nsr-family switching regulators, pcb & chassis industrial environment 4 - 74 edition 2/96 - ? melcher ag melcher
the power partners. 4.2 nsr: negative switching regulators nsr-family no input to output isolation single output of C5 to C36 v dc/50...288 w input voltage up to C80 v dc ? high efficiency up to 94 % ? wide input voltage range ? low input-to-ouptut differential voltage ? very good dynamic properties ? input undervoltage cut-out ? parallel configurations possible ? continuous no-load and short-circuit proof ? no derating safety according to iec 950 c table of contents page type survey .............................................................. 4 - 74 description ................................................................ 4 - 74 safety and installation instructions ........................... 4 - 75 immunity to environmental conditions ...................... 4 - 76 electromagnetic compatibility emc .......................... 4 - 77 electrical input and output data ............................... 4 - 78 characteristics and definitions .................................. 4 - 80 description of options ............................................... 4 - 81 mechanical data ....................................................... 4 - 83 type key and product marking ................................. 4 - 83 type survey table 1: type survey nominal nominal input nominal efficiency type options output output voltage input designation voltage current range voltage u o nom i o nom u i 1 u i nom h C5 v 12 a C7...C40 v C20 v 81% nsr 512-7 -9, l, i, p, r, c C5 v 10 a C8...C80 v C40 v 70% nsr 510-7 C12 v 8 a C15...C80 v 89% nsr 128-7 C15 v C19...C80 v 89% nsr 158-7 C24 v C29...C80 v C50 v 91% nsr 248-7 C36 v C42...C80 v C60 v 94% nsr 368-7 -9, l, i, p, r 1 see also data d u io min . (minimum differential voltage u i C u o ) description the nsr family of negative switching regulators is desig- ned as power supply modules for electronic systems. their major advantages include a high level of efficiency that re- mains virtually constant over the entire input range, high reliability, low ripple and excellent dynamic response. the modules are specially designed for secondary switched and battery driven applications with positive sys- tem ground. case c03: aluminium, black finish and self cooling. external input circuitry an external capacitor (see "application notes") is required in rectifier mode and in dc operation mode only, if the sum of the lengths of the two input lines between source and in- put is greater than approx. 5 m. for long connection lines the use of option l is recommended in order to reduce su- perimposed interference voltages or currents and to pre- vent oscillation. case c03
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the power partners. 4.2 control circuit p (option) vo go+ vi gi+ i o ? o r (option) i (option) i i ? i c e input
filter
l (opt.) c (opt.) fig. 1 block diagram note: check for hazardous voltages before altering any connections. do not open the module. the input and the output circuitry are not separated, i.e. the posi- tive path is internally interconnected! table 2: insulation concept for selv circuits nominal minimum required grade maximum minimum required measures to achieve the resulting safety mains of isolation, to be output safety status of the specified safety status status of the supply provided by the ac-dc voltage front end output circuit of the output circuit switching voltage front end, including mains from the regulator output (ac) supplied battery charger front end circuit none battery supply completely 60 v selv battery circuit none selv circuit separated from mains 80 v hazardous voltage battery input fuse 1 and unearthed, selv circuit circuit 2 non operator-accessible case 2 hazardous voltage battery input fuse 1 and earthed output earthed selv circuit circuit 3 and earthed 3 or non circuit operator-accessible case 250 v basic 60 v earthed selv circuit earthed input circuit 3 selv circuit elv circuit input fuse 1 and earthed selv earthed output circuit 3 circuit 80 v hazardous voltage input fuse 1 and earthed output earthed selv secondary circuit circuit 3 and earthed 3 or non circuit operator-accessible case double or reinforced 60 v selv circuit none selv circuit 80 v double or reinforced insu- input fuse 1 and unearthed and selv circuit lated unearthed hazardous non operator-accessible case 2 voltage secondary circuit 2 1 the installer shall provide an approved fuse (slow blow type with lowest rating suitable for the application, max. 12.5 a) in the positive or negative input conductor directly at the input of the switching regulator. for ul's purpose, the fuse needs to be ul-listed. if option c is fitted, a suitable fuse is built-in. 2 has to be insulated from earth by double or reinforced insulation according to the relevant safety standard, based on the maximum in- put voltage of the switching regulator. 3 the earth connection has to be provided by the installer according to the relevant safety standards, e.g. iec 950. safety and installation instructions safety if the output circuit of a switching regulator is operator-ac- cessible according to the iec 950 related safety standards, it shall be an selv circuit (safety extra low voltage circuit, i.e. a circuit, separated from mains by at least basic insula- tion, that is so designed and protected that under normal and single fault conditions, the voltage between any two conductors and between any conductor and earth does not exceed 60 v dc). in the following section an interpretation is provided of the iec 950 safety standard with respect to the safety status of the output circuit. however, it is the sole responsibility of the installer or user to assure the compliance with the relevant and applicable safety standards. if the following table is observed, the output of any switch- ing regulator is considered to be an selv circuit up to a nominal output voltage of 36 v.
