PSS/PSK-Family Switching Regulators, 19" Industrial Environment PSR: Positive Switching Regulators No:Input to:output: isolation Single output of 5.1,:12, 15, 24 or 36 V:DC/60...720'W Input voltage up to:80:V:-DC High: efficiency up to:97% Wide input: voltage:range = LOw-input to: outout differential: voltage Very good dynamic properties Input: undervoltage lock-out +: Active:current sharing for parallel: operation Output: voltage: adjustment; inhibit and sense lines = "Fast dynamic:response Continuous no-load: and short-circuit: proot = No derating Safety:according to:IEG/EN 60950, UL 1950 @nwAW CE Summary The PSS/PSK family of positive switching regulators is de- signed as power supply modules for electronic systems. Their major advantages include a high level of efficiency that remains virtually constant over the entire input range, high reliability, low ripple and excellent dynamic response. Modules with input voltages up to 80 V are specially designed for secondary switched and battery driven appli- cations. The standard case design with heat sink allows op- eration at nominal load up to 71C without additional cool- ing, suitable for 19" rack or chassis mounting. Replacing the heat sink by an optional cooling plate B or B1, allows chassis or wall mounting on top of a metal surface, acting as heat sink. Connector type according to DIN 41612: H15 for output current <16A H15 S4 with four high current jacks for output current 220A Table of Contents Page SUMIMALY eee eeeeeee cence ee eenee ener ee eeneeeeeaeeeeeaaeeesenaeeenaeees 5 - 46 Type Survey and Key Datta... eeeeeeeeeeeeeeeeneeeeens 5 - 47 Type Key and Product Marking .........c:ceeseeeesteeeees 5 - 47 Functional DeSCription 20... eeeceesseeeeesnreeeeneeeeeneeeees 5 - 48 Electrical Input Data 0... eeeeeeeseeeeenneeeeeeeeeeneeeee 5 - 48 Electrical Output Data... eeeeesseeeenteeeeeeeeeeeneeeees 5 - 49 Auxiliary FUNCTIONS 0... eee ee enneeeeenne rennet eeeneeeeees 5-51 PSS-Family PSK-Family ops cAL " 168 2.4 6.6" 1 4.4" 3uU 80 168 STe 6.6" Page Electromagnetic Compatibility (EMC) 0... ee 5-53 Immunity to Environmental Conditions... 5 - 54 Mechanical Datta... eee ceseeeeesneeeeeeeeeeeneeeeenaeeenees 5-55 Safety and Installation Instructions ....... eee 5-56 Description Of Options 0.0.0... eeceeeeeeeeeeeeeeeteeeneeeneeees 5 - 57 ACCOSSOLIOS 00... eeeeeee entrees eneeeeeeeeeeraeeeeenaeeeeneeeeenaeeeeeas 5 - 59 5 - 46 Edition 3/11.97/IN 1.98 - Melcher AGIndustrial Environment Switching Regulators, 19" PSS/PSK-Family Type Survey and Key Data Table 1: Type survey Output Output Input Input Efficiency Type Connector:|:: Options voltage current voltage range voltage designation type Us roth: [V] Ib nom [A] ULV]! Groom IV | amin [6]: | Mma 126] 5.4 12 8...80 40 78 79 PSS 5A12-7 H15 B, B1 16 PSK 5A16-7 . 20 PSK 5A20-7 H15 S4 P 25 8...40 20 82 82 PSK 5A25-7 Cc 12 12 15...80 40 90 91 PSS 1212-7 H15 16 89 90 PSK 1216-7 20 PSK 1220-7 H15 S4 3 153 12 19...80 90 92 PSS 1212-7 H15 16 89 90 PSK 1216-7 20 PSK 1220-7 H15 S4 24 12 29...80 50 93 94 PSS 2412-7 H15 16 PSK 2416-7 20 PSK 2420-7 H15 S4 36 12 42...80 60 95 96 PSS 3612-7 H15 16 94 95 PSK 3616-7 20 PSK 3620-7 H15 S4 1 See also Electrical Input Data: AUio min- 2 Efficiency at Uj nom and fo nom- 3 Output set to 15 V at R control input Type Key and Product Marking Type Key PSK 1220-7EPCBBI1 Positive switching regulator in case S01, KO1 ... PSS, PSK | Nominal output voltage in volt (5A for 5.1 V) ......... 5A...36 Nominal output current in AMpere ....... ee eee eens 12...25 Operational ambient temperature range Ty 2B. TT OO cece cette cnet eeaeteeeetneeeeeeeeeeeeas 40...71C (OPTION) oo. eee eeeeeeeeeteeeees Options: Inrush current limitation Potentiometer? ...........::00 ThyristOr CrOWDAD ......eeeeeeesteeesteeeeeneeeeenes Cooling plate large oo... eeeeesseeeeesneeeeeeees Cooling plate small ........ eee eeeeeeesteeeeeees Example: PSS 1212-7EPCB =A positive switching regulator with a 12 V, 12 A output, ambient temperature range of 25...71C, inrush current limitation, potentiometer, crowbar and large cooling plate B. Note: All units feature the following auxiliary functions which are not shown in the type designation: Input filter, inhibit, R control, sense lines, current sharing and test jacks. Produkt Marking Main face: Family designation, applicable safety approvals and recognition marks, warnings, pin allocation, Melcher pat- ent nos. and company logo. Back plate: Specific type designation, input voltage range, nominal output voltage and current, pin allocation of auxiliary functions and options, protection degree. Front plate: Identification of LED, test sockets