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industrial environment dc-dc converters <40 watt sr series edition 4/6.99 1/11 melcher the power partners. 20 watt dc-dc converters sr series single output of 5, 12, 15 or 24 v dc input voltage up to 180 v dc full input to output isolation 2.5 kv rms wide input voltage range high efficiency up to 81% efficient input filter very good dynamic characteristics parallel and series compatible continuous no-load and short circuit proof type survey and key data table 1: type survey output voltage input voltage range and efficiency 2 options u o nom i o nom u i min ... u i max h min h typ u i min ... u i max h min h typ u i min ... u i max h min h typ [v dc] [a] 19...45 v dc 1 [%] [%] 38...90 v dc 1 [%] [%] 76...180 v dc [%] [%] 5 4 bsr 2005-7 70 73 csr 2005-7 74 77 dsr 2005-7 74 77 -6, r 1 , i, p 12 1.67 bsr 2012-7 74 77 csr 2012-7 75 78 dsr 2012-7 75 78 15 1.34 bsr 2015-7 74 78 csr 2015-7 76 79 dsr 2015-7 76 79 24 0.84 bsr 2024-7 75 79 csr 2024-7 77 81 dsr 2024-7 77 81 1 with option r, shifted input voltage range, for bsr: 16...38 v dc, for csr: 32...76 v dc. not available for dsr. 2 efficiency at u i nom and i o nom . 151 5.9" 88 3.5" 32 1.3" safety according to iec/en 60950 lga summary the dc-dc converters of the sr series are power supply modules for electronic systems. their major advantages in- clude a high efficiency that remains virtually constant over the entire input voltage range, high reliability, low ripple and excellent dynamic response. the converters are designed for chassis mounting. table of contents page summary .......................................................................... 1 type survey and key data .............................................. 1 type key and product marking ........................................ 2 functional description ...................................................... 3 electrical input data ......................................................... 4 page electrical output data ...................................................... 5 immunity to environmental conditions ............................. 6 mechanical data .............................................................. 7 safety and installation instructions .................................. 8 description of options .................................................... 10
sr series dc-dc converters <40 watt industrial environment edition 4/6.99 2/11 melcher the power partners. type key and product marking type key b sr 20 05 -7 r i p input voltage range u i 19...45 v dc ............................................... b 38...90 v dc .............................................. c 76...180 v dc .............................................. d series ............................................................................ sr nominal output power in watt ......................................... 20 nominal output voltage in volt 5 v ........................................................... 05 12 v ........................................................... 12 15 v ........................................................... 15 24 v ........................................................... 24 ambient temperature range t a = ?5...71 c: plastic semi-conductors .............................. -7 hermetic semi-conductors (option) ............. -6 options: shifted input voltage range ......................... r inhibit input ................................................... i potentiometer .............................................. p example: bsr 2005-7rip = 20 watt dc-dc converter with a 5 v output, ambient temperature range of ?5...71 c, shifted input range of u i = 16...38 v dc, inhibit, and potentiometer. produkt marking basic type designation, applicable safety approval and recognition marks, ce mark, warnings and melcher company logo. specific type designation, input voltage range, nominal output voltage and current, pin allocation, identification of led and potentiometer. label with batch no., serial no. and data code comprising production site, modification status of the main pcb and date of production.
industrial environment dc-dc converters <40 watt sr series edition 4/6.99 3/11 melcher the power partners. functional description after passing through a line interference filter, the dc volt- age is chopped at a constant frequency of about 30 khz. after transformer isolation and rectification, an output filter reduces ripple to a minimum without compromising the dy- namic behaviour. the output voltage is routed to a control circuit with internal sense lines, where the output voltage is compared with a reference voltage. the voltage is regulated via a control transformer by varying the duty ratio of the for- ward converter. the converters have input transient protection by means of a zinc oxide vdr and input reverse polarity protection by means of a protective diode and a fuse. an internal inhibit signal keeps the output voltage switched off below approx. 