nsr-family switching regulators, pcb & chassis industrial environment 4 - 76 edition 2/96 - ? melcher ag melcher
the power partners. 4.2 standards and approvals all melcher power supplies are subject to manufacturing surveillance in accordance with iso 9001 standards. all units are ul recognized as per ul 1950, ul 1012 and can/csa c22.2 no. 234-m90. cleaning agents in order to avoid possible damage, any penetration of cleaning fluids is to be prevented, since the power supplies are not hermetically sealed. protection degree the protection degree is defined by ip 40. with option p this reduces to ip 20. immunity to environmental conditions table 3: mechanical stress test method standard test conditions status ca damp heat din 40046 part temperature: 40 2 c unit not steady state iec 68-2-3 relative humidity: 93 +2/-3 % operating mil-std-810d section 507.2 duration: 56 days ea shock din 40046 part 7 acceleration amplitude: 100 g n = 981 m/s 2 unit (half-sinusoidal) iec 68-2-27 bump duration: 6 ms operating mil-std-810d section 516.3 number of bumps: 18 (3 each direction) eb continuous shock din 40046 part 26 acceleration amplitude: 40 g n = 392 m/s 2 unit (half-sinusoidal) iec 68-2-29 bump duration: 6 ms operating mil-std-810d section 516.3 number of bumps: 6000 (1000 each direction) fc vibration din 40046 part 8 frequency (1 oct/min): 10...2000 hz unit (sinusoidal) iec 68-2-6 max. vibration amplitude: 0.35 mm (10...60 hz) operating mil-std-810d section 514.3 acceleration amplitude: 5 g n = 49 m/s 2 (60...2000 hz) test duration: 7.5 h (2.5 h each axis) fda random vibration din 40046 part 23 acceleration spectral density: 0.05 g 2 /hz unit not wide band iec 68-2-35 frequency band: 20...500 hz operating reproducibility high acceleration magnitude: 4.9 g rms test duration: 3 h (1 h each axis) kb salt mist din 40046 part 105 concentration: 5% (30 c) unit not cyclic iec 68-2-52 duration: 2 h per cycle operating (sodium chloride storage: 40 c, 93% rel. humidity nacl solution) storage duration: 22 h per cycle number of cycles: 3 table 4: temperature specifications, valid for air pressure of 800...1200 hpa (800...1200 mbar) temperature standard -7 option -9 characteristics conditions min max min max unit t a ambient temperature 1 u i min ... u i max C25 71 C40 71 c t c case temperature i o = 0... i o nom C25 95 C40 95 t s storage temperature 1 not operational C40 100 C55 100 1 mil-std-810d section 501.2 and 502.2 table 5: mtbf and device hours mtbf ground fixed ground mobile device hours 1 mtbf acc. to mil-hdbk-217d t c = 40 c t c = 70 c t c = 40 c t c = 70 c 130'000 h 58'000 h 36'000 h 17'000 h 1'050'000 h 1 statistical values , based on an average of 4300 working hours per year and in general field use
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the power partners. 4.2 electromagnetic compatibility emc immunity general condition: case not earthed table 6: immunity type tests phenomenon standard class coupling value waveform source test in per- level mode 4 applied imped. procedure oper. form. impulse voltage iec 255-4 iii i/o, i/c, o/c 5000 v p 1.2/50 m s 500 w 3 pos. and 3 neg. no - app. e4 5 +i/Ci impulses per (1976) coupling mode high frequency iec 255-4 iii i/o, i/c, o/c 2500 v p 400 damped 200 w 2 s per yes 1 disturbance app. e5 5 +i/Ci 1000 v p 1 mhz waves/s coupling mode (1976) electrostatic iec 801-2 3 contact discharge 6000 v p 1/50 ns 330 w 10 positive and yes 1 6 discharge (1991-04) to case 10 negative discharges electric field iec 801-3 2 antenna in 3 v/m sine wave mod- 261000 mhz yes 1 (1984) 1m distance ulated w. 1 khz fast transient/ iec 801-4 2 i/c 1000 v p bursts of 5/50 ns 50 w 1 min positive yes 2 6 burst (1988) 5 khz rep. rate 1 min negative transients with bursts per 15 ms burst coupling mode duration and a 300 ms period transient iec 801-5 ii i/c 1000 v p 1.2/50 m s 12 w 5 pos. and 5 neg. yes 2 6 (draft 1993-01) +i/Ci 500 v p 2 w impulses per coupling mode immunity to iec 801-6 2 i, o, signal wires 3 v rms 7 80% amplitude 50 w am 0.15...80 mhz yes 1 conducted modulated disturbancies with 1 khz 1 normal operation, no deviation from specifications 2 normal operation, temporary deviation from specs possible 3 with option c: manual reset 4 i = input, o = output, c = case 5 in correspondance with din 57435 part 303 and vde 0435 part 303 (1984-09) 6 option l neccessary 7 open circuit emission for emission levels refer to "electrical input and output data".
