100 Watt DC-DC Converters Q Series

Transcription

1 Bengn Envronment DC-DC Converters 100 Watt Q Seres 100 Watt DC-DC Converters Q Seres Input to output solaton Sngle output: Seres 24Q...48Q1000 Double output: Seres 24Q...48Q2000 Very hgh effcency of up to 86% Flexble output power Excellent surge and transent protecton Input to output electrc strength test 2800 V DC Redundant operaton (n+1), current sharng Extremely low nrush current, hot plug-n Externally adjustable output voltage and nhbt Very compact and fully functonal unt (20 mm wde) Telecoms compatble nput voltage range of 48Q unts accordng to prets ( V DC) Safety n accordance to IEC/EN 60950, UL 1950, EN LGA " 4 TE " " 3 U C Summary These extremely compact DC-DC converters ncorporate all necessary nput and output flterng, sgnallng and protecton features whch are requred n the majorty of ndustral applcatons. The converters provde mportant advantages such as flexble output power through prmary current lmtaton, very hgh effcency, excellent relablty, very low rpple and RFI nose levels, full nput to output solaton, neglgble nrush current and nput over-/undervoltage lockout. The outputs are contnuously open-/short-crcut proof. An solated output power good sgnal and an output OK LED at the front panel ndcate the operaton status. Full system flexblty and n+1 redundant operatng mode are possble due to vrtually unrestrcted seres or parallel connecton capabltes of all outputs. In parallel connecton of several unts, automatc current sharng s provded by a sngle wre nterconnecton. As a modular power supply module or as part of a dstrbuted power supply system, the low profle desgn sgnfcantly reduces the necessary power supply volume wthout sacrfcng hgh relablty. The fully enclosed, black coated alumnum case acts as heat snk and RFI sheld. The 19" cassette occupes 3U/4TE only, but can also be chasssmounted by means of four M 3 screws. Table of Contents Page Summary... 1 Type Survey and Key Data... 2 Type Key and Product Markng... 3 Functonal Descrpton... 4 Electrcal Input Data... 5 Electrcal Output Data... 6 Auxlary Functons Page Electromagnetc Compatblty (EMC) Immunty to Envronmental Condtons Mechancal Data Safety and Installaton Instructons Descrpton of Opton Accessores /19

2 Q Seres DC-DC Converters 100 Watt Bengn Envronment Type Survey and Key Data Table 1: Type survey Output 1 Output 2 Output power Input Voltage Range and Effcency 2 Opton U o nom I o U o nom I o T A = 50 C U mn...u max h mn U mn...u max h mn [V DC] [A] [V DC] [A] P o tot [W] V DC [%] V DC [%] Q1001-2R 83 48Q1001-2R 83 P Q2320-2R 85 48Q2320-2R Q2540-2R 85 48Q2540-2R Q2660-2R 86 48Q2660-2R Q2320-2R 85 48Q2320-2R Q2540-2R 85 48Q2540-2R Q2660-2R 86 48Q2660-2R Q2320-2R 85 48Q2320-2R Q2540-2R 85 48Q2540-2R Q2660-2R 86 48Q2660-2R 86 1 The cumulated power of both outputs may not exceed the total power for the specfed ambent temperature. 2 Effcency at U nom, I o nom and T A = 25 C. 3 Output 1 and 2, n parallel confguraton. 4 Output 1 and 2, n seres confguraton. 5 Symetrcal confguraton wth second output sem-regulated (±5% U o nom ). Output Confguraton The Q unt desgn allows hgh flexblty n output confguraton to cover almost every ndvdual requrement, by smply wrng the outputs n parallel, seres or symmetrcal confguratons as per followng fgures. For further nformaton and for parallel and seres operaton of several modules refer to: Electrcal Output Data. Sngle output V Load 1 Double output V 10 Fg. 1 Sngle output confguraton V Load 1 Double output 32 V Vo2 10 Vo2 10 Fg. 2 Parallel output confguraton 28 Double output U o + Load V+ 32 V Load 1 Fg. 3 Seres output confguraton (negatve sense at load only) 30 V+ 32 V Vo2 10 Load 2 Fg. 4 Symmetrcal common ground output confguraton U o Double output V Load 1 32 V 6 Load 2 Vo2 10 Fg. 5 Independent symmetrcal output confguraton 2/19

3 Bengn Envronment DC-DC Converters 100 Watt Q Seres Type Key and Product Markng Type Key Input voltage range U : V DC V DC Seres... Q Number of outputs: Sngle output... 1 Double output Q R P Nomnal voltage output 1 (man output), U o1 nom 5.1 V V V... 4, 5 24 V... 6 other voltages... 1, 2, 7, 8 Other specfcatons for man output Symmetrcal double output unts: Nomnal voltage output 1/output 2, U o1/2 nom 12 V/12 V (24 V seres connected) V/15 V (30 V seres connected) V/24 V (48 V seres connected) other symmetrcal voltages Operatonal ambent temperature range T A : C Output voltage control nput (Auxlary functon)... R 1 Potentometer (Opton)... P 1 1 Feature R excludes opton P and vce versa Example: 48Q2540-2P: DC-DC converter, nput voltage range V, double output, each provdng 15 V/ 3.3 A, equpped wth potentometer and operatng ambent temperature of C. Note: All unts feature the followng auxlary functons whch are not shown n the type desgnaton: Input and output flters, nhbt, sense lnes, current sharng, out OK sgnal and LED ndcator. Product Markng Basc type desgnaton, applcable safety approval and recognton marks, CE mark, warnngs, pn allocaton of nput, output and auxlary functons, Melcher patents and company logo. Identfcaton of LED and potentometer. Specfc type desgnaton, nput voltage range, nomnal output voltage and output current and degree of protecton. Label wth batch no., seral no. and data code ncludng producton ste, modfcaton status and date of producton. Confrmaton of successfully passed fnal test. 3/19

