation of single or double output modules with outputs 1 and 2 connected in series. 5 see: typical dynamic load regulation of u o1 and u o2 . 6 negative temperature coef ? cient (0... C 3 mv/cell and k) available on request. 7 measured according to iec/en 61204 sub clause 3.10 with a probe acc. to annex a of the same standards. (see: technical informa- tion: measuring and testing.)
rugged environment ac-dc converters >100 watt k series edition 4/4.99 7/28 melcher the power partners. table 4b: output data double output modules output lk 5320 lk 5540 lk 5660 (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 o output voltage 2 u i nom , i o nom 24.0 30.0 48.0 v u o p overvoltage protection 38 48 74 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 ol output current limit 4 u i min ... u i max 6.2 5.2 3.2 u o 7 output low frequency u i nom , i o nom 33 5mv pp voltage switching freq. iec/en 61204 15 15 20 noise 3 total bw = 20 mhz 100 100 180 d u o u static line regulation u i min ... u i nom 12 15 24 mv u i nom ... u i max i o nom d u o i static load regulation u i nom , i o =486096 (0.1...1) i o nom u o d 5 dynamic voltage u i nom 250 200 150 load deviation i o nom ? 1 / 2 i o nom t d 5 regulation recovery iec/en 61204 0.3 0.3 0.3 ms time a uo temperature coef ? cient t c min ... t c max C 2.2 C 2.2 C 2.6 mv/k of output voltage 6 0... i o nom 1 if the output voltages are increased above u o nom through r-input control, option p setting, remote sensing or option t, the output cur- rents should be reduced accordingly so that p o nom is not exceeded. 2 series connection for u o nom = 24 v, 30 v or 48 v, see: r-function for different output configurations . 3 shortest possible wiring for series connection at the connector. 4 see: typical output voltage regulation of single or double output modules with outputs 1 and 2 connected in series. 5 see: typical dynamic load regulation of u o1 and u o2 . 6 negative temperature coef ? cient (0... C 3 mv/cell and k) available on request. 7 measured according to iec/en 61204 sub clause 3.10 with a probe acc. to annex a of the same standards. (see: technical informa- tion: measuring and testing.)
k series ac-dc converters >100 watt rugged environment edition 4/4.99 8/28 melcher the power partners. table 4c: output data double output modules output lk 5320 lk 5540 (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 o output 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 19 19 24 24 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 ol output current limit 4 u i min ... u i max 6.2 6.2 5.2 5.2 u o 8 output low frequency u i nom , i o nom 3333mv pp voltage switching freq. iec/en 61204 12 12 10 10 noise total bw = 20 mhz 80 40 100 40 d u o u static line regulation u i min ... u i nom 12 12 15 15 mv u i nom ... u i max i o nom d u o i static load regulation u i nom , i o =48 5 60 5 (0.1...1) i o nom 5 u o d 6 dynamic voltage u i nom 100 100 load deviation i o nom ? 1 / 2 i o nom t d 6 regulation recovery iec/en 61204 0.3 0.3 ms time a uo temperature coef ? cient t c min ... t c max C 1.5 C 1.5 mv/k of output voltage 7 0... i o nom 1 depending upon the desired output con ? guration the wiring should be made as shown in: r-function for different output configura- tions . 2 same conditions for both outputs. 3 if 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. 4 see: typical output voltage regulation of single or double output modules with outputs 1 and 2 connected in series. 5 condition for speci ? ed output. other output loaded with constant current i o = i o nom . see ? g.: output voltage regulation of double output units . 6 see: typical dynamic load regulation of u o1 and u o2 . 7 negative temperature coef ? cient (0... C 3 mv/cell and k) available on request. 8 measured according to iec/en 61204 sub clause 3.10 with a probe acc. to annex a of the same standards. (see: technical informa- tion: measuring and testing)
rugged environment ac-dc converters >100 watt k series edition 4/4.99 9/28 melcher the power partners. table 4d: output data double output modules output lk 5660 (outputs independently loaded) 1 24 v/24 v characteristics conditions output 1 output 2 min typ max min typ max unit u o output voltage u i nom , i o nom 2 23.86 24.14 23.64 24.36 v u o p overvoltage protection 37 37 i o nom output current 3 u i min ... u i max 3.0 3.0 a t c min ... t c max i ol output current limit 4 u i min ... u i max 3.2 3.2 u o 8 output low frequency u i nom , i o nom 33mv pp voltage switching freq. iec/en 61204 10 10 noise total bw = 20 mhz 100 40 d u o u static line regulation u i min ... u i nom , 24 24 mv u i nom ... u i max , i o nom d u o i static load regulation u i nom , i o =96 5 (0.1...1) i o nom 5 u o d 6 dynamic voltage u i nom , i o = 80 load deviation i o nom ? 1 / 2 i o nom t d 6 regulation recovery iec/en 61204 0.3 ms time a uo temperature coef ? cient t c min ... t c max C 1.5 mv/k of output voltage 7 0... i o nom 1 depending upon the desired output con ? guration the wiring should be made as shown in: r-function for different output configura- tions . 2 same conditions for both outputs. 3 if 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. 4 see: typical output voltage regulation of single or double output modules with outputs 1 and 2 connected in series. 5 condition for speci ? ed output. other output loaded with constant current i o = i o nom . see ? g.: output voltage regulation of double output units . 6 see: typical dynamic load regulation of u o1 and u o2 . 7 negative temperature coef ? cient (0... C 3 mv/cell and k) available on request. 8 measured according to iec/en 61204 sub clause 3.10 with a probe acc. to annex a of the same standards. (see: technical informa- tion: measuring and testing.)