nsr-family switching regulators, pcb & chassis industrial environment 4 - 78 edition 2/96 - ? melcher ag melcher
the power partners. 4.2 electrical input and output data general conditions C t a = 25 c, unless t c is specified. C with option p or r, output voltage u o = u o nom at i o nom table 7a: input and output data characteristics conditions nsr 512 nsr 510 nsr 128 unit min typ max min typ max min typ max output u o output voltage u i nom , i o nom C4.97 C5.03 C4.97 C5.03 C11.92 C12.07 v i o nom output current u i min ... u i max 12.0 10.0 8.0 a i ol output current t c min ... t c max 12.0 15.6 10.0 13.0 8.0 10.4 limitation response u o ripple at output u i nom 35 50 35 50 80 150 mv pp (bw = 20 mhz) i o nom 60 85 1 60 85 1 d u o u static control deviation u i min ... u i max 30 45 30 45 50 85 mv versus input voltage u i i o nom 55 1 d u o i static control deviation u i nom 20 25 20 25 28 35 versus output current i o i o = 0 i o nom 55 1 u o d dynamic control u i nom 135 130 130 deviation 2 i o n om ? 1 / 3 i o nom t r dynamic load transient 40 50 60 m s time recovery 2 a uo temperature coefficient u i min ... u i max 1 1 2 mv/k d u o / d t c t c min ... t c max i o = 0... i o nom 0.02 0.02 0.02 %/k input u i input voltage i o = 0... i o nom C7 C40 C8 C80 C15 C80 v dc t c min ... t c max d u io min minimum differential C2 C3 C3 v voltage u i - u o 3 u i o undervoltage cut-out C6.3 C7.3 C7.3 i i 0 no load i o = 0 45 40 35 ma input current u i min ... u i max i i m peak value of u i nom 150 250 250 a inrush current 4 t i s rise time 4 555 m s t i r tail half value time 4 40 40 40 i i m peak value of u i nom 250 350 350 a inrush current 4 with option l t i s rise time 4 25 25 25 m s t i r tail half value time 4 125 125 125 u i rfi rfi level at input, vde 0871 (6.78) a a a db 0.01...30 mhz u i nom , i o nom ( m v) efficiency h efficiency u i nom , i o nom 81 76 88 % isolation u is isolation test voltage inputs/outputs 500 500 500 v dc electronics to case interconnected 1 lower row represents option -9 data only 2 see dynamic characteristics 3 the minimum differential voltage d u io min between input and output increases linearly from 0 to 1 v at t a = 46 c and 71 c ( t c = 70 c and 95 c) 4 definitions according to vde 0433, part 3
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the power partners. 4.2 table 7b: input and output data characteristics conditions nsr 158 nsr 248 nsr 368 unit min typ max min typ max min typ max output u o output voltage u i nom , i o nom C14.91 C15.09 C23.85 C24.14 C35.78 C36.22 v i o nom output current u i min ... u i max 8.0 8.0 8.0 a i ol output current t c min ... t c max 8.0 10.4 8.0 10.4 8.0 10.4 limitation response u o ripple at output u i nom 80 150 100 250 150 300 mv pp (bw = 20 mhz) i o nom d u o u static control deviation u i min ... u i max 70 105 150 220 200 270 mv versus input voltage u i i o nom 370 1 d u o i static control deviation u i nom 33 45 120 160 125 160 versus output current i o i o = 0 i o nom 65 1 320 1 u o d dynamic control u i nom 130 150 225 deviation 2 i o n o m ? 1 / 3 i o nom t r dynamic load transient 60 80 100 m s time recovery 2 a uo temperature coefficient u i min ... u i max 3 5 8 mv/k d u o / d t c t c min ... t c max i o = 0... i o nom 0.02 0.02 0.02 %/k input u i input voltage i o = 0... i o nom C19 C80 C29 C80 C42 C80 v dc t c min ... t c max d u io min minimum differential C4 C5 C6 v voltage u i - u o 3 u i o undervoltage cut-out C7.3 C12 C19 i i 0 no load i o = 0 35 35 40 ma input current u i min ... u i max i i m peak value of u i nom 250 250 250 a inrush current 4 t i s rise time 4 555 m s t i r tail half value time 4 40 40 40 i i m peak value of u i nom 350 350 350 a inrush current 4 with option l t i s rise time 4 25 25 25 m s t i r tail half value time 4 125 125 125 u i rfi rfi level at input, vde 0871 (6.78) a a a db 0.01...30 mhz u i nom , i o nom ( m v) efficiency h efficiency u i nom , i o nom 89 91 94 % isolation u is isolation test voltage inputs/outputs 500 500 500 v dc electronics to case interconnected 1 lower row represents option -9 data only 2 see dynamic characteristics 3 the minimum differential voltage d u io min between input and output increases linearly from 0 to 1 v at t a = 46 c and 71 c ( t c = 70 c and 95 c) 4 definitions according to vde 0433, part 3