and optional potentiometer. Rear side: Label with batch no., serial no. and data code comprising production site, modification status of the main PCB and date of production. Edition 3/11.97/IN 1.98 - Melcher AGPSS/PSK-Family Switching Regulators, 19" Industrial Environment Functional Description The switching regulators are designed using the buck con- verter topology. See also Technical Information: Topologies. The input is not electrically isolated from the output. During the on period of the switching transistor, current is trans- ferred to the output and energy is stored in the output choke in the form of flux. During the off period, this energy forces the current to continue flowing through the output, to the load and back through the freewheeling diode. Regulation is accomplished by varying the on to off duty ratio of the power switch. I I tT evi, Tu G2) 1 S 1 2 ' 0 These regulators are ideal for a wide range of applications, where input to output isolation is not necessary, or where already provided by an external front end (e.g. a trans- former with rectifier). To optimise customers needs, addi- tional options and accessories are available. 1 ; corres 1 of ' U, ry} a i a i | Control 12) | U \ IN 5 AX Option C} circuit @ 2 tofege est! (9) R 1 8) S- o> ho , ZS] I I Gi- \ t ' om + = eee Go- + @ Sea I Option P ! ne -~-4--d Fig. 1 ee Block diagram Electrical Input Data General Conditions: Ta = 25C, unless 7c is specified Table 2a: Input data Input PSS:5A12 PSS'1212 PSK: 5A16 PSK:1216 PSK '5A25 PSK:5A20 PSK::1220 Characteristics Conditions mine typ max mins typsmax minstypsmax Unit U; Operating input voltage ly =0... fo nom 8 40 8 80 15 80 vbc AU min| Min. diff. voltage U; Up Te min--- Te max 2.9 2.9 3 Uj Undervoltage lock-out 6.5 6.5 7.3 j No load input current ly =0, Us min... Ui max 50 50 50 mA linrp Peak value of inrush current | Uj nom, with option E 20 40 40 A uirrl | Input RFI level, EN 5501 1/22 | Ui nom, fo nom B B B 0.01...30 MHz Table 20: Input data Input PSS 1212: PSS 2412 PSS 3612 PSK'1216 PSK:2416 PSK:3616 PSK'1220 PSK 2420 PSK'3620 Characteristics Conditions min! typo max min! type max min typ. max Unit U; Operating input voltage ly =0...ho nom 19 80 29 80 42 80 Vv DC AU min| Min. diff. voltage U; Up Te min--- Te max 4 5 6 Uj Undervoltage lock-out 7.3 12 19 j No load input current ly =0, Us min... Ui max 50 50 50 mA linrp Peak value of inrush current | Uj nom, with option E 40 50 60 A ure | Input RFI level, EN 5501 1/22 | Ui nom, fo nom B B B 0.01...30 MHz 1 Output set to 15 V at R control input, see Auxiliary Functions. Edition 3/11.97/IN 1.98 - Melcher AGIndustrial Environment Switching Regulators, 19" PSS/PSK-Family Input Filter and Fuse An input filter and a fuse are incorporated in all modules as standard. The filter reduces emitted electrical noise and prevents oscillations caused by the negative input imped- ance characteristic of a switched mode regulator. The input fuse protects against severe defects. The maximum permissible additionally superimposed rip- ple u; of the input voltage (rectifier mode) at a specified in- put frequency # has the following values: Ui max = 10 Vp, at 100 Hz, or Vo, = 1000 Hz/f' + 1 V Electrical Output Data General Conditions: Ty = +25C, unless 7c is specified With R control output voltage Up = Uo nom at fo nom Sense lines connected at female connector Table 3a: Output data Inrush Current Depending on the input source and the input impedance, the inrush current into the regulator may peak several thou- sand amperes during the switch-on sequence. It also deter- mine the rating of input devices such as switches, relays, fuses etc. To protect these input devices by limiting the peak of the inrush current we recommend the use of the active inrush current limitation circuit, option E. Output PSS 5A12 PSK:5A16 PSK:5A20 PSK:5A25 Characteristics Conditions minsstyp: max-min typ max min typ: max. omins typ smax: Unit Uo Output voltage Ujinom, fo nom 5.07 5.13 | 5.07 5.13 | 5.07 5.13 | 5.07 513] V lo Output current 1 Ui min--- Ui max 0 12.0 0 16.0 0 20.0 0 25.0 A bot Output current limitation Teo min--- Te max 12.0 15.0 | 16.0 20.0 | 20.0 25.0 | 25.0 31.3 response Uo Output Switching freq. | Ui nom, fo nom , 20 40 20 40 20 40 20 40 | MVpp vonage Total BW 30 MHz 24 44 24 44 24 44 24 44 AU, yu | Static line regulation Uy min--- Ui max, fo nom 15 35 15 35 15 35 15 35 mV AU,| | Static load regulation Us nom: fo = 0... fo nom 10 25 10 25 10 25 10 25 Uod Dynamic Voltage deviat. | Ui nom 70 70 70 70 te regulation Recovery time | lorem? 9 bonon 40 40 40 40 us Uo Temperature coefficient Ui min--- Ui max +1 +1 +1 +1. |mV/K AUGJ/ATe (Te mins Tomax) | bo = 0..