RCM5/3 Series 5/3 W DC-DC Converters The RCM Series converters are reliable power supplies for railway and transportation systems. There are 2 input voltage ranges covering all common railway batteries. The output delivers 5 or 3 W at 2, 5 or 24 V. The converters are designed for chassis mounting and exhibit a closed housing with cooling openings. Many options are available, such as an output ORing FET for redundant operation, output voltage adjustment, interruption time of ms (class ST2), shutdown input, and an output voltage monitor controlling a relay (changeover contact). Features RoHS lead-free-solder product 2 input voltage ranges, covering all railway batteries Single output 2, 5 or 24 V Closed housing for chassis mounting Extremely high efficiency and high power density Low inrush current 3 connectors: Input, output, auxiliary Overtemperature, overvoltage, overcurrent, and overload protection Many options available Compliant to EN 555, EN 52-3-2, AREMA Fire and smoke: compliant to EN 45545 and NFPA 3 5 year warranty Safety-approved to the latest edition of IEC/EN 695- and UL/CSA 695- pending Table of Contents Description... Model Selection...2 Functional Description...3 Electrical Input Data...4 Electrical Output Data...7 Description of Options... Electromagnetic Compatibility (EMC)...2 Immunity to Environmental Conditions...4 Mechanical Data...5 Safety and Installation Instructions...6 Accessories...8
Model Selection Table : Standard models Input voltage Output Power Efficiency 2 Model Options V i min [V] V i cont [V] V i max [V] 4.4 6.8 (24) 45 5.4 43.2 5.4 () 37.5 54 4.4 6.8 (24) 45 5.4 43.2 5.4 () 37.5 54 V o nom [V] Short time; see table 2 for details. 2 Efficiency at T A = 25 C, V i nom, I o nom, V, only option D fitted. o nom I o nom [A] P o nom [W] η min [%] η typ 2 2.5 5 88 9 24RCM5-2 5. 5 24RCM5-5 24 6.25 5 9 9 24RCM5-24 2 2.5 5 9 92.5 RCM5-2 5. 5 RCM5-5 24 6.25 5 92 93 RCM5-24 2 25 3 89 9.5 24RCM3-2 24 2.5 3 9 9 24RCM3-24 2 25 3 9 92.5 RCM3-2 24 2.5 3 92 93.5 RCM3-24 D, M, Q, F, K Part Number Description Operating input voltage V i cont (continuously): 6.8 45 VDC...24 5.4 37.5 VDC... Series...RCM Output power: 5 W...5 3 W...3 Nominal output voltage: 2 V...-2 5 V...-5 24 V...-24 Auxiliary functions and options: Out OK, output voltage adjust, shutdown... D Interruption time...m ORing FET...Q Fuse built-in...f Pluggable Connectors... K RCM 5-24 D M Q F K Opt. D requires the auxiliary connector. Note: The sequence of options must follow the order above. Note: All models are RoHS-compliant for all six substances. Available combinations of options: 24/RCMxxx-xx (K) 24/RCMxxx-xxD (K) 24/RCMxxx-xxDF (K) 24/RCMxxx-xxDMQ (K) 24/RCMxxx-xxDMQF (K) Example: RCM5-24DMQ: DC-DC converter, input voltage range 5.4 to 37.5 V continuously, output providing 24 V /6.25 A, monitoring relay, output voltage adjust, shutdown input, interruption time ms, integrated ORing FET, operating ambient temperature T A = 4 to 7 C, RoHS-compliant for all six sub stances. Page 2 of 8
Product Marking Type designation, applicable safety approval and recognition marks, CE mark, pin allocation, and product logo. Input voltage range and input current, nominal output voltage and current, degree of protection, batch no., serial no., and data code including production site, version (modification status) and date of production. Functional Description The converters are designed as active clamp forward con verters with a switching frequency of approximately 2 khz. The built-in high-efficient input filter together with a small input capacitance generates very low inrush