HR/ER Series Data Sheet 144/288 Watt DC-DC Converters, 10:1 Input Range

Transcription

1 44/88 Watt DC-DC Converters, : Input Range 6.4" TE 8." 6 TE " " 4.4" U 4.4" U Features Extremely wide input voltage range from to 68 VDC in the same converter (HR Series) RoHS-compliant for all 6 substances Class I equipment Compliant with EN, EN --, EN 44. Input over- and programmable undervoltage lockout Shutdown function Inrush current limitation Interruption time ms Adjustable output voltages isolated outputs: no load, overload, and short-circuit proof Rectangular current limiting characteristic Parallel operation with active current sharing Very high efficiency up to 94% Immunity accord. to IEC 6-4-, -, -4, -, -6, -8, -9 All PCB boards protected by lacquer Very high reliability Safety-approved according to IEC/EN 69-, UL/CSA 69- nd Ed. on request Description The ER/HR Series of DC-DC converters represents versatile power supplies ideally suitable for use in transportation and other advanced electronic systems. The HR Series converters include a very broad input voltage range, very high efficiency, high reliability, low output voltage noise, and excellent dynamic response to load/line changes. HR converters can be connected to all conventional railway batteries. ER Series converters are optimized for connection to V railway batteries. The converter inputs are protected against surges and transients. An input over- and undervoltage lockout circuitry disables the outputs, when the input voltage is outside of the specified range. To avoid high input currents at operation with high-voltage batteries, the inhibit input allows for adjusting the undervoltage lockout to a suitable level, thus allowing the use of an appropriate external input fuse. The converters exhibit an inrush current limiter, preventing external circuit breakers and fuses from tripping at switch-on. The outputs are open- and short-circuit proof. Full input-to-output, input-to-case, output-to-case, and output to output isolation is provided. The converters are particularly suitable for railway applications. The HR converters can be Table of Contents Page Page Description... Model Selection... Functional Description... Electrical Input Data... 6 Electrical Output Data... 9 Auxiliary Functions... 4 Electromagnetic Compatibility (EMC)... 6 Immunity to Environmental Conditions... 8 Mechanical Data... 9 Safety and Installation Instructions... Description of Options... Accessories... 4 Copyright 6, Bel Power Solutions Inc. All rights reserved. BCD.8 Rev AF, -Jun-6 The Power Partners. Page of

2 44/88 Watt DC-DC Converters, : Input Range supplied by all common railway batteries of 4 V, 6 V, 48 V, 7 V, 96 V, V, and V nominal voltage. All boards are coated with a protective lacquer. The case design allows operation at nominal load up to 7 C with natural cooling. If forced cooling is provided, the ambient temperature may exceed 7 C, but the case temperature must remain below 9 C. A temperature sensor disables the outputs when the case temperature T C exceeds the limit. The outputs are auto- matically re-enabled, when the temperature drops below the limit. LED indicators display the status of the converter and allow for visual monitoring of the system at any time. The converters may either be plugged into a 9 " rack system according to IEC 697-, or be chassis mounted. Two heat sinks of different size and cooling plates for chassis mounting (option B, B) are available. Model Selection Table a: Model Selection of HR models Output Output Power Input voltage η 4 η Model Opt. V o nom I o nom V o nom I o nom P o nom V i min V i cont V i max min. typ. min. typ. [V] [A] [V] [A] [W] [V] [V] [V] [%] [%] [%] [%] to HR-9RG 4 B, B to HRL-9RG to HRP-9RG to HR4-9RG to HRP4-9RG to HR88-9RG to HRP88-9RG to HR-9RG B, B to HRL-9RG to HRP-9RG to HR4-9RG to HRP4-9RG to HR88-9RG to HRP88-9RG to HR-9RG B, B to HRL-9RG to HRP-9RG to HR4-9RG to HRP4-9RG to HR88-9RG to HRP88-9RG Efficiency at T A = C, V i = 4 V, I o nom, V o nom Efficiency at T A = C, V i = V, I o nom, V o nom Short time; see table for details 4 Both outputs connected in parallel Both outputs connected in series BCD.8 Rev AF, -Jun-6 The Power Partners. Page of

3 44/88 Watt DC-DC Converters, : Input Range Table b: Model Selection of ER models Output Output Power Input voltage η Model Opt. V o nom I o nom V o nom I o nom P o nom V i min V i cont V i max min. typ. [V] [A] [V] [A] [W] [V] [V] [V] [%] [%] to ER-9RG B, B to 68 ERL-9RG to ERP-9RG to 68 ER4-9RG to 68 ERP4-9RG to ER88-9RG to 68 ERP88-9RG to ER-9RG B, B to 68 ERL-9RG to ERP-9RG to 68 ER4-9RG to 68 ERP4-9RG to ER88-9RG to 68 ERP88-9RG to ER-9RG 4 B, B to 68 ERL-9RG to ERP-9RG to 68 ER4-9RG to 68 ERP4-9RG to ER88-9RG to 68 ERP88-9RG 4 Efficiency at T A = C, V i = V, I o nom, V o nom Short time; see table for details Both outputs connected in parallel 4 Both outputs connected in series BCD.8 Rev AF, -Jun-6 The Power Partners. Page of