nsr-family switching regulators, pcb & chassis industrial environment 4 - 80 edition 2/96 - ? melcher ag melcher
the power partners. 4.2 characteristics and definitions output protection a voltage suppressor diode protects the output against an internally generated overvoltage, which could occur due to a failure of the control circuit, which in worst case condi- tions fails into a short circuit. the suppressor diode is not designed to withstand externally applied overvoltages. the user should ensure that systems with melcher power sup- plies, in the event of a failure, do not result in an unsafe condition (fail-safe). dynamic characteristics parallel and series connection outputs of equal nominal voltages can be parallel-con- nected. however, the use of a single unit with higher output power, because of its power dissipation, is always a better solution. in parallel-connected operation, one or several outputs may operate continuously at their current limit knee-point which will cause an increase of the case temperature. conse- quently, the max. ambient temperature value should be re- duced by 10 k. outputs can be series-connected with any other module. in series-connection the maximum output current is limited by the lowest current limitation. galvanically separated source voltages are needed for each module! short circuit behaviour a constant 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. i o / i o nom 3/3 2/3 1/3 0 t 3 10 s 3 10 s u od u od t r t r u o i u o i t u o 1.2 1.0 0.8 0.6 0.4 0 0.2 0.4 1.0 1.2 0.2 0.6 0.8 1.4 u o / u o nom i o / i o nom i o nom i o l fig. 4 overload, short-circuit behaviour u o versus i o fig. 2 behaviour and characteristics under varying load condi- tions. temperature when a converter is located in free, quasi-stationary air at a temperature t a = 71 c and is operated at its nominal output power, the case temperature t c will be about 95 c after the warm-up phase measured at the measuring point of case temperature t c (see "mechanical data"). under practical operating conditions, the ambient tempera- ture t a may exceed 71 c, provided additional measures are taken to ensure that the case temperature t c does not exceed its maximum value of 95 c ( heat sink, fan, etc.). example: sufficient forced cooling allows t a max = 85 c. a simple check of the case temperature t c ( t c 95 c) at full load ensures correct operation of the system 0 10 20 30 40 50 60 70 80 ?0 50 60 70 80 90 100 p o [%] t a [ c] 90 100 110 t c max p o max
(convection cooling) p o max (forced cooling) fig. 3 output power derating versus ambient temperature
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the power partners. 4.2 table 8: inhibit characteristics characteristics conditions min typ max unit u inh inhibit input voltage to keep u o = on u i min ... u i max C0.8 +50 v dc regulator output voltage... u o = off t c min ... t c max C50 C2.4 t r switch-on time after inhibit command u i = u i nom 5ms t f switch-off time after inhibit command r l = u o nom / i o nom 10 i i off input current when inhibited i o = 0, u i = u i nom 10 ma fig. 6 output response as a function of inhibit signal fig. 7 inhibit current i inh versus inhibit voltage u inh description of options option i inhibit note: with open i-input, output is enabled ( u o = on). the inhibit input allows the switching regulators to be disa- bled via a control signal. in systems with several units, this feature can be used, for example, to control the activation sequence of the regulators by a logic signal (ttl, c-mos, etc.). an output voltage overshoot will not occur when the units are switched on or off. vi gi+ i vo go+ i inh u inh fig. 5 definition of i inh and u inh 100% 10% t t 0 0 u o / u o nom u inh t r t f 1 -1 -3 -5 -50 -40 20 40 -30 0 -20 -10 10 30 50 2 0 -2 -4 i inh [ma] u inh [v] u o on u o off u inh = ?.4 v
u inh = ?.8 v u o nom u o ? 1.08 ? u ex ? CCCCCC (u ref = C2.49 v 4%) u ref caution: to prevent damage u ex should not exceed u ref nor be positive! option r output voltage adjustment note: with an open r-pin, u o = 1.08 u o nom ! the output voltage u o can be adjusted either with an exter- nal resistance r ex or an external reference voltage u ex . the adjustment range is 0.65...1.08 of u o nom . the minimum dif- ferential voltage d u i o min between input and output voltages as specified in relevant tables must be maintained. options r and p cannot be supported simultaneously. fig. 8 voltage adjustment with u ex [v] fig. 9 voltage adjustment with r ex [ w | r ex u o ? 1.08 ? u o nom ? CCCCCCCCCC r ex + 4020 u o r ex ? 4020 ? CCCCCCCCCCCCCCC 1.08 ? u o nom C u o all formulae give approximate values only. vo go+ r u ref 4020 w u ex r ex vo go+ r 4020 w u ref