k series ac-dc converters >100 watt rugged environment edition 4/4.99 10/28 melcher the power partners. thermal protection a temperature sensor generates an internal inhibit signal which disables the outputs if the case temperature exceeds t c max . the outputs are automatically re-enabled if the tem- perature drops below this limit. output protection each output is protected against overvoltage which could occur due to a failure of the control circuit by means of a voltage suppressor diode which, under worst case condi- tions, may become a short circuit. the suppressor diodes are not designed to withstand externally applied over- voltages. overload at any of the two outputs will cause a shut-down of both outputs. a red led indicates the over- load condition. 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. it is recommended that continuous operation under simulta- neous extreme worst case conditions of the following three parameters be avoided: minimum input voltage, maximum output power and maximum temperature. -6 versions have reduced t a and t c 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 t a min 50 60 70 80 90 100 i o / i o nom t a [ c] 0.9 1.00 forced cooling convection cooling t c max -6 -7 -6 -7 05139 fig. 8 output current derating versus temperature for C 7 and C 9 units. ef ciency versus load 0.2 0.4 0.6 0.8 1 0 0.90 0.30 0.40 0.50 0.60 0.70 0.80 efficiency i o / i o nom u i = 230 v ac u i = 85 v ac 05007 fig. 9 ef ? ciency versus load at u i ; 230 v ac and 88 v ac switching frequency versus load 0.2 0.4 0.6 0.8 1 0 60 0 10 20 30 40 50 frequency [khz] load [ i o / i o nom ] 70 80 1.2 05008 fig. 10 switching frequency versus load. (the boost converter at the input stage has a ? xed frequency of 100 khz) parallel or series connection of units single or double output units with equal nominal output volt- age can be connected in parallel without any precautions 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: C parallel connection of double output units should always include both, main and second output to maintain good regulation of both outputs. C not more than 5 units should be connected in parallel. C series connection of second outputs without involving their main outputs should be avoided as regulation may be poor. C the maximum output current is limited by the output with the lowest current limitation if several outputs are con- nected in series.