4 44/88 Watt DC-DC Converters, : Input Range Part Number Description Operating input voltage V i cont (continuously): 6.8 VDC... HR, HRL, HRP 77 VDC... ER, ERL, ERP HR 4-9 R B G Number of outputs..., 7 Nominal voltage of main output V o nom V... V... 4 V V V... 8 Other voltages... 9 Nominal voltage of tracking output V o V... V V V V... 8 Other specifications or additional features Operational temperature range: T A : T A = 4 to 7 C, T C 9 C Other... -, -, -6 Auxiliary functions and options: Output voltage control input... R Cooling plate standard case... B, B Cooling plate for long case mm... B RoHS-compliant for all 6 substances... G 4 Customer-specific models. No safety-relevant changes compared to the respective basic model, e.g. different mechanical details, special markings, mounted front plates, reduced output voltage, etc. Converters with mm case (customer-specific models). Add to the model number, e.g. HR4-9RBG HR74-9RBG. The nominal voltages of both outputs are always equal. 4 G is always placed at the end of the part number. Note: The sequence of options must follow the order above. Example: HR4-9RBG: DC-DC converter, operating input voltage range 6.8 VDC, isolated outputs, each providing V, 8 A, control input R to adjust the output voltages, cooling plate B, and RoHS-compliant for all six substances. Product Marking Basic type designation: applicable approval marks, CE mark, warnings, pin designation, patents and product logo, identification of LEDs. Specific type designation: input voltage range, nominal output voltages and currents, degree of protection, batch no., serial no., and data code including production site, modification status, and date of production. BCD.8 Rev AF, -Jun-6 The Power Partners. Page 4 of

5 44/88 Watt DC-DC Converters, : Input Range Functional Description The input voltage is fed via an efficient filter to the interleaved switching boost converter (HR models), which provides the intermediate circuit voltage on the bulk capacitor C b. The inrush current is limited by the resistor R inr, which is shorted by V inr after the bulk capacitor was charged. The bulk capacitor sources a single-transistor forward converter with active clamp and provides the power during the interruption time of ms. The main transformer exhibits two separate secondary windings for the two outputs. The resultant voltages are rectified by synchronous rectifiers (not models with V o = 48 V) in order to provide the best efficiency. Their ripple voltages are smoothed by a dual power choke and output filters. The control logic senses the main output voltage V o and generates the control signal for the forward converter, with respect to the max. output current transferred via magnetic feedback to the control circuit of the forward converter, located on the primary side. The second output voltage is tracking the main output, but has its own current limiting circuit. If the main output voltage drops due to current limitation, the second output voltage will drop as well and vice versa. The output voltages can be adjusted by external means. Parallel operation of several converters is possible by interconnecting the T-pins to provide active current sharing. Both outputs can be connected in parallel or in series without any precaution. They exhibit a rectangular current limitation characteristic. Switchable preloads V PL (Version V or later) ensure good regulation even with no load at one output. A control output (D) and two LEDs signal correct operation of the converter. In case of an output overvoltage, the converter is disabled by a latch. Input over- and undervoltage lockout is provided. The undervoltage trigger level can be adjusted by an external resistor connected to PUL (pin 4) depending on the nominal voltage of the supplying battery. Temperature sensors on the primary and secondary side prevent the converter from excessive warm-up. A cooling plate for chassis-mounting is available (opt. B, B). JM8c 6 Vi+ 8 Vi PUL 4 C x Input filter C Y C Y VDR C i NTC + Boost converter ( khz interleaved) Primary control C b Auxiliary converter (8 khz) V inr + Rinr Magnetic feedback Forward converter (8 khz) Isolation NTC Synchr. rect. drive Synchr. rect. drive Secondary control logic + + Output filter V PL Output filter V PL C Y C Y C Y C Y 6 R 8T D S+ 4 Vo+ 8 Vo 4 S 6 Vo+ Vo models with x 48 V have rectifier diodes T-pin is not connected for models HRL Fig. Block diagram of HR, version V (or later) BCD.8 Rev AF, -Jun-6 The Power Partners. Page of

6 44/88 Watt DC-DC Converters, : Input Range JM7 6 Vi+ 8 Vi PUL 4 C x C Y Input filter VDR NTC C Y Inrush current control C b Auxiliary converter ( khz) V inr + Rinr Magnetic feedback Forward converter (8 khz) Isolation NTC Synchr. rect. drive Synchr. rect. drive Secondary control logic + Output filter V PL Output filter C Y C Y 6 + C Y C Y V PL 6 R 8T D S+ 4 8 Vo+ Vo 4 S Vo+ Vo models with V o = x 48 V have rectifier diodes T-pin is not connected for ERL models Fig. Block diagram of ER Electrical Input Data General Conditions: T A = C, unless T C is specified. Pin 4 (PUL) left open-circuit Pin 6 (R) and 8 (D) left open-circuit. Table a: Input data of HR models Model HR HRL HRP Unit Characteristics Conditions min typ max min typ max min typ max V i Operating input voltage I o = I o max V for s, without shutdown T C min T C max V i nom Nom. input voltage range 4 () 4 () 4 () V i abs Input voltage limits s,without damage I i Input current: HR V i max.. ( V).. V i min, I o nom.76 (.6).6. (.8) 9.. (.8).4 A HR4.76 (.6).6. (.8).4 HR88.7 (.86).8.7 (.) 6. P i No-load input power V i min V i max, I o = W P i inh Idle input power V i min V i max, V PUL = V... C x Input capacitance µf R i Input resistance mω I inr p Peak inrush current V i = V, I o nom A t inr r Time constant of I inr ms t on Start-up time V i min, I o nom t r Rise time after inhibit V i 6.8 V, I o nom, V PUL = V Not smoothed by the inrush current limiter According to ETS - BCD.8 Rev AF, -Jun-6 The Power Partners. Page 6 of

