HR / ER Series 144 / 288 Watt 10:1 DC-DC Converters

Transcription

1 HR / ER Series 44 / 88 Watt : DCDC Converters The ER/HR Series of DCDC 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. 6.4" TE 8 3." 6 TE 6.6" 6.6" 4.4" 3 U 4.4" 3 U Features Extremely wide input voltage range from to VDC in the same converter (HR Series) RoHScompliant 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 shortcircuit proof Rectangular current limiting characteristic Parallel operation with active current sharing Very high efficiency up to % Immunity according to IEC 64, 3, 4,, 6, 8, 9 All PCB boards protected by lacquer Very high reliability year warranty Safetyapproved to the latest edition of IEC/EN 69 and UL/CSA 69 on request Table of Contents Description... Model Selection... Functional Description... Electrical Input Data...7 Electrical Output Data... Auxiliary Functions... Electromagnetic Compatibility (EMC)...8 Immunity to Environmental Conditions... Mechanical Data... Safety and Installation Instructions...4 Description of Options... Accessories...6 belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8

2 44 / 88 W : DCDC Converters Description 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 highvoltage batteries, the inhibit input allows for adjusting the under voltage 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 switchon. The outputs are open and shortcircuit proof. Full inputtooutput, inputtocase, outputtocase, and output to output isolation is provided. The converters are particularly suitable for railway applications. The HR converters can be supplied by all common railway batteries with 4 V, 36 V, V, 7 V, 96 V, V, and V nominal voltage. All PCB 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 reenabled, 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 6973, 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 Efficiency Model Options η 4 η V o nom [V] I o nom [A] V o nom [V] I o nom [A] P o nom [W] V i min 3 [V] V i cont [V] V i max 3 [V] min [%] typ [%] min [%] typ [%] to 6.8 to 6.8 to 6.8 to 6.8 to 6.8 to 6.8 to HR39RG 4 HRL39RG 4 HRP39RG 4 HR49RG 4 HRP49RG 4 HR889RG 4 HRP889RG 4 B, B to 6.8 to 6.8 to 6.8 to 6.8 to 6.8 to 6.8 to HR39RG HRL39RG HRP39RG HR49RG HRP49RG HR889RG HRP889RG B, B to 6.8 to 6.8 to 6.8 to 6.8 to 6.8 to 6.8 to HR39RG HRL39RG HRP39RG HR49RG HRP49RG HR889RG HRP889RG B, B 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 3 Short time; see table for details 4 Both outputs connected in parallel Both outputs connected in series belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page of 7

3 44 / 88 W : DCDC Converters Table b: Model Selection of ER models Output Output Power Input voltage Efficiency Model Options η V o nom [V] I o nom [A] V o nom [V] I o nom [A] P o nom [W] V i min [V] V i cont [V] V i max [V] min [%] typ [%] to 77 to 77 to 77 to 77 to 77 to 77 to ER39RG 3 ERL39RG 3 ERP39RG 3 ER49RG 3 ERP49RG 3 ER889RG 3 ERP889RG 3 B, B to 77 to 77 to 77 to 77 to 77 to 77 to ER39RG ERL39RG ERP39RG ER49RG ERP49RG ER889RG EHRP889RG B, B to 77 to 77 to 77 to 77 to 77 to 77 to ER39RG 4 ERL39RG 4 ERP39RG 4 ER49RG 4 ERP49RG 4 ER889RG 4 ERP889RG 4 B, B Efficiency at T A = C, V i = V, I o nom, V o nom Short time; see table for details 3 Both outputs connected in parallel 4 Both outputs connected in series belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page 3 of 7