current of short duration. An antiparallel diode acts as reverse polarity pro tection together with the external circuit breaker or fuse. The circuitry providing the interruption time (opt. M) is located after the input filter. The rectification on the secondary side is provided by syn chronous rectifiers, in order to keep the losses as low as possible. The output voltage control logic is located on the secondary side and influences the primary logic through magnetic feedback. An auxiliary converter supplies all circuits with a stable bias voltage. An output ORing FET is available (option Q) and allows for a redundant power supply system. If there are no external circuit breakers, it is possible to order the converter with incor porated fuse (opt. F). Because this fuse is not accessible, a serial diode provides reverse polarity protection (only with option F or M). Opt. D encompasses an additional auxiliary connector and allows for output voltage adjust and a primary shutdown. An output voltage monitor controls a relay with a change-over contact. R R R R+ JM94f SD SD Vi+ Fuse (option F) NTC Primary control logic Opt. M Isolation Isolated driver Secondary control logic NTC OK OK2 OK Vi 2 Input filter C hu + Opt. Q Output filter Vo+ Vo PE C y Auxiliary converter C y C y Auxiliary connector (only with option D) Series diode, only fitted with opt. F or M 2 Bipolar suppressor diode with opt. F or M Fig. Block diagram Page 3 of 8
Electrical Input Data General conditions: - T A = 25 C, unless T C is specified. Table 2a: Input data of RCM5 models Model 24RCM5 RCM5 Unit Characteristics Conditions min typ max min typ max V i cont Operating input voltage continuous I o = I o max T C min T C max 6.8 (24) 45. 5.4 () 37.5 V i 2s for 2 s without shutdown 4.4 5.4 43.2 54 V i nom Nominal input voltage 24, (36) (72), (96), V i abs Input voltage limits 3 s without damage 55 65 I i Typical input current V i nom, I o nom 6.8.5 A P i No-load input power V i min V i max, I o = 2.5 4 4 2 6 P i SD Idle input power V i min V i max, V SD = V.7.5.7 2.5 C i Input capacitance 4 µf R i Input resistance mω I inr p Peak inrush current 75 A V i = V i max, P o nom t inr d Duration of inrush current.5.5 t on Start-up time after removal of shutdown V i min, P o nom V i min, P o nom V SD = 5 V 3 3 V W ms Table 2b: Input data of RCM3 models Model 24RCM3 RCM3 Unit Characteristics Conditions min typ max min typ max V i cont Operating input voltage continuous I o = I o max T C min T C max 6.8 (24) 45. 5.4 () 37.5 V i 2s for 2 s without shutdown 4.4 5.4 43.2 54 V i nom Nominal input voltage 24, (36) (72), (96), V i abs Input voltage limits 3 s without damage 55 65 I i Typical input current V i nom, I o nom 3.9 3 A P i No-load input power V i min V i max, I o = 4 6 4 6 P i SD Idle input power V i min V i max, V SD = V.5.5 C i Input capacitance 6 2 µf R i Input resistance 4 4 mω I inr p Peak inrush current 2 5 A V i = V i max, P o nom t inr d Duration of inrush current.5.5 t on Start-up time after removal of shutdown V i min, P o nom V i min, P o nom V SD = 5 V 3 3 V W ms Not smoothed by the inrush current limiter at start-up (for inrush current calculation) 2 Typ. value at V i max. At lower V i, the idle and low-load input power are smaller. Page 4 of 8