rugged environment ac-dc converters >100 watt k series edition 4/4.99 11/28 melcher the power partners. 0 0.2 0.4 0.6 0.8 1 i o2 / i o2 nom 13.5 14 14.5 15 15.5 16 [v] u o2 i o1 = 100% i o1 =50% i o1 =10% 16.5 05003 01 i o2 / i o2 nom 10.5 11 11.5 12.0 12.5 13 [v] u o2 i o1 =100% i o1 =50% i o1 =10% 0.2 0.4 0.6 0.8 05002 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 ? gures 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 5000 module connected in paral- lel will behave like the output of a k 4000 module; the paral- leled output is fully regulated. no precautions are neces- sary in using the r-input and the test sockets. fig. 11 lk 5320: d u o2 (typ.) vs. i o2 with different i o1 fig. 12 lk 5540: d u o2 (typ.) vs. i o2 with different i o1 u o u o nom 0.98 0.5 0 0.5 1.0 i o1 i ol i o i o nom 05001 output voltage regulation of single or double output modules with outputs 1 and 2 connected in series fig. 14 u o1 vs. i o1 (typ.) of single output units 0 0.2 0.4 0.6 0.8 1 i o2 / i o2 nom 21 22 23 24 25 26 27 [v] u o2 i o1 = 100% i o1 =50% i o1 =10% 05004 fig. 13 lk 5660: d u o2 (typ.) vs. i o2 with different i o1 hold-up time versus output power 0.2 0.4 0.6 0.8 1 0 0 20 160 40 60 80 100 120 140 time [ms] 180 i o / i o nom 05006 fig. 16 hold-up time t h versus output power u o2d u o1d u o1d t d t d u r u r t t t <10 s <10 s u o1 u o2 i o1 / i o1 nom 0 0.5 1 i o2 / i o2 nom 05005 fig. 15 typical dynamic load regulation of u o1 and u o2 . dynamic load regulation
k series ac-dc converters >100 watt rugged environment edition 4/4.99 12/28 melcher the power partners. 0 t t 0 inhibit 1 0.1 1 u o / u o nom t r t f 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 C ) 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 C ) should be connected to their respective power outputs (vo1+ and vo1 C ) 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 table 5: inhibit characteristics characteristic conditions min typ max unit u inh inhibit u o = on u i min u i max C 50 0.8 v voltage u o = off 2.4 50 i inh inhibit current u inh = 0 C 400 a t r rise time 30 ms t f fall time depending on i o 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. important: the output terminals vo1+ and vo1 C must always be connected to the load before connecting the sense lines s+ and s C , otherwise the unit will be dam- aged. fig. 19 output response as a function of inhibit control auxiliary functions i inhibit for remote on and off note: with open i input: output is disabled ( u o = off). the outputs of the module may be enabled or disabled by means of a logic signal (ttl, cmos, etc.) applied between the inhibit input i and the negative pin of output 1 (vo1 C ). in systems with several units, this feature can be used, for ex- ample, to control the activation sequence of the converters. if the inhibit function is not required, connect the inhibit pin 18 to pin 14 to enable the outputs (active low logic, fail safe). for output response refer to: hold-up time and output re- sponse . vi+ vi C vo C i vo+ i inh u inh 06031 1.6 0.8 0 C 0.8 C 50 u inh [v] i inh [ma] C 30 0 C 10 10 30 50 2.0 1.2 0.4 C 0.4 u inh = 0.8 v u o = on u o = off u inh = 2.4 v 06032 fig. 17 definition of u inh and i inh . fig. 18 typical inhibit current i inh versus inhibit voltage u inh
rugged environment ac-dc converters >100 watt k series edition 4/4.99 13/28 melcher the power partners. r vo1+ vo1 C s C u ext n p module module r ext r' ext 14 16 16 14 + s+ vo1+ vo1 C s C n p r 12 06003 remarks: C the r-function excludes option p (output voltage adjust- ment by potentiometer). C 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. C the r-input (as well as option p) is related to the main output. C 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. C 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 de- pending upon the desired output con ? guration. C in case of parallel connection the output voltages should be individually set within a tolerance of 1...2%. fig. 20 output voltage control for single output units lk 4000 by means of the r input table 7a: r ext for u o < u o nom ; approximate 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 [k ? ] u o [v] 1 r ext [k ? ] u o [v] 1 r ext [k ? ] u o [v] 1 r ext [k ? ] 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 ; approximate 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 [k ? ] u o [v] 1 r' ext [k ? ] u o [v] 1 r' ext [k ? ] u o [v] 1 r' ext [k ? ] 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 1 first column: single output units or double output units with separated outputs, second column: outputs in series connection programmable output voltage (r-function) as a standard feature, the modules offer an adjustable out- put voltage, identi ? ed 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 = CCCCCC ? 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 approximately 100...110% u o nom . warning: C u ext shall never exceed 2.75 v dc. C the value of r' ext shall never be less than the lowest value as indicated in table r' ext (for u 0 > u 0 nom ) to avoid damage to the unit!
