CP2660-7R

CP2660-7R POWER-ONE | Alldatasheet

Document overview

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Technical content

Features

• RoHS lead-free-solder and lead-solder-exempted products available
• Wide input voltage ranges up to 150 VDC
• 1, 2, 3 or 4 isolated outputs up to 96 V
• Class I equipment
• Compliant with EN 50155, EN 50121-3-2, EN 45545
• Very high efficiency up to 90%
• Extremely low inrush current, hot-swappable
• Excellent surge and transient protection
• Many output configurations available with flexible load distribution
• Externally adjustable output voltage
• Inhibit primary referenced
• Redundant operation (n+1), sense lines, current sharing option
• Extremly slim case (4 TE, 20 mm), fully enclosed
• Hipot test voltage up to 2.8 kVDC
• All PCBs coated with protective lacquer
• Telecom-compatible input voltage range of DP models according to ETS 300132-2
• CompactPCI-compatible output voltage (xP4720) Safety-approved to IEC/EN 60950-1 and UL/CSA 60950-1 2 nd Ed. Table of Contents Page Page

BCD20010-G Rev AG, 05-May-2014 Page 2 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. LEDs at the front panel and an isolated Out-OK signal (option) indicate the status of the converter. Voltage sup- pressor diodes and an independent second control loop protect the outputs against an internally generated over- voltage. The converters are designed using planar magnetics transformers and control circuits in hybrid technology. There are always two powertrains fitted to a converter, each consisting either of a regulated single output with syn- chronous rectifier or of a regulated main output with a tracking second output. The output power may be flexibly distributed among the main and the tracking output of each powertrain. Close magnetic coupling in the transformers and output conductors together with circuit symmetry ensure tight tracking of the auxiliary output. The switching frequency is fixed. As a modular power supply or as part of a distributed power supply system, the low-profile design significantly reduces the required volume without sacrificing high reliability. The converters are particularly suitable for 19" rack systems occupying 3U/4TE only, but they can also be chassis- mounted by means of four screws. Connector type is H15 (or H15S2 for some single-output models). The fully enclosed black-coated aluminium case acts as heat sink and RFI shield and protects the converter together with the coating of all components against environmental impacts. Model Selection Note: Only standard models are listed. Other voltage con- figurations are possible as well; please contact Power-One ! Table 1a: Model types BP, CP Output 1, 4 Output 2, 3 Input voltage range and efficiency Options Vo nom Po nom Po max Vo nom Po nom Po max ηηηηη 2 Vi min – Vi max4 ηηηηη 2 Vi min – Vi max4 3.3 92 132 - - - 84 8 BP1101-9R 84 8 CP1101-9R -7 5.1 122 183 - - - 87 8 BP1001-9R 88 8 CP1001-9R D, T 5, K 8 12 120 192 - - - 87.5 BP1301-9R 88.5 CP1301-9R B0, B1, B3 15 120 194 - - - 87.5 BP1501-9R 88.5 CP1501-9R G 24 120 192 - - - 88 BP1601-9R 89 CP1601-9R 3.3 46 66 5.1 60 91 86 BP2101-9R 86 CP2101-9R -7 5.1 60 91 5.1 60 91 87 BP2001-9R 88 CP2001-9R D, T 6 5.1 60 91 12 60 96 87 BP2020 -9R 88 CP2020-9R B0, B1, B3 12 60 96 12 60 96 87.5 BP2320-9R 88.5 CP2320-9R G 15 60 96 15 60 96 87.5 BP2540-9R 88.5 CP2540-9R 24 60 96 24 60 96 88 BP2660 -9R 89 CP2660-9R 5.1 60 91 12, 12 3 601 961 87 BP3020 -9R 88 CP3020-9R 5.1 60 91 15, 15 3 601 961 87.5 BP3040-9R 88.5 CP3040-9R 5.1 60 91 24, 24 3 601 961 87.5 BP3060-9R 88.5 CP3060-9R 24 60 96 5.1, 5.1 3 511 821 - - 87 CP3601-9R 5.1, 3.37 30 50 12, 12 3 601 961 85 BP4720-9R 9 - CP4720-9R 9 -7 12, 123 601 961 12, 123 601 961 87.5 BP4320-9R 88.5 CP4320-9R D 15, 153 601 961 15, 153 601 961 87.5 BP4540-9R 88.5 CP4540-9R B0, B1, B3 24, 243 601 961 24, 243 601 961 88 BP4660-9R 89 CP4660-9R G 1 The power of both outputs shall in sum not exceed the total power for the specified ambient temperature. 2 Min efficiency at Vi nom, Po nom, TA = 25 °C. Typical values are approx. 2% better. 3 Isolated tracking output (±5% Vo nom, if each output is loaded with ≥ 5% of Po nom). Parallel or series configuration is possible.

4 Short deviations below Vi min and beyond Vi max according to EN 50155 possible

5 Only available for models with 5.1 or 3.3 V output. 8 Option K only for xP1101 and xP1001: H15 standard connector. Models without option K exhibit a better efficiency: xP1101 is app rox 2% better, xP1001 approx 1% better than the models with option K. 9 Compatible to CompactPCI ® specification; for detailed specification contact Power-One. NFND: Not for new designs Preferred for new designs

BCD20010-G Rev AG, 05-May-2014 Page 3 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. Table 1b: Model types DP, EP Output 1, 4 Output 2, 3 Input voltage range and efficiency 2 Options Vo nom Po nom Po max Vo nom Po nom Po max ηηηηη 2 Vi min – Vi max4 ηηηηη 2 Vi min – Vi max4 3.3 92 132 - - - 84 8 DP1101-9R 83.5 8 EP1101-9R -7 5.1 122 183 - - - 88 8 DP1001-9R 87.5 8 EP1001-9R D, T 5, K 8 12 120 192 - - - 88 DP1301-9R 87.5 EP1301-9R B0, B1, B3 15 120 194 - - - 88 DP1501-9R 87 EP1501-9R G 24 120 192 - - - 88.5 DP1601-9R 87.5 EP1601-9R 3.3 46 66 5.1 60 91 86 DP2101-9R 86 EP2101-9R -7 5.1 60 91 5.1 60 91 88 DP2001-9R 87.5 EP2001-9R D, T 5.1 60 91 12 60 96 88 DP2020-9R 87.5 EP2020-9R B0, B1, B3 12 60 96 12 60 96 88 DP2320-9R 87.5 EP2320-9R G 15 60 96 15 60 96 88 DP2540-9R 87 EP2540-9R 24 60 96 24 60 96 88.5 DP2660-9R 87.5 EP2660-9R 5.1 60 91 12, 12 3 601 961 87.5 DP3020-9R 87.5 EP3020-9R 5.1 60 91 15, 15 3 601 961 88 DP3040-9R 88 EP3040-9R 5.1 60 91 24, 24 3 601 961 88 DP3060-9R 88 EP3060-9R 5.1, 3.37 30 50 12, 12 3 601 961 85 DP4720-9R 9 - EP4720-9R 9 -7 12, 123 601 961 12, 123 601 961 88 DP4320-9R 87.5 EP4320-9R D 15, 153 601 961 15, 153 601 961 87.5 DP4540-9R 87 EP4540-9R B0, B1, B3 24, 243 601 961 24, 243 601 961 88.5 DP4660-9R 87.5 EP4660-9R G Table 1c: Model types GP Output 1, 4 Output 2, 3 Input voltage range and efficiency 2 Options Vo nom Po nom Po max Vo nom Po nom Po max ηηηηη 2 Vi min – Vi max4 3.3 92 132 - - - 84 8 GP1101-9R -7 5.1 122 183 - - - 88 8 GP1001-9R D, T 5, K 8 12 120 192 - - - 88 GP1301-9R B0, B1, B3 15 120 194 - - - 88.5 GP1501-9R G 24 120 192 - - - 88 GP1601-9R 3.3 46 66 5.1 60 91 86 GP2101-9R -7 5.1 60 91 5.1 60 91 88 GP2001-9R D, T 6 5.1 60 91 12 60 91 87.5 GP2020-9R B0, B1, B3 12 60 96 12 60 96 88 GP2320-9R G 15 60 96 15 60 96 88.5 GP2540-9R 24 60 96 24 60 96 88 GP2660-9R 5.1 60 91 12, 12 3 601 961 87.5 GP3020-9R 5.1 60 91 15, 15 3 601 961 88.5 GP3040-9R 5.1 60 91 24, 24 3 601 961 88.5 GP3060-9R 5.1, 3.37 30 50 12, 12 3 601 961 - GP4720-9R 9 -7 12, 123 601 961 12, 123 601 961 88 GP4320-9R D 15, 153 601 961 15, 153 601 961 88.5 GP4540-9R B0, B1, B3 24, 243 601 961 24, 243 601 961 88 GP4660-9R G 1 The power of both outputs may in sum not exceed the total power for the specified ambient temperature. 2 Min efficiency at Vi nom, Po nom, TA = 25 °C. Typical values are approx. 2% better. 3 Isolated tracking output (±5% Vo nom, if each output is loaded with ≥ 5% of Po nom). Parallel or series configuration possible 5 Only available for models with 5.1 or 3.3 V output 8 H15 standard connector for xP1101 and xP1001 models; without option K, the η value for xP1101 is approx 2% better and for xP1001 approx 1% better than for models with option K. 9 Compatible to CompactPCI ® specification; for detailed specification contact Power-One. NFND: Not for new designs Preferred for new designs