-lonom +0,02 +0.02 +0.02 +0.02 | %/K Table 3b: Output data Output PSS:1212 PSK:1216 PSK:1220 PSS:1212 Characteristics Conditions min yp maa OE Syma MER ty pmax mR typ max Unit Us Output voltage Uinom, fo nom 11.93 12.07|11.93 12.07/11.93 12.07] 14.91 15.09) V L Output current Uj min. Uj max 0 12.0 0 16.0 0 20.0 0 12.0 A fot Output current limitation To min--- Te max 12.0 15.0 | 16.0 20.0 | 20.0 25.0 | 12.0 15.0 response Uo Output Switching freq. | Usnom, fo nom , 25 45 25 45 25 45 30 50 | MVpp vortage Total BW 20 MHz 29 49 29 49 29 49 34 54 AUpy | Static line regulation Uj min. Ui max: fo nom 40 70 40 70 40 70 50 80 mV AU,| | Static load regulation Ujnom, fo = 0...4o nom 30 650 30 50 30 50 35 55 Uod Dynamic Voltage deviat. | Uj nom 140 140 140 150 te veaulation Recovery time | enon <> 1 onan 60 60 60 60 us OUo Temperature coefficient Uj min. Uj max +3 +3 +3 +4 |mV/K AUJATe (To min--To max) | fp = 0.--lo nom +0,02 +0,02 +0.02 +0.02| %/K 1 See also Thermal Considerations. 2 See Technical Information: Measuring and Testing. 3 Output set to 15 V at R control input, see Auxiliary Functions. Edition 3/11.97/IN 1.98 - Melcher AGPSS/PSK-Family Switching Regulators, 19" Industrial Environment Table 3c: Output data Output PSK:12162 PSK'1220 PSS 2412 PSK:2416 Characteristics Conditions mine typ: max: min styps maxst mins tye max omin typ max | Unit Uo Output voltage Ui nom, fo nom 14.91 15.09| 14.91 15.09] 23.86 2414/2386 24.14) V lo Output current Uj min. Uj max 0 16.0 0 20.0 0 12.0 0 16.0 A fot Output current limitation Te min... To max 16.0 20.0 | 20.0 25.0 | 12.0 15.0 | 16.0 20.0 response Up Output Switching freq. | Ui nom, fo nom , 30 650 30 50 30 60 30 60 | MVpp vorage Total AW Owe 34 54 34 54 34 64 34 64 AU, uy | Static line regulation Uj min. Uj max: fo nom 50 80 50 80 80 170 80 170 | mV 5 AU, | Static load regulation Ui nom: bo = 0...fo nom 35 55 35 55 50 120 50 120 Uod Dynamic Voltage deviat. | Uj nom 150 150 180 180 te regulation Recovery time | /onom** nom 60 60 60 60 us QUo Temperature coefficient Uj min. Uj max +4 +4 +5 +5 |mV/K AUp/ATe (To min---To max) | fo = 0.--Lo nom +0.02 +0.02 +0.02 +0.02] %/K Table 3d: Output data Output PSK:2420 PSS :3612 PSK 3616 PSK:3620 Characteristics Conditions minstyp maxes mine max st omin typ omax.) comin typ: max.) Unit Uy Output voltage Ui nom, bo nom 23.86 24.14/35.78 36.22/35.78 36.22)35.78 36.22} V lo Output current Uj min. Uj max 0 20.0 0 12.0 0 16.0 0 20.0 A bot Output current limitation Te min... To max 20.0 25.0 | 12.0 15.0 | 16.0 20.0 | 20.0 25.0 response Up Output Switching freq. | Ui nom, fo nom 30 60 35 60 35 60 35 60 | MVpp voltage IEC/EN 61204 2 Total 34 64 39 64 39 64 39 64 noise ota BW = 20 MHz AU, y | Static line regulation Ui min. Ui max: fo nom 80 170 120 250 120 250 120 250 | mV AU, | Static load regulation Uy nom: fo = 0...o nom 50 120 60 200 60 200 60 200 Uod Dynamic Voltage deviat. | Uj nom 180 200 200 200 load ; I oll R nom onom 60 70 70 70 ts regulation | OVe'Y | le C/EN 612042 HS QUo Temperature coefficient Uj min. Uj max +5 +8 +8 +8 |mV/K AUJATe (To min-Te max) | fo = 0..-fo nom +0.02 +0.02 +0.02 +0.02] %/K 1 See also Thermal Considerations. 2 See Technical Information: Measuring and Testing. 3 Output set to 15 V at R control input, see Auxiliary Functions. U5 osoio. ~=6)ds Overtemperature Protection Yod | | AU, | AU,; The unit is self-protecting by an internal temperature moni- S 7 tor, which inhibits the output above To max. The output is au- u tomatically enabled again after temperature has droped be- id te tl ty low Tc max: ! | t Output Protection lollo nom | 1 | I A voltage suppressor diode which in worst case conditions fails into a short circuit, protects the output against an inter- ' nally generated overvoltage. Such an overvoltage could oc- 0 + curdue to a failure of either the control circuit or the switch- al 210 ps _ yt, 210 ps ing transistor. The output protection is not designed to with- Fig. 2 stand externally applied overvoltages. The user should en- sure that systems with Melcher power supplies, in the event D ic load lation. ynamic load regulation of a failure, do not result in an unsafe condition (fail-safe). Edition 3/11.97/IN 1.98 - Melcher AGIndustrial Environment Switching Regulators, 19" PSS/PSK-Family Thermal Considerations When a switching regulator is located in free, quasi-station- ary air (convection cooling) at a temperature Ta = 71C and is operated at its nominal output current /o nom, the case temperature 7c will be about 95C after the warm-up phase, measured at the Measuring point of case tempera- ture Tc (see