k series ac-dc converters >100 watt rugged environment edition 4/4.99 14/28 melcher the power partners. r' ext r ext 14 16 vo1 C vo1+ r vo2 C vo2 C vo2+ vo2+ 12 10 8 6 4 + C u o1 12 v 15 v 24 v 1 06005 r' ext r ext 14 16 vo1 C vo1+ r vo2 C vo2 C vo2+ vo2+ 12 10 8 6 4 u o2 0 v C 12/ C 15/ C 24 v +12/+15/+24 v u o1 1 1 + C 06006 r' ext r ext 14 16 vo1 C vo1+ r vo2 C vo2 C 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 r ext 14 16 vo1 C vo1+ r vo2 C vo2 C vo2+ vo2+ 12 10 8 6 4 + C u o1 24 v 30 v 48 v 1 2 06004 r' ext r ext 14 16 vo1 C vo1+ r vo2 C vo2 C vo2+ vo2+ 12 10 8 6 4 + C u o2 12 v 15 v 24 v C + 12 v 15 v 24 v u o1 1 1 06008 r-function for different output configurations fig. 21a lk 5000 with h15 connector. r-input for output voltage control. wiring for output voltage 24 v or 30 v or 48 v with main and second output connected in series. fig. 21b lk 5000 with h15 connector. r-input for output voltage control. wiring for output voltage 12 v or 15 v or 24 v with main and second output connected in parallel. fig. 21c lk 5000 with h15 connector. r-input for output voltage control. wiring of main and second output for two sym- metrical output voltages u o1 and u o2 : 12 v or 15 v or 24 v. fig. 21d lk 5000 with h15 connector. r-input for output voltage 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. 21e lk 5000 with h15 connector. r-input for output voltage control. wiring of main and second output for two output 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. remarks: double output units ? tted with h15 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. 1 a ceramic multilayer capacitor connected across the load re- duces ripple and spikes. 2 shortest possible wiring for series connection at the female con- nector
rugged environment ac-dc converters >100 watt k series edition 4/4.99 15/28 melcher the power partners. display status of leds u o1 > 0.95...0.98 u o1 adj u i max u i ov u i min u i uv u i u i abs ok i u o1 > 0.95...0.98 u o1 adj i o nom i ol i o ok i o l u o1 < 0.95...0.98 u o1 adj t c i t c max t ptc threshold u i inh i +50 v +0.8 v +2.4 v -50 v u inh threshold i o l led off led on led status undefined 06002 fig. 22 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 approximately 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 volt- age is 12 v, 15 v or 24 v respectively.
k series ac-dc converters >100 watt rugged environment edition 4/4.99 16/28 melcher the power partners. the k series has been successfully tested to the following specifications: electromagnetic compatibility (emc) a metal oxide vdr together with an input fuse and an input filter form an effective protection against high input tran- sient voltages which typically occur in most installations. 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/ C i 800 v p 100 s 100 ? 1 pos. and 1 neg. yes 4 1500 v p 50 s voltage surge per 3000 v p 5 s coupling mode 4000 v p 1 s 7000 v p 100 ns supply related ria 12 b +i/ C i 1.5 ? u batt 0.1/1/0.1 s 0.2 ? 1 positive yes 4 surge surge direct transient c +i/c, C i/c 960 v p 10/100 s5 ? 5 pos. and 5 neg. yes 4 d 1800 v p 5/50 s impulses e 3600 v p 0.5/5 s 100 ? f 4800 v p 0.1/1 s g 8400 v p 0.05/0.1 s indirect coupled h +o/c, C o/c 1800 v p 5/50 s transient j 3600 v p 0.5/5 s k 4800 v p 0.1/1 s l 8400 v p 0.05/0.1 s electrostatic iec/en 4 contact discharge 8000 v p 1/50 ns 330 ? 10 positive and yes a discharge 61000-4-2 air discharge 15000 v p 10 negative (to case) discharges electromagnetic iec/en 3 antenna 10 v/m am 80% n.a. 26 1000 mhz yes 4 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 v p bursts of 5/50 ns 50 ? 1 min positive yes a transient/burst 61000-4-4 2.5/5 khz over 1 min negative i/c, +i/ C i 4000 v p 15 ms; burst transients per direct period: 300 ms coupling mode surge iec/en 3 i/c 2000 v p 1.2/50 s 12 ? 5 pos. and 5 neg. yes a 61000-4-5 4 +i/ C i2 ? surges per conducted iec/en 3 i, o, signal wires 10 v rms am 80% 150 ? 0.15...80 mhz yes 4 disturbances 61000-4-6 (140 db v) 1 khz 1 related and previous standards are referenced in: technical information: standards . 2 i = input, o = output, c = case. 3 a = normal operation, no deviation from specifications, b = normal operation, temporary deviation from specs possible. 4 test in progress, please consult factory. note: previous standards are referenced in: technical in- formation: standards.
