Rugged Environment
DC-DC Converters >100 Watt
K Series
150 Watt DC-DC Converters
Input to output isolation
Single output: AK...EK 1000
Double output: AK...EK 2000
•
Extremely wide input voltage range
•
Input over- and undervoltage lock-out
•
Efficient input filter and built-in surge and transient
suppression circuitry
•
4 kV
rms
input to output electric strength test
•
Fully isolated outputs
•
Outputs open- and short-circuit proof
•
No derating over entire operating temperature range
Safety according to IEC/EN 60950
LGA
C
K Series
111
4.4"
3U
80
3.2"
16 TE
168
6.6"
Summary
The K series of DC-DC converters represents a broad and
flexible range of power supplies for use in advanced elec-
tronic systems. Features include high efficiency, high reli-
ability, low output voltage noise and excellent dynamic re-
sponse to load/line changes.
The converter inputs are protected against surges and tran-
sients occuring at the source lines. An input over- and
undervoltage lock-out circuitry disables the outputs if the
input voltage is outside the specified range. Certain types
include an inrush current limitation preventing circuit break-
ers and fuses from being damaged at switch-on.
All outputs are open- and short-circuit proof and are pro-
tected against overvoltages by means of a built-in suppres-
sor diode. The outputs can be inhibited by a logic signal ap-
plied to the connector pin 18 (i). If the inhibit function is not
used pin 18 must be connected with pin 14 to enable the
outputs.
LED indicators display the status of the converter and allow
visual monitoring of the system at any time.
Full input to output, input to case, output to case and output
to output isolation is provided. The modules are designed
and built according to the international safety standards
IEC/EN 60950 and have been approved by the safety
agencies LGA (Germany) and UL (USA). The UL Mark for
Canada has been officially recognized by regulatory au-
thorities in provinces across Canada.
The case design allows operation at nominal load up to
71°C in a free air ambient temperature. If forced cooling is
provided, the ambient temperature may exceed 71°C but
the case temperature must remain below 95°C under all
conditions.
A temperature sensor generates an inhibit signal which
disables the outputs if the case temperature
T
C
exceeds the
limit. The outputs are automatically re-enabled when the
temperature drops below the limit.
Various options are available to adapt the converters to in-
dividual applications.
The modules may either be plugged into 19" rack systems
according to DIN 41494, or be chassis mounted.
Table of Contents
Page
Page
Electromagnetic Compatibility (EMC) ............................ 18
Immunity to Environmental Conditions ........................... 20
Mechanical Data ............................................................ 21
Safety and Installation Instructions ................................ 22
Description of Options .................................................... 25
Accessories .................................................................... 31
Summary .......................................................................... 1
Type Survey and Key Data .............................................. 2
Type Key .......................................................................... 3
Functional Description ...................................................... 4
Electrical Input Data ......................................................... 5
Electrical Output Data ...................................................... 7
Auxiliary Functions ......................................................... 14
MELCHER
The Power Partners.
Edition 4/4.99
1/31
K Series
Type Survey and Key Data
DC-DC Converters >100 Watt
Rugged Environment
Non standard input configurations or special custom adaptions are available on request. See also:
Commercial Informa-
tion: Inquiry Form for Customized Power Supply.