4 Q Seres DC-DC Converters 100 Watt Bengn Envronment Functonal Descrpton The unts are desgned as forward converters usng prmary and secondary control crcuts n hybrd technology. The swtchng frequency s approxmately 200 khz under nomnal operatng condtons. The bult-n nput flter together wth a mnmum nput capactance generate very low nrush currents wth short duraton. After transformer solaton and rectfcaton, the output flter reduces rpple and nose to a mnmum wthout compromse to the dynamc ablty. The output voltage s fed back to the secondary control crcut va the sense lnes. The resultant error sgnal s sent to the prmary control crcut va a sgnal transformer. Double output modules have ther voltage regulaton of output 2 relyng on the close magnetc couplng of the transformer and the output nductor together wth the crcuts symmetry. The current lmtaton s located at the prmary sde, thus lmtng the total output current n overload condtons. Ths allows flex power operaton of each output for unsymmetrcal loads n the range from % of the total output power. In applcatons wth large dynamc load changes t s recommended to connect such load to output 1 only. Output 1 and output 2 can ether be seres- or parallel-connected (see: Electrcal Output Data). P (opton) Prmary Control Crcut Overvoltage Controller Output Control Crcut Out OK+ Out OK T R 12 V+ V Input Flter Output Flter C y Isolaton C y Fg. 6 Block dagram of a sngle output converter P (opton) Prmary Control Crcut Overvoltage Controller Output Control Crcut Out OK+ Out OK T R V+ V Input Flter C y Output Flter Output Flter Vo2 Isolaton C y 14 Fg. 7 Block dagram of a double output converter 4/19

5 Bengn Envronment DC-DC Converters 100 Watt Q Seres Electrcal Input Data General Condtons T A = 25 C, unless T C s specfed. Sense lnes connected drectly at the connector, nhbt (28) connected to V (32). R nput not connected; wth opton P, U o set to U o nom at U nom. Table 2: Input data Input 24Q 48Q Characterstcs Condtons mn typ max mn typ max Unt U Operatng nput voltage I o = 0...I o nom V DC U nom Input voltage nomnal T C mn...t C max U abs Input voltage lmts wthout damage I Typcal nput current 1 U nom, I o nom A P 0 No-load nput power U mn U max W I o = 0 P nh Idle nput power unt nhbted I nr p Peak nrush current 2 U nom, I o nom A t nr r Rse tme µs t nr h Tralng edge half-lfe Typcal nput current depends on ndvdual module 2 Accordng to prets (Ver. 3.1) Input Fuse A fuse mounted nsde the converter protects the module n case of falure aganst severe defects. The fuse can not be made externally accessble. Reverse polarty at the nput wll cause the fuse to blow. Table 3: Fuse specfcaton Module Fuse type Fuse ratng 24Q fast-blow Lttelfuse A, 125 V 48Q fast-blow Lttelfuse A, 125 V Input Transent Protecton A metal oxde VDR (Voltage Dependent Resstor) together wth the nput fuse and a symmetrcal nput flter from an effectve protecton aganst hgh nput transent voltages whch typcally occur n most nstallatons, but espacally n battery drven applcatons. Input Under-/Overvoltage Lock-Out If the nput voltage remans below approx. 0.9 U mn or exceeds approx. 1.1 U max an nternally generated nhbt sgnal dsables the output(s). When checkng ths functon the absolute maxmum nput voltage U abs should be consdered! Inrush Current Lmtaton The nherent nrush current value s lower than specfed n the prets (ver. 3.1) standard. The unts operate wth relatvely small nput capactance resultng n low nrush current of short duraton. As a drect consequence n a power-bus system the unts can be hot plugged-n or dsconnected causng neglgble dsturbance at the nput sde. 5/19

6 Q Seres DC-DC Converters 100 Watt Bengn Envronment Electrcal Output Data General Condtons: T A = 25 C, unless T C s specfed. R nput not connected; wth opton P, U o set to U o nom at U nom. Sense lnes connected drectly at the connector, nhbt (28) connected to V (32). Table 4a: Output data for sngle output modules and modules n parallel confguraton Output 24Q...48Q Q...48Q Q...48Q Q...48Q V 12.0 V 15.0 V 24.0 V Characterstcs Condtons mn typ max mn typ max mn typ max mn typ max Unt U o Output voltage 1 U nom, I o nom V U ow Worstcase output U mn...u max voltage T C mn...t C max U o P Overvoltage lmtaton I o = 0...I o nom of second control loop I o 2 Output current U mn...u max A I o nom Nomnal output current 7 T C mn...t C max I o L Output current lmt u 6 o Output Swtch. frequ. U nom, I o nom mv pp voltage BW = 20 MHz Total nose P o Output power 1 U mn...u max W T C mn...t C max u 3 6 o d Dynamc Voltage U nom, I o = ±500 ±500 ±500 ±700 mv load devaton I o nom 1 /2 I o nom t d 3 6 regulaton Recovery ms tme U o tr Output voltage U mn...u max V trmmng range 4 ( ) I o nom Table 4b: Output data for double output modules n seres confguraton Output 24Q...48Q Q...48Q Q...48Q V (2 12 V) 30 V (2 15 V) 48 V (2 24 V) Characterstcs Condtons mn typ max mn typ max mn typ max Unt U o Output voltage 1 U nom, I o nom V U ow Worstcase output U mn...u max voltage T C mn...t C max U o P Overvoltage lmtaton I o mn...i 5 o nom of second control loop I 2 5 o Output current U mn...u max A T Nomnal output current C mn...t C max A I o nom I o L Output current lmt u 6 o Output Swtch. frequ. U nom, I o nom mv pp voltage BW = 20 MHz Total nose P o Output power 1 U mn...u max W T C mn...t C max u 3 6 o d Dynamc Voltage U nom, I o = ±1000 ±1000 ±1400 mv load devaton I o nom 1 /2 I o nom t d 3 6 regulaton Recovery ms tme U o tr Output voltage U mn...u max V trmmng range 4 ( ) I o nom If the output voltages are ncreased above U o nom through R-nput control, opton P settng or remote sensng, the output power should be reduced accordngly so that P o max and T C max are not exceeded. 2 See: Output Current Lmtaton. Recovery tme untl U o remans wthn 1% of U o nom, see Dynamc Load Regulaton. Upper row represents settng va R-nput, lower row opton P range. 5 I o mn = 10% of I o nom for each output necessary (see also: Output Regulaton). Accordng to IEC/EN In parallel confguraton I o nom = I o1 nom + I o2 nom. 6/19