7 44/88 Watt DC-DC Converters, : Input Range Table b: Input data of ER models Model ER ERL ERP Unit Characteristics Conditions min typ max min typ max min typ max V i Operating input voltage I o = I o max V for s, without shutdown T C min T C max V i nom Nom. input voltage range V i abs Input voltage limits s,without damage I i Input current: ER V i max.. ( V).. V i min, I o nom.76 (.6). (.8). (.8) A ER4.76 (.6). (.8) ER88.7 (.86).7 (.) P i No-load input power V i min V i max, I o = W P i inh Idle input power V i min V i max, V PUL = V... C x Input capacitance µf R i Input resistance mω I inr p Peak inrush current V i = V, I o nom A t inr r Time constant of I inr ms t on Start-up time V i min, I o nom t r Rise time after inhibit V i 77 V, I o nom, V PUL = V Not smoothed by the inrush current limiter According to ETS - PUL Function and Fuse No fuse is incorporated in the converters. Consequently, an external fuse or a circuit breaker must be installed at system level to protect against severe defects. HR converters are designed for an extremly wide input voltage range, allowing for connection to all common railway batteries. However, the programmable input undervoltage lockout (PUL, pin 4) should be adjusted adequately, in order to limit the input current at low input voltage. Table specifies the values of the resistor R PUL, connected between PUL and Vi, versus the resultant minimum input voltage and the recommended external input fuse. Fig. shows more values of R PUL versus start-up voltage. For stationary batteries, a higher start-up voltage might be advantageous. V i min [V] 8 JMa Fig. R PUL versus switch-on voltage (HR models) 6 kω R PUL Table : PUL Specification (typ.) and recommended external fuses for HR/HRP models. Smaller fuses are possible for HRL models. Battery R PUL V i min (on / off) Fuse rating 4 V V V A, fast, Littlefuse 4 6 V 6.9 kω V 8 V 6 A, fast, Schurter /SP 48 V.7 kω 6 V V. A, fast, Schurter /SP 7 V 9. kω 8 V V 8 A, fast, Schurter /SP V. kω 6 V 7 V 6. A, slow, BEL fuse MRT V.9 kω 9 V 84 V A, slow, BEL fuse MRT all < Ω Converter disabled fuse size 6. mm fuse size mm for s ER models are designed for the input voltage range of a V railway battery. The input undervoltage lockout (PUL, pin 4) Table 4: PUL specification (typ.) and recommended external fuses for ER/ERP models. Smaller fuses are possible for ERL models. Battery R PUL V i min (on / off) Fuse rating V. kω 64. V 6. V 6. A, slow, BEL fuse MRT V 4. kω 74. V 69 V 6. A, slow, BEL fuse MRT V. kω 87.4 V 8.6 V 6. A, slow, BEL fuse MRT V. kω 96 V 9 V 6. A, slow, BEL fuse MRT V. kω.7 V 96 V A, slow, BEL fuse MRT -- < Ω Converter disabled fuse size 6. mm fuse size mm BCD.8 Rev AF, -Jun-6 The Power Partners. Page 7 of

8 44/88 Watt DC-DC Converters, : Input Range I i [A] JM87 pins. Consequently, a short current peak is present, when applying the input voltage. The inrush current peak value can be determined by following calculation; see also fig. 6: V i source I inr p = (R ext + R i ) V i [V] Fig. 4 Typ. input current vs input voltage at nominal load (HR) + L ext R ext Vi+ Vi R i C i Converter JMc Vo+ Vo Load I i [A] JM67 Fig. 6 Equivalent input ciruit 4 I inr [A] JM V i [V] Fig. Typ. input current vs input voltage at nominal load (ER) may be adjusted if requested. The PUL resistors are specified in table 4. Note: If PUL (pin 4) is connected to Vi (pin /), the converter is disabled; see Inhibit Function. Fig. 4 and show the input current versus the input voltage. Reverse Polarity and Input Transient Protection Reverse polarity protection of all models is provided by an antiparallel diode across the input, causing the external input fuse or circuit breaker to trip. ER models exhibit an additional serial diode on the input. The double stage symmetrical input filter together with a VDR (voltage depending resistor) form an effective protection against high input transient voltages, which typically occur in battery-driven mobile applications. At very high input voltage, the overvoltage lockout disables the converter in order to protect it from damage. Inrush Current Limitation The converters exhibit an electronic inrush current limiting circuit. This circuit is also functional, when the input voltage is removed and immediately reapplied. However, several capacitors are directly connected to the input η [%] ms Fig. 7 Inrush current at V i = V, I o nom (HR, ER) Efficiency 6. V i = V V i = V V i =.4 V JM I / I o o nom Fig. 8 Efficiency versus V i and I o (HR, both outputs connected in series) BCD.8 Rev AF, -Jun-6 The Power Partners. Page 8 of

9 44/88 Watt DC-DC Converters, : Input Range Electrical Output Data General Conditions: T A = C, unless T C is specified; Pin 4 (PUL) V Table a: Output data of HR/ER and HRL/ERL Model HR / ER HRL / ERL Unit Nom. output voltage V V Output Output Output Output Characteristics Conditions min typ max min typ max min typ max min typ max V o Output voltage V i nom,. I o nom V V o BR Output protection Output (suppressor diode) I o nom Output current nom. V i min V i max A I ol, I ol Output current limit T C min T C max I ol Output current limit v o Output noise incl. V i nom, I o nom mv pp spikes BW = MHz V o adj Adjustment by R-input 4 V i min V i max V V o u Static line/load regulation (. ) I o nom ± ± mv (total deviation of V o ) v o d Dynamic Voltage V i nom,. I o nom ± ± ± ± load deviation I o nom. I o nom t o d regulat. Recovery time and after turn on ms α vo Temperature coefficient T C min T C max %/K of output voltage I o nom Table b: Output data of HRP/ERP models Model HRP / ERP Unit Nom. output voltage V Output Output Characteristics Conditions min typ max min typ max V o Output voltage V i nom,. I o nom V V o BR Output protection Output (suppressor diode) I o nom Output current nom. V i min V i max A I ol, I ol Output current limit T C min T C max.. I ol Output current limit v o Output noise incl. V i nom, I o nom 6 6 mv pp spikes BW = MHz V o adj Adjustment by R-input 4 V i min V i max V V o u Static line/load regulation (. ) I o nom ± mv (total deviation of V o ) v o d Dynamic Voltage V i nom,. I o nom ± ± load deviation I o nom. I o nom t o d regulat. Recovery time and after turn on ms α vo Temperature coefficient T C min T C max %/K of output voltage I o nom If V o is increased above V o nom through R-, sense, or T-input, the output currents should be reduced so that P o nom is not exceeded. Both outputs connected in parallel See Output voltage regulation 4 For battery charger application, a defined negative temp. coefficient can be provided by using a temp. sensor (see Accessories) See Dynamic load regulation 6 Measured with a ceramic cap of µf across each output. BCD.8 Rev AF, -Jun-6 The Power Partners. Page 9 of

