Accessories
Temperature Sensors
Description
Melcher offers a wide range of battery charger systems
consisting of adapted power supplies and appropriate
temperature sensors. The (lead-acid) batteries are charged
according to the battery temperature and the properties of the
battery cells. When the battery is fully charged, it is maintained
at the float charge voltage, which represents the optimum point
for maximum available energy and optimum life expectancy of
the battery. It is essential to place the sensor as close to the
battery as possible thus sensing the battery temperature.
The most suited sensor model is defined mainly by three
parameters: The nominal battery voltage (e.g. 24 V or 48 V),
the temperature coefficient of the cells (e.g. –3.0 mV/K), and
the nominal floating charge voltage per cell at 20 °C (e.g. 2.27
V/cell). The latter two are specified in the data sheet of the
battery.
The temperature sensors K can be used with all Melcher
converters with the standard R-input. This input allows for the
control of the output voltage, see fig. 1. The open R input ex-
hibits a source voltage of 2.5 V with a source resistor of 4 kΩ.
The sensor can directly be connected to the R-input and is
powered from the battery voltage, as shown in fig. 2. The
sensor supersedes the internal voltage control circuit of the
converter and adjusts the output voltage exactly to what is
needed for the battery.
Note:
Some converters exhibit a current droop characteristic to
ease the operation in parallel connection. If the temperature sensor
K is connected to the R-input, it cancels the droop characteristic
and impedes current sharing. We recommend the use of
converters with true current sharing (option T).
Different models of battery sensors are available depending on
the battery specifications. Table 1 gives an overview of
available sensors.
Note:
Other types for different cell voltages, temperature co-
efficients, and cable lengths are available on request.
For example, if the application uses a 48 V battery consisting of
24 cells of 2.27 V, a temperature coefficient of – 3.0 mV/K and
2 m cable length, the sensor type is S-KSMH48-2.27-30-2.
Fig. 3 shows the charge voltage depending on the temperature
and the battery type. If the sensor is disconnected, the
converter output voltage is regulated to
V
o safe
. This voltage
prevents the battery from being overcharged even at high
temperature. Overcharging a battery is dangerous and can
cause the battery to explode.
Table of Contents
Page
Page
Mechanical Dimensions ........................................................ 3
Temperature Sensors for the T Series .................................. 3
Description ............................................................................ 1
Fail Safe Operation and Suitable Converters ....................... 2
Converters with DC Input ...................................................... 3
Copyright © 2016, Bel Power Solutions Inc. All rights reserved.
MELCHER
BCD20004 Rev AC, 12-Apr-2016
The Power Partners.
Page 1 of 2
Accessories
Temperature Sensors
Table 1: Sensors for converters with standard R input
Vo+
V
ref
= 2.5 V
+
Control
logic
N
Vo-
4 kΩ
R
Battery
voltage
nom.[V]
12
12
24
24
24
24
24
48
48
03099d
JM114
L
Sensor
type
S-KSMH12-2.27-30-2
S-KSMH12-2.27-35-2
S-KSMH24-2.27-30-2
S-KSMH24-2.27-35-2
S-KSMH24-2.31-35-0
S-KSMH24-2.31-35-2
S-KSMH24-2.35-35-2
S-KSMH48-2.27-30-2
S-KSMH48-2-27-35-2
Cell
voltage
[V]
2.27
2.27
2.27
2.27
2.31
2.31
2.35
2.27
2.27
Cell temp. Cable
coefficient length
[mV/K]
[m]
– 3.0
– 3.5
– 3.0
– 3.5
– 3.5
– 3.5
– 3.5
– 3.0
– 3.5
2
2
2
2
4.5
2
2
2
2
Fig. 1
Block diagram of Power-One converters suited to be
controled by a battery sensor.
Input
Power
supply
Vo+
Vo–
R
Load
+
– Sensor
wires
Sensor Temperature
sensor
cable
R
Vo+
ϑ
+
+
–
white
brown
Fuse
green
Battery
+
–
05174a
Vo–
Battery
Fig. 2
Block diagram of the sensor.
Temperature sensor
Fig. 4
Connection of a sensor to the standard R input
output voltage setting; see table 2. These converters differ from
the respective standard models in the nominal output voltage
and output current setting. Without the sensor connected to
the R-pin, the output voltage is set to
V
o safe
. This voltage is
higher than the nominal battery voltage such avoiding
discharging the battery, but still lower than the theoretically
needed float charge voltage. As soon as the sensor is
connected to the R-pin, the output voltage will be set to the
correct value. This is essential for best energy and battery life
time.