BCD20010-G Rev AG, 05-May-2014 Page 4 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. Part Number Description C P 2 5 40 -9 D T B1 G Input voltage Vi nom: Number of outputs: Single output (160 mm case) Nominal voltage output 1/output 4, Vo1/4 nom: other voltages Nominal voltage output 2 / output 3, Vo2/3 nom: other voltages and features Operational ambient temperature range TA: other 1 Customer-specific models. 2 Only available for 3.3 V and 5 V outputs. Option T excludes option R, except for single-output models; refer to table 1. 3 For single-output models with 3.3 V or 5 V output 4 Models with 220 mm case length. Just add 5000 to the standard model number. 5 G is always placed at the end of the part number; preferred for new designs. Note: The sequence of options must follow the order above. Example: CP2540-9DTB1G: DC-DC converter, input voltage 33.6 to 75 V, 2 regulated outputs each providing 15 V, equip- ped with option T for output 1, heatsink, ambient temperature of –40 to 71 °C, RoHS. Note: All models exhibit the following auxiliary functions, which are not shown in the type designation: input and output filters, primary referenced inhibit, sense lines (single-, double- and triple-output models only) and LED indicators. Product Marking Basic type designation, safety approval and recognition marks, CE mark, warnings, pin allocation, Power-One patents, company logo, specific type designation, input voltage range, nominal output voltages and output currents, degree of protection, batch no., serial no. and data code including production site, modification status and date of production. Identification of LEDs.

BCD20010-G Rev AG, 05-May-2014 Page 5 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. Output Configuration The P Series allows high flexibility in output configuration to cover almost every individual requirement, by simply wiring outputs in parallel, in series, or in independent config- uration, as shown in the following diagrams. Parallel or serial operation of several converters with equal output voltage is possible, however it is not advantageous to Fig. 3 Independent double-output configuration. Both outputs are fully regulated Fig. 2 Series output configuration of a double-output model. The second output is fully regulated. Fig. 4 Independent triple-output configuration. Output 3 is tracking Fig. 1 Standard configuration (single-output model) Load 1 Load 2 Vo2+ Vo4+ Vo2– Vo4– Vo1– Vo1+ Quadruple- output model Vi– Vi+ i28 01011-P Load 3 Vo3+ Vo3– Load 4 Fig. 5 Common ground configuration of output 1 with 4 and independent configuration of output 2 and 3 Fig. 6 Series configuration of all outputs (V o = 96 V for xP4660). The R1-input influences only outputs 1 and 4. For the values of R1 and R2 see Output Voltage Adjust. Load Vo– Vo+ Single-output model Vi– Vi+ i 01006-P 8Vo– Vo+ R 16 OK+ OK– connect converters in parallel without measures to provide reasonable current sharing. Choose suitable single-output models, if available. Note: Unused tracking outputs should be connected parallel to the respective regulated outputs. S1– S1+ Vo1– Vo1+ Vo2– Vo2+ Double-output model Vi– Vi+ i Load 01007-P S2+ S2– Load 1 Vo2+ Vo1– Vo2– S1– S1+ Vo1+ Triple-output model Vi– Vi+ i28 01010-P Load 2 Vo3+ Vo3– Load 3 Load 1 Vo2+ Vo1– S2+ S1– S1+ Vo1+ Double-output model Vi– Vi+ i28 01013b-P S2– Vo2– Load 2 Load Vo4– Vo4+ Vo1+ Vo2– Vo2+ Vo3+Quadruple- output model Vi– Vi+ i28 01012-P Vo1– Vo3–

BCD20010-G Rev AG, 05-May-2014 Page 6 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. Functional Description The power supplies are equipped with two independent flight-forward converters, switching 180° phase-shifted to minimize the ripple current at the input. They use primary and secondary control circuits in hybrid technology. The two converters, called "powertrains" (PT), each generate either a single output with synchronous rectifier or two isolated outputs, one fully regulated and the other one tracking (semi- regulated), thus providing up to four output voltages. In some models, both outputs of a powertrain are internally con- nected in parallel . The highly efficient input filter together with very low input capacitance results in very low and short inrush current. After transformer isolation and rectification the output filter reduces ripple and noise to a minimum without affecting the dynamic response. Outputs 3 and 4, if available, are tracking (semi- regulated) and rely upon the close magnetic coupling of the transformer and the output inductor together with the circuit symmetry for their voltage regulation. A current limitation circuit is located on the primary side of each powertrain, limiting the total output current of that powertrain in overload conditions. This allows flexible power operation of the outputs from each powertrain. All outputs can either be connected in series or in parallel; see Electrical Output Data . An auxiliary converter provides the bias voltages for the primary and secondary referenced control logic and the option circuits. An oscillator generates a clock pulse of 307 ±1% kHz, which is fed to the control logic of each powertrain. The pulsewidth modulation and the magnetic feedback are provided by special ASICs. The converter is only enabled, if the input voltage is within the operating voltage range. Double-output powertrains are equipped with an indepen- dent monitor sensing the output voltage of the tracking output. It influences the contol logic in order to reduce via the pulse width the voltages of both outputs. In addition, the tracking ouputs are protected by a suppressor diode. Outputs of single-output powertrains are also protected by a suppressor diode. The temperature of the heat sink is monitored and causes the converter to disable the outputs, until the temperature drops; then the converter automatically resumes. Fig. 7 Block diagram. Powertrains PT1 and PT2 have isolated outputs. Pin allocation see table 12 03107d PT1 PT2Auxiliary converter Clock generator PT1 PT2 Primary options Secondary options PWM controller, duty cycle limiter, non linear FF, ON/OFF control of sync. rectifier D, i, T Vi+ Vo1 Vo4 Vo2 Vo3 CY R Error amplifier, Vo monitor Output filter PT1 CY Output filter PT2 CY 2 x in double-output power trains Input filter Vi – Fuse

BCD20010-G Rev AG, 05-May-2014 Page 7 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. Electrical Input Data General Conditions: – T A = 25°C, unless TC is specified – Sense lines connected directly at the connector, inhibit (28) connected to Vi– (32) – R input open Table 2a: Input data Input BP GP CP Unit Characteristics Conditions min typ max min typ max min typ max V i Operating input voltage Io = 0 – Io max 16 36 21.6 50.4 33.6 75 V TC min – TC max Vi nom Nominal input voltage 24 36 48 Vi 100ms for ≤100 ms without lockout 14.4 40 20 52 28.8 81 Vi abs for ≤ 3 s without damage 0 50 0 63 0 100 Ii Typical input current 1 Vi nom, Io nom 5.6 3.7 2.8 A Pi 0 No-load input power 1 Vi min – Vi max 4 6.5 4 6.5 5 10 W Pi inh Idle input power 1 4 Io = 0 1 1.5 1 1.5 1 1.5 C i Input capacitance 220 220 107 µF Iinr p Peak inrush current 2 Vi max, Io max 61 64 66 A tinr rise Rise time inrush 50 32 30 µs t r Rise time inhibit 3 Io max – Vi nom 55 5 m s tf Fall time inhibit 3 55 5 td on Start-up time 3 0 → Vi min, Io max 110 150 300 Table 2b: Input data Input DP 2 EP Unit Characteristics Conditions min typ max min typ max Vi Operating input voltage Io = 0 – Io max 402 100.8 66 150 V TC min – TC max Vi nom Nominal input voltage 72 110 Vi 100ms for ≤ 100 ms without lockout 36 115 55 176 Vi abs for ≤ 3 s without damage 0 125 0 200 Ii Typical input current 1 Vi nom, Io nom 1.9 1.2 A Pi 0 No-load input power 1 Vi min – Vi max 5 11 5 12 W Pi inh Idle input power 1 4 Io = 0 1 1.7 1.1 1.7 C i Input Capacitance 15 15 µF Iinr p Peak inrush current 2 Vi max, Io max 57 65 A tinr rise Rise time inrush 20 20 µs tr Rise time inhibit 3 Io max, Vi nom 55 m s tf Fall time inhibit 3 56 td on Start-up time 3 0 → Vi min, Io max 200 200