10 44/88 Watt DC-DC Converters, : Input Range Table c: Output data of HR/ER4 and HRP/ERP4. General conditions as per table a Model HR4 / ER4 HRP4 / ERP4 Unit Nom. output voltage V V Output Output Output Output Characteristics Conditions min typ max min typ max min typ max min typ max V o Output voltage V i nom,. I o nom V V o BR Output protection Output (suppressor diode) I o nom Output current nom. V i min V i max A I ol, I ol Output current limit T C min T C max I ol Output current limit v o Output noise incl. V i nom, I o nom mv pp spikes BW = MHz V o adj Adjustment by R-input 4 V i min V i max V V o u Static line/load regulation (. ) I o nom ± ± mv (total deviation of V o) v o d Dynamic Voltage V i nom,. I o nom ± ± ± ± load deviation I o nom. I o nom t o d regulat. Recovery time and after turn on ms α vo Temperature coefficient T C min T C max %/K of output voltage I o nom If the output voltages are increased above V o nom through R-input control, remote sensing, or option T, the output currents should be reduced accordingly so that P o nom is not exceeded. Both outputs connected in parallel See Output voltage regulation 4 For battery charger applications, a defined negative temperature coefficient can be provided by using a temperature sensor (see Accessories) See Dynamic load regulation 6 Measured with a ceramic cap of µf across each output. BCD.8 Rev AF, -Jun-6 The Power Partners. Page of

11 44/88 Watt DC-DC Converters, : Input Range Table d: Output data of HR/ER88 and HRP/ERP88. General conditions as per table a Model HR88 / ER88 HRP88 / ERP88 Unit Nom. output voltage 48 V 48 V Output Output Output Output Characteristics Conditions min typ max min typ max min typ max min typ max V o Output voltage V i nom,. I o nom V V o BR Output protection Output (suppressor diode) I o nom Output current nom. V i min V i max.... A I ol, I ol Output current limit T C min T C max I ol Output current limit v o Output noise incl. V i nom, I o nom mv pp spikes BW = MHz V o adj Adjustment by R-input 4 V i min V i max V V o u Static line/load regulation (. ) I o nom ±. ±. (total deviation of V o ) v o d Dynamic Voltage V i nom,. I o nom ±.8 ±.8 ±. ±. load deviation I o nom. I o nom t o d regulat. Recovery time and after turn on ms α vo Temperature coefficient T C min T C max %/K of output voltage I o nom If the output voltages are increased above V o nom through R-input control, remote sensing, or option T, the output currents should be reduced accordingly so that P o nom is not exceeded. Both outputs connected in parallel See Output voltage regulation 4 For battery charger applications, a defined negative temperature coefficient can be provided by using a temperature sensor (see Accessories) See Dynamic load regulation 6 Measured with a ceramic cap of µf across each output. BCD.8 Rev AF, -Jun-6 The Power Partners. Page of

12 44/88 Watt DC-DC Converters, : Input Range Thermal Considerations If a converter is located in free, quasi-stationary air (convection cooling) at the indicated maximum ambient temperature T A max (see table Temperature specifications) and is operated within the specified input voltage range and nominal load, the temperature measured at the Measuring point of case temperature 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 upon the conditions of operation and integration into a system. The thermal conditions are influenced by input voltage, output current, airflow, and temperature of surrounding components and surfaces. T A max is therefore, contrary to T C max, an indicative value only. Caution: The installer must ensure that under all operating conditions T C remains within the limits stated in the table Temperature specifications. Notes: Sufficient forced cooling or enhanced cooling with the help of cooling plates (options B, B) allows for T A to be higher than 7 C (e.g. 8 C), as long as T C max is not exceeded. Thermal Protection Two temperature sensors generate an internal inhibit signal, which disables the converter in the case of overtemperature. The outputs automatically recover when the temperature drops below the limit. Interruption Time The integrated storage capacitor (C b ) is loaded to the boost voltage and ensures full output voltage with nominal load during an interruption time (or ride-through time) of at least ms, provided that V i was V before the interruption. This complies with EN class S. Output Protection The nd output of xx models is protected by a suppressor diode against overvoltage, which could occur due to a failure of the internal control circuit. This suppressor diode was not designed to withstand externally applied overvoltages. Overload at any of the outputs will cause both outputs to shutdown. Note: V o BR of the suppressor diode is specified in Electrical Output Data. If this voltage is exceeded, the suppressor diode generates losses and may become a short circuit. Note: The output voltage of the first output is monitored. If it exceeds typ. 4% of V o nom for ms, the converter is inhibited. To reactivate, V i must be removed or an inhibit signal applied to PUL (pin 4). Each output has its own current limiting circuit, providing a rectangular output characterisitc and protecting against short circuit. There is no limitation for the capacitive load, and battery charging is possible as well. Series and Parallel Connection Both outputs of the same converter can be series-connected or parallel-connected in order to double the output current or the output voltage respectively. Outputs of different converters may be series-connected. In parallel connection of several converters, the T-pins should be interconnected so that all converters share the output current equally; see fig. 9. HRL and ERL models have no T- pins and should not be operated in parallel connection. If both outputs of each converter are connected in series, Vo of both converters should be connected together and the T- pins as well. See fig.. Notes: Not more than converters should be connected in parallel. If several outputs are connected in series, the resulting voltage can exceed the SELV level. The PUL- pins (pin 4) should exhibit an individual PUL resistor for each converter. If the shutdown function is used, each PUL-pin must be controlled induvidually. The R-pins should be left open-circuit. If not, the output voltages must individually be adjusted prior to paralleling within to % or the R-pins should be connected together. Series connection of second outputs without involving their main outputs should be avoided, as regulation may be poor. Converter # Converter # JM88a Max. converters in parallel connection Vo+ 6 Vo+ 4 S+ T 8 S 4 Vo Vo 8 Vo+ 6 Vo+ 4 S+ T 8 S 4 Vo Vo 8 Load Fig. 9 Parallel connection with OR-ing diodes and sense lines connected at the load Lead lines with equal length and cross section Diodes for redundant operation only BCD.8 Rev AF, -Jun-6 The Power Partners. Page of