rugged environment ac-dc converters >100 watt k series edition 4/4.99 17/28 melcher the power partners. table 11: mtbf values at speci ed type ground benign ground fixed ground mobile unit case temperature 40 c40 c70 c50 c mtbf 1 lk 4301 C 7er 514'000 88'000 38'000 35'000 h 1 calculated in accordance with mil-hdbk 217f. table 10: temperature speci ? cations, values given are for an air pressure of 800...1200 hpa (800...1200 mbar) temperature -6 (lk 4003) standard -7 option -9 characteristics conditions min max min max min max unit t a ambient temperature u i min ... u i max C 25 60 C 25 71 C 40 71 c t c case temperature i o = 0... i o nom C 25 90 C 25 95 C 40 95 t s storage temperature not operational C 40 100 C 40 100 C 55 100 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 g n = 981 m/s 2 unit (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 g n = 392 m/s 2 unit (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 g n = 49 m/s 2 (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 g n 2 /hz unit wide band din 40046 part 23 frequency band: 20...500 hz operating reproducibility acceleration magnitude: 4.9 g n 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 90 80 70 60 50 40 30 20 10 0 0 .01 0 .05 0.1 0.5 1 2 5 10 20 30 [db v] mhz 0 .02 07063 a b fig. 23 typical disturbance voltage (quasi-peak) at the input accord- ing to cispr 11/22 and en 55011/22, measured at u i nom and i o nom . 50 40 30 20 10 0 30 50 100 200 500 1000 [db v/m] [mhz] a b 07038 fig. 24 typical radiated electromagnetic field strength (quasi-peak) according to cispr 11/22 and en 55011/22, normalized to a distance of 10 m, measured at u i nom and i o nom .
k series ac-dc converters >100 watt rugged environment edition 4/4.99 18/28 melcher the power partners. 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 (+/ C ) 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 = ? 3.5 = ? 4.1 09002 42 gravitational axis fig. 26 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. fig. 25 case k02 with heatsink, case aluminium, black finish and self cooling, weight: approx. 1.55 kg note: C d 15 mm, recommended minimum distance to next part to ensure proper air circulation at full output power. C free air locations: the module should be moun- ted with ? ns in vertical position to achieve a maximum air ? ow through the heat sink. 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 european projection note: long case with s-type heatsink or cooling plate b2 elongated by 60 mm for 220 mm rack depth, is available on re- quest. (front panel will have no leds and no test jacks.)
rugged environment ac-dc converters >100 watt k series edition 4/4.99 19/28 melcher 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 con- nector. pin no. 24, the protective earth pin present on all lk ac-dc converters is leading, ensuring that it makes con- tact with the female connector first. table 12: h15 and h15 s2 connector pin allocation pin connector type h15 s2 connector type h 15 no. lk 4003 lk 4301, lk 4501, lk 4601 lk 5000 4 vo1+ output 1 vo1+ output 1 vo2+ output 2 6 vo1+ vo2+ 8 vo1 C output 1 vo1 C output 1 vo2 C output 2 10 vo1 C vo2 C 12 s+ sense s+ sense vo1+ output 1 14 s C sense s C sense vo1 C output 1 16 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 20 d 3 save data d save data d save data v 3 acfail 22 t current sharing t current sharing t current sharing 24 2 protective earth protective earth protective earth 26 n neutral n neutral n neutral 28 n n n 30 p phase p phase p phase 32 p p p 1 feature r excludes option p and vice versa 2 leading pin (pregrounding) 3 option d excludes option v and vice versa 4/6 30/32 type h15 s2 10001 4 32 type h15 10002 fig. 27 view of module's male connectors installation instructions the k series ac-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/h15 s2 (see: accessories ) . other installation methods may not meet the safety requirements. the ac-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. an input fuse is built-in in the connection from pins no. 30 and 32 (p~) 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 C /vo1 C ) to enable the output(s). do not open the modules, or guarantee will be invali- dated.