1 Typical values depending on model

2 According to ETS 300132-2

3 See fig. 18

4 Converter inhibited

BCD20010-G Rev AG, 05-May-2014 Page 8 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. Vi+ Vi– Vo+ Vo– Lext Rext Ci Ri JM001 Cext Load Converter Input Fuse and Reverse Polarity A fuse mounted inside the converter protects against further damage in case of a failure. The fuse is not user-accessible. Reverse polarity at the input will cause the fuse to blow. Table 3: Fuse specification Model Fuse type Rating Reference BP very fast blow 2 × 10 A, 125 V Littelfuse Pico 251 GP very fast blow 2 × 10 A, 125 V Littelfuse Pico 251 CP very fast blow 10 A, 125 V Littelfuse Pico 251 DP very fast blow 7 A, 125 V Littelfuse Pico 251 EP very fast blow 5 A, 250 V Littelfuse Pico 263 Input Transient Protection A VDR (Voltage Dependent Resistor), the input fuse, and a symmetrical input filter form an effective protection against input transients, which typically occur in most installations, but especially in battery-driven mobile applications. Nominal battery voltages in use are: 24, 36, 48, 60, 72, 96, and 110 V. In most cases each nominal value is specified in a tolerance of –30% to +25%, with short excursions to ±40% or even more. In some applications, surges according to RIA 12 are specified in addition to those defined in IEC 60571-1 or EN 50155. The power supply must not switch off during these surges, and since their energy can practically not be absorbed, an extremely wide input range is required. The P Series input range has been designed and tested to meet these requirements; see Electromagnetic Immunity. Input Under-/Overvoltage Lockout If the input voltage is below approx. 0.9 Vi min or exceeds approx. 1.1 Vi max , an internally generated inhibit signal disables the output(s). However, short extentions specified in EN 50155 will be withstood without shutdown. Inrush Current The inherent inrush current value is lower than specified in the standard ETS 300132-2 (ver. 3.1). The units operate with relatively small input capacitance resulting in low inrush current of short duration. As a result in a power-bus system the units can be hot plugged-in or disconnected causing negligible disturbance at the input side. Input Stability with Long Supply Lines If a P Series converter is connected to the power source with long input lines exhibiting a considerable inductance, an additional external capacitor connected in parallel to the input improves the stability and avoids oscillations. Actually, a P Series converter with nominal load acts like a negative resistor, as the input current rises when the input voltage decreases. It tends to oscillate with a resonant frequency determined by the line inductance L ext and the input capacitance Ci + Cext and damped by the resistors Ri + Fig. 8 Input configuration Table 4: Recommended values for C ext Model Capacitance Voltage BP 1500 µF 40 V GP 1000 µF 63 V CP 470 µF 100 V DP 220 µF 125 V EP 100 µF 200 V Rext. The whole system is not linear at all and eludes a simple calculation. One basic condition is given by the formula: R ext << — Vin²—Po

• η Rext is the series resistor of the source voltage including input lines. If this condition is not fulfilled, the converter cannot reach stable operating conditions. Worst case conditions are a low input voltage V i and a high output power Po. Low inductance Lext of the input lines and a parallel connected input capacitor Cext are helpful. Recommended values for Cext are given in table 4, which should allow stable operation up to an input inductance of 2 mH. Ci is specified in table 2.

BCD20010-G Rev AG, 05-May-2014 Page 9 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. Electrical Output Data General Conditions: – T A = 25°C, unless TC is specified. – Sense lines connected directly at the connector, inhibit (28) connected to Vi– (32). – R input not connected Table 5a: Output data for single-output powertrains Output Single-output powertrain 3.3 V 5.1 V 12 V Unit Characteristics Conditions min typ max min typ max min typ max voltage TC min – TC max (0.02 – 1) Io max Io nom Nominal output current 14 12 5 A Io max Max. output current Vi min – Vi max 20 18 8 vo Output Switch. frequ. Vi nom, Io max 55 1 5 m V pp noise 4 Total incl. spikes BW = 20 MHz 20 20 30 vo d Dynamic Voltage Vi nom 0.7 0.8 1.2 V load deviation Io max ↔ 1/2 Io max td 5 regulation Recovery time 0.4 0.3 0.15 ms range (via R input) (0.1 – 1) Io max αVo Temp. coefficient of Vo Io nom, TC min – TC max ±0.02 ±0.02 ±0.02 %/K Table 5b: Output data for single-output powertrains. General conditions as in table 5a Output Single-output powertrain 15 V 24 V Unit Characteristics Conditions min typ max min typ max Vo Output voltage 1 Vi nom, Io nom 14.93 15 15.08 23.88 24 24.12 V Vow Worstcase output Vi min – Vi max 14.78 15.23 23.64 24.36 voltage TC min – TC max (0.02 – 1) Io max Vo P Overvoltage protection 2 17.1 18 18.9 28.5 30 31.5 Io nom Nominal output current 4 2.5 A Io max Max. output current Vi min – Vi max 6.5 4 vo Output Switch. frequ. Vi nom, Io max 15 15 mV pp noise 4 Total incl. spikes BW = 20 MHz 40 50 vo d Dynamic Voltage Vi nom 1.2 0.5 V load deviation Io max ↔ 1/2 Io max td 5 regulation Recovery time 0.2 0.15 ms Vo tr Output voltage trim 1.1 Vi min – Vi max 8.1 16.5 13 26.4 V range (via R input) (0.1 – 1) Io max αVo Temp. coefficient of Vo Io nom, TC min – TC max ±0.02 ±0.02 %/K 1 If the output voltages are increased above Vo nom through R-input control or remote sensing, the output power should be reduced accordingly, so that Po max and TC max are not exceeded. 2 Breakdown voltage of the incorporated suppressor diode at 10 mA (3.3 V, 5.1 V) or 1 mA ( ≥12 V). Value for 3.3 V for version ≥112. Exceeding this value might damage the suppressor diode.

3 See Output Power at Reduced Temperature

4 Measured according to IEC/EN 61204 with a probe described in annex A

5 Recovery time until Vo returns to ±1% of Vo; see Dynamic Load Regulation

BCD20010-G Rev AG, 05-May-2014 Page 10 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. Table 5d: Output data for double-output powertrains. General conditions as in table 5a Output Double-output powertrain 15 V 24 V Unit Main output Tracking output Main output Tracking output Characteristics Conditions min typ max min typ max min typ max min typ max Vow Worstcase output Vi min – Vi max 14.78 15.23 See Output 23.64 24.36 See Output voltage TC min – TC max Voltage Regulation Voltage Regulation (0.02 – 1) Io max Vo P Overvoltage protection 2 none 17.1 18 18.9 none 28.5 30 31.5 Vo L Overvoltage limitation6 none 17.6 none 28.8 Io nom Nominal output current 2 2 1.25 1.25 A Io max Max. output current Vi min – Vi max 3.25 3.25 2 2 vo Output Switch. frequ. Vi nom, Io max 15 15 15 15 mV pp noise 4 Total incl. spikes BW = 20 MHz 40 40 50 50 vo d Dynamic Voltage Vi nom 1.2 1.2 0.5 0.5 V load deviation Io max ↔ 1/2 Io max td 5 regulation Recovery time 0.2 0.2 0.15 0.15 ms Vo tr Output voltage trim 1.1 Vi min – Vi max 8.1 16.5 See Output 13 26.4 See Output V range (via R input) (0.1 – 1) Io max Voltage Regulation Voltage Regulation αVo Temp. coefficient of Vo Io nom ±0.02 ±0.02 %/K TC min – TC max 1 If the output voltages are increased above Vo nom through R-input control or remote sensing, the output power should be reduced accordingly, so that Po max and TC max are not exceeded. 2 Breakdown voltage of the incorporated suppressor diode at 1 mA. Exceeding this voltage might damage the suppressor diode.