13 44/88 Watt DC-DC Converters, : Input Range JM84a Converter # Converter # Vo+ 6 Vo 4 Vo+ S+ T 8 S 4 Vo 8 Vo+ 6 Vo Vo+ 4 S+ 8 T 4 S Vo 8 Load Max. converters in parallel connection T + Power bus Fig. Parallel connection of double-output models with the outputs of each converter connected in series, using option T. The signal at the T pins are referenced to Vo. Output Voltage Regulation If both outputs are connected in parallel or in series, the converter exhibits a rectangular output characterisitic; see fig.. The typ. dynamic load regulation illustrates fig.. Output is under normal conditions regulated to V o nom, irrespective of the output currents. However, V o depends upon the load distribution; see fig.. Converters with version V (or later) have incorporated switchable preloads and do not need a minimum load. Note: If output is not used, connect it in parallel with output! This ensures good voltage regulation and efficiency. V o /V o nom.98 V o [V] A Fig. Models HR/ER: V o versus I o with various I o V o [V] V o I o /I o nom. V od Fig. Typical dynamic load regulation of V o. t d V o ±% V o ±% V od µs µs t d c JM89c I o = A I o = 7. A I o =. A I o =. A I o =. A I o =. A JM68 I o = A I o =. A I o = A I o =. A I o =. A t t I o. 98a.. I o I ol I o /I o nom Fig. Output characteristic V o versus I o (both outputs connected in parallel or in series) A Fig. 4 Models HR/ER88: V o versus I o with various I o I o BCD.8 Rev AF, -Jun-6 The Power Partners. Page of

14 44/88 Watt DC-DC Converters, : Input Range Auxiliary Functions Inhibit Function The PUL input (pin 4) can also be used as inhibit (for the PUL function see table and 4). The response time t on and the rise time t r are specified in table. V o /V o nom. PUL t d on t on t r Fig. Typical output response to the PUL-signal (inhibit) The current coming out from pin 4 (PUL) is typ.. ma (< ma). If pin 4 is left open-circuit, the voltage is typ. V. The converter is disabled when V PUL is mv. 8 Vi+ t hu t off JM7 t f JM9c t Sense Lines This feature allows for compensation of voltage drops across the connector contacts and if necessary, across the load lines. We recommend connecting the sense lines directly at the female connector. To ensure correct operation, both sense lines (S+, S ) should be connected to their respective power outputs (Vo+ and Vo ), and the voltage difference between any sense line and its respective power output (as measured on the connector) should not exceed the values specified in table 6. Important: Sense lines should be connected! Incorrectly connected sense lines may activate the overvoltage protection resulting in a permanent short-circuit of the output. Open sense lines are allowed, but result in inaccurate output voltages. Output Voltage Adjust As a standard feature, the converters offer an adjustable output voltage. The control input R (pin 6) accepts either a control voltage V ext or a resistor R ext to adjust the output voltage. When input R is not connected, the output voltage is set to V o nom. a) Adjustment by means of an external control voltage V ext between pin 6 (R) and pin 4 (S ): The control voltage range is..87 V and allows for an adjustment in the range of approx. 4 % of V o nom. V o. V V ext V o nom R PUL I PUL V PUL 4 PUL Output Caution: Applying an external control voltage >.87 V may damage the converter. b) Adjustment by means of an external resistor: Vi PE Depending on the value of the required output voltage, the resistor shall be connected either: between pin 6 (R) and pin 4 (S ) to adjust the output voltage in the range of approx. 4 % of V o nom. Fig. 6 Circuit for the inhibit function Current Share Function If the pins 8 (T) of parallel-connected converters are connected together, the converters share the output current evenly. Refer to section Parallel and Series Connection. Not for HRL and ERL models. V o R ext 4 kω V o nom V o or: between pin 6 (R) and pin (S+) to adjust the output voltage in the range of % of V o nom. (V o. V) R ext 4 kω. V (V o /V o nom ) Caution: To prevent the converter from damage, the value of R ' ext shall never be less than the value for increasing V o to %! Table 6: Maximum voltage compensation allowed using sense lines Vi+ JM9a S+ Output Total voltage difference Voltage difference voltage between sense lines and between their respective outputs Vo and S V <. V <. V V <. V <.6 V Vi V ref =. V + 4 kω Control logic 6 R S 4 R ext R ext + V ext 48 V <. V <. V Fig. 7 Output voltage adjustment BCD.8 Rev AF, -Jun-6 The Power Partners. Page 4 of