Table 1a: Type survey AK
Output 1
Output 2
Input Voltage
Options
h
min
[%]
78
80
80
82
78
79
79
78
79
79
-9
E
3
D
V
6
P
T
B1
B2
U
o nom
[V DC]
5.1
12.0
15.0
24.0
24.0
4
30.0
4
48.0
4
12.0
15.0
24.0
I
o nom
[A]
2
20.0
10.0
8.0
5.0
5.0
4.0
2.5
5.0
4.0
2.5
U
o nom
[V DC]
-
-
-
-
-
-
-
12.0
5
15.0
5
24.0
5
I
o nom
[A]
2
-
-
-
-
-
-
-
5.0
4.0
2.5
U
i min
...U
i max
8...35 V DC
AK 1001-7R
AK 1301-7R
AK 1501-7R
AK 1601-7R
AK 2320-7R
AK 2540-7R
AK 2660-7R
AK 2320-7R
AK 2540-7R
AK 2660-7R
Table 1b: Type survey BK, FK, CK
Output 1
Output 2
Input Voltage Range and Efficiency
1
Options
h
min
[%]
79
82
84
86
80
82
84
80
82
84
-9
E
3
D
V
6
P
T
B1
B2
U
o nom
[V DC]
5.1
12.0
15.0
24.0
24.0
4
30.0
4
48.0
4
12.0
15.0
24.0
I
o nom
[A]
2
25.0
12.0
10.0
6.0
6.0
5.0
3.0
6.0
5.0
3.0
U
o nom
[V DC]
-
-
-
-
-
-
-
12.0
5
15.0
5
24.0
5
I
o nom
[A]
2
-
-
-
-
-
-
-
6.0
5.0
3.0
U
i min
...U
i max
14...70 V DC
BK 1001-7R
BK 1301-7R
BK 1501-7R
BK 1601-7R
BK 2320-7R
BK 2540-7R
BK 2660-7R
BK 2320-7R
BK 2540-7R
BK 2660-7R
h
min
[%]
79
81
82
84
80
80
80
80
80
80
U
i min
...U
i max
20...100 V DC
FK 1001-7R
FK 1301-7R
FK 1501-7R
FK 1601-7R
FK 2320-7R
FK 2540-7R
FK 2660-7R
FK 2320-7R
FK 2540-7R
FK 2660-7R
h
min
[%]
80
82
85
86
81
83
84
81
83
84
U
i min
...U
i max
28...140 V DC
CK 1001-7R
CK 1301-7R
CK 1501-7R
CK 1601-7R
CK 2320-7R
CK 2540-7R
CK 2660-7R
CK 2320-7R
CK 2540-7R
CK 2660-7R
Table 1c: Type survey DK, EK
Output 1
Output 2
Input Voltage Range and Efficiency
1
Options
h
min
[%]
-
84
84
84
81
80
83
81
80
83
-9
E
3
D
V
6
P
T
B1
B2
U
o nom
[V DC]
5.1
12.0
15.0
24.0
24.0
4
30.0
4
48.0
4
12.0
15.0
24.0
1
2
I
o nom
[A]
2
25.0
12.0
10.0
6.0
6.0
5.0
3.0
6.0
5.0
3.0
U
o nom
[V DC]
-
-
-
-
-
-
-
12.0
5
15.0
5
24.0
5
I
o nom
[A]
2
-
-
-
-
-
-
-
6.0
5.0
3.0
U
i min
...U
i max
44...220 V DC
DK 1001-7R
DK 1301-7R
DK 1501-7R
DK 1601-7R
DK 2320-7R
DK 2540-7R
DK 2660-7R
DK 2320-7R
DK 2540-7R
DK 2660-7R
h
min
[%]
79
83
86
87
81
82
85
81
82
85
U
i min
...U
i max
67...385 V DC
-
EK 1301-7R
EK 1501-7R
EK 1601-7R
EK 2320-7R
EK 2540-7R
EK 2660-7R
EK 2320-7R
EK 2540-7R
EK 2660-7R
3
4
5
6
Efficiency at
U
i nom
and
I
o nom
.
If the output voltages are increased above
U
o nom
via R-input control, option P setting, remote sensing or option T, the output currents
should be reduced accordingly so that
P
o nom
is not exceeded.
Option E only for CK, DK, EK types.
Series connection of output 1 and 2.
Second output semi-regulated.
Option V for K 1001 types only.
MELCHER
The Power Partners.