Mechanical Daia). Under practical operating conditions, the ambient tempera- ture Ta may exceed 71C, provided additional measures (heat sink, fan, etc.) are taken to ensure that the case tem- perature 7c does not exceed its maximum value of 95C. Example: Sufficient forced cooling allows Ta max = 85C. A simple check of the case temperature Tc (Tc <95C) at full load ensures correct operation of the system. loll nom A Forced cooling \ VO ee > - - on eee ee 0.9 4 0.8 4 0.7 7 0.6 4 ; 05-+--------------! Pie LZ To max 0.4 - 0.3 0.2 4 0.14 0 ic | | | | | Th [C] Tamin 50 60 70 80 90 4100 * Fig. 3 Ouiput current derating versus temperature. -e0s0 I I | I Convection coolin Auxiliary Functions S Sense Lines Note: Sense lines should always be connected! It is rec- ommended to connect the sense lines directly at the female connector. See also Technical Information. This feature enables compensation of voltage drop across the connector contacts and the load lines. In case the sense lines are connected at the load rather than directly at the connector, the user must ensure that Up max (between Vo+ and Go-) is not exceeded. Applying generously dimensioned cross-section load leads avoids troublesome voltage drop. To minimize noise pick-up wire sense lines in parallel or twisted. To ensure correct operation, both sense lines must be con- nected to their respective power output potential. The volt- age difference between any sense line and its respective power output pin (as measured on the connector) should not exceed the values given in the following table. i Inhibit for Remote On and Off Note: With open i input, output is enabled (U = on) The inhibit input allows the switching regulator output to be disabled via a control signal. In systems with several units, this feature can be used, for example, to control the activa- tion sequence of the regulators by a logic signal (TTL, C- MOS, etc.). An output voltage overshoot will not occur when switching on or off. The inhibit characteristics are refer- enced to the S remote sense terminal. Parallel and Series Connection Outputs of equal nominal voltages can be parallel-con- nected. Use the current sharing feature (CS) for even distri- bution of the output current. See also Auxiliary Functions. Outputs can be series-connected with any other module. In series-connection the maximum output current is limited by the lowest current limitation. Electrically separated source voltages are needed for each module! Short Circuit Behaviour Aconstant current limitation circuit holds the output current almost constant whenever an overload or a short circuit is applied to the regulator's output. It acts self-protecting and recovers in contrary to the fold back method automati- cally after removal of the overload or short circuit condition. Ug/Up nom 1.2 1.0 0.8 0.6 0.4 0.2 0 Fig. 4 Overload, short-circuit behaviour U, versus |p. h nom 05038 lolly nom 02 04 06 O08 $10 1.2 1.4 Table 4: Maximum allowed voltage compensation Nominal output::|:: Total voltage difference::: |: Voltage difference voltage between-both:sense-lines between and their:respective: output Go= and: S= 5.1V <0.5V <0.25 V 12, 15, 24, 36 V <1.0V <0.25 V Pee eee ees 06046 90 Vi+ Oi OR Load ocs o Gi- Fig. 5 O Vit Se O 06047 I _A Finn I I I [Yrs I O Gi- s- O Lo-- eee es Fig. 7 Definition of linn and Unn Edition 3/11.97/IN 1.98 - Melcher AG5 PSS/PSK-Family Switching Regulators, 19" Industrial Environment Inn [MA] 5 06034 4 3 2 1 U, off 0 -50 -40 -30 -20 -10 0 Fig. 6 Typical inhibit current linn versus inhibit voltage Uinn 10 20 30 40 50 Un [VJ Table 5: Inhibit characteristics 06001 U,/U nom { 0.1 0 Inhibit 1 0 Fig. 8 Ouiput response as a function of inhibit signal Characteristics Conditions min:-typ::max Unit Uinn | Inhibit input voltage to keep | Up=on | Umin...Ui max 50 +0.8 VDC regulator output voltage... Up = off To min-- TC max 42.4 +50 ty Switch-on time after inhibit command U, = Uinom 100 ms ti Switch-off time after inhibit command | = Yo nom /o nom 25 finn Input current when inhibited U, = Uinom 25 mA R Control for Output Voltage Adjustment Note: With open R input, Up = Ub nom. The output voltage U, can either be adjusted with an exter- nal reference voltage (Uex:) or with an external resistor (Fy or Aa). The adjustment range is 0...Uo max. The minimum dif- ferential voltage AUio min between input and output (see Electrical Inout Data) should be maintained. Undervoltage lock-out = minimum input voltage. Fig. 9 Voltage adjustment with U,.,, between R and S Caution: To:prevent damage U.s4'should not exceed 20: V; nor be negative: and: As:shauld:never-be-less than 47: kW. Fig. 10 Voltage adjustment with external resistor Ry or Ro b) Uy = 0...100% Us nom, using Ay between R and S-: 4000 Q+ U __Upnom* Fi fi = Uo nom Uo Uo = RR, + 4000 C) Up = Us nom---Uo max, USINg Ao between R and S+: 4000 Q * U* (Us nom 2.5 V) R. me a) Uy = 0...Up max, USING Usyt between R and S: 2.5 V + (Uy Up nom) Uext = 2.5 V * Us Up = Uo nom * et ly = Us nom * 2.5 V_* Fe @ nom . 