4 44 / 88 W : DCDC Converters 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...3 V... 4 V V...7 V...8 Other voltages...9 Nominal voltage of tracking output V o 3 V... V V V...7 V...8 Other specifications or additional features Operational temperature range: T A : T A = 4 to 7 C, T C 9 C...9 Other...,, 6 Auxiliary functions and options: Output voltage control input... R Cooling plate standard case...b, B Cooling plate for long case mm...b RoHScompliant for all 6 substances... G 4 Customerspecific models. No safetyrelevant 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 (customerspecific models). Add to the model number, e.g. HR49RBG HR749RBG. 3 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: HR49RBG: DCDC 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 RoHScompliant for all six substances. Product Marking Basic type designation, approval marks, CE mark, warnings, pin allocation, patents, MELCHER logo, specific type de signation, input voltage range, nominal output voltages and output currents, degree of protection, identification of LEDs, batch no., serial no. and data code including production site, version, and production date. belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page 4 of 7

5 44 / 88 W : DCDC Converters 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 singletransistor forward con verter 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 = 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 Tpins 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 under voltage 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 warmup. A cooling plate for chassismounting is available (opt. B, B). JM8c 6 Vi+ 8 3 Vi 3 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 V have rectifier diodes Tpin is not connected for models HRL Fig. Block diagram of HR3, version V (or later) belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page of 7

6 44 / 88 W : DCDC Converters JM7 6 Vi+ 8 3 Vi 3 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 C Y C Y 6 R 8T D S+ 4 Vo+ 8 Vo 4 S 6 Vo+ + C Y C Y Vo Output filter V PL Fig. Block diagram of ER3 models with V o = x V have rectifier diodes Tpin is not connected for models HRL belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page 6 of 7

7 44 / 88 W : DCDC Converters Electrical Input Data General conditions: T A = C, unless T C is specified. Pin 4 (PUL) left opencircuit Pin 6 (R) and 8 (D) left opencircuit. 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 cont. I o = I o max V i s For s without shutdown T C min T C max... V i nom Nominal input voltage range 4 () 4 () 4 () V i abs Input voltage limits 3 s, without damage I i Input current: HR3 HR4 HR88 V i max.. ( V).. V i min, I o nom (.36) (.36) (.86) (.38) P i Noload input power V i min V i max, I o = 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 ma t inr r Time constant of I inr t on Startup time V i min, I o nom t r Rise time after inhibit (.83) (.83) (.33) V i 6.8 V, I o nom, V PUL = V V A W ms 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 i s For s without shutdown T C min T C max V i nom Nominal input voltage range V i abs Input voltage limits 3 s, without damage I i Input current: ER3 ER4 ER88 V i max.. ( V).. V i min, I o nom (.36) (.36) (.86).3 (.38)...7 P i Noload input power V i min V i max, I o = 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 ma (.83) (.83) (.33) V A W t inr r Time constant of I inr t on Startup time V i min, I o nom t r V i 77 V, I o nom, Rise time after inhibit V PUL = V ms Not smoothed by the inrush current limiter According to ETS 33 belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page 7 of 7

8 44 / 88 W : DCDC Converters 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 extremely 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 3 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. 3 shows more values of R PUL versus startup voltage. For stationary batteries, a higher startup voltage might be ad vantageous. V i min [V] JMa Fig. 3 R PUL versus switchon voltage (HR models) 6 kω R PUL ER models are designed for the input voltage range of a V railway battery. The input under voltage lockout (PUL, pin 4) may be adjusted if requested. The PUL resistors are specified in table 4. Table 3: 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 recommended 4 V V V 3 A fast, Littlefuse V 6.9 kω V 8 V 6 A fast, Schurter / SP V 3.7 kω 6 V V. A fast, Schurter / SP 7 V 9. kω 38 V 3 V 8 A fast, Schurter / SP 96 V. kω 6 V 7 V 6.3 A slow, BEL fuse MRT V.9 kω 9 V 84 V. A slow, BEL fuse MRT all < Ω Converter disabled fuse size mm fuse size mm 3 for s 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 recommended V. kω 64. V 6. V 6.3 A slow, BEL fuse MRT V 4. kω 74. V 69 V 6.3 A slow, BEL fuse MRT V 3. kω 87.4 V 8.6 V 6.3 A slow, BEL fuse MRT V. kω 96 V 9 V 6.3 A slow, BEL fuse MRT V. kω.7 V 96 V. A slow, BEL fuse MRT < Ω Converter disabled fuse size mm fuse size mm Note: If PUL (pin 4) is connected to Vi (pin 3/3), the converter is disabled; see Inhibit Function. Fig. 4 and show the input current versus the input voltage. I i [A] JM87 I i [A] 4 3 JM67 V i [V] Fig. 4 Typ. input current vs input voltage at nominal load (HR3) 8 4 V i [V] Fig. Typ. input current vs input voltage at nominal load (ER3) belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page 8 of 7