6 Output voltage limitation by an additional control loop

Table 5c: Output data for double-output powertrains. General conditions as in table 5a Output Double-output powertrain 5.1 V 12 V Unit Main output Tracking output Main output Tracking output Characteristics Conditions min typ max min typ max min typ max min typ max Vow Worstcase output Vi min – Vi max 4.95 5.25 See Output 11.82 12.18 See Output voltage TC min – TC max Voltage Regulation Voltage Regulation (0.02 – 1) Io max Vo P Overvoltage protection 2 none 6.45 6.8 none 14.3 15 15.8 Vo L Overvoltage limitation6 none 6.5 none 14.4 Io nom Nominal output current 5.0 5.0 2.5 2.5 A Io max Max. output current Vi min – Vi max 8.0 8.0 4 4 vo Output Switch. frequ. Vi nom, Io max 5 5 15 15 mV pp noise 4 Total incl. spikes BW = 20 MHz 20 20 30 30 vo d Dynamic Voltage Vi nom 0.8 0.8 1.2 1.2 V load deviation Io max ↔ 1/2 Io max td 5 regulation Recovery time 0.3 0.3 0.15 0.15 ms range (via R input) (0.1 – 1) Io max Voltage Regulation Voltage Regulation αVo Temp. coefficient of Vo Io nom ±0.02 ±0.02 % /K TC min – TC max

BCD20010-G Rev AG, 05-May-2014 Page 11 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. Parallel and Series Connection The first outputs of power trains with equal nominal output voltage can be connected in parallel. Where available, we recommend ordering option T. Any output can be connected in series with any other output. If the main and the tracking output of the same power train are connected in series, consider that the effect of the R-input is doubled. Notes :

• If a tracking output is not used, connect it in parallel to the respective regulated main output.
• Connection of several outputs in parallel should include measures to approximate all output currents. 3.3 and 5 V outputs with option T have current-share pins (T or T1), which must be interconnected. For other outputs, the load lines should exhibit similar resistance. Parallel connection of regulated outputs without such precautions is not recommended.
• The maximum output current of series-connected outputs is limited by the output with the lowest current limit. Fig. 9 Series connection of double-output models. Sense lines connected at the connector. Load Vo1+ Vo2– Vo1– S1– S1+ Vo2+ Vi– Vi+ i Out OK – Out OK+ Vi– Vi+ i Out OK – Out OK+ i+– Vo1+ Vo2– Vo1– S1– S1+ Vo2+ Rp JM033 Double-output model S2+ S2– S2+ S2– Double-output model 428
• Rated output voltages above 48 V (SELV = Safety Extra Low Voltage) require additional safety measures in order to comply with international safety standards. Parallel operation of two double-output converters with series-connected outputs is shown in fig. 10. The link between the T1 pins ensures proper current sharing, even though only the first outputs are influenced by T1. Sense lines are connected directly at the connector, and load lines have equal length and section. Redundant Systems An example of a redundant system using converters with 2 regulated ouputs (xP2020) is shown in fig. 11. Load 1 is powered with 5.1 V and load 2 with 12 V. The converters are separated with ORing diodes. If one converter fails, the remaining one still delivers the power to the loads. If more power is needed, the system may be extended to more parallel converters (n+1 redundancy). Current sharing of the 5.1 V outputs is ensured by the interconnected T1 pins, whereas the sense lines are Fig. 10 Parallel operation of 2 double-output converters with series-connected outputs. Vo1+ Vo2– Vo1– Vo2+ Double-output model Vi– Vi+ i Out OK – Out OK+ Vi– Vi+ i Out OK – Out OK+ i+– Vo1+ Vo2– Vo1– S1– S1+ Rp 06158b Vo2+ S2– S2+ S2– S2+ S1– S1+ Double-output model Load

BCD20010-G Rev AG, 05-May-2014 Page 12 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. Hot Swap Important: For applications using the hot swap capabilities, dynamic output voltage changes during plug-in and plug-out operations may occur. Hold-up time The converters provide virtually no hold-up time. If a hold-up time is required, use external output capacitors or input capacitors of adequate size and decoupling diodes. Formula for additional external input capacitor: 2 • P whereas: Ci ext [mF] = external input capacitance Po = output power [W] η = efficiency [%] th = hold-up time [ms] Vi min [V] = minimum input voltage Vti = threshold level [V] Output Voltage Regulation Line and load regulation of the regulated outputs is so good that input voltage and output current have virtually no influence to the output voltage. However, if the tracking output is not loaded, the second control loop may slightly reduce the voltage of the main output. Thus, unused tracking outputs should be connected in parallel to the respective main output. The dynamic load regulation is shown in fig. 12. Tracking Outputs The main outputs 1 and 2 are regulated to Vo nom independent of the output current. If the loads on outputs 3 and 4 are too low (<10% of I o nom), their output voltage tends to rise. Vo3 and Vo4 depend upon the load distribution: If all outputs are loaded with at least 10% of Io nom, Vo3 and Vo4 remain within ±5% of Vo nom. The diagrams fig. 13 to 16 show the regulation of the tracking output under different load conditions up to the current limit. If I o1 = Io4 and Io2 = Io3 or if the tracking outputs are connected in series with their respective regulated outputs, then V o3 and Vo4 remain within ±1% of Vo nom provided that the load is at least Io min. A 2nd control loop protects the tracking outputs against overvoltage by reducing the voltage of the respective regulated main output. Because the P Series converters exhibit main transformers and main chokes in planar technology, the tracking outputs follow the main outputs very closely. Note: If the tracking output ( Vo3 or Vo4 is not loaded, it should be connected in parallel to the respective main output ( Vo3 parallel to Vo2, Vo4 parallel to Vo1). connected after the ORing diodes to maintain the correct output voltage. For the 12 V outputs, no current-share feature (option T) is available. As a result, 2 little diodes D s (loaded by little resistors Rs) simulate the voltage drop of the ORing diodes. Reasonable current sharing is provided by load lines of equal length and section. Fig. 11 Redundant configuration Vo1+ Vo2– Vo1– Vo2+ Double-output model Vi– Vi+ i Out OK– Out OK+ Vi– Vi+ i Out OK– Out OK+ i+– Vo1+ Vo2– Vo1– S1– S1+ Rp Vo2+ S2– S2+ S2– S2+ S1– S1+ Double-output model Load 2 06157b Load 1 DS RS DS RS Wires of equal length and sectinon Fig. 12 Typical dynamic load regulation of output voltage Vod Vod td td Vo ±1% Vo ±1% t t ≥ 10 µs ≥ 10 µs Vo 0.5 Io/Io nom 05102c

BCD20010-G Rev AG, 05-May-2014 Page 13 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. Output Current Limitation All outputs are continously protected against open-circuit (no load) and short-circuit by an electronic current limitation. Single- and double-output powertrains have a rectangular current limitation characteristic. In double output power- trains only the total current is limited allowing free choice of load distribution between the two outputs of each power train up to a total I o1 + Io4 = Io max or Io2 + Io3 = Io max. Thermal Considerations and Protection If a converter is mounted upright in free air, allowing unrestricted convection cooling, and is operated at its nominal input voltage and output power at T A max (see table Temperature specifications ), the temperature measured at the measurement point on the case TC (see Mechanical Data) will approach TC max after an initial warm-up phase. However the relationship between TA and TC depends heavily on the operating conditions and system integration. The thermal conditions are influenced significantly by the input voltage, the output current, airflow, and the temperature of the adjacent elements and surfaces. T A max is therefore contrary to TC max only an indicative value. A temperature sensor fitted on the main PCB disables the output, when the case temperature exceeds TC max. The converter automatically resumes, when the temperature drops below this limit. An additional temperature sensor on each power train reduces the output current limit of that power train, when the temperature exceeds a safe level. Output Power at Reduced Temperature Operating the converters with an output current between Io nom and Io max requires a reduction in maximum ambient temperature or forced air cooling in order to keep TC below 95 °C. When TC max is exceeded, the thermal protection is activated and disables the outputs. Note: Forced cooling or an additional heat sink can improve the reliability or allow TA to go beyond TA max, provided that TC max is not exceeded. In rack systems without proper thermal management the converters should not be packed too closely together! In such cases the use of a 5 or 6 TE front panel is recommended. Fig. 17 Output power derating versus T A. TA min 50 60 70 80 90 °C Po TA forced coolingconvection cooling TC max 05117aPo max Po nom Fig. 16