2.5 V + (Ao + 4000 QO) Us nom * 4000 Table 6: Maximum adjustable output voliage Characteristics Conditions PSS 5A12 PSS 1212 PSS:2412 PSS 3612 PSK:5A16 PSK:1216 PSK 2416 PSK:3616 PSK:5A20 PSK:1220 PSK: 2420 PSK:3620 PSK:5A25 min: typ:max minestypomax min: typmax mins typ: max Unit Us max | Maximum adjustable Us nom: fo nom 5.6 16.0 26.0 42.5 Vv output at R control input CS Current Sharing Test Sockets For parallel operation of several modules, interconnecting all CS pins ensures that the output currents are evenly dis- tributed. This feature improves transient load performance and increases system reliability. All paralleled units should be supplied by equal input voltage (U,) and interconnecting leads should have equal length and cross section to ensure equal voltage drop. Test sockets (pin @ = 2 mm) for measuring the output volt- age U, internally at the cxonnector terminals, are located at the front side of the module. The test sockets are protected by a series resistor. LED Output Voltage Indicator A green output indicator LED shines when the output volt- age is higher than approx. 3 V. Edition 3/11.97/IN 1.98 - Melcher AGIndustrial Environment Switching Regulators, 19" PSS/PSK-Family Electromagnetic Compatibility (EMC) Electromagnetic Immunity General condition: Case not earthed. Table 7: Immunity type tests Phenomenon : | Standard: :|Class Coupling Value Waveform Source Test In Per- Level mode* applied Inmped: procedure oper: |form:/+ 1 MHz burst IEC lll i/o, i/c, ofc 2500 V, 400 damped 200 2s per yes A disturbance 60255-22-1 +i/4i, +0/-0 1000 V, 1 MHz waves/s coupling mode Voltage surge IEC 60571-1 i/e, +i/-i 800 V, 100 us 100 Q yes B 1500 V, 50 ps 1 pos. and 1 neg. voltage surge per 5 coupling mode 3000 V, 5 us 4000 V, ius 7000 Vp 100 ns Electrostatic IEC/EN 4 |contact discharge| 8000 V, 1/50 ns 330 10 positive and yes A discharge 61000-4-2 to case 10 negative discharges Electromagnetic | IEC/EN 3 antenna 10 V/m AM 80% 26...1000 MHz yes A field 61000-4-3 1 kHz Electrical fast IEC/EN 3 i/c, +i/-i 2000 V, |bursts of 5/50 ns} 502 1 min positive yes A transient/burst | 61000-4-4 4 4000 Vp 5 kHz rep. rate 1 min negative B4 transients with bursts per 15 ms burst coupling mode duration and a 300 ms period Surge IEC/EN 3 i/c 2000 V, 1.2/50 us 12.Q | 5pos.and5neg. | yes B 61000-4-5 +i 1000 V> 20 surges per coupling mode Conducted IEC/EN 3 i, 0, signal wires 10 Vims AM 80% 150 Q 0.15...80 MHz yes A disturbancies 61000-4-6 (140 dBuv) 1 kHz 1 For related and previous standards see Technical Information: EMC. 27 = input, o = output, c = case. 3 A= Normal operation, no deviation from specifications, B = Normal operation, temporary deviation from specs possible. 4 With option C, manual reset might be necessary. Electromagnetic Emission For emission levels refer to Electrical Input Data. [dBuV] 90 07021 80 EN 55022 A 70 60 EN 55022 B 50 40 30 20 10 0 MHz a N lO - Ww - N Ww oO oo o 96 So 6 o - ao oO oO oO Fig. 11 Typical disturbance voliage (quasi-peak) at the input ac- cording to EN 55011/22 measured at Uj nom and Io nom- Edition 3/11.97/IN 1.98 - Melcher AGPSS/PSK-Family Switching Regulators, 19" Industrial Environment Immunity to Environmental Conditions Table 8: Mechanical stress Test: Method Standard Test:Conditions Status Ca Damp heat IEC/DIN IEC 60068-2-3 Temperature: 40 42C Unit not steady state MIL-STD-810D, section 507.2 | Relative humidity: 93 +2/-3.% operating Duration: 56 days Ea Shock IEC/EN/DIN EN 60068-2-27 | Acceleration amplitude: 100 g, = 981 m/s? Unit (half-sinusoidal) MIL-STD-810D, section 516.3 | Bump duration: 6 ms operating Number of bumps: 18 (3 each direction) Eb Bump IEC/EN/DIN EN 60068-2-29 | Acceleration amplitude: 40 g, = 392 m/s? Unit (half-sinusoidal) MIL-STD-810D, section 516.3 | Bump duration: 6 ms operating Number of bumps: 6000 (1000 each direction) Fe Vibration IEC/EN/DIN EN 60068-2-6 Acceleration amplitude: 0.35 mm (10...60 Hz) Unit (sinusoidal) MIL-STD-810D, section 514.3 5 gn = 49 m/s? (60...2000 Hz) | operating Frequency (1 Oct/min): 10...2000 Hz Test duration: 7.5 h (2.5 h each axis) Fda | Random vibration | IEC 60068-2-35 Acceleration spectral density: 0.05 g2/Hz Unit wide band DIN 40046, part 23 Frequency band: 20...500 Hz operating Reproducibility Acceleration magnitude: 4.9 dims high Test duration: 3h (1h each axis) Kb Salt mist, cyclic IEC/EN/DIN IEC 60068-2-52 | Concentration: 5% (30C) Unit not (sodium chloride Duration: 2h per cycle operating NaCl solution) Storage: 40C, 93% rel. humidity Storage duration: 22 h per cycle Number of cycles: 3 Table 9: Temperature specifications, valid for an air pressure of 800...1200 hPa (800...1200 mbar) Temperature Standard:-7 Option: -9 Characteristics Conditions min max: min max Unit Ta, | Ambient temperature ' Operational 2 25 71 -40 71 C Tc | Case temperature 25 95 -40 95 Ts | Storage temperature ' Non operational -40 100 55 100 1 MIL-STD-810D section 501.2 and 502.2. 