0.7...0.9 u i min . the outputs are protected against continuous open circuit by means of an internal, electronically switched pre-load and against continuous short circuit by the current limiting circuit. no output voltage overshoot will occur when plugging in or disconnecting the module, switching the input voltage on/ off, inhibiting the unit or after reset. in the event of a main control circuit failure, the maximum output voltage u o is restricted to approx. 1.2 u o nom by means of an independent second control circuit. when the converters are located in free, stationary air at a temperature t a max = 71 c and are operated at nominal power, the case temperature t c max will reach approx. 85 c after a certain warm-up time (case temperature t c at the measuring point, see: mechanical data ). under certain operating conditions the ambient tempera- ture t a max may be allowed to exceed 71 c provided that additional measures are taken to ensure the case tempera- ture t c max remains below 85 c. forward converter 30 khz control circuit p (option) i (option) + 4.7 nf 2.2 nf + ( ) input filter 2.2 nf 03051 fig. 1 block diagram
sr series dc-dc converters <40 watt industrial environment edition 4/6.99 4/11 melcher the power partners. electrical input data general conditions t a = 25 c, unless t c is specified with option i, pin i is connected with u o with option p, u o = u o nom at i o nom table 2: input data input bsr csr dsr characteristics conditions min typ max min typ max min typ max unit u i input standard i o = 0... i o nom 19 (30) 45 38 (60) 90 76 (120) 180 v dc ( u i nom ) voltage option r t c min ... t c max 16 (24) 38 32 (48) 76 n.a. i inr p peak inrush current u i nom 28 22 10 a t inr r rise time 0.2 0.3 0.4 ms t inr h time to half-value 1 0.7 1 u i rfi rfi level at input en 55022 b b b 0.01...30 mhz 50 ? /50 h u i = u i nom si primary fuse rating slow blow 3.15 2 1.6 a u i tr input transient 1.2/5 s 0.8 1.5 2.5 kv suppression vde 0433 i i inh residual input current 5 min. after 1...6 1...4 1...4 ma with converter inhibited start i i uv input current after 5 min. 1 1 1 undervoltage lock-out u i < 0.7 u i min 1.75 1.50 1.25 0 15 20 35 40 25 30 45 bsr 20 0.75 1.00 0.50 0.25 i i [a] u i [v] i o = i o nom i o = 1 / 2 o nom i o = 0 u i min = 19 v dc 03052 600 400 200 0 30 40 70 80 50 60 90 csr 20 1000 800 u i [v] i i [ma] u i min = 38 v dc i o = i o nom i o = 1 / 2 i o nom i o = 0 03053 fig. 2 input current i i versus input voltage u i fig. 3 input current i i versus input voltage u i 500 400 300 0 60 80 140 160 200 100 120 180 dsr 20 100 i i [ma] u i [v] i o = i o nom i o = 1 / 2 i o nom i o = 0 u i min = 76 v dc 03054 1.0 0.8 0.6 0.4 0 0 0.2 0.8 1.0 0.4 0.6 1.2 1.4 0.2 i i [a] i o / i o nom i o nom i o l u i = 30 v dc (bsr) u i = 60 v dc (csr) u i = 120 v dc (dsr) 1 1 1 03055 fig. 4 input current i i versus input voltage u i fig. 5 input current i i versus input voltage u i 1 switch-off point of internal pre-load
industrial environment dc-dc converters <40 watt sr series edition 4/6.99 5/11 melcher the power partners. electrical output data general conditions t a = 25 c, unless t c is specified with option i, pin i is connected with u o with option p, u o = u o nom at i o nom table 3: output data output ..sr 2005.. sr 2012 .. sr 2015 .. sr 2024 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 4.97 5.03 11.92 12.07 14.91 15.09 23.85 24.14 v dc i o output current u i min ... u i max 0 4 0 1.67 0 1.34 0 0.84 a i o l output current limitation u i min ... u i max 4.8 1.84 1.47 0.92 t c min ... t c max u o l overvoltage limit with failure of main 5.3 6.8 13.5 16.0 16.5 19.0 27.0 31.0 v dc second control loop control circuit u o total output voltage u i min ... u i max 30 40 10 20 10 20 10 20 mv pp noise (bw = 20 mhz) 1 i o nom d u o u static line regulation 12 24 10 20 10 20 12 25 mv d u o i static load regulation u i nom 12 25 20 40 25 50 30 60 i o = 0... i o nom u o d dynamic voltage deviat. u i nom 70 25 25 25 t d load re- recovery time 1 ? 1 / 5 i o nom 70 150 200 300 s gulation iec/en 61204 a uo temperature coefficient u i min ... u i max 1 2 3 5 mv/k d u o / d t c i o = 0... i o nom 0.02 0.02 0.02 0.02 %/k 1 according to iec/en 61204. see: technical information: measuring and testing . 2 see: dynamic characteristics . i o / i o nom 1 u od u od t d t d d u o i d u o i t u o 0 t 10 s 10 s 05010 fig. 6 dynamic load regulation. 40 30 10 10 0 0.25 0.5 0.75 1.0 2024 20 2015 2012 2005 0 1 1 1 1 ? u o i [mv] i o / i o nom 05066 1 switch-off point of internal pre-load fig. 7 static load regulation. output voltage u o versus output current i o . 1.2 1.0 0.8 0.6 0.4 0 00.2 0.4 1.0 1.2 0.2 0.6 0.8 1.4 i o / i o nom u o / u o nom i o nom i o l 05067 fig. 8 short-circuit behaviour. output voltage u o versus output current i o .