7 Bengn Envronment DC-DC Converters 100 Watt Q Seres Parallel or Seres Connecton of Outputs and/or Unts Sngle or double output unts wth equal nomnal output voltage can be connected n parallel wthout any precauton by nterconnectng the T-pns for approxmate equal current sharng. (See: Auxlary Functons.) Any double output unt wth ts outputs n parallel behaves lke a sngle output unt,.e. s fully regulated. There s no nconvenence or restrcton usng the R-nput and the sense lnes. Sngle output unts and/or man and second outputs of double output unts can be connected n seres wth any other (smlar) output. For double output modules consder, that the effect va sense lnes, R-nput or opton P s doubled. + R p Sngle (double) T output Out OK+ Out OK V+ V () (Vo2 ) Sngle (double) T output load Note: Parallel connecton of several double output unts should always nclude both, man and second output to mantan good regulaton of all outputs. Seres connecton of second outputs wthout nvolvng ther man outputs should be avoded as regulaton may be poor. The maxmum output current s lmted by the output wth the lowest current lmtaton f several outputs are connected n seres. Rated output voltages above 48 V (SELV = Safety Extra Low Voltage) need addtonal measures n order to comply wth nternatonal safety requrements. + R p Double output Out OK+ Out OK V+ V Vo2 Double output Out OK load Out OK+ Out OK Vo2 Out OK V+ V+ () V + V (Vo2 ) Fg. 8 Parallel connecton of outputs and/or several modules, sense lnes connected at connector sde + Fg. 9 Seres connecton of outputs and/or several modules, sense lnes connected at connector sde only Dynamc Load Regulaton U o I o /I o nom U od t d U o ±1% U o ±1% U od 10 µs 10 µs Fg. 10 Control devaton of U o versus dynamc load change t d t t Hold up Tme The modules provde vrtually no hold up tme. If hold up tme s requred, use external output capactors or decouplng dodes and nput capactors of adequate sze. Formula for addtonal external nput capactor 2 P o t h 100 C ext = h (U 2 t U mn2 ) where as: C ext = external nput capactance [mf] P o = output power [W] h = effcency [%] t h = hold-up tme [ms] U mn = mnmum nput voltage [V] U t = threshold level [V] 7/19

8 Q Seres DC-DC Converters 100 Watt Bengn Envronment General Condtons: T A = 25 C, unless T C s specfed. R nput not connected; wth opton P, U o set to U o nom at U nom. Sense lnes connected drectly at the connector, nhbt (28) connected to V (32). Table 5a: Output data for double output modules n symmetrcal confguraton Output 24Q...48Q Q...48Q V/12 V 15 V/15 V Characterstcs Condtons Output 1 Output 2 Output 1 Output 2 mn typ max mn typ max mn typ max mn typ max Unt U o Output voltage 1 U nom, I o nom V U ow Worstcase output U mn...u max see Output see Output voltage T C mn...t C max voltage regulaton voltage regulaton U o P Overvoltage lmtaton I o mn...i 5 o nom of second control loop I o 5 Output current U mn...u max A I o nom Nomnal output current 2 T C mn...t C max I o L Output current lmt u 6 o Output Swtch. frequ. U nom, I o nom mv pp voltage BW = 20 MHz Total nose P o Output power 1 U mn...u max W T C mn...t C max u 3 6 o d Dynamc Voltage U nom, I o1 = ±500 ±500 mv load devaton 1 /2 1 /4 I o nom t d 3 6 regulaton Recovery I o2 = 1 /2 I o nom ms tme U o tr Output voltage U mn...u max V trmmng range 4 ( ) I o nom Table 5b: Output data for double output modules n symmetrcal confguraton Output 24Q...48Q V/24 V Characterstcs Condtons Output 1 Output 2 mn typ max mn typ max Unt U o Output voltage 2 U nom, I o nom V U ow Worstcase output U mn...u max see Output voltage T C mn...t C max voltage regulaton U o P Overvoltage lmtaton I o mn...i 5 o nom of second control loop I o 5 Output current U mn...u max A I o nom Nomnal output current 2 T C mn...t C max 4.4 I o L Output current lmt u 6 o Output Swtch. frequ. U nom, I o nom mv pp voltage BW = 20 MHz Total nose P o Output power 1 U mn...u max 110 W T C mn...t C max u 3 6 o d Dynamc Voltage U nom, I o1 = ±700 mv load devaton 1 /2 1 /4 I o nom t d 3 6 regulaton Recovery I o2 = 1 /2 I o nom 0.35 ms tme U o tr Output voltage U mn...u max V trmmng range 4 ( ) I o nom If the output voltages are ncreased above U o nom through R-nput control, opton P settng or remote sensng, the output power should be reduced accordngly so that P o max and T C max are not exceeded. Same condtons for both outputs. 2 Value of total current, I o1 + I o2. See Output Current Lmtaton. 3 Recovery tme untl U o remans wthn 1% of U o nom, see: Dynamc Load Regulaton. 4 Upper row represents settng va R-nput, lower row opton P range. 5 I o mn = 10% of I o nom for each output necessary (see also: Output Regulaton). 6 Accordng to IEC/EN /19