Input Transient and Reverse Polarity Protection A suppressor diode and a symmetrical input filter form an effective protection against input transients, which typically occur in many installations, but especially in battery-driven mobile applications. If the input voltage has the wrong polarity, the incorporated antiparallel diode causes the external input circuit breaker or fuse to trip. With option M or F (incorporated fuse), an active reverse-polarity protection circuit prevents from any damage. Input Under-/ Overvoltage Lockout If the input voltage is out of range, an internally generated inhibit signal dis ables the converter to avoid any damage. Inrush Current and Stability with Long Supply Lines The converter operates with relatively small input capacitance C i resulting in low inrush current of short duration. If a converter is connected to the power source through supply lines with reasonable length, no additional measures are necessary to ensure stable operation. Only in the case of very long supply lines exhibiting a con siderable inductance L ext, an additional external capacitor C ext connected across the input pins improves the stability and prevents oscillations; see fig. 2. + L ext R ext C ext Vi+ R i Converter C i r i JM85d Vo+ Load Table 3: Recommended values for the capacitor C ext V B nom RCM5 RCM3 Rated voltage 24 V 5 μf 3 μf 4 V 36 V μf 2 μf 63 V Vi Vo 72 V 22 μf 44 μf 25 V V μf 2 μf 2 V Fig. 2 Input configuration Actually, the RCM Series converter with its load acts as negative resistor r i, because the input current I i rises, when the input voltage V i is decreased. It tends to oscillate with a resonant fre quency determined by the line inductance L ex t and the input capacitance C i + C ext, damped by the resistor R ext. The whole system is not linear at all and eludes a simple calculation. One basic condition is given by the formula: L ext P o max dv i C i + C ext > (r i = ) R ext V i min ² di i R ext is the series resistor of the voltage source including supply lines. If this condition is not fulfilled, the converter may not reach stable operating conditions. Worst case conditions are at lowest V i and highest output power P o. Recommended values for C ext for different batteries are listed in table 3, which should allow for stable operation up to an input inductance of 2 mh. C i is specified in table 2. Page 5 of 8
Efficiency The efficiency depends on the model and on the input voltage. η [%] RCM5-2DMQ η [%] RCM5-24DMQ V i = 5 V V i = V JM27 V i = 5 V V i = V JM2b 9 9 8 V i = 37 V 8 V i = 37 V 7 7 6.2.4.6.8 P / P o o nom Fig. 3a Efficiency versus V i and P o (RCM5-2DMQ) 6.2.4.6.8 P / P o o nom Fig. 3b Efficiency versus V i and P o (RCM5-24DMQ) η [%] RCM3-24DMQ V i = 5 V V i = V JM28 9 8 V i = 37 V 7 6.2.4.6.8 P / P o o nom Fig. 3c Efficiency versus V i and P o (RCM3-24DMQ) Page 6 of 8
Electrical Output Data General conditions: - T A = 25 C, unless T C is specified - R input not connected Table 4a: Output data of RCM5 models. Output 2 V 5 V 24 V Unit Characteristics Conditions min typ max min typ max min typ max V o Output voltage V i nom,.5 I o nom.88 2 2.2 23.76 24 24.24 V ow Worst case output voltage V i min V i max T C min T C max, - I o nom.64 2.36 23.28 24.72 V o droop Output voltage droop - 2-4 mv/a V o L Overvoltage shutdown 6 4 28 V o P Overvoltage protection 2 4.3 5 5.8 28.5 3 3.5 I o nom Nominal output current 2.5 6.25 I o L Output current limit T C min T C max 3. 