9 44 / 88 W : DCDC Converters 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 batterydriven 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 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 ) I inr [A] JM86 JMc + L ext R ext Vi+ R i C i Converter Vo+ Load 4 3 Vi Vo. 3 4 ms Fig. 6 Equivalent input ciruit Fig. 7 Inrush current at V i = V, I o nom (HR3, ER3) Efficiency η [%] V i = V JM 9 8 V i = V V i =.4 V I / I o o nom Fig. 8 Efficiency versus V i and I o (HR3, both outputs connected in series) belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page 9 of 7

10 44 / 88 W : DCDC Converters Electrical Output Data General Conditions: T A = C, unless T C is specified; Pin 4 (PUL) V Table a: Output data of HR/ER3 and HRL/ERL3 Model HR3 / ER3 HRL3 / ERL3 Unit Nom. output voltage V V Characteristics Conditions Output Output Output Output min typ max min typ max min typ max min typ max V o Output voltage V i nom,. I o nom V o BR Output protection (suppressor diode) Output I o Output current nom V i min V I i max ol, I ol Output current limit T C min T C max I ol Output current limit, 3 V o Output noise incl. spikes V i nom, I o nom BW = MHz mv pp V o adj Adjustment by Rinput V V i min V i max Static line/load regulation V (. ) I 3 3 o u o nom ± ± (total deviation of V o ) mv V Dynamic Voltage V i nom,. I o nom o d ± ± ± ± load deviation I o nom. I o nom regulation Recovery time and after turn on 3 3 ms t o d α v o Temperature coefficient of output voltage I o nom, T C min T C max ±. ±. ±. ±. %/K V A Table b: Output data of HRP/ERP3 models Model HRP3 / ERP3 Unit Nom. output voltage Characteristics Conditions V Output Output min typ max min typ max V o Output voltage V i nom,. I o nom V o BR Output protection (suppressor diode) Output I o Output current nom. V i min V I i max ol, I ol Output current limit.3.3 T C min T C max I ol Output current limit 4.6 V o Output noise incl. spikes V i nom, I o nom BW = MHz 6 6 mv pp V o adj Adjustment by Rinput V V i min V i max Static line/load regulation V (. ) I 3 o u o nom ± (total deviation of V o ) mv V Dynamic Voltage V i nom,. I o nom o d ± ± load deviation I o nom. I o nom regulation Recovery time and after turn on 3 ms t o d α v o Temperature coefficient of output voltage I o nom, T C min T C max ±. ±. %/K If V o is increased above V o nom through R, sense, or Tinput, the output currents should be reduced so that P o nom is not exceeded. Both outputs connected in parallel 3 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. V A belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page of 7