9 Bengn Envronment DC-DC Converters 100 Watt Q Seres Output Voltage Regulaton of Double Output Modules In symmetrcal confguraton the man output 1 s under normal condtons regulated to U o nom, ndependent of the output currents. Note that f the load on output 2 s too small (<0.1 I o nom ), ts voltage wll rse, possbly actvatng the overvoltage protecton, whch wll then reduce the voltage on both outputs. U o2 s dependent upon the load dstrbuton: When each output s loaded wth at least 10% of I o nom, the devaton of U o2 remans wthn ±5% of the value of U o nom. The followng fgures explan the regulaton wth varyng load dstrbutons up to the current lmt. If I o1 = I o2 or the two outputs are n seres-connecton, the devaton of U o2 remans wthn ±1% of the value of U o nom provded that the load s more than 10% of I o nom. U o2 = (U o V) U o2 = U o1 U o2 = (U o1 0.5 V) I o Fg /48Q2320 output 2 voltage devaton vs. output 2 current wth dfferent currents on output 1 U o2 = (Uo V) U o2 = U o1 U o2 = (U o V) U o2 = U o1 U o2 max = 14.2 V U o2 max = 18 V U o2 max = 28 V I o1 = 7.2 A I o1 = 5.6 A I o1 = 4.0 A I o1 = 2.4 A I o1 = 0.8 A I o1 = 6.0 A I o1 = 4.6 A I o1 = 3.3 A I o1 = 2.0 A I o1 = 0.66 A U o2 = (U o1 0.5 V) I o Fg /48Q2540 output 2 voltage devaton vs. output 2 current wth dfferent currents on output I o1 = 4.0 A I o1 = 3.1 A I o1 = 2.2 A I o1 = 1.3 A I o1 = 0.44 A U o2 = (U o1 1.0 V) I o Fg /48Q2660 output 2 voltage devaton vs. output 2 current wth dfferent currents on output 1 Output Voltage Overshoot Protecton Neglgble output voltage overshoot may occur f the module s ether hot plugged-n or dsconnected, the nput voltage s swtched on or off, the module s swtched wth an nhbt sgnal, or after a reset of a short crcut and power falure. Second Control Loop A fully ndependent second control loop lmts the output voltage to approxmately 1.25 U o nom (e.g. sense lnes wred ncorrectly). It further protects the load n the unlkely event of a malfuncton of the man control crcut. In double output modules output 1 s fully regulated wth overvoltage protecton on output 2, through ths second control loop. There s no specfc bult-n protecton aganst externally appled overvoltages. Contnuous Open-Crcut and Short-Crcut Proof All outputs are fully protected aganst contnuous open crcut, e.g. aganst no load condton (for the 24Q...48Q2000 characterstcs refer to: Output Voltage Regulaton of Double Output Modules) and all outputs are fully protected aganst contnuous short crcut condton by means of the electronc current lmtaton on the prmary sde (see: Output Current Lmtaton). Output current lmtaton Sngle output unts and seres- or parallel-connected double output unts have a quas rectangular constant current lmtaton characterstc. In double output unts, the total current s lmted, allowng free choce of load dstrbuton between the two outputs, up to a total I o1 + I o2 I o max (see: Output Voltage Regulaton of Double Output). In overload (I o1 + I o2 > I o max ) both output voltages are smultaneously reduced. Independent outputs wth symmetrcal current loads both have a rectangular current lmtaton characterstc. Current dstrbuton n overload s dependent upon the type of overload. A short-crcut n one output wll cause the full current flow nto that output whereas a resstve overload results n more even dstrbuton and n a reduced output voltage. U o /U o nom I o /I o nom Fg. 14 Current lmtaton behavour of a sngle or a double output unt wth seres- or parallel-connected outputs I o nom I o L /19

10 Q Seres DC-DC Converters 100 Watt Bengn Envronment Typcal Effcency h [%] U max U nom U mn 80 I o [A] Fg. 15 Effcency versus nput voltage and output current (per output). Typcal values of 24Q2320 at U o nom. Thermal Consderatons If a converter s located uprght n free flowng, quas-statonary ar (convecton coolng) at the ndcated maxmum ambent temperature T A max (see table: Temperature specfcatons) and s operated at ts nomnal nput voltage and output power, the temperature measured at the Measurng pont of case temperature T C (see: Mechancal Data) wll approach the ndcated value T C max after the warm-up phase. However, the relatonshp between T A and T C depends heavly on the condtons of operaton and ntegraton nto a system. The thermal condtons are nfluenced by nput voltage, output current, arflow and temperature of surroundng components and surfaces. T A max s therefore, contrary to T C max, an ndcatve value only. Cauton: The nstaller must ensure that under all operatng condtons T C remans wthn the lmts stated n the table: Temperature specfcatons. The unt does not provde nternal overtemperature protecton. Notes: Suffcent forced coolng or an addtonal heat snk allows operaton at full output power and mproves the relablty or allows T A to be hgher than T A max (e.g. 65 C) as long as T C max s not exceeded. In rack systems wthout proper thermal management, the modules must not be packed too densely! In such cases the use of a 5 or 6TE front panel s recommended. P o [%] convecton coolng Fg. 16 Output current deratng versus T A forced coolng T C max T A [ C] Auxlary Functons Inhbt for Remote On and Off Note: If ths functon s not actvely used, the nhbt pn 28 must be nterconnected wth the negatve nput pn 32 to enable the output(s). A non-connected pn 28 wll be nterpreted by the nternal logc as an actve nhbt sgnal and therefore output(s) wll reman dsabled: Fal safe functon. An nhbt nput enables (logc low, pull down) or dsables (logc hgh, pull up) the output f a logc sgnal e.g. TTL, CMOS s appled. In systems consstng of several unts, ths feature may be used, for example, to control the actvty sequence of the converters by means of logc sgnals, or to allow the unt's source for a proper start up before full load s appled (e.g. n combnaton wth LT unts). U I nh U nh I V+ 32 V 26 Vo+ 4 Vo+ 6 Vo Vo 10 Fg. 17 Defnton of nput and output parameters 14 I o U o RL Table 6: Inhbt characterstcs Characterstcs Condtons mn typ max Unt U nh Inhbt U o = on U mn...u max V DC voltage T Uo = off C mn...t C max I nh Inhbt current U nh = 50 V 500 µa U nh = 0 V 40 U nh = 50 V +500 U nh = 100 V Output Response The output response when enablng and dsablng the output by the nhbt nput s shown n the followng fgure. U o /U o normal U on off U nh [V] t d on t r Fg. 18 Output response as a functon of nput voltage (on/off swtchng) or nhbt control tf t t t 10/19

