HP Series Data Sheet
120–192 Watt 10:1 DC-DC Converters
Features
• Extremely wide input voltage range from 12.5 to 154
VDC in the same model
• RoHS-compliant
• Class I equipment
• Compliant with EN 50155, EN 50121-3-2, and IEC/EN
61000-4-2, -3, -4, -5, -6, -8.
• Fire&smoke: Compliant with EN 45545 and NF-F-16
• Input over- and programmable undervoltage lockout
including inhibit function
• Low inrush current
• 10 ms interruption time
• 1 to 4 independent, isolated outputs: no load, overload,
and short-circuit proof
• Rectangular current limiting characteristic
• Redundant operation (n+1), sense lines, active current
sharing option, output voltage adjust
111
4.4"
3U
20
0.8"
4 TE
164
6.5"
• Hipot test voltage 2.8 kVDC
• Very high efficiency up to 92.5 %
• All PCB boards protected by lacquer
• Extremely slim case (4 TE, 20 mm), fully enclosed
• Very high reliability
Safety-approved to the latest edition of IEC/EN
60950-1 and UL/CSA 60950-1.
Description
These extremely compact DC-DC converters incorporate all
necessary input and output filters, signaling and protection
features, which are required in the majority of applications.
The converters provide important advantages, such as
flexible output power through total current limitation,
extremely high efficiency, excellent reliability, very low ripple
and RFI noise levels, full input-to-output isolation, negligible
inrush current, soft start, over temperature protection, inter-
ruption time, and input over- and undervoltage lockout.
The converters are particularly suitable for rugged environ-
ments, such as railway applications. They have been designed
in accordance with the European railway standards EN 50155
and EN 50121-3-2. All printed circuit boards are coated with a
protective lacquer. The converter covers a total input voltage
range from 12.5 to 154 VDC in the same model. The input is
protected against surges and transients occurring on the
source lines. The outputs are continuously open- and short-
circuit proof.
Full system flexibility and n+1 redundant operating mode are
possible due to series or parallel connection capabilities of the
Table of Contents
Page
Page
Immunity to Environmental Conditions .............................. 20
Mechanical Data ................................................................. 22
Safety and Installation Instructions .................................... 23
Description of Options ........................................................ 25
Accessories ........................................................................ 26
Model Selection .................................................................... 2
Functional Description .......................................................... 5
Electrical Input Data ............................................................. 8
Electrical Output Data ........................................................ 11
Auxiliary Functions ............................................................. 16
Electromagnetic Compatibility (EMC) ................................ 18
Copyright © 2017, Bel Power Solutions Inc. All rights reserved.
BCD.00316 Rev AI, 19-May-2017
MELCHER
The Power Partners.
Page 1 of 26
HP Series Data Sheet
120–192 Watt 10:1 DC-DC Converters
outputs under the specified conditions. When several con-
verters with T option are connected in parallel, a single-wire
connection between these converters ensures good current
sharing. LEDs at the front panel and an isolated output OK
signal indicate the status of the converter. Voltage suppressor
diodes and an independent overvoltage monitor protect the
outputs against an internally generated overvoltage.
The converters are designed using transformers with planar
technology. The input voltage is fed to a booster, which
generates approximately 70 V. If
V
i
is higher, the booster
becomes simply a diode. The resulting intermediate voltage
supplies the powertrains.
There are two powertrains fitted to a converter, each con-
sisting either of a regulated single output with synchronous
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 inductors
together with circuit symmetry ensure a small deviation
between main and tracking output.
A storage capacitor charged to approx. 70 V enables the
powertrains to operate during the specified interruption time.
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 3 U /4 TE only, but
they can also be chassis-mounted by screws or fitted with a
heat sink. The connector type is H15. The fully enclosed
black-coated aluminum case acts as heat sink and RFI shield,
such protecting the converter together with the coating of all
components against environmental impacts.
Model Selection
Note:
Only standard models are listed. Other voltage configura-
tions are possible on request.