24 V tracking output Vo = f(Io), Vi = Vi nom

Fig. 15

15 V tracking output Vo = f(Io), Vi = Vi nom

Fig. 13

5 V tracking output V o4 versus Io4 (powertrain 1) or

Vo3 versus Io3 (powertrain 2). Vi = Vi nom Fig. 14

12 V tracking output V o4 versus Io4 (powertrain 1) or

Vo3 versus Io3 (powertrain 2). V i = Vi nom 4 8 12 16 A0 JM077a 6.0 V 5.0 V Io3 or Io4 Vo3 or Vo4 4.5 V 5.5 V Io1 or Io2 = 12.8 A Io1 or Io2 = 6.4 A Io1 or Io2 = 3.2 A Io1 or Io2 = 1.6 A Io1 or Io2 = 0.4 A 1 2 3 4 A0 05178c 26 V 24 V Io3 or Io4 Vo3 or Vo4 23 V 25 V Io1 or Io2 = 4 A Io1 or Io2 = 3 A Io1 or Io2 = 2 A Io1 or Io2 = 1 A Io1 or Io2 = 0.2 A 1 230 05179c 15 V Io3 or Io4 Vo3 or Vo4 14 V 16 V

6 A54

17 V Io1 or Io2 = 6.5 A Io1 or Io2 = 4.8 A Io1 or Io2 = 3.2 A Io1 or Io2 = 1.6 A Io1 or Io2 = 0.4 A 2 4 6 8 A0 Io1 or Io2 = 8 A Io1 or Io2 = 6 A Io1 or Io2 = 4 A Io1 or Io2 = 2 A 05180c 14 V 12 V Io3 or Io4 Vo3 or Vo4 11 V 13 V Io1 or Io2 = 8 A Io1 or Io2 = 6 A Io1 or Io2 = 4 A Io1 or Io2 = 2 A Io1 or Io2 = 0.4 A

BCD20010-G Rev AG, 05-May-2014 Page 14 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. Auxiliary Functions Primary Inhibit (Remote On / Off) The inhibit input enables (logic low, pull down) or disables (logic high, pull up or open-circuit) the output, if a logic signal (TTL, CMOS) is applied. 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. Note: If this function is not used, pin 28 must be connected with pin 32, otherwise the internal logic will disable the output. Fig. 18 Output response as a function of V i (on/off switching) or inhibit control The output response after enabling or disabling the output by the inhibit input is shown in the figure below. See also Input Data. Table 6: Inhibit characteristics Characteristic Conditions min typ max Unit Vinh Inhibit Vo = on Vi min – Vi max –50 0.8 V Voltage Vo = off TC min – TC max 2.4 50 I inh Inhibit current Vinh = –50 V –1000 µA Vinh = 0 V –40 Vinh = 50 V 900 Output Voltage Adjust of Vo1 and Vo4 Note: With open R-input, Vo = Vo nom. The converters offer adjust of the voltage of powertrain 1. Powertrain 2 can not be adjusted (except for single-output models). The programming is performed either by an external control voltage V ext or an external resistor R1 or R2, connected to the R-input. Trimming is limited to the values given in the table Electrical Output Data . With double-output powertrains, both outputs are influenced by the R-input setting simultaneously. Fig. 19 Output adjust of V o1 and Vo4 with an external voltage Vext. The other outputs are not influenced. Fig. 20 Output adjust of Vo1 and Vo4 using R1 or R2. The other outputs are not influenced. Caution: To prevent damage, Vext should not exceed 20 V, nor be negative. Note: If output voltages are set higher than Vo nom , the output currents should be reduced accordingly, so that the maximum specified output power is not exceeded. a) Adjustment by means of an external voltage: Note: The secondary referenced inhibit function, refers to the description of option i. tr Vi t t t0.8 Vi min Vinh [V] 2.4 0.1 Vo/Vo nom tf td on 0.99 1.01 06159a b) Adjustment by means of an external resistor: The adjust resistor R1 is connected between pin 16 and S– (14) to set Vo < V o nom, or the adjust resistor R2 is connected between pin 16 and S+ (12) to set Vo > Vo nom. Note: R inputs of n converters with paralleled outputs may be connected together, but if only one external resistor is used, its value should be R 1/n or R2/n. Load 1 Load 4 Vo4+ Vo1– Vo4– Vo1+ Double- output powertrain Vi– Vi+ i +Vext– JM034a 2nd powertrain Load 1 Load 4 Vo4+ Vo1– Vo4– Vo1+ Double- output powertrain Vi– Vi+ i JM035a 2nd powertrain

BCD20010-G Rev AG, 05-May-2014 Page 15 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. Table 7a: R1 for Vo < Vo nom; approximate values (Vi nom, Io nom, series E 96 resistors); R2 not fitted Vo nom = 3.3 V Vo nom = 5.1 V Vo nom = 12 V Vo nom = 15 V Vo nom = 24 V Vo (V) R1 [k ΩΩΩΩΩ] Vo (V) R1 [k ΩΩΩΩΩ] Vo [V] 1 R1 [k ΩΩΩΩΩ] Vo [V] 1 R1 [k ΩΩΩΩΩ] Vo [V] 1 R1 [k ΩΩΩΩΩ] 14.5 29 110.0 23.5 47 182.0 Table 7b: R2 for Vo > Vo nom ; approximate values (Vi nom, Io nom, series E 96 resistors); R1 not fitted Vo nom = 3.3 V Vo nom = 5.1 V Vo nom = 12 V Vo nom = 15 V Vo nom = 24 V Vo (V) R1 [kΩΩΩΩΩ] Vo (V) R1 [k ΩΩΩΩΩ] Vo [V] 1 R1 [k ΩΩΩΩΩ] Vo [V] 1 R1 [k ΩΩΩΩΩ] Vo [V] 1 R1 [k ΩΩΩΩΩ] 13.2 26.4 174 16.5 33.0 232 1 First column: single-output powertrains or double-output powertrains with separated/paralleled outputs, second column: outputs in series connection. Sense Lines Important: Sense lines should always be connected. Incorrectly connected sense lines may damage the converter. If sense pins are left open-circuit, the output voltages are not accurate. This feature enables compensation of voltage drop across the connector contacts and the load lines including ORing diodes in true redundant systems. Applying generously dimensioned cross-section load leads avoids troublesome voltage drop. To minimize noise pick-up, wire sense lines parallel or twisted to the respective output line. To be sure, connect the sense lines directly at the female connector. The voltage difference between any sense line and its respective power output pin (as measured on the connector) should not exceed the following values at nominal output voltage. Table 8: Voltage compensation allowed using sense lines Output type Total drop Negative line drop 3.3, 5.1 V output <0.5 V <0.25 V 12, 15, 24 V output <1.0 V <0.5 V LEDs The P Series converters exhibit a green LED "In OK", signaling that the input voltage is within the specified range. A green LED "Out-OK" indicates for each powertrain that the respective power train is working correctly, i.e. that its output control loop is locked. This proves with high probability that the regulated output exhibit the correct voltage; see also Option D. Note: Single-output models exhibit only 1 LED "Out-OK". 2nd Control Loop The 2 nd output voltage of double-output power trains is watched by an independent monitoring circuit. In the case of an overvoltage, the primary control logic of the power train is influenced to reduce the duty cycle, resulting in a lower voltage on both outputs. Such an overvoltage may occur, when the 1 st output is fully charged and the 2 nd output is nearly unloaded – particularly with dynamic load changes.