11 Bengn Envronment DC-DC Converters 100 Watt Q Seres Table 7: Output response tme wth outputs resstvely loaded and R-nput and Popton not used 24Q 48Q Characterstcs Condtons mn typ max mn typ max Unt t d on Turn-on delay tme U = 0 U mn, R L = U o nom /0.5 I o nom 5 5 ms U = 0 U nom, R L = U o nom /I o nom t r Output voltage rse tme U = 0 U nom, R L = U o nom /I o nom U nh = V, R L = U o nom /I o nom t f Output voltage fall tme U = U nom 0, R L = U o nom /I o nom 3 3 U nh = V, R L = U o nom /I o nom Current Sharng (T Functon) The current sharng faclty should be used where several unts are to be operated n parallel for hgh relablty n+1 redundant systems or n order to provde hgher output powers. Usng ths feature reduces the stress on the unts and further mproves the relablty of the system. Interconnecton of the current sharng termnals T causes the unts to share the output current to the average of all unts. The current tolerance of each unt s approx. ±20% of the sum of ts nomnal output currents I o1 nom + I o2 nom. In n+1 redundant systems, a falure of a sngle unt wll not lead to a system falure f the outputs are decoupled by dodes. See also: Sense Lnes. Snce the voltage on the T pn s referenced to the sense pn, the nstaller must ensure that the pns of all unts are at the same electrcal potental,.e. voltage drops >50 mv R-Control for Output Voltage Adjustment Note: Wth open R nput, U o U o nom. R excludes opton P. All modules offer a programmable output voltage feature. The programmng s performed ether by an external control voltage U ext or an external resstor R 1 /R 2, connected to the R-nput. Trmmng s lmted to the values gven n the table below (see also: Electrcal Output Data). Wth a dsconnected R-nput, the output voltage s set to U o nom. Smultaneous use of the R-nput functon and opton P s Cauton: To prevent damage, U ext should not exceed 20 V, nor be negatve. a) Adjustment by means of an external control voltage U ext between R (16) and (14) U o s dependent upon U ext : U o U o nom U ext U ext 2.5 V U o U o nom 2.5 V Double output V+ V Vo Load 1 Load 2 Fg. 19 Output voltage programmng usng a control voltage U ext R + U ext across the connecton lnes between these pns shall be avoded. 24Q...48Q 2000 DC-DC converters wth outputs connected n seres can also be paralleled wth current sharng, f pns of all unts are connected together. See Sense Lnes. If the output voltages are programmed to a voltage other than U o nom by means of the R pn or opton P, the outputs should be adjusted ndvdually wthn a tolerance of ±1%. The current sharng wll be less accurate when operatng wth dynamc loads. Important: For applcatons usng the hot plug-n capabltes, dynamc output voltage changes durng the plugn/plug-out cycles must be consdered. not possble. If opton P s bult-n, the R-nput wll reman actve but ts functon must not be used; do not connect pn R at all! Wth double output modules, both outputs are affected by the R-nput settngs. If output voltages are set hgher than U o nom, the output currents should be reduced accordngly, so that the maxmum specfed output power s not exceeded. b) Adjustment by means of an external resstor: The resstor can ether be connected between the pns R (16) and (14) to set U o < U onom, or between the pns R (16) and (12) to set U o > U o nom. Note: R nputs of n unts wth paralleled outputs may be paralleled, too, but f only one external resstor s to be used, ts value should be R 1 /n, or R 2 /n respectvely. Sngle output V+ V R 1 R 2 Fg. 20 Output voltage programmng usng R 1 or R 2 R Load 1 11/19

12 Q Seres DC-DC Converters 100 Watt Bengn Envronment Table 8a: R 1 for U o < U o nom ; approxmate values (U nom, I o nom, seres E 96 resstors); R 2 = 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 1 [kω] U o [V] 1 R 1 [kω] U o [V] 1 R 1 [kω] U o [V] 1 R 1 [kω] Table 8b: R 2 for U o > U o nom ; approxmate values (U nom, I o nom, seres E 96 resstors); R 1 = 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 2 [kω] U o [V] 1 R 2 [kω] U o [V] 1 R 2 [kω] U o [V] 1 R 2 [kω] Frst column: sngle output unts or double output unts wth separated/paralleled outputs, second column: outputs n seres connecton Output good sgnal (Out OK) The solated Out OK output gves a status ndcaton of the module and the output voltage. It can be used for control functons such as data protecton, central system montorng or as a part of a self-testng system. It can be connected to get a centralzed fault detecton or may be used for other system specfc applcatons at the prmary or the secondary sde of the converter. Connectng the Out OK as per fgure below, U OK <1.5 V ndcates that the output voltage U o1 of the converter s wthn the range U t1 low...u t1 hgh. U t1 low corresponds wth U o1 normal, U t1 hgh wth U o1 normal, where U o1 normal s the effectve output voltage appearng n normal condton. (Usng the R-nput or the opton P, the montor level s trackng the programmed output voltage.) In case of an error condton,.e. the output voltage U o1 s out of the range U t1 low...u t1 hgh due to an overload condton or to an external overvoltage, U OK wll be almost as hgh as the voltage U p. The output s formed by a NPN transstor capable of drvng ma max. The emtter (Out OK ) can be connected to prmary V or secondary to get an open collector output. Wth several ndependent unts the Out OK pns can be seres-connected n order to get a system level sgnal. If one of the unts fals the seres-connected outputs rse to a hgh mpedance. Ths seres-connecton can be completed by other transstors provdng extended user specfc error nformaton. Out OK R p Sngle output Out OK+ Out OK V+ V Double output Out OK+ Out OK V+ V Vo Load 1 Load 2 Fg. 21 Seres connecton of the output good sgnal at the prmary sde of the converters for system supervson 12/19