k series ac-dc converters >100 watt rugged environment edition 4/4.99 20/28 melcher the power partners. table 13: isolation characteristic input to input to output to output to unit case output case output electric required according to 1.5 3.0 1 CC kv rms strength iec/en 60950 2.1 4.2 1 CC kv dc test voltage actual factory test 1 s 2.8 5.6 1 1.4 0.14 ac test voltage equivalent 2.0 4.0 1 1.0 0.1 kv rms to actual factory test insulation resistance at 500 v dc > 300 > 300 > 300 > 100 2 m ? 1 in accordance with iec/en 60950 only subassemblies are tested in factory with this voltage. 2 tested at 100 v dc. for creepage distances and clearances refer to: technical information: safety. due to high current values, all lk units provide two inter- nally 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 over- stress 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 available for con- vection cooling. this should be verified by measuring the case temperature when the unit is installed and operated in the end-use application. the maximum specified case tem- perature t c max shall not be exceeded. see also: thermal considerations. 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. 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. standards and approvals all ac-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, based on 250 v ac and 400 v dc ? double or reinforced insulation between input and output, based on 250 v ac and 400 v dc ? basic insulation between output and case based on 200 v ac and dc. ? operational insulation between output and output ? 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 (overvoltage category iii based on a 110 v primary cir- cuit, overvoltage category ii based on a 230 v primary circuit). ? the ul 1950 recognition limits the maximum case tem- perature of the standard modules to t c = t c max C 10 k = 95 c. the ac-dc converters are subject to manufacturing sur- veillance in accordance with the above mentioned ul, csa, en and with iso 9001 standards. 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. important: testing by applying ac voltages will result in high and dangerous leakage currents flowing through the y-capacitors (see fig.: block diagram ).
rugged environment ac-dc converters >100 watt k series edition 4/4.99 21/28 melcher the power partners. leakage currents in ac-dc operation leakage currents flow due to internal leakage capacitance and rfi suppression y-capacitors. the current values are proportional to the mains voltage and nearly proportional to the mains frequency and are specified at an input voltage of 254 v (50 hz) where phase, neutral and protective earth are correctly connected as required for class i equipment. v mi 500 ? 1500 ? 10 k ? 220 nf 22 nf 10061 under test conditions the leakage current flows through a measuring instrument (mi) as described in fig.: measuring instrument for earth leakage current tests , which takes into account impedance and sensitivity of a person touching unearthed accessible parts. the current value is calculated by dividing the measured voltage by 500 ? . if inputs of k- units are connected in parallel, their individual leakage cur- rents are added. fig. 28 measuring instrument (mi) for earth leaking current tests according to iec/en 60950. vo+ vo C n p 10062 n p mi for earth leakage current fig. 29 test set-up table 14: leakage currents characteristic class i unit lk 4000, lk 5000 maximum earth permissible according to iec/en 60950 3.5 ma leakage current specified value at 254 v, 50 hz 0.82 safety of operator accessible output circuit if the output circuit of an ac-dc converter is operator ac- cessible, it shall be an selv circuit according to the iec/en 60950 related safety standards. the following table shows a possible installation configura- tion, compliance with which causes the output circuit of an k series ac-dc converter to be an selv circuit according to iec/en 60950 up to a configured output voltage (sum of nominal voltages if in series or +/ C configuration) of 36 v. however, it is the sole responsibility of the installer to as- sure the compliance with the relevant and applicable safety regulations. more information is given in: technical infor- mation: safety . table 15: safety concept leading to an selv output circuit conditions ac-dc converter installation result nominal voltage grade of insulation measures to achieve the resulting safety status of the ac-dc between input and output safety status of the output circuit converter output circuit provided by the ac-dc converter mains double or reinforced earthed case 1 and installation selv circuit 250 v ac according to the applicable standards 1 the earth connection has to be provided by the installer according to the relevant safety standards, e.g. iec/en 60950. ac-dc con- verter mains selv earth connection + C ~ ~ 10021 fuse fuse fig. 30 schematic safety concept. use fuses and earth connec- tion as per: installation instructions and table: safety con- cept leading to an selv output circuit .