BCD20010-G Rev AG, 05-May-2014 Page 16 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. high input transient voltages, which typically occur in most installations, but especially in battery-driven mobile applications. The P Series has been successfully tested to the following specifications: Electromagnetic Compatibility (EMC) A metal oxide VDR together with an input fuse and a symmetrical input filter form an effective protection against Electromagnetic Immunity Table 9: Immunity type tests Phenomenon Standard Level Coupling Value Waveform Source Test In Perf. mode 1 applied imped. procedure oper. crit. 2 Supply related RIA 12 B +i/–i 1.5 • Vbatt 0.1/1/0.1 s 0.2 Ω 1 positive yes A surge EN 50155 1.4 • Vbatt 1 Ω surge Direct transients RIA 12 D 4 –i/c, +i/–i ± 1800 Vp 5/50 µs 5 Ω 5 pos. and 5 neg. yes B EN 50155: G5 ±8400 Vp 0.05/0.1 µs 100 Ω impulses Indirect coupled 1995 H –o/c, +o/–o, –o/–i 1800 V p 5/50 µs transients L 8400 V p 0.05/0.1 µs Electrostatic IEC/EN 4 6 contact discharge 8000 V p 1/50 ns 330 Ω 10 positive and yes B discharge 61000-4-2 air discharge 15000 V p 10 negative (to case) discharges Electromagnetic IEC/EN x 7 antenna 20 V/m 80% AM, 1 kHz n.a. 80 – 1000 MHz yes A field 61000-4-3 8 antenna 20 V/m 80% AM, 1 kHz n.a. 800 – 1000 MHz yes A

10 Vm 1400 – 2100 MHz

5 V/m 2100 – 2500 MHz

Electrical fast IEC/EN 3 9 direct coupl. (fig. 9) ±2000 V p9 bursts of 5/50 ns, 50 Ω 60 s positive yes A transient s/burst 61000-4-4 4 +i/c, –i/c,+i/– i ±4000 Vp 5 kHz over 15 ms, 60 s negative yes Bburst period: 300 transients per 3 capacit. (fig. 10), o/c ±2000 V p ms coupling mode yes B Surges IEC/EN 3 3 +i/c, –i/c ±2000 V p3 1.2/50 µs 12 Ω 5 pos. and 5 neg. yes B 61000-4-5 23 +i/–i 1000 V p3 2 Ω surges per coupling mode Conducted IEC/EN 3 10 i, o, signal wires 10 VAC AM 80% 150 Ω 0.15 – 80 MHz yes A disturbances 61000-4-6 (140 dBµV) 1 kHz Power frequency IEC/EN 11 100 A/m 60 s in all 3 axis yes A magnetic field 61000-4-8 1 i = input, o = output, c = case. 2 A = Normal operation, no deviation from specs, B = Temporary deviation from specs possible. 3 Measured with an external input capacitor specified in table 4. Complies with EN 50121-3-2:2006 table 7.3 and EN 50121-4:2006 table 2.3. 4 Corresponds to EN 50155:2001, waveform A, and EN 50121-3-2:2000 table 7.2. 5 Corresponds to EN 50155:2001, waveform B. 6 Exceeds EN 50121-3-2:2006 table 9.3 and EN 50121-4:2006 table 1.4. 7 Corresponds to EN 50121-3-2:2006 table 9.1 and exceeds EN 50121-4:2006 table 1.1. 8 Corresponds to EN 50121-3-2:2006 table 9.2 and EN 50121-4:2006 table 1.2 (compliance with digital mobile phones). 9 Corresponds to EN 50121-3-2:2006 table 7.2 and EN 50121-4:2006 table 2.2. 10 Corresponds to EN 50121-3-2:2006 table 7.1 and EN 50121-4:2006 table 3.1 (radio frequency common mode). 11 Corresponds to EN 50121-4:2006 table 1.3.

BCD20010-G Rev AG, 05-May-2014 Page 17 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. Electromagnetic Emissions All conducted emissions (fig. 20) have been tested according to IEC/EN 55022 (similar to EN 55011, much better values than requested by EN 50121-3-2, table 3.1). The limits in fig. 21 apply to quasipeak values, which are always lower then peak values. Fig. 21b CP 1001-7RB1 Typical disturbance voltage at the input (V i nom, Ii nom, resitive load, quasi peak). Fig. 21a BP 2320-7RD Typical disturbance voltage at the input (V i nom, Ii nom, resitive load, quasi peak). 0.1 0.5 dBµV MHz 07128b EN 55011 A qp EN 55011 B qp In addition, the values for average must keep a limit 10 dBµV below the limits in fig. 20 (not shown). Radiated emissions have been tested according to IEC/EN 55011 (similar to EN 55022), class A, as requested in EN 50121-3-2, table 6.1. The test is executed with horizontal and vertical polarization. The worse result is shown in fig. 22. Fig. 22a Radiated disturbances (quasi peak) in 10 m distance: BP4660-9RD, V i nom, Vo = 24 V, Io = 4 × 1.25 A Fig. 22b Radiated disturbances (quasi peak) in 10 m distance: EP3020-7R, Vi nom, Vo = 12 V, Io = 2 × 2.5 A JM0036a 30 50 100 200 500 1000 MHz dBµV/m TÜV-Divina, ESVS 30:R&S, BBA 9106/UHALP 9107:Schwarzb., QP, 2009-05-29 Testdistance 10 m, BP4660-9RD B01395787 U00006 U i=24 V, Uo=24 V Io= 4 x 1.25 A EN 55011 A JM0037a 30 50 100 200 500 1000 MHz dBµV/m TÜV-Divina, ESVS 30:R&S, BBA 9106/UHALP 9107:Schwarzb., QP, 2009-04-17 Testdistance 10 m, EP3020-7R, U i=24 V, Uo=12 V Io= 2 x 2.5 A EN 55011 A 0.1 0.5 dBµV MHz 07127b EN 55011 B qp EN 55011 A qp

BCD20010-G Rev AG, 05-May-2014 Page 18 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. Immunity to Environmental Conditions Table 10: Mechanical and climatic stress Test method Standard T est conditions Status Cab Damp heat IEC/EN 60068-2-78 T emperature: 40 ±2 °C Converter steady state MIL-STD-810D section 507.2 Relative humidity: 93 +2/-3 % not Duration: 56 days operating Kb Salt mist, cyclic IEC/EN 60068-2-52 Concentration: 5% (30 °C) for 2 h Converter (sodium chloride Storage: 40°C, 93% rel. humidity not NaCl solution) Duration: 3 cycles of 22 h operating -- Salt mist, sodium EN 50155:2007, clause 12.2.10 Temperature: 35 ±2 °C Converter chloride solution class ST2 Duration: 16 h not operat. Fc Vibration IEC/EN 60068-2-6 Acceleration amplitude: 0.35 mm (10 – 60 Hz) Converter (sinusoidal) MIL-STD-810D section 514.3 5 g n = 49 m/s2 (60 - 2000 Hz) operating Frequency (1 Oct/min): 10 – 2000 Hz Test duration: 7.5 h (2.5 h in each axis) Fh Random vibration IEC/EN 60068-2-64 Acceleration spectral density: 0.05 g n2/Hz Converter broad band Frequency band: 8 – 500 Hz operating (digital control) and Acceleration magnitude: 4.9 g n rms guidance T est duration: 1.5 h (0.5 h in each axis) Eb Bump IEC/EN 60068-2-29 Acceleration amplitude: 25 g n = 245 m/s2 Converter (half-sinusoidal) MIL-STD-810D section 516.3 Bump duration: 6 ms operating Number of bumps: 6000 (1000 in each direction) Ea Shock IEC/EN 60068-2-27 Acceleration amplitude: 50 g n = 490 m/s2 Converter (half-sinusoidal) MIL-STD-810D section 516.3 Bump duration: 11 ms operating Number of bumps: 18 (3 in each direction) -- Shock EN 50155:2007 sect. 12.2.11 Acceleration amplitude: 5.1 g n Converter EN 61373 sect. 10, class B, Bump duration: 30 ms operating body mounted1 Number of bumps: 18 (3 in each direction) -- Simulated long life EN 50155:2007 sect. 12.2.11 Acceleration spectral density: 0.02 g n2/Hz Converter testing at EN 61373 sect. 8 and 9, Frequency band: 5 – 150 Hz operating increased random class B, body mounted 1 Acceleration magnitude: 0.8 g n rms vibration levels Test duration: 15 h (5 h in each axis)

1 Body mounted = chassis of a railway coach

Table 11: Temperature specifications, valid for an air pressure of 800 – 1200 hPa (800 – 1200 mbar) Temperature -7 (option) -9 (standard) Characteristics Conditions min typ max min typ max Unit TA Ambient temperature Converter operating 1 –25 71 –40 71 °C TC Case temperature 2 –25 95 1 –40 95 1 TS Storage temperature Non operational –40 100 –55 100 Rth C-A Thermal resistance case to ambient in still air 1.6 3 1.6 3 K/W 1 Operation with Po max requires reduction to TA max = 50 °C, TC max = 85° C respectively; see Thermal Considerations .

