Rugged Environment
AC-DC Converters >100 Watt
K Series
150 Watt AC-DC Converters with PFC
Input to output isolation
Single output: LK 4000 5.1, 12, 15, 24 V
Double output: LK 5000 2
×
12, 2
×
15, 2
×
24 V
•
Universal input voltage range
•
Power factor
>0.95,
harmonics
<IEC/EN
61000-3-2
•
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 overload, 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 4000/5000-series of AC-DC converters represents a
flexible range of power supplies for use in advanced elec-
tronic systems. Features include full power factor correc-
tion, high efficiency, high reliability, low output voltage noise
and excellent dynamic response to load/line changes.
The converter inputs are protected against surges and tran-
sients occurring at the source lines. An input over- and
undervoltage lock-out circuitry disables the outputs if the
input voltage is outside the specified ranges. Inrush current
limitation is included preventing circuit breakers and fuses
from being damaged at switch-on.
All outputs are overload, open- and short-circuit proof and
are protected against overvoltages by means of a built-in
suppressor diode. The outputs can be inhibited by a logic
signal applied to the connector pin 18 (i). If the inhibit func-
tion is not used pin 18 must be connected with pin 14 to en-
able 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 inch rack sys-
tems according to DIN 41494, or be chassis mounted.
Important:
These products are intended to replace the
LK 1000 and LK 2000 in order to comply with IEC/EN
61000-3-2.
Table of Contents
Page
Page
Electromagnetic Compatibility (EMC) ............................ 16
Immunity to Environmental Conditions ........................... 17
Mechanical Data ............................................................ 18
Safety and Installation Instructions ................................ 19
Description of Options .................................................... 22
Accessories .................................................................... 28
Summary .......................................................................... 1
Type Survey and Key Data .............................................. 2
Type Key .......................................................................... 2
Functional Description ...................................................... 3
Electrical Input Data ......................................................... 4
Electrical Output Data ...................................................... 6
Auxiliary Functions ......................................................... 12
MELCHER
The Power Partners.
Edition 4/4.99
1/28
K Series
Type Survey and Key Data
AC-DC Converters >100 Watt
Rugged Environment
Non standard input/output configurations or special custom adaptions are available on request. See also:
Commercial In-
formation: Inquiry Form for Customized Power Supply.
1
Table 1: Type survey LK
Output 1
Output 2
Input voltage range and efficiency
1
Options
2
U
o nom
[V DC]
5.1
12.0
15.0
24.0
24.0
3
30.0
3
48.0
3
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
4
15.0
4
24.0
4
I
o nom
[A]
2
-
-
-
-
-
-
-
6.0
5.0
3.0
U
i min
...U
i max
85...255 V AC
7
LK 4003-6R
6
LK 4301-7R
LK 4501-7R
LK 4601-7R
LK 5320-7R
LK 5540-7R
LK 5660-7R
LK 5320-7R
LK 5540-7R
LK 5660-7R
h
min
[%]
78
85
85
86
83
83
84
83
83
84
-9
E
D
V
5
P
T
B1
B2
3
4
5
6
7
Efficiency at
U
i nom
and
I
o nom
.
If the output voltages are increased
above
U
o nom
via R-input control, op-
tion P setting, remote sensing or op-
tion T, the output currents must be
reduced accordingly so that
P
o nom
is
not exceeded.
Series connection of output 1 and 2
see:
R-Function for different output
configurations.
Second output semi-regulated.
Option V for K 4003 types only.
LK 4003-6R types are specified for a
max. ambient temperature
T
A
= 60°C
and a max. case temperature
T
C
=
90°C. (see:
Output power derating).
For DC-input please ask your local
Melcher partner.