2 See Thermal Considerations and Overtemperature Protection. Table 10: MTBF and device hours MTBF Ground: Benign Ground: Fixed Ground: Mobile Device: Hours" MTBF acc. to MIL-HDBK-217F To = 40C To = 40C To = 70C Tc = 50C 335'000 h 138'000 h 35'000 h 33'000 h 2'100'000 h 1 Statistical values, based on an average of 4300 working hours per year and in general field use Edition 3/11.97/IN 1.98 - Melcher AGIndustrial Environment Switching Regulators, 19" PSS/PSK-Family Mechanical Data 7TE 5TE Dimensions in mm. Tolerances +0.3 mm unless otherwise specified. b+ pa | E | 30.3 3.27 uropean 74 20.34 Projection 171.9 (DIN 41494) jo CF 50 76 8 ej | 11084 AAA | anal 4e- 4xM4) o w = 09028 ~CSCC~C~S bo ---O; LED OK green | Potentiometer | oO 4-5 (option P) , Test sockets oto | tid ol N l I 1 111 #05 103 30.5 147.8. 50.5 51.5 I | | | | | | | | Ml | | | | | | | | I | Front plate Main face 168.5405 a 11.8] _ 25.9 Fig. 12 Case S01, weight 1.3 kg Aluminium, fully enclosed, J 3 i ys i 3 i 3 3 i ys 3 i 3 | black finish and self cooling. 7TE OTE 30.3 3.27 | 74 20.34 | ; 159 145 Moai | bee | ! ! | i ps je-' @ | 1 1 | | . 1 i i | 1 |; LED OK green | | in i. Potentiometer | | Slaof y 7-7? (option P) o 0 ~] |~ [| Test sockets 8) IEA THT ET et oath tS) tog bn | ! ! | 7 | 00 | 7 oyN | | 7 | i | Lo | || | Measuring point of | wo 5 i | | case temperature To BETH ATE TPP TEA EE PoE | | 1 50 171.93 (DIN 41494) Front plate Main face 168.5 Back plate Note: | : d 215 mm, recommended minimum dis- tance to next part to ensure proper air cir- culation at full output power. free air locations: the module should be mounted with fins in vertical position to achieve a maximum air flow through heat sink. Fig. 13 Case K01, weight 1.6 kg ! ! Aluminium, fully enclosed, black finish and self cooling. Edition 3/11.97/IN 1.98 - Melcher AGPSS/PSK-Family Switching Regulators, 19" Industrial Environment Safety and Installation Instructions Connector Pin Allocation The connector pin allocation table defines the electrical potentials and the physical pin position on the connector. Pin no. 24 is the protective ground pin and is leading, i.e. at- taching the female connector, this pin provides electrical Table 11: H15 and H15 S4 connector pin allocation contact first. The modules should only be wired via the fe- male connector H15 or H15 S4 (according to DIN 41612) to ensure requested safety! 10010 Electrical: Determination Type H15 Type: H15:S4 Fixtures for connector PinNo. | Ident. | Pin No. | Ident. retention clips V (see Accessory Products) Output voltage (positive) 4 Vo+ Output voltage (positive) 6 Vo+ 4/6 Vo+ Output voltage (negative) 8 Go- Output voltage (negative) 10 Go- 8/10 Go- Type H15 Crowbar trigger input (option C) 12 Cc 12 Cc Inhibit input 14 i 14 i 10010 R-input (output voltage programming) ' 16 R 16 R Fixtures for oon : . retention clips Sense line (negative) 18 s- 18 s- (see Accessory Products) Sense line (positive) 20 S+ 20 S+ Current sharing control input 22 cs 22 cs Protective ground (leading pin) 24 24 a) 30/32 eeceeecceeeeeece ences 46 Input voltage (negative) 26 Gi- 26/28 Gi- Type 15 S4 Input voltage (negative) 28 Gi- Input voltage (positive) 30 Vit ; Fig. 14 Input voltage (positive) 32 Vie 30/32 Vi+ ven of male H15 and H15 S4 con- nector Not available with option P Installation Instruction Installation of the switching regulators must strictly follow the national safety regulations in compliance with the enclo- sure, mounting, creepage, clearance, casualty, markings and segregation requirements of the end-use application. Check for hazardous voltages before altering any connec- tions. Connections can be made using fast-on, screw or sol- dering technique, by means of female H15 connectors. The input and the output circuit are not separated. i.e. the negative path is internally interconnected! The units should be connected to a secondary circuit. Do not open any module. Ensure that a unit failure (e.g. by an internal