Table 1: Model types
Output 1, 4
V
o nom
[V]
5.1
12
15
24
5.1
5.1
5.1
12
15
24
5.1
5.1
5.1
12,
15,
15,
24,
1
2
3
4
5
6
Output 2, 3
P
o 50 6
[W]
184
192
192
192
92
92
92
96
96
96
92
92
92
96
96
96
96
V
o nom
[V]
-
-
-
-
5.1
12
15
12
15
24
12, 12
4
15, 15
4
24, 24
4
12, 12
4
15, 15
4
24, 24
4
24, 24
4
P
o nom 5
P
o 50 6
[W]
[W]
-
-
-
-
61
61
61
61
61
60
60
60
60
60
60
60
60
-
-
-
-
92
92
92
92
92
96
96
96
96
96
96
96
96
V
i min3
[V]
12.5
Input voltage
V
i cont
[V]
16.8 – 137.5
η
2 41
η
110 2
Model
Options
P
o nom 5
[W]
122
122
122
122
61
61
61
61
61
60
61
61
61
60
60
60
60
V
i max3
min typ min. typ
[V] [%] [%] [%] [%]
154
86.5
89
87
90.5
HP1001-9RTG
HP1301-9RTG
HP1501-9RTG
HP1601-9RTG
HP2001-9RG
HP2020-9RG
HP2040-9RG
HP2320-9RG
HP2540-9RG
HP2660-9RG
HP3020-9RG
HP3040-9RG
HP3060-9RG
HP4320-9RG
HP4540-9RG
HP4560-9RG
HP4660-9RG
U, V, B
89
12.5
16.8 – 137.5
154
86.5
89
87
90
90.5
U, V, T,
B
91
89.5
12.5
12.5
16.8 – 137.5
16.8 – 137.5
154
154
86.5 87.5
88.5
88
86.5 89
87
92.5
91
88
90
90
90
U, V, B
U, V, T
B
U, V, B
87
12
4
15
4
15
4
24
4
12.5
16.8 – 137.5
154
86.5 87.5
87
88
Efficiency at
T
A
= 25 °C,
V
i
= 24 V,
I
o nom
,
V
o nom
Efficiency at
T
A
= 25 °C,
V
i
= 110 V,
I
o nom
,
V
o nom
Short time; see table 2 for details!
Isolated tracking output
P
o nom
is specified at
T
amb
= 71 °C
P
o 50
is specified at
T
amb
= 50 °C and
V
i
=
≥
22 V. For
V
i
=
≤
22, only 90% of
P
o 50
are continuously possible.
BCD.00316 Rev AI, 19-May-2017
MELCHER
The Power Partners.
Page 2 of 26
HP Series Data Sheet
120–192 Watt 10:1 DC-DC Converters
Part Number Description
H P 4 6 60 -9 R B1 G
Continuous operating input voltage
V
i
:
16.8 to 137.5 VDC .............................................. H
Series
............................................................................ P
Number of outputs:
Single output (160 mm case)
4 ..........................................
1
Double output (160 mm case)
4 ........................................
2
Triple output (160 mm case)
4 ...........................................
3
Quadruple output (160 mm case)
4 ................................
4
Nominal voltage output 1 /output 4,
V
o1/4 nom
:
5.1 V ..................................................................... 0
12 V ...................................................................... 3
15 V ...................................................................... 5
24 V ...................................................................... 6
other voltages
1 .......................................................................
7, 8
Other specifications and additional features
1
.............. 01, ...99
Nominal voltage output 2 /output 3,
V
o2/3 nom
:
5.1 V ................................................................... 01
12 V .................................................................... 20
15 V .................................................................... 40
24 V .................................................................... 60
other voltages and features
1 ............................
80, ... 99
Operational ambient temperature range
T
A
:
– 40 to 71 °C ........................................................ -9
other
1
.................................................................. 0
Output voltage adjust (auxiliary function) .............................. R
3
Options:
Current sharing .................................................. T
2
UVL (preadjusted
V
i min
) ................................. Uxx
5
V (rotary switch to adjust
V
i min
) ......................... V
6
Heatsink 10, 20, 30 mm ....................... B0, B1, B3
RoHS-compliant for all 6 substances .................................... G
1
2
3
4
5
6
Customer-specific models.
Only available for single-output powertrains. Option T excludes option R, except for single-output models; refer to table 12. T is standard
for single-output models
The R-input influences the first power train only; refer to table 12.
Models with 220 mm case length. Just add 5000 to the standard model number, e.g. HP3020-9RG
→
HP8020-9RG.
For full compatibility with former P Series, the start voltage can be preadjusted depending on the nominal battery voltage. Excludes opt. V.
Excludes opt. U.
Note:
The sequence of options must follow the order above.
Example:
HP4660-9RB1G: DC-DC converter, input voltage
16.8 to 137.5 V, 4 outputs providing 24 V each, heatsink B1,
ambient temperature of – 40 to 71 °C, RoHS-compliant.
Note:
All models exhibit the following auxiliary functions, which
are not reflected in the type designation: input and output filters,
primary referenced PUL (programmable undervoltage shutdown
with inhibit function), sense lines (single-, double-, triple-output
models only), and LED indicators.
Product Marking
Basic type designation, approval marks, CE mark, warnings,
pin allocation, patents, MELCHER logo, specific type de-
signation, input voltage range, nominal output voltages and
output currents, degree of protection, identification of LEDs,
batch no., serial no. and data code including production site,
version, and production date.
BCD.00316 Rev AI, 19-May-2017
MELCHER
The Power Partners.
Page 3 of 26
HP Series Data Sheet
120–192 Watt 10:1 DC-DC Converters
Output Configuration
The HP Series allows high flexibility in output configuration to
cover almost every individual requirement, by simply wiring
outputs in parallel, in series, or in independent configuration,
as shown in the following diagrams.