Type Key
Type Key
Input voltage range
U
i
: 85…255 V AC ............................. L
Series ............................................................................... K
Number of outputs (4 for single, 5 for double outputs) 4...5
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) ......... 20
15 V/15 V
1
(30 V series connection) ......... 40
24 V/24 V
1
(48 V series connection) ......... 60
other symmetrical voltages ................. 70...99
Operational ambient temperature range
T
A
:
–25…71°C .................................................. -7
–40…71°C .................................................. -9
–25…60°C .................................................. -6
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 (V2, V3) ................................ V
Current sharing ............................................ T
Cooling plate standard case ...................... B1
Cooling plate for long case 220 mm .......... B2
1
L K 5 5 40 -7 E R P D V T B1
2
2
3
3, 4
3
External wiring of main and second output depending upon the desired output configuration (see:
R-Function for different output con-
2
Feature R excludes option P and vice versa.
figurations.
4
Option V for LK 4000 types with 5 V outputs.
Option D excludes option V and vice versa.
Example:
LK 5540-7PD3: Power factor corrected AC-DC converter, input voltage range 85...255 V AC, double output,
each providing 15 V/5 A, equipped with potentiometer and undervoltage monitoring option. Ambient tempera-
ture –25...71°C.
Edition 4/4.99
2/28
MELCHER
The Power Partners.
Rugged Environment
Functional Description
AC-DC Converters >100 Watt
K Series
The input voltage is fed via an input fuse, an input filter, a
rectifier and an inrush current limiter to a single transistor
boost converter. This converter provides a sinusoidal in-
put current (IEC/EN 61000-3-2, class D equipment) and
sources a capacitor with a voltage of 360-370 VDC. This
capacitor sources a single transistor forward converter.
Each output is powered by a separate secondary winding
on the main transformer. The resultant voltages are recti-
fied and their ripples smoothed by a power choke and an
output filter. The control logic senses the main output volt-
age
U
o1
and generates, with respect to the maximum ad-
missible output currents, the control signal for the primary
switching transistor.
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
03001
Forward converter (approx. 80 kHz)
26
N∼ 28
1
Y
Boost converter (PFC)
Input filter
360 V DC
4
Output
filter
C
i
+
Y
Control circuit
16
18
20
22
12
4
6
8
10
R
i
D/V
T
S+
Vo+
3
Y
Vo–
2
P~ 30
32
24
Y
14 S–
Fig. 1
Block diagram of single output converters LK 4000
P
–
+
03002
Forward converter (approx. 80 kHz)
N~ 26
28
1
Y
Boost converter (PFC)
Input filter
Output 1
filter
C
i
+
360 V DC
4
Y
Control circuit
16
18
20
22
R
i
D
T
12 Vo1+
14 Vo1–
4
Vo2+
6
8
Vo2–
10
3
Y
P~ 30
32
Y
24
Y
Output 2
filter
2
Y
Fig. 2
Block diagram of symmetrical double output converters LK 5000
1
2
3
4
–
+
Transient suppressor (VDR).
Inrush current limiter (NTC or option E), -9 versions exclude the NTC.
Input fuse.
Hold-up capacitor.
MELCHER
The Power Partners.
Edition 4/4.99
3/28
K Series
Electrical Input Data
AC-DC Converters >100 Watt
Rugged Environment
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 2: Input data
Input
Characteristics
Conditions
min
85
230
0.8
9.0
3.5
480
3200 4000
80
EN 55022
U
i nom
,
I
o nom
–400
–400
100
B
B
400
400
V DC
V
P
120
µF
10
5
mΩ
A
rms
W
LK
typ
max
255
Unit
V AC
3, 4
U
i
U
i nom
I
i
P
i o
P
i inh
R
i
R
NTC
C
i
U
i RFI
Operating input voltage
I
o
= 0…I
o nom
T
C min
…
T
C max
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
U
i nom
,
I
o nom 1
U
i min
…
U
i max
unit inhibited
T
C
= 25°C
U
i abs
Input voltage limits
(without damage)
1
With double output modules, both outputs loaded with
I
o nom
.