Edition 4/4.99
2/31
Rugged Environment
Type Key
Type Key
Input voltage range
U
i
:
DC-DC Converters >100 Watt
K Series
C K 2 5 40 -7 E R P D V T B1
8...35 V DC
14...70 V DC
20...100 V DC
28...140 V DC
44...220 V DC
67...385 V DC
............... A
.............. B
.............. F
.............. C
.............. D
.............. E
Series ............................................................................... K
Number of outputs ....................................................... 1...2
Single output units:
Nominal voltage output 1 (main output),
U
o1 nom
5.1 V ....... 0, 1, 2
12 V ............... 3
15 V ........... 4, 5
24 V ............... 6
other voltages ........... 7, 8
Other specifications for
single output modules ...... 01...99
Symmetrical double output units:
Nominal voltage output 1/output 2,
U
o1/2 nom
12 V/12 V
1
(24 V series connection)
15 V/15 V
1
(30 V series connection)
24 V/24 V
1
(48 V series connection)
other symmetrical voltages
............. 20
............. 40
............. 60
...... 70...99
Operational ambient temperature range
T
A
:
–25…71°C .............. -7
–40…71°C .............. -9
customer specific ........ -0...-6
Auxiliary functions and options:
Inrush current limitation .................................................... E
Output voltage control input ............................................ R
Potentiometer (output voltage adjustment) ...................... P
Save data signal (D0...DD, to be specified) .................... D
ACFAIL signal (V0, V2, V3, to be specified) .................... V
Current sharing ................................................................ T
Cooling plate standard case .......................................... B1
Cooling plate for long case 220 mm .............................. B2
1
3
2
2
4
4, 5
2
3
4
5
External wiring of main and second output depending upon the desired output configuration (see:
R-Function for Different Output
Configurations).
Feature R excludes option P and vice versa.
Option E available for CK, DK and EK types.
Option D excludes option V and vice versa.
Option V available for K 1001 type.
Example:
CK 2540-7PD3: DC-DC converter, input voltage range 28...140 V, double output, each providing 15 V/ 5 A,
equipped with potentiometer and undervoltage monitoring option. Ambient temperature –25...71°C.
MELCHER
The Power Partners.
Edition 4/4.99
3/31
K Series
Functional Description
DC-DC Converters >100 Watt
Rugged Environment
The input voltage is fed via an input fuse, an input filter, and
an inrush current limiter to the input capacitor. This capaci-
tor sources a single transistor forward converter. Each out-
put is powered by a separate secondary winding of the
main transformer. The resultant voltages are rectified and
their ripples smoothed by a power choke and output filter.
The control logic senses the main output voltage
U
o1
and
generates, with respect to the maximum admissible output
currents, the control signal for the primary switching tran-
sistor.
The second output of double output units is controlled by
the main output but has independent current limiting. If the
main output is driven into current limitation, the second out-
put voltage will fall as well and vice versa.
P
03057
26
Vi+
28
2
1
16 R
Y
18 i
20 D/V
22 T
12 S+
4
Vo+
6
Forward converter
(approx. 120 kHz)
Y
Input filter
Control circuit
Output
filter
8
Vo–
10
4
3
Y
Vi–
30
32
24
Y
14 S–
Fig. 1
Block diagram of single output converters AK…EK 1000
P
–
+
03058
16 R
Vi+
26
28
2
1
Y
18 i
20 D
22 T
Forward converter
(approx. 110 kHz)
Y
Input filter
Control circuit
Output 1
filter
12 Vo1+
14 Vo1–
4
6
Vo2+
4
3
Y
Y
Vi–
30
32
Y
Y
Output 2
filter
8
10
Vo2–
24
Fig. 2
Block diagram of symmetrical double output converters AK...EK 2000
1
2
3
4
–
+
Transient suppressor (VDR) in CK, DK, EK, FK types
Transient suppressor (diode) in AK, BK, CK, FK types
Inrush current limiter in CK, DK, EK types (NTC or Opt. E), -9 versions exclude the NTC
Input fuse
MELCHER
The Power Partners.