2 Overtemperature shutdown at TC > 95 °C (PTC)

3 See table 17 for long case and heatsink options B0, B1, B3. Reliability Table 12: MTBF and device hours Ratings at specified Model Ground Ground fixed Ground Demonstrated hours benign mobile between failures 1 Case Temperature 40 °C 40 °C 70 °C 50 °C MTBF acc. to CP 340 000 h 88 000 h 42 000 h 40 000 h 757 000 h MIL-HDBK-217F, notice 2 1 Statistical values, based upon an average of 4300 working hours per year and in general field use over 5 years; upgrades and customer-induced errors are excluded.

BCD20010-G Rev AG, 05-May-2014 Page 19 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. 111 100 127 (164) (19.8) M3; 4 deep Measuring point of case temperature TC 20.32 (4 TE) 13.43 100 LEDs "Out OK" 09099f Front plate Main face Back plate 13.22 8.14 6.4 104 64.9 (17.6) = ∅ 4.5 PT1 PT2 pin 4 pin 32 LED "In OK" 59.23 Alternative LED positions for customer-specific models with long case: a = "In OK", b = "Out 1 OK", c = "Out 2 OK" (front panel XMD168-G) AIRFLOW (5.5) pin 4 A B C D H G F E KeyCode System for long case (add 5000 to the part number) Rear face HEAT SINK (Opt. Bx) Output 2 Output 1 c a b Mechanical Data The converters are designed for insertion into a 19" rack according to IEC 60297-3. Dimensions in mm. Note: Long case, elongated by 60 mm for a 220 mm rack depth, is available on request: Add 5000 to the part number ! Fig. 23 Case Q04, weight app. 500 g Aluminium, fully enclosed, black finish and self cooling European Projection

BCD20010-G Rev AG, 05-May-2014 Page 20 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. Fig. 24b View of male H15S2 connector (with high-current contacts) used in P1000 and P1100 without option K. Recent H15-S2 connectors have no CodeKey system. Safety and Installation Instructions Connector Pin Allocation The connector pin allocation table defines the electrical potentials and the physical pin positions on the H15 and H15S2 connector. Pin no. 26, protective earth, is a leading pin to ensure that it makes contact with the female connector first. Notes:

• The current through each standard H15 contact depends on the female connector, the ambient temperature and the air flow in the region of the connector. We recommend to limit the mean current to 15 A at 50 °C and to 13 A at 71 °C.
• High currents require a large cross-sectional area of the connections to the female contacts. We recommend solder or screw terminal contacts. Each faston connection exhibits a resistance of typ. 4 m Ω ( max. 8 m Ω), which makes it less suitable for high currents.
• For single-output models with option K, both output contacts must always be used and connected in parallel to the load with large cross-sectional area wires or thick copper lands. The efficiency is lower with option K. 32 28 24 20 16 12 30 26 22 18 14 8/10 4/6 S10051a Table 13: Pin allocation Pin P 1000 P2000 P3000 P4000 41 Vo+ Output 1 pos. Vo1+ Output 1 pos. Vo1+ Output 1 pos. Vo1+ Output 1 pos. 61 Vo+ Output 1 pos. Vo2+ Output 2 pos. Vo2+ Output 2 pos. Vo2+ Output 2 pos. 82 Vo– Output 1 neg. Vo1– Output 1 neg. Vo1– Output 1 neg. Vo1– Output 1 neg.6 102 Vo– Output 1 neg. Vo2– Output 2 neg. Vo2– Output 2 neg. Vo2– Output 2 neg. 12 S+ Sense + S1+ Sense 1 + S1+ Sense 1 + Vo4+ Output 4 pos. 14 S– Sense – S1– Sense 1 – S1– Sense 1 – Vo4– Output 4 neg.6

16 R Adjust of Vo R1 Adjust of Vo1 R1 Adjust of Vo1 R1 Adjust of Vo1/4

T1 Current share 3 T1 Current share 3 18 T 5 Current share S2+ Sense 2 + Vo3+ Output 3 pos. Vo3+ Output 3 pos. 20 n.c. Not connected S2– Sense 2 – Vo3– Output 3 neg. Vo3– Output 3 neg. Out OK+ Out OK+ 4 Out OK+ Out OK+ 4 Out OK+ Out OK+ 4 Out OK+ Out OK+ 4 Out OK– Out OK– 4 Out OK– Out OK– 4 Out OK– Out OK– 4 Out OK– Out OK– 4 26 Prot. earth PE Prot. earth PE Prot. earth PE Prot. earth PE 28 i Inhibit primary i Inhibit primary i Inhibit primary i Inhibit primary 30 Vi+ Input pos. Vi+ Input pos. Vi+ Input pos. Vi+ Input pos. 32 Vi– Input neg. Vi– Input neg. Vi– Input neg. Vi– Input neg. 1 Pin 4/6 (high-current contact) for P1000 models with 3.3 V or 5.1 V output (H15S2 connector, no option K) 2 Pin 8/10 (high-current contact) for P1000 models with 3.3 V or 5.1 V output (H15S2 connector, no option K) 3 Option T1 for 3.3 V and 5.1 V powertrains: Only Io1 is influenced

4 Option D

5 Not connected, if option T is not fitted. 6 Powertrains with 5.1 V and 3.3 V outputs have a common return: Vo1– and Vo4– are connected together. Fig. 24a View of male standard H15 connector 32 28 24 20 16 12 8 4 30 26 22 18 14 10 6 10025a

• High-current contacts of P1000 models exhibit no restriction of the output current. Their resistance is only typ. 1 m Ω.

BCD20010-G Rev AG, 05-May-2014 Page 21 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. Table 14: Isolation Characteristic Input to Outputs Output Out OK signals to 3 Unit outputs 1 case+outputs to case to output 4 input case outputs Insulation resistance >300 2 >300 2 >100 >300 2 >100 >100 M Ω Creepage distances 4.0 3.25 1.0 1.0 m m

1 Pretest of subassemblies in accordance with EN 50116 and IEC/EN 60950

2 Tested at 500 VDC

3 Option D

4 Powertrain with 5.1 and 3.3 V output have a commun return. 5 2nd value valid for models with version V114 (or later) Installation Instructions These converters are components, intended exclusively for inclusion within other equipment 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, clearance, casualty, markings and segregation requirements of the end- use application. Connection to the system shall be made via the female connector H15 or H15S2 (see Accessories). Other installation methods may not meet the safety requirements. Check for hazardous voltages before altering any connections. Pin 26 (PE) is a leading pin and is reliably connected to the case. For safety reasons it is essential to connect this pin to the protective earth. The Vi– input (pin 32) is internally fused. This fuse is designed to protect the converter against overcurrent caused by a failure, but may not be able to satisfy all requirements. External fuses in the wiring to one or both input pins (no. 30 and/or no. 32) may therefore be necessary to ensure compliance with local requirements. Important: Whenever the inhibit function is not in use, pin 28 (i) should be connected to pin 32 (Vi–) to enable the output(s). Do not open the converters, or the warranty will be invalidated. Make sure that there is sufficient airflow available for convection cooling. 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; see also Safety of Operator-Accessible Output Circuits . Standards and Approvals The P Series converters are approved according to the safety standards IEC/EN 60950-1 and UL/CSA 60950-1 2 nd Ed. They have been evaluated for:

• Class I equipment
• Building in
• Double or reinforced insulation based on 250 VAC or 240 VDC between input and output and between input and auxiliary circuits
• Overvoltage category II
• Pollution degree 2 environment
• The converters fulfill the requirements of a fire enclosure. CB-scheme is available (CB 06 07 24238 800). The converters are subject to manufacturing surveillance in accordance with the above mentioned UL standards and with ISO 9001:2000. Cleaning Agents The converters are not hermetically sealed. In order to avoid possible damage, any penetration of liquids shall be avoided. Protection Degree The DC-DC converters correspond to protection degree IP 40, provided that the female connector is fitted to the converter. Railway Applications The converters have been designed observing the railway standards EN 50155:2007 and EN 50121-3-2:2006. All boards are coated with a protective lacquer. The P Series converters are certified to the fire protection class S1 according to DIN 5510-2:2007. All models with version V114 (or later) are certified to EN 45545. They also comply with NF-F-16, Class I3/F2 (except when operated in a vertical position, i.e. with the connector on top or on bottom). Isolation The electric strength test is performed in the factory as routine test in accordance with EN 50116 and IEC/EN 60950 and should not be repeated in the field.