Valid for -7, -6, versions with NTC, (-9 versions exclude the NTC). Initial switch-on cycle. Subsequent switch-on/off cycles increase the
inrush current peak value.
3
AC frequency range 47...63 Hz.
4
For DC-input please ask your local Melcher partner
2
Input Fuse
A fuse mounted inside the converter protects the module
against severe defects. (If operated from a DC-source this
fuse may not fully protect the module when the input volt-
age exceeds 200 V DC! In applications where the convert-
ers operate at source voltages above 200 V DC an external
fuse or a circuit breaker at system level should be in-
stalled!)
Reverse Polarity Protection
Should the input voltage to the unit be supplied from a DC
source the built-in bridge rectifier provides reverse polarity
protection.
Inrush Current Limitation
The modules of the versions -7, -6, incorporate an NTC re-
sistor in the input circuitry which - at initial turn on - reduces
the peak inrush current value by a factor of 5...10 to protect
connectors and switching devices from damage. Subse-
quent switch-on cycles within short periods will cause an
increase of the peak inrush current value due to the warm-
ing-up of the NTC resistor. See also:
E option.
Inrush Current Peak Value
Table 3: Fuse Specification
Module
LK4/5000
1
1
Fuse type
slow-blow
Fuse rating
SP T
4 A, 250 V
Fuse size 5
×
20 mm
Input Under-/Overvoltage Lock-out
If the input voltage remains below approx. 65 V AC or ex-
ceeds approx. 280 V AC an internally generated inhibit sig-
nal disables the output(s). When checking this function the
absolute maximum input voltage rating
U
i abs
should be
considered! Between
U
i min
and the undervoltage lock-out
level the output voltage may be below the value defined in
table:
Output data
(see:
Technical Information: Measuring
and Testing).
Input Transient Protection
A VDR together with the input fuse and a symmetrical input
filter form an effective protection against high input tran-
sient voltages.
The inrush current peak value (initial switch-on cycle) can
be determined by following calculation:
U
i rms
•
√2
I
inr p
= ––––––––––––––––
(R
s ext
+
R
i
+
R
NTC
)
04001
R
s ext
I
inr p
R
i
R
NTC
U
i rms
C
i
Fig. 3
Equivalent circuit diagram for input impedance
MELCHER
The Power Partners.
Edition 4/4.99
4/28
Rugged Environment
Input Inrush Current Characteristic
I
inr
[A]
AC-DC Converters >100 Watt
Static Input current Characteristic
04006
K Series
130
100
l
i
[A
rms
]
3
2.5
2
1.5
1
04002
U
i
= 255 V
rms
U
i
= 115 V
rms
50
0.5
50
100
150
200
250
U
i
[V AC]
300
Fig. 6
Input current versus input voltage at I
o nom
1
0
1
2
3
t
[ms]
Fig. 4
Theoretical input inrush current versus time at U
i
255 V
rms
and 115 V
rms
, R
ext
= 0
Harmonic Currents
The harmonic distortion is well below the limits specified in
IEC/EN 61000-3-2, class D.
I
i [mA/W]
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0
3
5
7
9
11
13
15
17
19
Harm.
Limit class D according
to IEC/EN 61000-3-2
04042
Power Factor, Harmonics
Power factor correction is achieved by controlling the input
current waveform synchronously with the input voltage
waveform. The power factor control is active under all oper-
ating conditions.
Power Factor
1
0.95
0.9
0.85
0.8
0.75
0.7
0
0.2
0.4
0.6
0.8
1
I
o
/I
o nom
U
i
= 230 V AC
U
i
= 85 V AC
04004
Fig. 5
Harmonic currents at the input, IEC/EN 61000-3-2, class D.
U
i
= U
i nom
, I
o
= I
o nom
.
Fig. 7
Power factor versus output power at U
i
230 V AC and
85 V AC.
MELCHER
The Power Partners.
Edition 4/4.99
5/28
Making friends through disassembly
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