5 6.5 7.2 Switching frequency V v o Output noise 3 i nom, I 4 8 o nom Total incl. spikes BW = 2 MHz 6 2 v od Dynamic load Voltage deviation 5 V i nom, 7 t 4 d regulation Recovery time..9 I o nom 5 5 ms α vo Temperature coefficient of v o (NTC) - I o nom, T C min T C max -.2 -.2 %/K V V A mv pp Table 4b: Output data of RCM3 models. Output 2 V 24 V Unit Characteristics Conditions min typ max min typ max V o Output voltage V i nom,.5 I o nom.88 2 2.2 23.76 24 24.24 V ow Worst case output voltage V i min V i max T C min T C max, - I o nom.64 2.36 23.28 24.72 V o droop Output voltage droop - 2-4 mv/a V o L Overvoltage shutdown 6 4 28 V o P Overvoltage protection 2 4.3 5 5.8 28.5 3 3.5 I o nom Nominal output current 25 2.5 I o L Output current limit T C min T C max 27 3 3.5 5 Switching frequency V v o Output noise 3 i nom, I 6 8 o nom Total incl. spikes BW = 2MHz 8 2 v od Dynamic load Voltage deviation 5 V i nom, 2 t 4 d regulation Recovery time..9 I o nom 5 5 ms α vo Temperature coefficient of v o (NTC) - I o nom, T C min T C max -.2 -.2 %/K If the output voltage is increased above V o nom through R-input control, the output power should be reduced accordingly, so that P o max and T C max are not exceeded. 2 Breakdown voltage of the incorporated suppressor diode at ma. Exceeding this value might damage the suppressor diode. 3 Measured according to IEC/EN 624 with a probe described in annex A 4 Recovery time until V o returns to ±% of V o ; see fig. 4. 5 No overshoot at switch on. 6 Output overvoltage protection by an electronic circuitry. V V A mv pp Page 7 of 8
Output Voltage Regulation Line and load regulation of the output is so good that input voltage and output current have virtually no influence to the output voltage. V o V od V o ±% V o ±% V od t d t d t I o /I o nom.5 µs µs 52c Fig. 4 Typical dynamic load regulation of output voltage t Thermal Considerations and Protection A temperature protection is incorporated in the primary and secondary control logic each. It generates an internal inhibit signal, which disables the converter in case of over tem per a ture. The converter automatically recovers, when the temper a ture drops below the limit. See fig. 5. The relationship between T A and T C depends heavily upon the conditions of operation and integration into a system. Caution: The installer must ensure that under all operating con ditions T C remains within the limits stated in table 8. P o [W] 3 RCM3 24 Convection cooling 8 RCM5 2 6 T C max JM245 5 6 7 8 9 T A [ C] Fig. 5 Typical output power derating versus temperature; vertical mounting position, free convection cooling. Output Current Limitation The output is continuously protected against open-circuit (no load) and short-circuit by an electronic current limitation with rectangular characteristic; see fig. 5. V o V o nom.98.5 JM29 I o.5. I ol I o nom Fig. 6 Rectangular current limitation Page 8 of 8
Series and Parallel Connection The outputs of several RCM Series converters may be con nected in series. Note: If the sum of the output voltages is greater than 6 V, it cannot be considered as SELV (Safety Extra Low Voltage) according to the safety standards. Several RCM models of the same type can be operated in parallel connection. To ensures proper current sharing, the load lines should have equal length and section. The output voltage exhibits a slight droop characteristic, which facilitates current sharing. In addition, the output voltage tends to be lowered with increasing temperature. Redundant Systems For redundant systems, we recommend the options Q and D, see Options. LE D Indicator The converters exhibit a green LED Out OK, signaling that the output voltage is within the specified range. Page 9 of 8