sr series dc-dc converters <40 watt industrial environment edition 4/6.99 6/11 melcher the power partners. immunity to environmental conditions table 4: 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) table 5: temperature specifications, valid for air pressure of 800...1200 hpa (800...1200 mbar) temperature standard -7 3 option -6 4 characteristicsconditions min max min max unit t a ambient temperature 1 operational 2 25 71 25 71 c t c case temperature 25 85 25 85 t s storage temperature 1 non operational 40 85 40 85 1 mil-std-810d section 501.2 and 502.2 2 see: thermal considerations 3 plastic semiconductor devices 4 hermetic semiconductor devices table 6: mtbf and device hours mtbf ground fixed ground mobile mtbf acc. to mil-hdbk-217d t c = 40 c t c = 70 c t c = 40 c t c = 70 c standard -7 155'000 h 69'000 h 31'500 h 13'000 h option -6 100'000 h 46'000 h 28'000 h 18'000 h 1 statistical values, based on an average of 4300 working hours per year and in general field use 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 current, 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. note: sufficient forced cooling or an additional heat sink al- lows t a to be higher than 71 c (e.g. 85 c) as long as t c max is not exceeded.
industrial environment dc-dc converters <40 watt sr series edition 4/6.99 7/11 melcher the power partners. mechanical data dimensions in mm. tolerances 0.3 mm unless otherwise indicated. fig. 9 case: c01 (weight: bsr 550 g, csr and dsr 555 g). aluminium, black finish, fully enclosed, self cooling. potentiometer (option p) + u o u o 77.5 10 10 1 4.3 min. 8 5 0.5 10.7 1 43 1 (45) 88 1 151 1 32.2 0.5 6.35 1 distance between m4 fixing screws 144 measuring point of case temperature t c green led output voltage indicator - - adj 23 0.5 26.5 60 10.5 0.5 46.5 21.3 1 6.3 x 0.8 10 10 10 11 1 + - fuse 09045 input output input output european projection
sr series dc-dc converters <40 watt industrial environment edition 4/6.99 8/11 melcher the power partners. standards and approvals the dc-dc converters correspond to class i equipment. all types are lga approved to iec/en 60950 standards. the units have been evaluated for: building in, basic insulation between input and case/output, based on 250 v ac and 400 v dc, basic insulation between output and case, based on 250 v ac and 400 v dc, the use in a pollution degree 2 environment, connecting the input to a 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 en 60950 and iso 9001 standards. protection degree the protection degree of the dc-dc converters is ip 40, exept in the vicinity of the terminals, where it depends on the installation. 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 7: isolation characteristic input input output unit to to to case output case electric required according 2.0 2.5 1 1.0 kv rms strength to iec/en 60950 test actual factory test 2.8 3.5 1 1.4 kv dc voltage 1 s insulation resistance >100 >100 >100 m ? at 500 v dc 1 in accordance with iec/en 60950 only subassemblies are tested in factory with this voltage. safety and installation instructions installation instructions our dc-dc converters are components, intended exclu- sively for inclusion within other equipment by an industrial assembly operation or by professional installers. installation must strictly follow the national safety regulations in compli- ance with the enclosure, mounting, creepage, clearance, casualty, markings and segregation requirements of the end-use application. see also: technical information: in- stallation and application. connection to the system shall be made via the 6.3 0.8 mm faston contacts at the cover side of the unit according to mechanical data. the dc-dc converters are provided with an earth pin ( ), 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 if required in: safety of operator accessible output circuit . an input fuse is built-in in the connection from the vi+ termi- nal of the unit. since this fuse is designed to protect the unit in case of an overcurrent and does not necessarily cover all customer needs, an external fuse suitable for the applica- tion and in compliance with the local requirements should be installed in the wiring to one or both input pins (vi+ and/ or vi ). important: whenever the inhibit function is not in use, pin i should be connected to pin vo1 to enable the out- put. do not open the modules, or guarantee will be invali- dated. 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 not be exceeded . see also: ther- mal considerations. 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.