Parallel or serial operation of several converters with equal
output voltage is possible, using the current share option T to
JM144a
provide reasonable current sharing. Choose suitable single-
output models, if available.
Note:
Unused tracking outputs should be connected in parallel to
the respective regulated outputs.
JM147a
Triple-output
model
Vo1+
S1+
i
R
PUL
30
4
12
Single-output
model
R
Vo+
Vo+
16
4
6
12
22
S1–
28
Load 1
14
8
6
PUL
Vo1–
Vo2+
i
R
PUL
S+
28
PUL
OK+
OK–
Vi+
Vi–
Vo2–
Vo3+
Vo3–
Load 2
10
18
Load
24
14
8
10
32
Load 3
20
30
32
Vi+
Vi–
S–
Vo–
Vo–
Fig. 1d
Independent triple-output configuration. Output 3 is
tracking
JM148b
Fig. 1a
Standard configuration (single-output model)
JM145a
Double-output
model
Vo2+
S2+
i
R
PUL
30
32
6
18
20
10
4
12
14
8
Quadruple-
output
Vo1+
model
Vo1–
i
R
PUL
4
8
12
14
6
10
18
20
Load 1
Load 4
Vo4+
28
S2–
28
PUL
Vo4–
Vo2+
PUL
Vo2–
Vo1+
Load
30
32
Vi+
Vi–
Vo2–
Vo3+
Vo3–
Load 2
Vi+
Vi–
S1+
S1–
Vo1–
Load 3
Fig. 1b
Series output configuration of a double-output model.
The second output is fully regulated.
JM146a
Fig. 1e
Common ground configuration of output 1 with 4 and
independent configuration of output 2 and 3
JM149b
Double-output
model
Vo1+
S1+
i
R
PUL
30
32
Quadruple- Vo3+
output
Vo3–
model
4
12
14
8
6
18
20
10
18
20
6
10
Vo2+
Load 1
S1–
28
i
R
PUL
Vo2–
28
PUL
PUL
Vo4+
Vo4–
Load
12
14
4
16
8
R
2
R
1
Vo1–
Vo2+
30
Vi+
Vi–
Vo1+
R
Vo1–
Vi+
Vi–
S2+
S2–
Vo2–
Load 2
32
Fig. 1c
Independent double-output configuration. Both outputs
are fully regulated
BCD.00316 Rev AI, 19-May-2017
Fig. 1f
Series configuration of all outputs (V
o
= 96 V for HP4660).
The R-input influences only outputs 1 and 4. For the
values of R1 and R2 see Output Voltage Adjust.
MELCHER
The Power Partners.
Page 4 of 26
HP Series Data Sheet
120–192 Watt 10:1 DC-DC Converters
Functional Description
The converters are designed using transformers with planar
technology. The input voltage is fed to a booster, which
generates a voltage of approx. 70 V. If
V
i
is higher, the booster
becomes simply a diode. The storage capacitor
C
hu
is charged
by a current source to max. 70 V and enables the powertrains
to operate during the specified interruption time. The resulting
intermediate voltage, between 45 V (during interruption time)
and 154 V, supplies the powertrains.
There are two powertrains fitted to a converter, each con-
sisting either of a regulated single output with synchronous
rectifier or of a regulated main output with a tracking 2
nd
output.
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 3 U / 4 TE only, but
they can also be chassis-mounted by screws or fitted with a
heat sink. Connector type is H15. The fully enclosed
Aluminum case acts as heat sink and RFI shield, such
protecting the converter together with the coating of all
components against environmental impacts. The converters
are equipped with two independent forward converters,
switching 180° phase-shifted to minimize the input ripple
current. These two forward converters are called
"powertrains" (PT), exhibiting 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. The output power may be
flexibly distributed among the main and the tracking output of
a double-output powertrain. Close magnetic coupling in the
transformers and output inductors together with circuit
symmetry ensure small deviation between main and tracking
output.
The low input capacitance results in low and short inrush
current. After the isolating transformer 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). An individual current limiter
built in to of each powertrain limits the total output current of
that powertrain in an overload condition. This allows flexible
power distribution of the outputs of 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 auxiliary
circuits. The converter is only enabled, if the input voltage is
within the operating voltage range and above the
programmable undervoltage lockout threshold (PUL) – such
limiting the input current dependent on the nominal battery
voltage.
All output are equipped with a suppressor diode and an
independent monitor sensing the output voltage of the main
output. In the case of an overvoltage, it influences the control
logic respectively.
The temperature is monitored and induces the converter to
disable the outputs. After the temperature has dropped, the
converter automatically resumes.
BCD.00316 Rev AI, 19-May-2017
MELCHER
The Power Partners.
Page 5 of 26
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