Description of Options Option D: Output Monitor, Output Adjust, Shutdown Option D consists of several auxiliary functions and en compasses an additional auxiliary connector. Output Voltage Adjust (R) Note: With open R-input, V o = V o nom. The converter allows for adjusting the output voltage in the range of 8 to 5% of V o nom. The adjust is accomplished by an external resistor R ext or R ext2, connected to the R-input; see fig. 7. Depending on the value of the required output voltage, the resistor shall be connected: either: Between the R-pin and R to adjust the output voltage to a value below V o nom : V o R ext 4 kω 5.8 kω V o nom V o Note: R ext = Ω reduces V o to 8%. or: Between the R-pin and R+ to adjust the output voltage to a value greater than V o nom : (V o 2.5 V) R ext2 4 kω Ra 2.5 V (V o /V o nom ) Note: R ext2 = Ω increases V o to 5%. Ra = 3 kω for V o nom = 2 V Ra = xxx kω for V o nom = 5 V Ra = 68 kω for V o nom = 24 V JM244 Vi+ Bias Ra R+ Vi V ref = 2.5 V + 4 kω Control logic 5.8 kω R R Vo R ext2 R ext Fig. 7 Output voltage control via R-input Output Voltage Monitor (D) The output voltage V o is monitored. When V o is in range, a relay with a change-over contact is activated, connecting OK with OK. Note: The trigger levels are typ. ±5 % of V onom (with open R-input). Data of relay contacts:.4 A /5 VDC Primary Shutdown (SD) The output of the converter may be enabled or disabled by a logic signal (e.g. CMOS) applied between the shutdown pin SD and SD (= Vi ). If the shutdown function is not re quired, pin SD can be left open-circuit. Voltage on pin SD: Converter operating: Converter disabled: The output response is shown in fig. 8. 2 to 54 V or open-circuit 2 to +2 V Note: In systems consisting of several converters, this feature may be used to control the activation sequence by logic signals or to enable the power source to start up, before full load is applied. Page of 8
Option M: Interruption Time The interruption time t hu is specified in the railway standard EN 555:27 clause 5...4: It is tested at the nominal battery voltage for interruption and short-circuit of the input. After such an event, the system is ready for another such event after s. Fig. 8 shows the output voltage V o with option M. t hu = ms (Class S2) in all other cases. For less critical applications, option M is not required (class S, no interruption time). V o /V o nom t r t hu t f t d on. SD t on t off JM93a t Fig. 8 Typical output response to the SD-signal. If option M is not fitted, t hu = ms. Option Q: ORing FET for Redundant Systems The outputs of 2 parallel connected converters are separated with ORing diodes (built by FETs). If one converter fails, the remaining one must be capable to still deliver the full power to the load. If more power is needed, the system may be extended to more parallel converters (n+ re dundancy). Current sharing must be ensured by load lines of equal section and length. In addition, a slight droop characteristic of the output voltage and a negative temperature coefficient are helpful as well. To keep the losses as small as possible, the ORing diode is replaced by a FET. The voltage drop is approx. 22 mv (not dependent of I o ). Note: In the case of a failing converter, the output voltage is maintained by the redundant converters. However, the failing item should be identified and replaced. We recommend the Out OK function (option D). Option F: Incorporated Fuse The railway standard EN 555 disadvises fuses in the con verters. Consequently, the installer must preview an external fuse or circuit breaker. However, when this is not possible, an in corporated fuse is available (option F). This fuse is not accessible and will not trip, except if the converter is defect. Note: Converters with option F or option M are protected against input reverse polarity by a series diode. Table 5: Recommended external fuses (same as with option F) Converter Specification Ordering number 24RCM5 5 A fast acting BEL ADE (P) 5-R 24RCM3 25 A fast acting BEL ADE (P) 25-R RCM5 5 A fast acting Littelfuse 57 5.MXEP RCM3 8 A fast acting Littelfuse 57 8.MXEP Option K: Pluggable Connectors This option allows the use of pre-assembled pluggable connectors; for details see Accessories. Note: Female connectors must be ordered separately. Page of 8