15 44/88 Watt DC-DC Converters, : Input Range Notes: If the output voltages are increased above V o nom via R-input control, sense lines, or option T, the output currents should be reduced, so that P o nom is not exceeded. The second output of double-output models follows the voltage of the controlled main output. Input Power supply Vo+ Vo R 99d Load Output Voltage Monitor The output voltage monitor generates a logic "low" signal (NPN open-collector output) at the D-output (pin ), when V o.96 V o nom. For converters with version V (or later), the voltage at S+ (corresponding to V o ) must be.96 V o nom and.4 V o nom (typ. values). Then, a green LED (Out OK) at the frontplate is illuminated. If the output voltage is adjusted by the R-input, the trigger levels are corrected accordingly. At low D-output, the current is limited by a Ω protective resistor; for converters with Version V (or later) I D should be ma. If the D-output is high (open collector), V D should be 7 V. For previous converters: ma and V. Note: Output overvoltage activates a latch; see Output Protection. Fig. 9 Connection of a temperature sensor Cell voltage [V].4 + ϑ Temperature sensor + Battery 69b JM9 S+.4. Input NPN open D collector Ω S 4 I D R p V D... Fig. 8 Output voltage monitor Indicators Two green LED indicators are visible at the front plate: - Out OK; see Output Voltage Monitor - In OK. This signal is activated when V i is below 8 V and greater than V i min, whereas V i min is defined by the adjust resistor connected to the PUL input (pin 4). Battery Charging / Temperature Sensor All converters with an R-input are suitable for battery charger application. For optimal battery charging and life expectancy of the battery an external temperature sensor can be connected to the R-input. The sensor is mounted as close as possible to the battery and adjusts the output voltage accoring to the battery temperature. Depending upon cell voltage and the temperature coefficient of the battery, different sensor types are available, see Accessories.. V o safe. 4 C V C =.7 V, mv/k V C =. V, mv/k V C =.7 V,. mv/k V C =. V,. mv/k Fig. Trickle charge voltage versus temperature for defined temperature coefficient. V o nom is the output voltage with open R-input. BCD.8 Rev AF, -Jun-6 The Power Partners. Page of

16 44/88 Watt DC-DC Converters, : Input Range Electromagnetic Compatibility (EMC) A metal oxide VDR together and an efficient input filter form an effective protection against high input transient voltages, which typically occur in most installations. The converters have been successfully tested to the following specifications: Electromagnetic Immunity Table 7: Electromagnetic immunity (type tests) Phenomenon Standard Level Coupling Value Waveform Source Test In Perf. mode applied imped. procedure oper. crit. Electrostatic IEC/EN 4 contact discharge 8 V p / ns Ω positive and yes A discharge 6-4- negative air discharge V p (to case) discharges Electromagnetic IEC/EN x 4 antenna V/m AM 8% / khz n.a. 8 MHz yes A field 6-4- antenna V/m AM 8% / khz n.a. 8 MHz yes A V/m 4 MHz V/m MHz V/m 6 MHz antenna V/m % duty cycle, n.a. 9 ± MHz yes A Hz rep. rate Electrical fast IEC/EN 6 capacitive, o/c ± V p bursts of / ns Ω 6 s positive yes A transients/burst i/c, +i/ i./ khz over 6 s negative ±4 V p ms; burst transients per direct period: ms coupling mode Surges IEC/EN 7 i/c ± V p./ µs 4 Ω /. µf pos. and neg. yes A i/ i surges per ± V p 4 Ω /. µf coupling mode Conducted IEC/EN 8 i, o, signal wires VAC AM 8% Ω. 8 MHz yes A disturbances (4 dbµv) khz Power frequency IEC/EN 9 -- A/m 6 s in all axis yes A magnetic field Pulse IEC/ EN - -- ± A/m pulses per axis yes A magnetic field repetit. rate s i = input, o = output, c = case A = normal operation, no deviation from specs.; B = normal operation, temporary loss of function or deviation from specs possible Exceeds EN --: table 6. and EN -4:6 table.4. 4 Corresponds to EN --: table 6. and exceeds EN -4:6 table.. Corresponds to EN --: table 6. and EN -4:6 table. (compliance with digital mobile phones). 6 Corresponds to EN --: table. and EN -4:6 table.. 7 Covers or exceeds EN --: table 4. and EN -4:6 table.. 8 Corresponds to EN --: table. and EN -4:6 table. (radio frequency common mode). 9 Corresponds to EN -4:6 table.. BCD.8 Rev AF, -Jun-6 The Power Partners. Page 6 of

17 44/88 Watt DC-DC Converters, : Input Range Electromagnetic Emissions All models comply with Class A according to EN / for conducted and radiated emissions. dbµv/m 6 VUS EMC Labatory, Vin=4VDC, Iout=xA, C. Testdistance m, Class A, HR-9RG, B979, U4, 6.7. EN A JM8 dbµv VUS EMC Labatory, Vin = 4 VDC, Iout = x A, C. Testdistance m, Class A, HR-9RG, B979, U4, EN A qp 6 EN A av JM6 4.. MHz MHz Fig. Typ. radiated emissions accord. to EN /, antenna m distance, measured at V i = 4 V and I o nom (HR-9RG). Fig. Typ. conducted emissions (peak/quasipeak and average) at the input according to EN /, measured at V i = 4 V and I o nom (HR-9RG). dbµv/m 6 VUS EMC Labatory, Vin = VDC, Iout=xA, C. Testdistance m, Class A, HR-9RG, B979, U4, 6.7. EN A JM9 4 dbµv VUS EMC Labatory, Vin = VDC, Iout = x A, C. Testdistance m, Class A, HR-9RG, B979, U4, EN A qp EN A av.. MHz JM7 MHz Fig. 4 Typ. radiated emissions accord. to EN /, antenna m distance, measured at V i = V and I o nom (HR-9RG, ER-9RG). Fig. Typ. conducted emissions (peak/quasipeak and average) at the input according to EN /, measured at V i = V and I o nom (HR-9RG, ER-9RG). BCD.8 Rev AF, -Jun-6 The Power Partners. Page 7 of