13 Bengn Envronment DC-DC Converters 100 Watt Q Seres Table 9: Output OK data Characterstcs Condtons mn typ max Unt U OK Out OK voltage good: U t1 low < U 01 < U t1 hgh, I OK < 0.5 ma V I OK Out OK current error: U o1 < U t1 low, U OK 15 V 25 µa error: U o1 > U t1 hgh, U OK 15 V 1 Hgher current capablty s avalable on request U p Output Control Crcut 1 k 22 Out OK+ 20 V 24 I OK U OK Fg. 22 Output OK functon U p Dmensonng of resstor value R p 0.5 ma R p Out OK Cauton: The Out OK s protected by an nternal seres resstor and a Zener dode. To prevent damage, the appled current I OK should be lmted to ±20 ma maxmum and the appled voltage U OK to ±25 V maxmum. Dsplay status of LED Table 10: Dsplay status of LED LED Out OK Operatng condton green normal operaton x ncorrect sense lne connecton off overload output overvoltage output undervoltage no nput voltage nput voltage too low nhbt open/hgh nput voltage too hgh x = dependent on actual operatng condton Sense Lnes Important: Sense lnes must always be connected! Incorrectly connected sense lnes may actvate the overvoltage lmtaton,.e. shutng down the output. Ths feature enables compensaton of voltage drop across the connector contacts and the load lnes ncludng the dode n true redundant wred-or system confguratons. In case the sense lnes are connected at the load rather than drectly at the connector, the user must ensure that U o max (between and ) s not exceeded. Applyng generously dmensoned cross-secton load leads avods troublesome voltage drop. To mnmze nose pck-up wre sense lnes parallel or twsted. For unsymmetrcal loads t s recommended to connect the sense lnes drectly at the female connector. To ensure correct operaton, both sense lnes must be connected to ther respectve power output potental. Wth double output unts the sense lnes must be connected to output 1 only. Cauton should be exercsed when outputs are seres-connected as the compensated voltage s effectvely doubled (refer to: Electrcal Output Data). The voltage dfference between any sense lne and ts respectve power output pn (as measured on the connector) should not exceed the followng values at nomnal output voltage. Table 11: Voltage compensaton allowed usng sense lnes Output Total voltage dfference between sense voltage lnes and ther respectve outputs 5.1 V <0.5 V 12, 15, 24 V <1.0 V Double output V+ V Double output V+ V Vo2 Load Fg. 23 Sense lnes connecton for redundant (n+1) or parallel operaton usng wred-or dodes T T Vo /19

14 Q Seres DC-DC Converters 100 Watt Bengn Envronment Electromagnetc Compatblty (EMC) A metal oxde VDR together wth an nput fuse and a symmetrcal nput flter form an effectve protecton aganst hgh nput transent voltages whch typcally occur n most nstallatons, but especally n battery drven applcatons. The Q seres has been successfully tested to the followng specfcatons: [dbµv] Fg. 24 Typcal dsturbance voltage (quas-peak) at the nput accordng to CISPR 11/22 and EN 55011/22, measured at U nom and I o nom. Electromagnetc Immunty Table 13: Immunty type tests A B MHz Electromagnetc Emssons Table 12: Emssons at U nom and I o nom Types Level CISPR 11/EN CISPR 14/ CISPR 22/EN EN MHz 30 MHz 30 MHz 24Q1000 B - <lmt 24Q2000 B A 1 <lmt 48Q1000 B A 1 <lmt 48Q2000 B A 1 <lmt 1 Level B wth external ferrtes n the load lnes. [dbµv/m] Fg. 25 Typcal radated electromagnetc feld strength (quaspeak) accordng to CISPR 11/22 and EN 55011/22, normalzed to a dstance of 10 m, measured at U nom and I o nom A B 1000 [MHz] Phenomenon Standard 1 Level Couplng Value Waveform Source Test In Permode 2 appled mped. procedure oper. form. 3 Electrostatc IEC/EN 3 contact dscharge 6000 V p 1/50 ns 330 Ω 10 postve and yes B dscharge negatve ar dscharge 8000 V p (to case) dscharges Electromagnetc IEC/EN 3 antenna 10 V/m AM 80% n.a MHz yes A feld khz Electromagnetc ENV x 20 V/m 50% duty cycle, 900 ±5 MHz yes A feld, 200 Hz repetton pulse modulated frequency Electrcal fast IEC/EN 4 capactve, o/ 2000 V p bursts of 5/50 ns 50 Ω 1 mn postve yes B transent/burst khz over 1 mn negatve drect, /c, +/ 4000 V p 15 ms; burst transents per perod: 300 ms couplng mode Surge IEC/EN 2 /c 1000 V p 1.2/50 µs 12 Ω 5 pos. and 5 neg. yes B surges per +/ 2 Ω couplng mode 19 Pfl V p 0.1/0.3 ms <100 A 3 pos. 5 repettons yes A 4 Conducted IEC/EN 3, o, sgnal wres 3 V rms AM 80% 150 Ω MHz yes A dsturbances (130 dbµv) 1 khz 1 Related and prevous standards are referenced n Techncal Informaton: Standards. 4 Vald for 48Q only. 2 = nput, o = output, c = case, = protectve earth. 3 A = Normal operaton, no devaton from specfcatons, B = Temporary devaton from specs possble. 14/19