Electromagnetic Compatibility (EMC) Electromagnetic Immunity Table 6: Electromagnetic immunity (type tests). Corresponds or Exceeds EN52-3-2:26 and AREMA Phenomenon Standard Level Coupling mode Value applied Electrostatic discharge (to case) Electromagnetic field Electrical fast transients/burst Surges Conducted disturbances IEC/EN 6-4-2 4 IEC/EN 6-4-3 IEC/EN 6-4-4 IEC/EN 6-4-5 IEC/EN 6-4-6 i = input, o = output, c = case Waveform Source imped. contact discharge 6 V p 33 Ω /5 ns air discharge 8 V 5 pf p Test procedure In oper. Perf. crit. 2 pos. & neg. discharges yes A x antenna 2 V/m AM 8% / khz N/A 8 8 MHz yes A 3 3 3 antenna capacitive, o/c i/c, +i/ i direct coupling 2 V/m 8 MHz 2 V/m 4 2 MHz AM 8% / khz N/A 5 V/m 2 27 MHz 3 V/m 5 6 MHz ±2 V p bursts of 5/5 ns; 2.5/5 khz over 5 ms; burst period: 3 ms 5 Ω 6 s positive 6 s negative transients per coupling mode i/c ±2 V p 42 Ω.5 μf 5 pos. & 5 neg. +i/ i ± V p.2 / 5 µs surges per 2 Ω coupling mode i/c, +i/ i ±2 V p 9 μf 3 i, o, signal wires VAC (4 dbµv) yes yes yes AM 8% / khz 5 Ω.5 8 MHz yes A 2 A = normal operation, no deviation from specs.; B = normal operation, temporary loss of function or deviation from specs possible A A A B Page 2 of 8
Electromagnetic Emissions All conducted emissions (fig. 9) have been tested as per EN 55, group, class A. These limits are much stronger than requested in EN 52-3-2:26, table 2., and coin cide with EN 52-4:26, table.. The values in fig. 9 are quasipeak values, which are always lower then peak values. The average values must respect a margin of dbµv below the limits for quasipeak. Radiated emissions have been tested according to EN 55, group, class A. These limits are similar to the requi re ments of EN 52-3-2:26 and EN 52-4:26, both calling up EN 6-6-4+A:2, table. The tests were executed with horizontal and vertical polarization. The worse result is shown in fig.. dbµv RCM5-24DMQF; Vi = V, Vo = 24 V; Io = 6.25 A Class A, 3-Oct-26 dbµv RCM3-24DMQF; Vi = V, Vo = 24 V; Io = 2.5 A Class A, 2-Apr-27 8 EN 55 A qp JM2 8 EN 55 A qp JM22 6 EN 55 A av 6 EN 55 A av 4 4 2 2.2.5 2 5 2 MHz.2.5 2 5 2 MHz Fig. 9a RCM5-24: Typ. disturbance voltage at the input (V i = V, I i nom, resistive load, quasi peak and average) Fig. 9b RCM3-24: Typ. disturbance voltage at the input (V i = V, I i nom, resistive load, quasi peak and average) dbµv/m 6 VUS EMC Labatory, RCM5-24DMQF; Vi = VDC, Vo = 24 V / 6.25 A Testdistance m, Class A, 3-Oct-26; ESVS 3, Rhode & Schwarz JM22 dbµv/m 6 VUS EMC Labatory, 3RCM5-24DMQF; Vi = VDC, Vo = 24 V / 2.5 A Testdistance m, Class A, 2-Apr-27; ESVS 3, Rhode & Schwarz JM22 5 5 4 4 3 3 2 2 3 5 2 5 MHz Fig. a RCM5-24: Typ. radiated disturbances in m distance (V i = V, I i nom, resistive load, quasi peak). 3 5 2 5 MHz Fig. b RCM3-24: Typ. radiated disturbances in m distance (V i = V, I i nom, resistive load, quasi peak). Page 3 of 8