18 44/88 Watt DC-DC Converters, : Input Range Immunity to Environmental Conditions Table 8: Mechanical and climatic stress (type tests) Test method Standard Test conditions Status Cab Damp heat IEC/EN Temperature: 4 ± C Converter steady state MIL-STD-8D section 7. Relative humidity: 9 +/- % not Duration: 6 days operating Db Damp heat test, EN :7, clause.. Temperature: C and C Converter cyclic IEC/EN Cycles (respiration effect): not Duration: 4 h operating Bd Dry heat test EN :7, clause..4 Temperature: 7 C Converter steady state IEC/EN Duration: 6 h operating Ad Cooling test EN :7, clause.. Temperature, duration 4 C, h Conv. not steady state IEC/EN Performance test + C operating -- Salt mist test EN :7, clause.. Temperature: ± C Converter sodium chloride class ST Duration: 48 h not (NaCl) solution operating Fc Vibration IEC/EN Acceleration amplitude:. mm ( 6 Hz) Converter (sinusoidal) MIL-STD-8D section 4. g n = 49 m/s (6 - Hz) operating Frequency ( Oct/min): Hz Test duration: 7. h (. h in each axis) Fh Random vibration IEC/EN Acceleration spectral density:. g n /Hz Converter broad band Frequency band: 8 Hz operating (digital control) and Acceleration magnitude: 4.9 g n rms guidance Test duration:. h (. h in each axis) Eb Bump IEC/EN Acceleration amplitude: g n = 4 m/s Converter (half-sinusoidal) MIL-STD-8D section 6. Bump duration: 6 ms operating Number of bumps: 6 ( in each direction) Ea Shock IEC/EN Acceleration amplitude: g n = 49 m/s Converter (half-sinusoidal) MIL-STD-8D section 6. Bump duration: ms operating Number of bumps: 8 ( in each direction) -- Shock EN :7 clause.., Acceleration amplitude:. g n Converter EN 67 sect., Bump duration: ms operating class B, body mounted Number of bumps: 8 ( in each direction) -- Simulated long life EN :7 clause.., Acceleration spectral density:. g n / Hz Converter testing at EN 67 sect. 8 and 9, Frequency band: Hz operating increased random class B, body mounted Acceleration magnitude:.8 g n rms vibration levels Test duration: h ( h in each axis) Body mounted = chassis of a railway coach Temperatures Table 9: Temperature specifications, valid for an air pressure of 8 - hpa (8 - mbar) Temperature -9 Unit Characteristics Conditions min typ max T A Ambient temperature Converter operating 4 7 C T C Case temperature 4 9 T S Storage temperature Non operational 8 See Thermal Considerations. Overtemperature lockout at T C >9 C (An NTC resistor on primary and secondary heatsink). BCD.8 Rev AF, -Jun-6 The Power Partners. Page 8 of

19 44/88 Watt DC-DC Converters, : Input Range Reliability Table : MTBF and device hours Ratings at specified Model Ground Ground fixed Ground Life Device Unit case temperature benign mobile test hours 4 C 4 C 7 C C C Bellcore SR HR h Life test with converters during 6 days, cycling at 6 C; confidience level 6%. Statistical values, based on an average of 4 working hours per year and in general field use over years; upgrades and customer-induced errors are excluded. Mechanical Data Dimensions in mm. The converters are designed to be inserted into a 9" rack, 6 mm long, according to IEC European Projection (7. to 7.9) M4 7 TE TE.7. JM9 Measuring point of case temperature T C (U) Out OK In OK d Front plate Main face Back plate x Screw holes of the frontplate Fig. Case S for HR and ER models with heat sink; Aluminum, black finish (EP powder coated); weight approx.. kg Notes: d mm, recommended minimum distance to next part in order to ensure proper air circulation at full output power. free air location: the converter should be mounted with fins in a vertical position to achieve maximum airflow through the heat sink. BCD.8 Rev AF, -Jun-6 The Power Partners. Page 9 of

20 44/88 Watt DC-DC Converters, : Input Range Dimensions in mm. The converters are designed to be inserted into a 9" rack, 6 mm long, according to IEC European Projection TE 9 TE.7. JM9 d (U) 6.4. Out OK In OK Measuring point of case temperature T C. ( ) Front plate Main face Back plate 68. x Screw holes of the frontplate Mounting slots for chassis or wall mounting Fig. 6 Case K for HRP and ERP models with heat sink; Aluminum, black finish (EP powder coated); weight approx..8 kg Notes: d mm, recommended minimum distance to next part in order to ensure proper air circulation at full output power. free air location: the converter should be mounted with fins in a vertical position to achieve maximum airflow through the heat sink. BCD.8 Rev AF, -Jun-6 The Power Partners. Page of

21 44/88 Watt DC-DC Converters, : Input Range ±. 68 Fig. 7 Option B: Aluminum case S with large cooling plate; black finish (EP powder coated). Suitable for front mounting. Total weight approx.. kg European Projection Note: Long case with option B, elongated by 6 mm for mm rack depth, is available on request. (No LEDs) JM94 7 TE 4 TE.7 M 4 Out OK In OK (U) Measuring point of case temperature T C ( ) 47. Fig. 8 Option B: Aluminum case S with small cooling plate; black finish (EP powder coated). Suitable for mounting with access from the backside. Total weight approx..4 kg. BCD.8 Rev AF, -Jun-6 The Power Partners. Page of