11 44 / 88 W : DCDC Converters 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 Characteristics Conditions Output Output Output Output min typ max min typ max min typ max min typ max V o Output voltage V i nom,. I o nom V o BR Output protection (suppressor diode) Output I o Output current nom V i min V I i max ol, I ol Output current limit T C min T C max I ol Output current limit, V o Output noise incl. spikes V i nom, I o nom BW = MHz mv pp V o adj Adjustment by Rinput V V i min V i max Static line/load regulation V (. ) I 3 3 o u o nom ± ± (total deviation of V o ) mv V Dynamic Voltage V i nom,. I o nom o d ±3 ±3 ±3 ±3 load deviation I o nom. I o nom regulation Recovery time and after turn on 3 3 ms t o d α v o Temperature coefficient of output voltage I o nom, T C min T C max ±. ±. ±. ±. %/K V A 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 V V Characteristics Conditions Output Output Output Output min typ max min typ max min typ max min typ max V o Output voltage V i nom,. I o nom V o BR Output protection (suppressor diode) Output I o Output current nom... V i min V I i max ol, I ol Output current limit T C min T C max I ol Output current limit, 4.. V o Output noise incl. spikes V i nom, I o nom BW = MHz mv pp V o adj Adjustment by Rinput V V i min V i max Static line/load regulation V (. ) I 3 3 o u o nom ±. ±. (total deviation of V o ) mv V Dynamic Voltage V i nom,. I o nom o d ±.8 ±.8 ±. ±. load deviation I o nom. I o nom regulation Recovery time and after turn on 3 3 ms t o d α v o Temperature coefficient of output voltage I o nom, T C min T C max ±. ±. ±. ±. %/K If the output voltages are increased above V o nom through Rinput 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 3 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. V A belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page of 7

12 44 / 88 W : DCDC Converters Thermal Considerations If a converter is located in free, quasistationary air (con vection cooling) at the indicated maximum ambient temperature T A max (see table Temperature specifica tions) 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 warmup 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 in di cative value only; see also fig. 9. P o [W] 3 HRP3 4 8 HR3 HRL3 Convection cooling 6 T C max JM T A [ C] Fig. 9 Power derating for HRP/HR/HRL3 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 ridethrough time) of at least ms, provided that V i was V before the interruption. This complies with EN :7 class S. Output Protection The nd output of doubleoutput 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 shut down. 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 in hibited. To reactivate, V i must be removed or an inhibit signal must be applied to PUL (pin 4). Each output has its own current limiting circuit, providing a rectangular output characteristic and protecting against short circuit. There is no limitation for the capacitive load, and battery charging is possible as well. belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page of 7

13 44 / 88 W : DCDC Converters Series and Parallel Connection Both outputs of the same converter can be seriesconnected or parallelconnected in order to double the output current or the output voltage respectively. Outputs of different converters may be seriesconnected. In parallel connection of several converters, the Tpins should be interconnected so that all converters share the output current equally; see fig.. HRL and ERL models have no Tpins 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 Tpins as well. See fig.. Converter # Converter # JM88a Max. converters in parallel connection Vo+ Vo+ S+ T S Vo Vo Vo+ Vo+ S+ T S Vo Vo Load Lead lines with equal length and cross section Diodes for redundant operation only JM84a Converter # Converter # Vo+ 6 Vo 4 Vo+ S+ T 8 S 4 Vo 8 6 Vo+ Vo Vo+ 4 S+ 8 4 T S Vo 8 Max. converters in parallel connection T + Power bus Load Fig. Parallel connection with ORing diodes and sense lines connected at the load Fig. Parallel connection of doubleoutput models with the ouputs of each converter connected in series, using option T. The signal at the T pins are referenced to Vo. 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 PULpin must be controlled individually. The Rpins should be left opencircuit. If not, the output voltages must individually be adjusted prior to paralleling within to % or the Rpins should be con nected together. Series connection of second outputs without involving their main outputs should be avoided, as regulation may be poor. belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page 3 of 7

14 44 / 88 W : DCDC Converters Output Voltage Regulation If both outputs are connected in parallel or in series, the converter exhibits a rectangular output characteristic; see fig.. The typ. dynamic load regulation illustrates fig. 3. V o /V o nom.98 V o V od V o ±% V o ±% V od t d t d. t I o I ol I o /I o nom 98a.. I o /I o nom. µs µs c t Fig. Output characteristic V o versus I o (both outputs connected in parallel or in series) Fig. 3 Typical dynamic load regulation of V o. 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. 4 a and fig.4b. 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 with output! This ensures good voltage regulation and efficiency. V o [V] V o [V].3... JM89c I o = A I o = 7. A I o =. A I o =. A I o =. A I o =. A JM I o = A I o =. A I o = A I o =. A I o =. A A I o A I o Fig. 4a Models HR/ER3 : V o versus I o with various I o Fig. 4b Models HR/ER88: V o versus I o with various I o belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page 4 of 7