k series ac-dc converters >100 watt rugged environment edition 4/4.99 22/28 melcher the power partners. e inrush current limitation the converters may be supplemented by an electronic cir- cuit (option e, replacing the standard built-in ntc) to achieve an enhanced inrush current limiting function. table 17: inrush current characteristics with option e characteristics lk unit u i = 230 v ac typ max i inr p peak inrush current C 21.7 a t inr inrush current duration 35 50 ms input filter control converter fet c i r i r s rectifier pfc - control 11001 fig. 32 inrush current with option e, u i = 230 v ac, p o = p o nom precaution: subsequent switch-on cycles at start-up are limited to max. 10 cycles during the ? rst 20 seconds (cold unit) and at continuing on/off ( t c =95 c) max. 1 cycle every 8 sec. vo+ vo C vo+ vo C load vo+ vo C 11003 input filter control converter fet c i r i r s rectifier pfc - control 11001 fig. 31 option e block diagram fig. 33 an example of poor wiring for connection in parallel description of options table 16: survey of options option function of option characteristics -9 extended operational ambient temperature range t a = C 40...71 c e electronic inrush current limitation circuitry active inrush current limitation p 1 potentiometer for fine adjustment of output voltage adjustment range +10/ C 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 1 option r excludes option p and vice versa 2 option d excludes option v and vice versa 3 only available if main output voltage u o1 = 5.1 -9 extended temperature range option -9 extends the operational ambient temperature range from C 25...71 c (standard) to C 40...71 c. the power supplies provide full nominal output power with free air con- vection cooling. option -9 excludes inrush current limitation by ntc. p potentiometer the potentiometer provides an output voltage adjustment range of +10/ C 60% of u o nom and is accessible through a hole in the front cover. this feature enables compensation for 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. t current sharing this option ensures that the output currents are approxi- mately shared between all paralleled modules and in- creases system reliability. to use this facility, simply inter- connect the t pins of all modules and make sure, that pins 14, the s C pins (k 4000) or the vo1 C pins (k 5000) 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 dif ? cult 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.
rugged environment ac-dc converters >100 watt k series edition 4/4.99 23/28 melcher the power partners. fig. 34 paralleling of single output units using option t with the sense lines connected at the load load max. 5 units in parallel connection + C power bus module vo2 C vo2+ vo1 C vo1+ t module vo2 C vo2+ vo1 C vo1+ t 11037 load 1 1 1 2 2 3 3 s+ vo+ vo C s C n p t n p s+ vo+ vo C s C t 1 max. 5 units connected in parallel 11004 1 leads should have equal length and cross sections and should run in the same cable loom. 2 diodes recommended in redundant operation only 3 dc common point fig. 35 paralleling of double output units using option t with power bus
k series ac-dc converters >100 watt rugged environment edition 4/4.99 24/28 melcher the power partners. vo1+ vo1 C d u d i d r p input 11007 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 t + u h low, l, u d 0.4 v at i d = 20 ma fig. 37 option d5...dd: npn output, u o1 40 v, i d 20 ma table 19: d-output logic signals version of d u i u t + u h resp. u o > u t con guration d1, d2, d3, d4, d0 low high jfet d5, d6, d7, d8, d9, dd high low npn option 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 C . the d output reco- vers when the monitored voltage(s) exceed(s) u t + u h . the table 18: undervoltage monitoring functions output type monitoring minimum adjustment range typical hysteresis u ho [% of u t ] jfet npn u i u o1 of threshold level u t for u t min ... u t max u ti u to u ho d1 d5 no yes - 3.5...40 v 1 2.5...0.6 d2 d6 yes no 355 v dc 4 -- d3 d7 yes yes 355 v dc 4 (0.95...0.985 u o1 ) 2 "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 yes 355 v dc 4 3.5...40 v 3 2.5...0.6 dd yes yes 355 v dc 4 3.5...40 v 1 2.5...0.6 1 threshold level adjustable by potentiometer 2 fixed value. tracking if u o1 adjusted via r-input, option p or sense lines. 3 the threshold level permanently adjusted according to customer speci ? cation 2% at 25 c. any value within the speci ? ed range is basically possible but causes a special type designation in addition to the standard option designations (d0/d9)! 4 option d monitors the boost regulator output voltage. the trigger level is adjusted in the factory to 355 v dc. threshold level u ti is adjusted in the factory. the threshold level u to is either adjusted by a potentiometer, accessible through a hole in the front cover, or factory adjusted to a ? xed value speci ? ed by the customer. option d exists in various versions d0...dd as shown in the following table. vo1+ vo1 C d u d i d r p input 11006 fig. 36 option d0...d4: jfet output, i d 2.5 ma 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 t + u h high, h, i d 25 a at u d = 5.25 v