22 44/88 Watt DC-DC Converters, : Input Range Safety and Installation Instructions Connector Pin Allocation The connector pin allocation table defines the electrical potentials and the physical pin positions on the H connector. The protective earth is connected by a leading pin (no. 4), ensuring that it makes contact with the female connector first Fixtures for retention clips Fig. 9 View of module's male connectors Table : Pin allocation Sb Pin no. Name Function 4 Vo+ Pos. output 6 Vo+ Pos. output 8 Vo Neg. output Vo Neg. output S+ Pos. sense line 4 S Neg. sense line 6 R Output voltage adjust 8 T Current share D Out OK PE Protection earth 4 PUL Programmable undervoltage lockout Vi+ Pos. input + Vi Neg. input Leading pin (pre-connecting) Not connected for HRL models Installation Instructions The converters are components, intended exclusively for inclusion within other equipment by an industrial assembly operation or by professional installers. Installation must strictly follow the national safety regulations in compliance with the enclosure, mounting, creepage, clearance, casualty, markings, and segregation requirements of the end-use application. Connection to the system shall be made via the female connector H; see Accessories. Other installation methods may not meet the safety requirements. Pin no. ( ) is connected with the case. For safety reasons it is essential to connect this pin reliably to protective earth. Notes: The PUL function (pin 4) must be programmed to enable the outputs. PUL should be connected to Vi (pins + ) by a resistor to adjust the start-up voltage; see table. Otherwise, the input current may become too high at low input voltage. Do not open the converter, or warranty will be invalidated. If the second output is not used, connect it in parallel with the main output. Make sure that there is sufficient airflow available for convection cooling and verifiy it by measuring the case temperature T C, when the converter is installed and operated in the end-use application; see Thermal Considerations. Ensure that a converter failure (e.g. an internal short-circuit) does not result in a hazardous condition. Standards and Approvals The converters are safety-approved to UL/CSA 69- nd Ed. and IEC/EN 69- nd Ed. The converters correspond to Class I equipment (with case connected to ground). They have been evaluated for: Building-in Basic insulation between input and case based on VA. Double or reinforced insulation between input and outputs Functional insulation between outputs Overvoltage category II Pollution degree environment Max. altitude: m The converters fulfill the requirements of a fire enclosure. The output voltage is considered as SELV, except HR/HRP/ ER/ERP88 with both outputs in series connection. The converters are subject to manufacturing surveillance in accordance with the above mentioned standards and ISO 9:8. CB-scheme is available on request. Protection Degree and Cleaning Liquids The protection degree is IP 4, provided that the female connector is fitted to the converter. In order to avoid possible damage, any penetration of cleaning fluids has to be prevented, since the power supplies are not hermetically sealed. Railway Application and Fire Protection The converters have been designed by observing the railway standards EN, EN --, and EN -4. All boards are coated with a protective lacquer. The converters comply with NF-F6 (I/F). They also comply with EN 44-, EN 44- (), if installed in a technical compartment or cabinet. BCD.8 Rev AF, -Jun-6 The Power Partners. Page of

23 44/88 Watt DC-DC Converters, : Input Range Table : Isolation Characteristic Input to case Output(s) to Output to Unit and output(s) case output Electric Factory test > s.8.4. kvdc strength AC test voltage equivalent test to factory test... kvac Insulation resistance at VDC > > > MΩ Creepage distances.. -- mm According to EN 4 and IEC/EN 69, subassemblies connecting input to output are pre-tested with.6 kvdc or 4 kvac. Tested at VDC Input to outputs: 6.4 mm Isolation and Protective Earth The electric strength test is performed in the factory as routine test according to EN 4 and IEC/EN 69 and should not be repeated in the field. The Company will not honor warranty claims resulting from incorrectly executed electric strength tests. The resistance case to the earth pin (<. Ω) is tested with A for s. Description of Options B, B Cooling Plates Where a cooling surface is available, we recommend the use of a cooling plate instead of the standard heat sink. The mounting system should ensure that the maximum case temperature T C max is not exceeded. The cooling capacity is calculated by (η see Model Selection): (% η) P Loss = V o I o η For the dimensions of the cooling plates; see Mechanical Data. BCD.8 Rev AF, -Jun-6 The Power Partners. Page of

24 44/88 Watt DC-DC Converters, : Input Range Accessories A variety of electrical and mechanical accessories are available including: Front panels for 9" DIN-rack: Schroff or Intermas, or 6TE /U; see fig. and the data sheet BCD.49. Mating H connectors with screw, solder, faston, or press-fit terminals. Coding clips for connector coding HZZ Pair of connector retention clips HZZ9-G Connector retention brackets HZZ6-G (CRB-HKMS); see fig.. Cable hood for H connectors: - HZZ4-G, screw version - HZZ4-G, use with retention brackets HZZ8-G - HZZ4-G, metallic version providing fire protection Cage clamp adapter HZZ44-G; see fig.. DIN-rail mounting assembly HZZ6-G (DMB-K/S) Wall-mounting plate K (HZZ-G) for models with option B Additional external input and output filters Different battery sensors S-KSMH... for using the converter as a battery charger. Different cell characteristics can be selected; see fig. 7, table, and Battery Charging / Temperature Sensors. to Ncm Fig. Connector retention brackets HZZ6-G (CRB-HKMS) Fig. Connector retention clips to fasten the H connector to the rear plate; see fig. 9. HZZ9-G consists of clips. For additional accessory product information, see the accessory data sheets listed with each product series or individual model at our web site Fig. Cage clamp adapter HZZ44-G Fig. Different front panels BCD.8 Rev AF, -Jun-6 The Power Partners. Page 4 of

25 44/88 Watt DC-DC Converters, : Input Range European Projection 6 (.") Fig 4 Different cable hoods L L = m (standard length) other cable lengths on request Fig. 7 Battery temperature sensor 6 (.") 9a adhesive tape 9.8 (.4") Table : Battery temperature sensors Battery Sensor Cell Cell temp. Cable voltage type voltage coefficient length nom. [V] [V] [mv/k] [m] Fig. Chassis- or wall-mounting plate HZZ-G (Mounting plate K) S-KSMH S-KSMH S-KSMH S-KSMH S-KSMH S-KSMH S-KSMH S-KSMH S-KSMH Note: Other temperature coefficients and cable lengths are available on request. Fig. 6 DIN-rail mounting assembly HZZ6-G (DMB-K/S) NUCLEAR AND MEDICAL APPLICATIONS - These products are not designed or intended for use as critical components in life support systems, equipment used in hazardous environments, or nuclear control systems. TECHNICAL REVISIONS - The appearance of products, including safety agency certifications pictured on labels, may change depending on the date manufactured. Specifications are subject to change without notice. Copyright 6, Bel Power Solutions Inc. All rights reserved. BCD.8 Rev AF, -Jun-6 The Power Partners. Page of