15 44 / 88 W : DCDC Converters Auxiliary Functions Inhibit Function The PUL input (pin 4) can also be used as inhibit (for the PUL function see table 3 and 4). The response time t on and the rise time t r are specified in table. The current coming out from pin 4 (PUL) is typ.. ma (< ma). If pin 4 is left opencircuit, the voltage is typ. V. The converter is disabled when V PUL is mv. JM7 V o /V o nom t r t hu t f JM39c 8 Vi+. t d on t on t off R PUL I PUL V PUL 4 PUL Output PUL 3 3 Vi t PE Fig. Typical output response to the PULsignal (inhibit) Fig. 6 Circuit for the inhibit function Current Share Function If the pins 8 (T) of parallelconnected converters are con nected together, the converters share the output current evenly. Refer to section Parallel and Series Connection. Not for HRL and ERL models. 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. Table 6: Maximum voltage compensation allowed using sense lines Output voltage Total voltage difference between sense lines and their respective outputs Voltage difference between Vo and S V <. V <. V V <. V <.6 V V <. V <. V Important: Sense lines should be connected! Incorrectly con nected sense lines may activate the overvoltage protection resulting in a permanent shortcircuit of the output. Open sense lines are allowed, but result in inaccurate output voltages. belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page of 7

16 44 / 88 W : DCDC Converters 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 Caution: Applying an external control voltage >.87 V may damage the converter. b) Adjustment by means of an external resistor: 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. 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 %! Vi+ JM9a S+ Vi V ref =. V + 4 kω Control logic 6 R S 4 R ext R ext + V ext Fig. 7 Output voltage adjustment Notes: If the output voltages are increased above V o nom via Rinput control, sense lines, or option T, the output currents should be reduced, so that P o nom is not exceeded. The second output of doubleoutput models follows the voltage of the controlled main output. Output Voltage Monitor The output voltage monitor generates a logic low signal (NPN opencollector output) at the Doutput (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 Rinput, the trigger levels are corrected accordingly. At low Doutput, the current is limited by a Ω protective resistor; for converters with Version V (or later) I D should be ma. If the Doutput 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. JM9 S+ R p Input NPN open D collector Ω S 4 I D V D Fig. 8 Output voltage monitor belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page 6 of 7

17 44 / 88 W : DCDC Converters 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 Rinput are suitable for battery charger application. For optimal battery charging and life expectancy of the battery an external temperature sensor can be con nected to the Rinput. The sensor is mounted as close as possible to the battery and adjusts the output voltage according to the battery temperature. Depending upon cell voltage and the temperature coefficient of the battery, different sensor types are available; see Accessories. Cell voltage [V].4 639b Input Power supply Vo+ Vo R 399d Load V o safe Temperature sensor Fig. 9 Connection of a temperature sensor Battery. 3 4 C V C =.7 V, 3 mv/k V C =.3 V, 3 mv/k V C =.7 V, 3. mv/k V C =.3 V, 3. mv/k Fig. Trickle charge voltage versus temperature for defined temp. coefficient. V o nom is the output voltage with open Rinput. belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page 7 of 7