rugged environment ac-dc converters >100 watt k series edition 4/4.99 25/28 melcher the power partners. 0 1 0.95 0 u ci [v dc] 0 t t t t low min 4 t low min 4 t high min t h 1 358 355 input voltage failure switch-on cycle input voltage sag switch-on cycle and subsequent input voltage failure u d high u d low u d 0 jfet npn t u o1 u o1 nom u d high u d low u d t low min 4 t h 1 0 0 u d high u d low u d 0 jfet npn u o1 u d high u d low u d t low min 4 u to output volta g e failure 0 i d high i d low i d t 0 i d high i d low i d t t t t 2 33 33 u o1 nom u to + u ho input voltage monitoring output voltage monitoring 11044 d-signal with respect to input and output voltage versus time: 1 hold-up time see section: electrical input data . 2 with output voltage monitoring, hold-up time t h = 0. 3 the signal will remain high if the d output is connected to an external source. 4 t low min = 100...170 ms, typically 130 ms. fig. 38 relationship between u ci , u o1 , u d , u o1 /u o nom versus time
k series ac-dc converters >100 watt rugged environment edition 4/4.99 26/28 melcher the power partners. vo1+ vo1 C v u v i v r p input 11009 v acfail signal (vme) available for units with u o1 = 5.1 v. this option de ? nes an undervoltage monitoring circuit for the input or input and main output voltage equivalent to op- tion d and generates the acfail signal (v signal) which conforms to the vme standard. the low state level of the acfail signal is speci ? ed 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. see also ? g.: hold-up time versus output power . table 20: undervoltage monitor functions v output monitoring minimum adjustment (vme compatible) u i u o1 range of threshold level u ti u to v2 yes no 355v dc 1 C v3 yes yes 355v dc 1 0.95...0.985 u o1 2 1 option d monitors the boost regulator output voltage. the trig- ger level is adjusted in the factory to 355 v dc. 2 fixed value between 95% and 98.5% of u o1 . v output (v2, v3): connector pin v is internally connected to the open collec- tor of a npn transistor. the emitter is connected to the negative potential of output 1. u v 0.6 v (logic low) corre- sponds to a monitored voltage level ( u i and/or u o1 ) < u t . the current i v through the open collector should not ex- ceed 50 ma. the npn output is not protected against exter- nal overvoltages. u v should not exceed 60 v. u i , u o1 status v output, u v u i or u o1 u t + u h high, h, i v 25 a at u v = 5.1 v fig. 39 output con ? guration of options v2 and v3 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 C . the v output recovers when the monitored voltage(s) exceed(s) u t + u h . the threshold level u ti is ad- justed in the factory to 355 v dc. the threshold level u to either is adjusted during manufacture to a determined cus- tomer speci ? ed value.
rugged environment ac-dc converters >100 watt k series edition 4/4.99 27/28 melcher the power partners. 3 5.1 v 4.875 v 0 u ci [v dc] 0 t t 358 355 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 volta g e failure 0 u v high u v low u v 3 u ti + u hi t low min 2 t low min 2 t low min 2 3 3 4 4 u v high u v low u v 0 v3 t 3 t low min 2 t low min 2 3 3 t h 1 2.0 v t h 1 4 3 4 t low min 2 v3 5.1 v 4.875 v 0 u o1 2.0 v input voltage monitoring output voltage monitoring 11045 t t t t fig. 40 relationship between u ci , u o1 , u v , i v and u o1 /u o nom ver- sus time. 1 vme request: minimum 4 ms 2 t low min = 40...200 ms, typically 80 ms 3 u v level not de ? ned at u o1 < 2.0 v 4 the v signal drops simultaneously with the output voltage if the pull-up resistor r p is connected to vo1+. the v signal remains high if r p is connected to an external source.
k series ac-dc converters >100 watt rugged environment edition 4/4.99 28/28 melcher the power partners. accessories a variety of electrical and mechanical accessories are available including: C front panels for 19" rack mounting, schroff and intermas systems. C mating h15 and h15 s2 connectors with screw, solder, fast-on or press-fit terminals. C connector retention facilities. C code key system for connector coding. C chassis mounting plates for mounting the 19" cassette to a chassis/wall where only frontal access is given. C universal mounting bracket for din-rail or chassis moun- ting. for more detailed information please refer to: accessory products . h15 and h15 s2 female connector, code key system front panels mounting plate, connector retention clips universal mounting bracket for din-rail mounting. b1 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 suf ? cient cooling capacity to guarantee that the maximum case tem- perature t c max is not exceeded. the cooling capacity is cal- culated by: (100% C ) p loss = CCCCCCCCCC ( u o ? i o ) ef ? ciency h see: type survey . elongated case for 220 mm rack depth: option b2.

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