short-circuit) does not result in a hazardous condi- tion. See also Safety of operator accessible output circuit. Note: Additional information on input circuitry, grounding and parallel operation of units is given in Technical Informa- tion: Application Notes. Protection Degree The protection degree is IP 30 (equipped with potentio- meter adjustable option: IP 20). It applies only if the module is plugged-in or the female connector is properly attached to the module. Isolation Electric strength test voltage between input interconnected with output and case: 750 V DC, 1 s. This test is performed as factory test in accordance with IEC/EN 60950 and UL 1950 and should not be repeated in the field. Melcher will not honour any guarantee claims resulting from electric strength field tests. Standards and Approvals All switching regulators are UL recognized according to UL 1950, UL recognized for Canada to CAN/CSA C22.2 No. 234-M90 and SEV approved to IEC/EN 60950 and CISPR 14/EN 55014 standards. The units have been evaluated for: * Building in, * Operational insulation from input to output and input/out- put to case, * The use in a pollution degree 2 environment. * Connecting the input to a secondary circuit which is sub- ject to a maximum transient rating of 750 V. The switching regulators are subject to manufacturing sur- veillance in accordance with the above mentioned UL and CSA and with ISO 9001 standards. Safety of Operator Accessible Output Circuit If the output circuit of a switching regulator is operator-ac- cessible, it shall be an SELV circuit according to IEC/EN 60950 related safety standards. The following table shows some possible installation con- figurations, compliance with which causes the output circuit of the switching regulator to be an SELV circuit according to IEC/EN 60950 up to a configured nominal output voltage of 30 V, or 48 V if option C is fitted. However, it is the sole responsibility of the installer or user to assure the compliance with the relevant and applicable safety regulations. More information is given in Technical Information: Safety. 5 - 56 Edition 3/11.97/IN 1.98 - Melcher AGIndustrial Environment Switching Regulators, 19" PSS/PSK-Family Table 12: Insulation concept leading to an SELV output circuit Conditions: |: Frontend Switching: regulator. Result Supply. Minimum required :grade:::)Maximum::|: Minimum required safety Measures: to:achieve: the Safety status of voltage of:isolation; tobe: provided'|: DC: output: |: status: of the front-end Specified Safety. status of the: | the switching by: the AC-DC front:end;:::: |: voltage output:circuit output circuit regulator: output including: mains: supplied:::|:from:the circuit battery charger frontend: Battery Double or Reinforced <60V SELV circuit None SELV circuit supply, >60V Earthed hazardous voltage | Input fuse 3 and earthed 4 Earthed SELV considered oD : 5 a secondary circuit or non accessible case circuit as secon- dary circuit Unearthed hazardous Input fuse * and unearthed, Unearthed SELV voltage secondary circuit | non accessible case > circuit Hazardous voltage Input fuse $ and earthed output | Earthed SELV secondary circuit circuit4 and earthed 4 or non circuit accessible case > Mains Basic <60V Earthed SELV circuit 4 None <250 V AC ELV circuit Input fuse * and earthed output ircuit4 4 +60 V Hazardous voltage circuit * and earthed or non An user accessible case secondary circuit Double or reinforced <60V SELV circuit None SELV circuit >60V Double or reinforced insu- | Input fuse ? and unearthed Unearthed SELV lated unearthed hazardous | and non accessible case circuit voltage secondary circuit > 1 The front end output voltage should match the specified input voltage range of the switching regulator. 2 The conductor to the Gi- terminal of the switching regulator has to be connected to earth by the installer according to the relevant safety standard, e.g. IEC/EN 60950. 3 The installer shall provide an approved fuse (slow blow type with the lowest current rating suitable for the application, max. 12.5 A) in a non-earthed input conductor directly at the input of the switching regulator. If Vo+ is earthed, insert the fuse in the Gi- line. For ULs purpose, the fuse needs to be UL-listed. 4 The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC/EN 60950. 