18 44 / 88 W : DCDC Converters 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 mode Value applied Electrostatic discharge (to case) Electromagnetic field Electrical fast transients / burst Surges Conducted disturbances Power frequency magnetic field Pulse magnetic field Waveform Source imped. IEC/EN contact discharge 8 V p 33 Ω / ns air discharge V pf p IEC/EN 643 IEC/EN 644 Test procedure In oper. Perf. crit. pos. & neg. discharges yes A x 4 antenna V/m AM 8% / khz N/A 8 MHz yes A antenna 3 antenna V/m 8 MHz V/m 4 MHz AM 8% / khz N/A V/m MHz 3 V/m 6 MHz V/m % duty cycle, Hz rep. rate 3 6 capacitive, o/c ± V p bursts of / ns; 4 i/c, +i/ i direct ±4 V p. / khz over ms; burst period: 3 ms N/A Ω 9 ± MHz pulse modul. 6 s positive 6 s negative transients per coupling mode IEC/EN i/c ± V p 4 Ω pos. & neg / µs surges per +i/ i ± V p. μf coupling mode IEC/EN 646 IEC/EN 6 IEC/EN i, o, signal wires VAC (4 dbµv) yes yes yes yes AM 8% / khz Ω. 8 MHz yes A A/m 6 s in all 3 axes yes A ±3 A/m pulses per axis 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 3 Exceeds EN 3:6 table.3 and EN 4:6 table.4. 4 Corresponds to EN 3:6 table. and exceeds EN 4:6 table.. Corresponds to EN 3:6 table. and EN 4:6 table. (compliance with digital communication devices). 6 Corresponds/exceeds EN 3:6 table 3. and EN 4:6 table Covers EN 3:6 table.3 and EN 4:6 table Corresponds to EN 3:6 table 3. and EN 4:6 table 4. (radio frequency common mode). 9 Corresponds to EN 4:6 table.3. yes A A A A A belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page 8 of 7

19 44 / 88 W : DCDC Converters Electromagnetic Emissions All conducted emissions (fig. and ) have been tested according to EN, group, class A. These limits are much stronger than requested in EN 3:6, table., and coin cide with EN 4:6, table.. The limits in fig. and apply to quasipeak values, which are always lower then peak values. In addition, the values for average must hold a limit dbµv below the limits in fig. and (not shown). Radiated emissions have been tested according to EN, group, class A. These limits are similar to the requi re ments of EN 3:6 and EN 4:6, both calling up EN 664+A:, table. The tests were executed with horizon tal and vertical polarization. The worse result is shown in fig. and 3. dbµv VUS EMC Labatory, Vin = 4 VDC, Iout = x A, C. Testdistance m, Class A, HR39RG, B93739, U4, 6.7. dbµv VUS EMC Labatory, Vin = VDC, Iout = x A, C. Testdistance m, Class A, HR39RG, B93739, U4, EN A qp 8 EN A qp 6 EN A av JM6 6 EN A av JM MHz Fig. Typ. conducted emissions (peak/quasipeak and average) at the input, measured at V i = 4 V and I o nom (HR39RG)... MHz Fig. Typ. conducted emissions (peak/quasipeak and average) at the input, measured at V i = V and I o nom (HR39RG, ER39RG). dbµv/m 6 VUS EMC Labatory, Vin = 4 VDC, Iout=xA, C. Testdistance m, Class A, HR39RG, B93739, U4, 6.7. dbµv/m 6 VUS EMC Labatory, Vin = VDC, Iout=xA, C. Testdistance m, Class A, HR39RG, B93739, U4, 6.7. EN A JM8 EN A JM MHz 3 MHz Fig. 3 Typ. radiated emissions in m distance, measured at V i = 4 V and I o nom (HR39RG). Fig. 4 Typ. radiated emissions in m distance, measured at V i = V and I o nom (HR39RG, ER39RG). belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page 9 of 7