15 Bengn Envronment DC-DC Converters 100 Watt Q Seres Immunty to Envronmental Condtons Table 14: Mechancal stress Test Method Standard Test Condtons Status Ca Damp heat IEC/DIN IEC Temperature: 40 ±2 C Unt not steady state MIL-STD-810D secton Relatve humdty: 93 +2/-3 % operatng Duraton: 21 days Ea Shock IEC/EN/DIN EN Acceleraton ampltude: 15 g n = 147 m/s 2 Unt (half-snusodal) MIL-STD-810D secton Bump duraton: 11 ms operatng Number of bumps: 18 (3 each drecton) Eb Bump IEC/EN/DIN EN Acceleraton ampltude: 10 g n = 98 m/s 2 Unt (half-snusodal) MIL-STD-810D secton Bump duraton: 16 ms operatng Number of bumps: 6000 (1000 each drecton) Fc Vbraton IEC/EN/DIN EN Acceleraton ampltude: 0.15 mm ( Hz) Unt (snusodal) MIL-STD-810D secton g n = 20 m/s 2 ( Hz) operatng Frequency (1 Oct/mn): Hz Test duraton: 3.75 h (1.25 h each axs) Table 15: Temperature specfcatons, vald for ar pressure of hpa ( mbar) Temperature Standard Characterstcs Condtons mn max Unt T A Ambent temperature Operatonal C T C Case temperature T S Storage temperature Non operatonal R th C Temperature coeffcent 2 K/W of case n stll ar 1 See: Thermal Consderatons Table 16: MTBF and devce hours Ratngs at specfed Modules Ground Bengn Ground Fxed Devce Hours 1 Unt Case Temperature 40 C 40 C MTBF acc. to 24Q ' ' '000 h MIL-HDBK-217F 48Q ' '000 1 Statstcal values, based on an average of 4300 workng hours per year and n general feld use, over 3 years 15/19

16 Q Seres DC-DC Converters 100 Watt Bengn Envronment Mechancal Data Dmensons n mm. Tolerances ±0.3 mm unless otherwse ndcated. European Projecton ± ± Frontplate M3; 4 deep 164 ± ± Measurng pont of case temperature T C Rearface Manface (DIN 41494) Backplate (4 TE) Fg. 26 Case Q01, weght 480 g Alumnum, fully enclosed, black fnsh and self coolng Potentometer (opton P) LED "OUT OK" green 19.8 Note: Long case, elongated by 60 mm for 220 mm rack depth s avalable on request. 16/19

17 Bengn Envronment DC-DC Converters 100 Watt Q Seres Safety and Installaton Instructons Connector Pn Allocaton The connector pn allocaton table defnes the electrcal potentals and the physcal pn postons on the H15 connector. Pn no. 26, the protectve earth pn present on all 24Q and 48Q DC-DC converters s leadng, ensurng that t makes contact wth the female connector frst. Table 17: Pn allocaton of the H 15 connector Pn Electrcal determnaton Q 1000 Q 2000 No. 4 Output voltage (postve) 6 Output voltage (postve) 8 Output voltage (negatve) 10 Output voltage (negatve) Vo2 12 Sense lne (postve) 2 14 Sense lne (negatve) 2 16 Output voltage control nput 1 R R 18 Current sharng control nput T T 20 Do not connect (nternal Gnd.) Output good sgnal (postve) Out OK+ Out OK + 24 Output good sgnal (negatve) Out OK Out OK 26 Protectve ground 2 28 Inhbt control nput 3 30 Input voltage (postve) V+ V+ 32 Input voltage (negatve) V V 1 Wth opton P, R-nput must reman unconnected. 2 Leadng pn (pre-connectng). 3 If not actvely used, connect to pn Fg. 27 Vew of male H15 connector Standards and approvals All Q seres DC-DC converters correspond to class I equpment. They are UL recognzed accordng to UL 1950, UL recognzed for Canada to CAN/CSA C22.2 No and LGA approved to IEC/EN standards. The unts have been evaluated for: Buldng n Basc nsulaton between nput and case and double or renforced nsulaton between nput and output, based on ther maxmum rated nput voltage Basc nsulaton between Out OK and case and double or renforced nsulaton between Out OK and nput and between Out OK and output, based on ther maxmum rated nput voltage Use n a polluton degree 2 envronment Connectng the nput to a crcut whch s subject to a maxmum transent ratng of 1500 V The DC-DC copnverters are subject to manufacturng survellance n accordance wth the above mentoned UL, CSA, EN and wth ISO 9001 standards. Installaton Instructons The Q seres DC-DC converters are components, ntended exclusvely for ncluson wthn other equpment by an ndustral assembly operaton or by professonal nstallers. Installaton must strctly follow the natonal safety regulatons n complance wth the enclosure, mountng, creepage, clearance, casualty, markngs and segregaton requrements of the end-use applcaton. Connecton to the system shall be made va the female connector H15 (see: Accessores). Other nstallaton methods may not meet the safety requrements. The DC-DC converters are provded wth pn no. 26 ( ), whch s relably connected wth the case. For safety reasons t s essental to connect ths pn to the protectve earth of the supply system f requred n the table: Safety concept leadng to an SELV output crcut. The V nput (pn no. 32) s nternally fused. Ths fuse s desgned to protect the unt n case of overcurrent and may not be able to satsfy all customer requrements. External fuses n the wrng to one or both nput pns (no. 30 and/or no. 32) may therefore be necessary to ensure complance wth local requrements. Important: Whenever the nhbt functon s not n use, pn no. 28 () must be connected to pn no. 32 (V ) to enable the output(s). Do not open the modules, or guarantee wll be nvaldated. Due to hgh output currents, the 24Q and 48Q 1001 unts provde two nternally parallel connected contacts for both the postve and the negatve output path (pns 4/6 and pns 8/10 respectvely). It s recommended to connect the load to both female connector pns of each path n order to keep the voltage drop across the connector pns to an absolute mnmum. Make sure that there s suffcent ar flow avalable for convecton coolng. Ths should be verfed by measurng the case temperature when the unt s nstalled and operated n the user s applcaton. The maxmum specfed case temperature T C max shall not be exceeded. See also: Thermal Consderatons. Check for hazardous voltages before alterng any connectons. Ensure that a unt falure (e.g. by an nternal short-crcut) does not result n a hazardous condton. See also: Safety of operator accessble output crcut. Cleanng Agents In order to avod possble damage, any penetraton of cleanng fluds s to be prevented, snce the power supples are not hermetcally sealed. Degree of Protecton Condton: Female connector ftted to the unt. IP 30: All unts, except those wth opton P (potentometer). IP 20: All unts ftted wth opton P (ncludes potentometer). 17/19