5 Has to be insulated from earth by double or reinforced insulation according to the relevant safety standard, based on the maximum output voltage from the front end. Description of Options -9 Extended Temperature Range This option defines an extended operational ambient tem- perature range of Ta = 40...71C. P Potentiometer Note: Option P is not recommended if several modules are operated in parallel connection. Option P excludes R function. The output voltage Up can be adjusted with a screwdriver in the range from 0.9...1.1 of the nominal output voltage Up nom- However, the minimum differential voltage AU, 9 min between input and output voltages as specified in Electrical Input Data should be maintained. E Inrush Current Limitation Note: This option requires increased minimum input volt- age of up to 1 V, dependend on input range. In bat- tery driven applications the use of option E is essen- tial due to very low battery impedances. Inrush current can reach several thousand amperes de- pending on the source and input line conditions. Immedi- ately after the initial application of the input supply, the in- rush current into a switching regulator is limited by parasitic components of the voltage source and power supply input only. The power supply input presents a very low imped- ance to such currents and when driven from a low imped- ance source, for example a battery, the inrush current can peak at several orders of magnitude above the continuous DC input current. Option E dramatically reduces this peak current to a level of U;/1 Q and is recommended for any ap- plication to protect series elements such as switches or cir- cuit brakers and rectifiers. After startup, the resistor is by- passed for normal operation. FAI 11030 Startup Soft start Inrush limit Normal operation (1 Q resistor bypassed) Edition 3/11.97/IN 1.98 - Melcher AG t [ms] 0 40 (typical) 100 (typical) Fig. 15 Option E: Inrush current versus time 5-57PSS/PSK-Family Switching Regulators, 19" Industrial Environment C Thyristor Crowbar Note: The thyristor can be deactivated by removal of the in- put voltage only. The inhibit signal cannot deactivate the thyristor. Option C protects the load against power supply malfunc- tion. It is not designed to sink external currents. As a central overvoltage protection device, the crowbar is usually connected to the external load via distributed in- ductance of the lines. For this reason, the overvoltage at the load can temporarily exceed the trigger voltage U,c. De- pending on the application, further decentralized overvolt- age protection elements may have to be used additionally. A fixed-value monitoring circuit checks the output voltage Table 13: Crowbar trigger levels U, and when the trigger voltage Up c is reached, the thyris- tor crowbar triggers and disables the output. An external connection C (crowbar trigger control) is pro- vided. When crowbar option is used with two or more power supplies in parallel connection, all crowbar trigger terminals (C) should be interconnected. This ensures all crowbar cir- cuits triggering simultaneously in order to disable all out- puts at once. The crowbar trigger voltage is maintained be- tween Vo+ and Go- and to prevent false triggering, the user should ensure that Up max (between Vo+ and Go-) is not ex- ceeded. Characteristics Condition PSS: 5A12 PSS:1212 PSS 2412 PSS'3612 PSK:5A16 PSK:'1216 PSK: 2416 PSK:3616 PSK:5A20 PSK:'1220 PSK: 2420 PSK:3620 PSK'5A25 mines types max Mine Sctypss max Mines type cmax minty omaxc ont Ugc | Trigger voltage | To min... To max 6.3 67 17.8 18.9 28.89 30.6 47.0 50.0 |} VDC U, min. UG} max 14.3 15.21 43.0 45.51 & Delay time ly =0...ho nom 1.5 1.5 1.5 1.5 us 1 Crowbar Trigger voltage with option P B,B1 Cooling Plate Where a cooling surface is available, a cooling plate (option B, or option B1) can be used instead of the standard heatsink. The mounting system must ensure sufficient cool- ing capacity to guarantee that the maximum case tempera- 5 47.2 38.5 io o ture To max is not exceeded. The required cooling capacity can be calculated by the following formula: 100% -7 Ploss = a * (Up * Ip) 6.5 11.2 -EEEEE = I-I-EEEE 140 127 l 13 133.4 20.2 168 ane Fig. 16 Option B, large cooling plate Weight: 1.2 kg Edition 3/11.97/IN 1.98 - Melcher AGIndustrial Environment Switching Regulators, 19" PSS/PSK-Family 5 47.2 38.5 | 11028 =[=[-I=I=I-T= =[-I-I-1-I--F= 111 101 1 | | | | | | | | | | | | | ep ral | F-fp nnn * 168 20.5 171.93 (DIN 41494) Fig. 17 Option B1, small cooling plate Weight: 1.2 kg Accessories A variety of electrical and mechanical accessories are available including: Front panels for 19" rack mounting, Schroff and Intermas systems, 12 and 16 TE. Mating H15 and H15 S4 connectors with screw, solder fast-on or press-fit terminals. Connector retention facilities. DIN-rail mounting adaptor. For more detailed information please refer to Accessory Products. Edition 3/11.97/IN 1.98 - Melcher AG