The standard converters may also be used for battery charging
controled by the temperature sensor. However, the correct
output voltage at low temperature might not be reached. If the
sensor is used only for decreasing the output voltage, for
instance, if using a 15 V power supply to charge a 12 V battery,
Sensor002a
Fail Safe Operation and Suitable Converters
To prevent batteries from overcharging but still maintain a
minimum charge in case of interruption of the cable from the
sensor to the converter, we offer models with special nominal
Cell voltage [V]
2.45
2.40
V
o max
2.35
2.30
2.25
2.20
2.15
V
o safe
2.10
–20
06123c
L
V
ref
= 2.5 V
–10
0
10
20
30
40
50 °C
Vo+
4 kΩ
R
+
Control
logic
N
Vo-
R
safe
V
C
= 2.27 V, –3 mV/K
V
C
= 2.31 V, –3 mV/K
V
C
= 2.27 V, –3.5 mV/K
V
C
= 2.31 V, –3.5 mV/K
Fig. 3
Float charge voltage versus temperature for different
temperature coefficients.
Fig. 5
Connection of R
safe
, if standard converter models are used.
MELCHER
BCD20004 Rev AC, 12-Apr-2016
The Power Partners.
Page 2 of 2
Accessories
Temperature Sensors
Table 2: Special models for battery charging
V
nom
[V]
12
24
36
48
60
1
2
3
V
safe
[V]
12.84
25.68
38.52
51.36
64.2
P
o
= 50 W
LM1781-7R
LOK4140-2RLD
LM1782-7R
LOK4240-2RLD
LM1783-7R
LM1784-7R
LOK4740-2RLD
LM1785-7R
P
o
= 70 W
LH1781-2R
LH1782-2R
LH1783-2R
LH1784-2R
LH1785-2R
P
o
= 100 W
P
o
= 125 W
LS4740-9ER
2
LWR1140-6EM1
LS5740-9ER
2
LWR1240-6EM1
LWR1840-6EM1
P
o
= 150 W
LK4740-9ER
CK1740-9R
3
LK5740-9ER
CK2740-9R
3
P
o
= 250 W
LWN1140-6EM1
P
o
= 280 W
P
o
= 375 W
P
o
= 500 W
LKP 5740 -9ER LKP5741-5ER
LWN1240-6EM1
LWN1840-6EM1
LKP5740-9ER
1
LKP5741-5ER
1
LWN1740-6EM1
LXR1240-6M1
LXN1240-6M1
LXR1840-6EM1
LXN1840-6EM1
LXR1740-6M1
LXN1740-6M1
LS5740-9ER
1 2
LK5740-9ER
1
LWR1740-6EM1 CK2740-9R
1 3
Both outputs connected in series.
Similar models with DC input (DS/LS1740, DS/LS2740) are available as well.
DC input; DK/LK1740 and DK/LK2740 are available as well.
NFND
Not for new designs
then disconnecting the sensor results in a dangerous situation.
We recommend to add a resistor between the R input and its
reference, which adjusts the output voltage with disconnected
sensor to
V
o safe
. This is shown in fig. 5.
Mechanical Dimensions
All dimensions in mm.
European
Projection
Converters with DC Input
9.8 (0.4")
Most of the models listed in table 2 have an AC input. However,
there are applications requiring battery charging from a DC
source – sometimes even without electrical isolation.
For this purpose, DC-DC converters of Q, P, M, S, K, or R
Series may be used, such as all switching regulators PSx,
provided that they exhibit the standard R input.
For safe operation, we recommend to provide a resistor
R
safe
with the correct value (see fig. 5).
L
56 (2.2")
26 (1.02")
09125a
L = 2 m (standard length)
other cable lengths on request
adhesive tape
Fig. 6
S-KSMH temperature sensor.
Temperature Sensors for the T Series
T Series battery chargers exhibit a cell voltage selector switch
to set the required floating charge voltage directly at the
converter. A special temperature sensor T matches to the T
Series. All details are provided in the T Series data sheet at our
web site.
NUCLEAR AND MEDICAL APPLICATIONS - These products are not designed or intended for use as critical components in life support systems,
equipment used in hazardous environments, or nuclear control systems.
TECHNICAL REVISIONS - The appearance of products, including safety agency certifications pictured on labels, may change depending on the
date manufactured. Specifications are subject to change without notice.
Copyright © 2016, Bel Power Solutions Inc. All rights reserved.
www.belpowersolutions.com
MELCHER
BCD20004 Rev AC, 12-Apr-2016
The Power Partners.
Page 3 of 2
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