Immunity to Environmental Conditions Table 7: Mechanical and climatic stress. Air pressure 8 2 hpa Test method Standard Test Conditions Status Ad Be Db 2 Ka Low temperature start-up test Dry heat test, cycle A Cyclic damp heat test Salt mist test sodium chloride (NaCl) solution - Functional random vibration test - Simulated long life testing EN 555:27, clause 3.4.4 IEC/EN 668-2- EN 555:27, clause 3.4.5 IEC/EN 668-2-2 EN 555:27, clause 3.4.7 IEC/EN 668-2-3 EN 555:27, clause 3.4. IEC/EN 668-2- EN 555:27 clause 3.4..4 EN 6373:2 clause 8, class B, body mounted EN 555:27 clause 3.4..2 EN 6373:2 clause 9, class B, body mounted - Shock test EN 555:27 clause 3.4..3 EN 6373:2 clause, class B, body mounted - Vibration sinusoidal AREMA Part..5. class C, D, E, I, J - Mechanical shock AREMA Part..5. class C, D, E, I, J Body mounted = chassis of a railway coach Temperature, duration: - 4 C, 2 h Performance test: +25 C Not operating Temperature: 7 C Operating Duration: 6 h perf. crit. A Temperature: 55 C and 25 C Cycles (respiration effect): 2 Duration: 2x 24 h Temperature: 35 ±2 C Duration: 48 h Not operating Converter not operating Acceleration amplitude:. g n =. m/s 2 Operating Frequency band: 5 5 Hz perf. crit. A Test duration: 3 min ( min in each axis) Frequency band: 5 5 Hz Not operating Acceleration amplitude:.58 g n = 5.72 m/s 2 Test duration: 5 h (5 h in each axis) Acceleration amplitude: 5. g n Operating Bump duration: 3 ms perf. crit. A Number of bumps: 8 (3 in each direction) Acceleration amplitude: Frequency: Test duration:.3 (5 2 Hz).5 g n = 4.7 m/s 2 Operating 2 Hz perf. crit. A 2 h (4 h in each axis) Acceleration amplitude: g n = 98 m/s 2 Operating Bump duration: ms perf. crit. A Number of bumps: 8 (3 in each direction) Temperatures Table 8: Temperature specifications, valid for an air pressure of 8 2 hpa (8 2 mbar) Temperature EN 555:27 Class OT4 Unit Characteristics Conditions min max minutes T A Ambient temperature Converter operating - 4 7 85 C T C Case temperature - 4 9 T S Storage temperature Not operational - 55 85 Measured at the measurement point T C ; see Mechanical Data. Reliability Table 9: MTBF and device hours Ratings at specified case temperature between failures Model MTBF Accord. to IEC 6238 RCM5-24DMQF 37 6 h RCM3-24DMQF 26 h Page 4 of 8
Mechanical Data 4.5 (4x) Measuring point of case temperaturet C 48 JM23b 4.5 (4x) Measuring point of case temperaturet C 76.45 2 52.5 64.5 94.9 6 6 78 96.7 29.5 68.2 36. 6. 2.9 76.6 88.6 98 6.5 4.9 75.45 JM25b Standard models RCM5 38 7 2 Standard models RCM3 29.5 67.5 4.9 74.5 3. 36. 6.3 RCM5 with option K 38 7 RCM3 with option K Fig. a Case of RCM5 (RCM) weight approx. 52 g, Aluminum, EP-powder coated pluggable JM247 connector Fig. 2a Case of RCM3 (RCM2) weight approx. 82 g, Aluminum, EP-powder coated JM246 pluggable connector 6 6.4 Fig. b Plugged connector for RCM5 with option K 5.9 7.7 Fig. 2b Plugged connector for RCM3 with option K Page 5 of 8
Safety and Installation Instruction Connectors and Pin Allocation of RCM5 - Input connector, 3 pins: Wago 236-43: Vi+, Vi, PE; wire section:.8 2.5 mm 2, 28 2 AWG; with option K: Phoenix Contact 923762 - Output connector, 2 pins: Wago 236-42: Vo+, Vo ; wire section:.8 2.5 mm 2, 28 2 AWG with option K: Phoenix Contact 923759 - Auxiliary connector: Phoenix Contact 73883; pin allocation see fig. 3. Vo+ Vo R R+. R R n.c. n.c. OK OK OK OK2 n.c. n.c. SD SD Vi Vi+ PE Fig. 3 Pin allocation of RCM5 Connectors and Pin Allocation of RCM3 - Input connector, 3 pins: Wago 745-353: Vi, Vi+, PE wire section:.2 6 mm 2, 24 AWG with option K: Weidmüller 485 - Output connector, 2 pins: Wago 745-62/6, Vo, Vo+ wire section:.2 6 mm 2, 24 AWG with option K: Weidmüller 4839 - Auxiliary connector: Phoenix Contact 73883; pin allocation see fig. 4. Vo+ Vo Fig. 4 Pin allocation of RCM3 R R+ R R n.c. n.c. OK OK OK OK2 n.c. n.c. SD SD Vi Vi+ PE Installation Instruction These converters are components, intended exclusively for inclusion