BCD20010-G Rev AG, 05-May-2014 Page 22 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. Table 15: Safety concept leading to an SELV output circuit Conditions Front end DC-DC converter Result Nominal Minimum required grade Maximum DC Minimum required safety Measures to achieve the Safety status supply of insolation, to be pro- output voltage status of the front end specified safety status of the of the DC-DC voltage vided by the AC-DC front from the front output circuit output circuit converter end, including mains end 1 output circuit supplied battery charger Mains Functional (i.e. there is ≤168 V Primary circuit (The nominal Double or reinforced insula- SELV circuit ≤250 VAC no need for electrical iso- voltage between any input tion, based on 250 VAC and lation between the mains pin and earth shall not ex- 240 VDC (provided by the supply circuit and the ceed 250 VAC or 240 VDC.) DC-DC converter) and DC-DC converter input earthed case circuit) Basic Earth related hazardous Double or reinforced insula- voltage secondary circuit tion, based on the maximum (The nominal voltage nominal output voltage from between any input pin and the front end (both provided earth shall not exceed by the DC-DC converter) and 250 VAC or 240 VDC.) earthed case Unearthed hazardous Supplementary insulation, voltage secondary circuit based on 250 VAC and DC and double or reinforced insulation, based on the maximum nominal output voltage from the front end (both provided by the DC-DC converter) and earthed case 2 Supplementary Unearthed hazardous Basic insulation, based on voltage secondary circuit 3 250 VAC and DC (provided by the DC-DC converter) 1 The front end output voltage should match the specified input voltage range of the DC-DC converter. The maximum rated input voltage of EP types is 150 V according to IEC/EN 60950. 2 The earth connection has to be procided by the installer according to the relevant safety standards, e.g., IEC/EN 60950. 3 Has to be insulated from earth by at least supplementary insulation (by the installer) according to the relevant safety standar ds, e.g. IEC/EN 60950, based on the maximum nominal output voltage from the front end. If the converter case is accessible, it has to be earthed or the front end output circuit has to be insulated from the converter case by at least basic insulation, bas ed on the maximum nominal mains supply voltage. Safety of Operator-Accessible Output Circuits If the output circuit of a DC-DC converter is operator accessible, it shall be an SELV circuit according to the IEC/ EN 60950 related safety standards. The following table shows some possible installation configurations, compliance with which causes the output circuit of the DC-DC converter to be an SELV circuit according to IEC/EN 60950 up to a configured output voltage (sum of nominal voltages if in series or +/– configuration) of 35 V. However, it is the sole responsibility of the installer to ensure the compliance with the relevant and applicable safety regulations. Use fuses and earth connections as per table below. See also Installation Instructions. Fig. 25 Schematic safety concept AC-DC front end DC-DC con- verter Mains SELV Earth connection 10052a Battery Max. 250 VAC or 240 VDC Max. 250 VAC or 240 VDC Fuse Fuse

BCD20010-G Rev AG, 05-May-2014 Page 23 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. Description of Options Option D: Out OK Monitor Option D monitors the state of the output error amplifiers on both power trains rather than the input voltage, output voltage, or the current limit. It signals a fault, when one of the error amplifiers reaches its limit, which means that at least one output voltage is not within its regulation limits. This could occur, because the input voltage is below the minimum level or the load current is too high. This function is not adjustable. A galvanically isolated open-collector output generates the “Out OK” signal. The circuit monitors simultaneously that

• the input voltage is present - same logic as LED “In OK”
• the output voltages are within their limits - same logic as LED(s) “Out OK”. The open collector is conducting, if the monitored conditions are fulfilled. This option is located on a subassembly allowing special circuit design on customer request. V pDimensioning of resistor value Rp ≥ –––––– 50 mA Caution: The Out OK circuit is protected by a Zener diode. To prevent damage, the applied current IOK should be limited to ±50 mA. The Zener diode should not be exposed to more than 0.25 W. Option T: Active Current Sharing For 3.3 V and 5.1 V outputs only. The current share facility should be used, when several converters are operated in parallel. Examples could be high reliability n+1 redundant systems or systems providing higher output power. Using this feature reduces the stress of individual converters and improves the reliability of the system. Interconnection of the current-sharing pins T or T1 causes the converters to share their output currents evenly. Fig. 26 Output OK circuit (option D) Output monitoring circuit

22 Out OK+

Out OK– Rp VOK IOK 20 V Vp06151a Table 16: Output OK data Characteristics / Conditions min typ max Unit VOK Out OK voltage Output good, IOK < 50 mA 0.8 1.5 V IOK Out OK current Output out of range, VOK < 18 V 25 µA In redundant systems, the outputs of the converters are decoupled by ORing diodes. Consequently, a failure of one converter will not lead to a system failure. Since the voltage on the T or T1 pin is referenced to the sense pin S–, the installer must ensure that the S– pins of all parallel converters are at the same electrical potential and that there are no voltage drops across the connection lines between these pins. Double-output converters with outputs connected in series can also be paralleled with current sharing, if pins Vo1– of all converters are connected together; see fig. 10. If the output voltages of parallel connected single-output converters are programmed to a voltage other than V o nom by means of the R pin, the outputs should be adjusted individually within a tolerance of ±1%. Note: Option T is only available for 3.3 V or 5.1 V single-output power trains and only for output 1. In double- or triple-output models, option T1 (pin 16) influences only output 1. Then the R-function is not present, since no pin is left for that function. Option B0, B1, B3: Heat Sink The converter is fitted with an additional heat sink. Table 17: Thermal resistance case to ambient (approx. values) Case Thermal resistance Thickness of case Standard, 160 mm long 1.6 K/W < 20 mm Case, 220 mm long1 1.4 K/W < 20 mm Option B0 1.4 K/W < 30 mm Option B1 1.3 K/W < 40 mm Option B3 1.2 K/W < 50 mm 1 Add 5000 to the part number ! Option G RoHS compliant for all six substances. Option G should be chosen for new designs.

BCD20010-G Rev AG, 05-May-2014 Page 24 of 25 P Series Data Sheet 90 – 195 Watt DC-DC Converters MELCHER The Power Partners. Accessories A wide variety of electrical and mechanical accessories are available:

• Mating connectors including faston, screw, solder, or press-fit terminals
• Front panels, system Schroff, for 19" rack 3 U, configuration 4 TE (G04-Q04), 5 TE (G05-Q04), or 6 TE (G06-Q04)
• Front panels system Schroff, for 19" rack 6 U, configuration 5 TE (G05-6HE-Q04) Universal mounting bracket for DIN-rail and chassis mounting. The label is located on the bottom side of the P Series converter. H15 female connector with code key system NUCLEAR AND MEDICAL APPLICATIONS - Power-One products are not designed, intended for use in, or authorized for use as critical components in life support systems, equipment used in hazardous environments, or nuclear control systems without the express wr itten consent of the respective divisional president of Power-One, Inc. 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.
• Mechanical mounting supports for chassis, DIN-rail, and PCB mounting
• Connector retention brackets HZZ01217-G (CRB-Q)
• Different cable connector housings (cable hoods) For additional information, see the accessory data sheets listed with each product series or individual model at www.power-one.com. Front panel G05-6HE-Q04 accommodating two P units for a 19" DIN-rack with 6 U, 5 TE. The labels are visible on the back side. Connector retention bracket HZZ01217-G (CRB-Q)