industrial environment dc-dc converters <40 watt sr series edition 4/6.99 9/11 melcher the power partners. table 8: insulation concept leading to an selv output circuit conditions front end dc-dc converter result supply minimum required grade maximum minimum required safety measures to achieve the safety status of voltage of isolation, to be provided dc output status of the front end specified safety status of the the dc-dc by the ac-dc front end, voltage output circuit output circuit converter output including mains supplied from the circuit battery charger front end 1 mains operational (i.e. there is 180 v 1 primary circuit basic insulation, based on earthed selv 250 v ac no need for electrical 250 v ac (provided by the circuit isolation between the main dc-dc converter), input supply voltage and the fuses 2 , output suppressor dc-dc converter input diode 3 , earthed output circuit voltage) and earthed 4 or non user accessible case 5 basic 60 v 6 earthed selv circuit 4 operational insulation (pro- selv circuit vided by the dc-dc converter) supplementary elv circuit basic insulation, based on >60 v 1 unearthed hazardous 250 v ac (provided by the voltage secondary circuit 5 dc-dc converter) double or reinforced 60 v 1 selv circuit operational insulation (pro- vided by the dc-dc converter) 120 v 6 tnv-3 circuit basic insulation, based on the >60 v 1 double or reinforced insu- maximum output voltage from lated unearthed hazardous the front end (provided by the voltage secondary circuit 6 dc-dc converter) 1 the front end output voltage should match the specified input voltage range of the dc-dc converter. the nominal voltage between any input pin and earth can be up to 250 v ac or 400 v dc. 2 the installer shall provide an approved fuse (type with the lowest rating suitable for the application) in both input lines dir ectly at the input of the dc-dc converter (see fig.: schematic safety concept ). for ul s purpose, the fuse needs to be ul-listed. 3 the suppressor diode should be dimensioned in such a way, that in the case of an insulation fault the diode is able to limit th e output voltage to selv (<60 v) until the input fuse blows (see fig.: schematic safety concept ). 4 the earth connection has to be provided by the installer according to the relevant safety standard, e.g. iec/en 60950 (see also fig.: schematic safety concept ). 5 has to be insulated from earth by at least supplementary insulation according to the relevant safety standard, based on the max imum output voltage from the front end. 6 the front end output voltage should match the specified input voltage range of the dc-dc converter. 7 has to be insulated from earth by at least supplementary insulation according to the relevant safety standard, based on the max imum mains supply voltage. ac-dc front end dc-dc con- verter mains suppressor diode selv earth connection + ~ ~ 10023 battery max. 250 v ac or 400 v dc max. 250 v ac or 400 v dc fuse fuse fig. 10 schematic safety concept. use fuse, suppressor diode and earth connection as per table safety concept leading to an selv output circuit . 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 44 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 .
sr series dc-dc converters <40 watt industrial environment edition 4/6.99 10/11 melcher the power partners. description of options -6 hermetic semiconductor the converters are equipped with hermetic semiconduc- tors instead of the standard plastic ones as far as such components are electrically and mechanically compatible. p potentiometer the potentiometer provides an output voltage adjustment range of 5% from the nominal output voltage u o nom and is accessible from the connector side. this option can be used, for example, to compensate for voltage drops in the supply lines. r shifted input voltage range option r allows the operation of bsr and csr converter series from either 24 or 48 v input voltages. the input volt- age tolerance is 30...25% as required by iec 571: rules for electronic equipment used on rail vehicles . 2.5 0 10 15 30 35 20 25 40 1.5 2.0 1.0 0.5 i i [a] u i [v] u i max = 38 v dc u i min = 16 v dc i o / i o nom i o = 1 / 2 i o nom i o = 0 bsr with option r 11033 600 400 200 0 20 30 60 70 40 50 80 1000 800 u i [v] i i [ma] u i max = 72 v u i min = 38 v i o / i o nom i o = 1 / 2 i o nom i o = 0 csr with option r 11034 fig. 11 input current i i versus input voltage u i fig. 12 input current i i versus input voltage u i i inhibit the dc-dc converter can be switched on or off with a con- trol signal via the inhibit input i. in systems with several units, this feature can be used, for example, to control the activation sequence of the units with a logic signal (ttl, c- mos, etc.). note: a non-used inhibit input should be connected to the negative output to enable the unit. vi+ vi vo i vo+ i inh u inh 06031 fig. 14 definitions of i inh and u inh 6 4 2 0 2 50 40 20 40 30 0 60 20 10 10 30 50 u inh [v] i inh [a] u inh = 0.8 v u inh = 2.4 v u o on u o off 11035 0 t t 0 inhibit 1 0.1 1 u o / u o nom t r t f 06001 fig. 13 output response as a function of inhibit signal fig. 15 inhibit current i inh versus inhibit voltage u inh
industrial environment dc-dc converters <40 watt sr series edition 4/6.99 11/11 melcher the power partners. table 9: inhibit characteristics characteristics conditions .. sr 2005 .. sr 2012 .. sr 2015 .. sr 2024 unit min typ max min typ max min typ max min typ max u inh inhibit input u o = on u i min ... u i max 50 +0.8 50 +0.8 50 +0.8 50 +0.8 v dc voltage to t c min ... t c max keep output u o = off r l = u o nom / i o nom +2.4 +50 +2.4 +50 +2.4 +50 +2.4 +50 voltage... ... i inh inhibit input current 400 400 400 400 a at u inh = 0 t r switch-on time after r l = u o nom / i o nom 40 80 80 110 ms inhibit command u i nom t f switch-off time after 2 75 75 80 inhibit command

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