Edition 4/4.99
4/31
Rugged Environment
Electrical Input Data
DC-DC Converters >100 Watt
K Series
General Conditions
–
T
A
= 25°C, unless
T
C
is specified.
– Pin 18 connected to pin 14,
U
o
adjusted to
U
o nom
(option P); R input not connected.
– Sense line pins S+ and S– connected to Vo+ and Vo– respectively.
Table 2a: Input data
Input
Characteristics
Conditions
min
8
15
9.0
2.5
1.5
65
3
AK
typ
max
35
min
14
BK
typ
max
70
30
6.0
2.5
1.5
100
3
FK
min
20
48
3.75
2.5
1.5
70
3
typ
max
100
Unit
V DC
U
i
U
i nom
I
i
P
i0
P
i inh
R
i
R
NTC
C
i
U
i RFI
U
i abs
Operating input voltage
Nominal input voltage
Input current
No-load input power
Idle input power
Input resistance
NTC resistance
2
Input capacitance
Conducted input RFI
Radiated input RFI
Input voltage limits
without damage
I
o
= 0…I
o nom
T
C min
…
T
C max
U
i nom
,
I
o nom 1
U
i min
…
U
i max
unit inhibited
A
W
T
C
= 25°C
mΩ
µF
830
EN 55022
U
i nom
,
I
o nom
0
A
A
1250
300
B
A
450
1200
B
B
1800
40
0
80
0
100
V DC
Table 2b: Input data
Input
Characteristics
Conditions
min
28
60
3.0
2.5
1.5
150
800
660
EN 55022
U
i nom
,
I
o nom
0
B
B
154
0
1000
170
1600
260
B
B
400
4
0
400
CK
typ
max
140
min
44
110
1.6
2.5
1.5
180
3200
210
B
B
400
V DC
400
µF
DK
typ
max
220
min
67
220
0.8
2.5
1.5
mΩ
A
W
EK
typ
max
385
V DC
U
i
U
i nom
I
i
P
i0
P
i inh
R
i
R
NTC
C
i
U
i RFI
U
i abs
1
2
Operating input voltage
Nominal input voltage
Input current
No-load input power
Idle input power
Input resistance
NTC resistance
2
Input capacitance
Conducted input RFI
Radiated input RFI
Input voltage limits
without damage
I
o
= 0…I
o nom
T
C min
…
T
C max
U
i nom
,
I
o nom 1
U
i min
…
U
i max
unit inhibited
T
C
= 25°C
3
4
With double output modules, both outputs loaded with
I
o nom
.
Valid for -7 versions with NTC, (-9 versions exclude the NTC). Initial switch-on cycle. Subsequent switch-on/off cycles increase the in-
rush current peak value.
AK, BK and FK types have no NTC (inrush current limiter) fitted.
1 s max., duty cycle 1% max.
Input Transient Protection
A suppressor diode or a VDR (depending upon the input
voltage range) together with the input fuse and a symmetri-
cal input filter form an effective protection against high input
transient voltages which typically occur in most installa-
tions, but especially in battery driven mobile applications.
Nominal battery voltages in use are: 12, 24, 36, 48, 60, 72,
110 and 220 V. In most cases each nominal value is speci-
fied in a tolerance of –30%...+25%.
In certain applications, surges according to RIA 12 are
specified in addition to those defined in IEC 571-1. The
power supply must not switch off during these surges and
since their energy can practically not be absorbed an ex-
tremely wide input range is required. The EK input range for
110 V batteries has been designed and tested to meet this
requirement.
Inrush Current Limitation
The CK, DK, EK modules incorporate an NTC resistor in
the input circuitry which - at initial turn on - reduces the peak
inrush current value by a factor of 5...10 to protect connec-
tors and switching devices from damage. Subsequent
switch-on cycles within short periods will cause an increase
of the peak inrush current value due to the warming-up of
the NTC resistor. See also:
E option.
MELCHER
The Power Partners.
Edition 4/4.99
5/31
PCB Design
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