20 44 / 88 W : DCDC Converters Immunity to Environmental Conditions Table 8: Mechanical and climatic stress Test method Standard Test Conditions Status Cab Db Be Ad Ka Fc Fh Ea Damp heat steady state Cyclic damp heat test Dry heat test steady state Low temperature startup test Salt mist test sodium chloride (NaCl) solution Vibration (sinusoidal) Random vibration broad band (digital control) & guidance Shock (halfsinusoidal) IEC/EN MILSTD8D section 7. EN :7, clause IEC/EN 6683 EN :7, clause 3.4. IEC/EN 668 EN :7, clause IEC/EN 668 Temperature: 4 ± C Relative humidity: 93 +/3 % Duration: 6 days Temperature: C and C Cycles (respiration effect) Duration: x 4 h Converter not operating Converter not operating Temperature: 7 C Converter Duration: 6 h operating Temperature, duration: 4 C, h Converter Performance test: + C not operating EN :7, clause 3.4. Temperature: 3 ± C IEC/EN 6686 MILSTD8D section 4.3 Duration: Acceleration amplitude: Frequency ( Oct/min): Test duration: h.3 mm ( 6 Hz) IEC/EN Acceleration spectral density:. g n /Hz IEC/EN 6687 MILSTD8D section 6.3 Shock EN :7 clause 3.4., EN 6373: sect., class B, body mounted Simulated long life testing at increased random vibration levels EN :7 clause 3.4.., EN 6373: sect. 8 and 9, class B, body mounted Body mounted = chassis of a railway coach Frequency band: Acceleration magnitude: Test duration: Converter not operating g n = 49 m/s (6 Hz) Converter Hz operating 7. h (. h in each axis) 8 Hz 4.9 g n rms. h (. h in each axis) Converter operating Acceleration amplitude: g n = 49 m/s Converter Bump duration: ms operating Number of bumps: 8 (3 in each direction) Acceleration amplitude: Bump duration: Number of bumps: Acceleration spectral density: Frequency band: Acceleration magnitude: Test duration:. g n 3 ms 8 (3 in each direction). g n /Hz Hz.8 g n rms h ( h in each axis) Converter operating crit. A Converter operating crit. A Temperatures Table 9: Temperature specifications, valid for an air pressure of 8 hpa (8 mbar) Model 9 Unit Characteristics Conditions min typ max T C Case temperature 4 9 C T A Ambient temperature Converter operating 4 7 T S Storage temperature Not operational 8 See Thermal Considerations. Overtemperature lockout at T C >9 C (An NTC resistor on primary and secondary heatsink). belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page of 7

21 44 / 88 W : DCDC Converters Reliability Table : MTBF and device hours Ratings at specified Model Ground benign Ground fixed Ground mobile Life test Device hours Unit case temperature 4 C 4 C 7 C C C Bellcore SR33 HR h Life test with 3 converters during 6 days, cycling at 6 C; confidence level 6%. Statistical values, based on an average of 43 working hours per year and in general field use over years; upgrades and customerinduced 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 (7. to 7.9) M4 7 TE TE JM9 Measuring point of case temperature T C (3U) Out OK In OK d Front plate Main face Back plate 6. Ø x 9.8 Ø.8..9 Screw holes of the frontplate European Projection Fig. Case S3 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 moun ted with fins in a vertical position to achieve maximum airflow through the heat sink. belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page of 7

22 44 / 88 W : DCDC Converters Dimensions in mm. The converters are designed to be inserted into a 9 rack, 6 mm long, according to IEC TE 9 TE JM93 d (3U) Out OK In OK Measuring point of case temperature T C. ( ) Front plate Main face Back plate. Ø x Ø.8. Screw holes of the frontplate Mounting slots for chassis or wall mounting European Projection Fig. 6 Case K3 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 moun ted with fins in a vertical position to achieve maximum airflow through the heat sink. belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page of 7

23 44 / 88 W : DCDC Converters ±. 3 Fig. 7 Option B: Aluminum case S3 with large cooling plate; black finish (EP powder coated). Suitable for front mounting. Total weight approx.. kg Note: Long case with option B, elongated by 6 mm for mm rack depth, is available on request. (No LEDs) JM 7 TE 4 TE 3.7 M 4 Out OK In OK (3U) Measuring point of case temperature T C ( ) Fig. 8 Option B: Aluminum case S3 with small cooling plate; black finish (EP powder coated). Suitable for mounting with access from the backside. Total weight approx..4 kg. 47. belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page 3 of 7