by an industrial assembly process or by a professionally competent person. Installation must strictly follow the national safety regulations in respect of the enclosure, mounting, creepage distances, clearances, markings and segregation requirements of the end-use application. Connection to the system shall only be effected with cables with suitable wire section. The auxiliary connector shall be connected via the suitable female connector; see Accessories. Other installation methods may not meet the safety requi rements. Check that PE is safely connected to protective earth. No fuse is incorporated in the converter (except for option F). An external circuit breaker or a fuse in the wiring to one or both input pins. Do not open the converters, or the warranty will be invalidated. Make sure that there is sufficient airflow available for convection cooling and that the temperature of the bottom plate is within the specified range. This should be verified by measuring the case temperature at the specified measuring point, when the converter is operated in the end-use application. T C max should not be exceeded. Ensure that a failure of the converter does not result in a hazardous condition. Standards and Approvals The RCM Series converters are approved according to the last edition of IEC/EN 695- and UL/CSA 695-. They have been evaluated for: Class I equipment Building in Double or reinforced insulation based on 25 VAC or 24 VDC between input and output, and between input and the relay contacts (OK, OK, OK2) Pollution degree 2 environment. The converters are subject to manufacturing surveillance in accordance with the above mentioned UL standards and with ISO 9. Page 6 of 8
Cleaning Liquids and Protection Degree The converters are not hermetically sealed. In order to avoid possible damage, any penetration of liquids shall be avoided. The converters correspond to protection degree IP 3. Railway Applications The RCM Series converters have been designed observing the railway standards EN 555:27, EN 52-3-2:26, and AREMA. All boards are coated with a protective lacquer. The converters comply with the fire & smoke standard EN 45545:26, HL to HL3. Insulation Test The electric strength test is performed in the factory as routine test in accordance with EN 554, EN 555:27, and AREMA. It should not be repeated in the field, and the Company will not honor warranty claims resulting from incorrectly executed electric strength tests. Table : Isolation Characteristics Input to Output to Case OK contacts to Unit Output Case + Output Input Case Outputs Electric strength test Factory test s 4.2 2.86 2.86 2.86 2.86 2.86 kvdc AC test voltage equivalent to factory test 3. 2. 2. 2. 2. 2. kvac Insulation resistance >3 2 >3 2 >3 >3 >3 >3 MΩ Creepage distances 5. 3.5 3.5 3.5 3.5 3.5 mm Pretest of subassemblies in accordance with IEC/EN 695 2 Tested at 5 VDC Page 7 of 8
Accessories Female Connectors A suitable female auxiliary connector HZZ45-G (Phoenix Contact 79344) is available; see fig. 5. Wire section:.2.5 mm 2, 24 6 AWG. Fig. 5 Female connector 4 pins, HZZ45-G (Phoenix Contact 79344) For converters RCM5 with option K, use (see fig. 6): HZZ3-G (3 poles, Phoenix Contact 94267) HZZ3-G (2 poles, Phoenix Contact 94254). Wire section:.2 2.5 mm 2, 24 2 AWG. For converters RCM3 with option K, use (see fig. 7): HZZ33-G (3 poles, Weidmüller 658) HZZ32-G (2 poles, Weidmüller 655). Wire section:.5 mm 2, 24 8 AWG Fig. 6 Female connectors for RCM5 with option K Fig. 7 Female connectors for RCM3 with option K 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. Page 8 of 8