18 Q Seres DC-DC Converters 100 Watt Bengn Envronment Isolaton The electrc strength test s performed as factory test n accordance wth IEC/EN and UL 1950 and should not be repeated n the feld. Melcher wll not honour any guarantee clams resultng from electrc strength feld tests. Table 18: Isolaton Characterstc Input Input Output Output Out OK Out OK Out OK Unt to case to output to case to output to nput to case to output Electrc Requred accordng to kv rms strength IEC/EN test voltage kv DC Actual factory test 1 s AC test voltage equvalent kv rms to actual factory test Insulaton resstance at 500 V DC >300 >300 >300 >100 2 >300 >300 >300 MΩ 1 In accordance wth IEC/EN only subassembles are tested n factory wth ths voltage. 2 Tested at 300 V DC. For creepage dstances and clearances refer to: Techncal Informaton: Safety. Safety of operator accessble output crcut If the output crcut of a DC-DC converter s operator accessble, t shall be an SELV crcut accordng to the IEC/EN related safety standards The followng table shows some possble nstallaton confguratons, complance wth whch causes the output crcut of the DC-DC converter to be an SELV crcut accordng to Table 19: Insulaton concept leadng to an SELV output crcut IEC/EN up to a confgured output voltage (sum of nomnal voltages f n seres or +/ confguraton) of 35 V. However, t s the sole responsblty of the nstaller to ensure the complance wth the relevant and applcable safety regulatons. More nformaton s gven n: Techncal Informaton: Safety. Condtons Front end DC-DC converter Result Nomnal Mnmum requred grade Maxmum Mnmum requred safety Measures to acheve the Safety status of supply of nsulaton, to be pro- DC output status of the front end specfed safety status of the the DC-DC voltage vded by the AC-DC front voltage output crcut 8 output crcut converter output end, ncludng mans from the crcut suppled battery charger 8 front end 1 Mans Basc 60 V ELV crcut Supplementary nsulaton, SELV crcut 150 V AC based on 150 V AC (provded by the DC-DC converter) and earthed case 2 75 V 9 Hazardous voltage Supplementary nsulaton, secondary crcut based on 150 V AC and double or renforced nsulaton 3 (both provded by the DC-DC converter) and earthed case 2 Mans 60 V Earthed SELV crcut 2 Operatonal nsulaton (prov- 250 V AC ded by the DC-DC converter) ELV crcut Input fuse 4, output suppressor Earthed SELV dodes 75 V Unearthed hazardous, earthed output crcut 2 crcut and earthed voltage secondary crcut or non user accessble case Earthed hazardous voltage Double or renforced nsulaton 3 SELV crcut secondary crcut 2 or (provded by the DC-DC earthed ELV crcut 2 converter) and earthed case 2 Double or renforced 60 V SELV crcut Operatonal nsulaton (provded by the DC-DC converter) 75 V TNV-2 crcut Basc nsulaton 3 and earthed 75 V Double or renforced nsucase 6 lated unearthed hazardous voltage secondary crcut 7 18/19

19 Bengn Envronment DC-DC Converters 100 Watt Q Seres 1 The front end output voltage should match the specfed nput voltage range of the DC-DC converter. 2 The earth connecton has to be provded by the nstaller accordng to the relevant safety standards, e.g. IEC/EN Based on the maxmum rated output voltage from the front end. 4 The nstaller shall provde an approved fuse wth the lowest ratng sutable for the applcaton n a non-earthed nput conductor drectly at the nput of the DC-DC converter (see fg.: Schematc safety concept). For UL s purposes, the fuse needs to be UL-lsted. See also: Input Fuse. 5 Each suppressor dode should be dmensoned n such a way, that n the case of an nsulaton fault the dode s able to lmt the output voltage to SELV (<60V) untl the nput fuse blows (see fg.: Schematc safety concept). 6 The earth connecton has to be provded by the nstaller accordng to the relevant safety standards, e.g. IEC/EN If the converter case cannot be connected to earth, the front end output crcut has to be nsulated from the converter case by at least basc nsulaton, based on the maxmum nomnal output voltage from the front end. The converter case can then be consdered to be a double nsulated accessble part. 7 Has to be nsulated from earth accordng to the relevant safety standards, e.g. IEC/EN 60950, by at least supplementary nsulaton, based on the maxmum nomnal output voltage from the front end. 8 Q-unts marked "Input SELV" requre an SELV or a TNV nput crcut or an nput crcut whch s nsulated from prmary by double or renforced nsulaton and from earth by at least supplementary nsulaton. 9 The nomnal voltage between any nput pn and earth can be up to 75 V AC or DC. ~ Mans ~ AC-DC front end Battery Fuse Fuse DC-DC converter Suppressor dode SELV Earth connecton Fg. 28 Schematc safety concept Use fuse, suppressor dode and earth connectons as per table: Safety concept leadng to an SELV output crcut. Use fuse(s) also f requred by the applcaton. See: Installaton Instructons. Earth connecton Earth connecton Descrpton of Opton Opton P Output Voltage Adjustment Opton P s a bult-n mult-turn potentometer whch provdes an output voltage adjustment of ±10% of U o nom. The potentometer s accessble through a hole n the front cover. Statc voltage drops across connectors and wres can easly be compensated. Wth double output modules, both outputs are affected by the potentometer settngs. If dfferent unts are parallel-connected, ther ndvdual output voltages should be set wthn a tolerance of ±1%. If output voltages U o are set hgher than U o nom, the output currents should be reduced accordngly, so that the maxmum specfed output power s not exceeded. Accessores A great varety of electrcal and mechancal accessores are avalable ncludng: Matng connectors ether wth fast-on, screw, solder or press-ft termnals Connector retenson facltes Front panels for 19" rack mountng n 3U or 6U confguraton Addtonal external nput or output flters and chokes Mechancal mountng supports for chasss, DIN-ral and PCB mountng For more precse detals please refer to: Accessory Products. Unversal mountng bracket for DIN-ral mountng. 19/19