24 44 / 88 W : DCDC Converters 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. Sb Fixtures for retention clips Fig. 9 View of module s male connectors Table : Pin allocation Pin Name Function 4 Vo+ Output positive 6 Vo+ Output positive 8 Vo Output negative Vo Output negative S+ Sense line positive 4 S Sense line negative 6 R Output voltage adjust 8 T Current share D Out OK PE Protection earth 4 PUL Programmable undervoltage lockout Vi+ Input positive Vi Input negative Leading pin (preconnecting) 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 enduse 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. ( Notes: ) is connected with the case. For safety reasons it is essential to connect this pin reliably to protective earth. The PUL function (pin 4) must be programmed to enable the outputs. PUL should be connected to Vi (pins 3 + 3) by a resistor to adjust the startup voltage; see table 3. 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 verify it by measuring the case temperature T C, when the converter is installed and operated in the enduse application; see Thermal Consider ations. Ensure that a converter failure (e.g. an internal short circuit) does not result in a hazardous condition. belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page 4 of 7

25 44 / 88 W : DCDC Converters Standards and Approvals The converters are safetyapproved 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: Buildingin 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:. CBscheme 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 3, and EN 4. All boards are coated with a protective lacquer. The converters comply with NFF6 (I/F). They also comply with EN 44, EN 44, if installed in a technical compartment or cabinet. 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. Table : Isolation Characteristics Input to Case + Outputs Output(s) to Case Output to Output Electric strength test Factory test s kvdc AC test voltage equivalent to factory test... kvac Insulation resistance >3 >3 > MΩ Creepage distances mm According to EN 4 and IEC/EN 69, subassemblies connecting input to output are pretested with.6 kvdc or 4 kvac. Tested at VDC 3 Input to outputs: 6. 4 mm Unit 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. belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page of 7

26 ER / HR Series 44 / 88 W : DCDC Converters Accessories A variety of electrical and mechanical accessories are available including: Front panels for 9 DINrack: Schroff or Intermas, or 6TE / 3U; see fig. 3 and the data sheet BCD.49. Mating H connectors with screw, solder, faston, or pressfit terminals; see fig. 3 Coding clips for connector coding HZZ Pair of connector retention clips HZZ9G; see fig. 3 Connector retention brackets HZZ6G; see fig. 33 Cage clamp adapter HZZ44G; see fig. 34 Cable hood for H connectors (fig 3): HZZ4G, screw version HZZ4G, use with retention brackets HZZ8G HZZ43G, metallic version providing fire protection Wallmounting plate K (HZZ3G) for models with option B; see fig. 36 DINrail mounting assembly HZZ6G (DMBK/S); see fig. 37 Additional external input and output filters Different battery sensors SKSMH... for using the converter as a battery charger. Different cell characteristics can be selected; see fig. 38, table 3, and Battery Charging / Temperature Sensors. For additional accessory product information, see the accessory data sheets listed with each product series or individual model at our web site belfuse.com/powersolutions. Fig. 3 Different mating connectors Fig. 3 Different front panels Fig.3 Connector retention clips to fasten the H connector to the rear plate; see fig. 9. HZZ9G consists of clips. to 3 Ncm Fig. 33 Connector retention brackets HZZ6G Fig. 34 Cage clamp adapter HZZ44G belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page 6 of 7

27 ER / HR Series 44 / 88 W : DCDC Converters Fig. 3 Different cable hoods Fig. 36 Chassis or wallmounting plate HZZ3G (Mounting plate K) European Projection 9.8 (.4") 6 (.") 9a L 6 (.") L = m (standard length) other cable lengths on request Fig. 37 DINrail mounting assembly HZZ6G (DMBK/S) adhesive tape Fig. 38 Battery temperature sensor Table 3: Battery temperature sensors Battery voltage nom. [V] Sensor type Cell voltage [V] Cell temp. coefficient [mv/k] Cable length [m] SKSMH SKSMH SKSMH SKSMH SKSMH SKSMH SKSMH SKSMH SKSMH 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. belfuse.com/powersolutions BCD.8 Rev AH, 7Jun8 8 Bel Power Solutions & Protection Page 7 of 7