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the power partners. 4.2 option -9 extended temperature range the operational ambient temperature range is extended to t a = C40...71 c. option p potentiometer option p excludes r option. the output voltage u o can be adjusted with a screwdriver in the range from 0.921.08 of the nominal output voltage u o nom . however, the minimum differential voltage d u io min between input and output voltages as specified in "electrical input and output data" should be maintained. option c thyristor crowbar this option is recommended to protect the load against power supply malfunction, but it is not designed to sink ex- ternal currents. a fixed-value monitoring circuit checks the output voltage u o . when the trigger voltage u oc is reached, the thyristor crowbar triggers and disables the output. it may be deacti- vated by removal of the input voltage. in case of a switching transistor defect, an internal fuse prevents excessive cur- rent. note: as a central overvoltage protection device, the crow- bar is usually connected to the external load via distributed inductance of the lines. for this reason, the overvoltage at the load can temporarily exceed the trigger voltage u oc . de- pending on the application, further decentralized over- voltage protection elements may have to be used addition- ally. option c is not available for nsr 368 type. table 9: crowbar trigger levels characteristics conditions C5 v C12 v C15 v C24 v unit min max min max min max min max u o c trigger voltage u i min ... u i max C5.8 C6.8 C13.5 C16 C16.5 C19 C27 C31 v i o = 0... i o nom t s delay time t c min ... t c max 1.5 1.5 1.5 1.5 m s option u ambient temp. range acc. ul recognition underwriters laboratories (ul) have approved the nsr- family as recognized components up to an ambient tem- perature of t a max C 25 k, given by the upper temperature limit of the standard pcb material. if the full maximum am- bient temperature t a max is required with ul approval, op- tion u should be requested. it consists of an alternative pcb material with a higher maximum temperature specifi- cation. the european approval boards have in contrast to ul ac- cepted the standard pcb material to be operated up to t a max = 71 c without any further precautions. option l input filter option l is recommended to reduce superimposed inter- ference voltages, and to prevent oscillations, if input lines exceed approx. 5 m in total length. the fundamental wave (approx. 120 khz) of the reduced interference voltage be- tween vi+ and giC has, with an input line inductance of 5 m h a maximum magnitude of 4 mv rms . the input impedance of the switching regulator at 120 khz is about 50 m w . the harmonics are small in comparison with the fundamental wave. see also data: rfi. with option l, the maximum permissible additionally super- imposed ripple u i of the input voltage (rectifier mode) at a specified input frequency f i has the following values: input voltage up to 80 v: u i max = 22 v pp at 100 hz or v pp = 2200 hz/ f i ? 1 v input voltage up to 40 v: u i max = 12 v pp at 100 hz or v pp = 1200 hz/ f i ? 1 v
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the power partners. 4.2 mechanical data dimensions in mm. tolerances 0.3 mm unless otherwise specified. gi+ go+ vo i vi u o u o gr 7.5 27.5 18.5 11.3 40 7.5 10 7.5 10 (14) 7.5 10 2 4.3 min. 8 5 0.5 144 12.5 1 43 1 (45) 88 1 7 2 151 1 32.2 0.5 2.8 x 0.8 8.1 1 6.35 1 6.3 x 0.8 distance between m4 mounting screws measuring point
of case temperature t c led-output
voltage indicator potentiometer
(option p) fig. 10 case c03 (weight 440 g) type key and product marking type key nsr 12 8 -7 l i r p c negative switching regulator in case c03 .................. nsr blank .................................................................................. nominal output voltage in volt ............................... C5...C36 nominal output current in ampere ............................. 8...12 ambient temperature range t a = C25...71 c ................................................... -7 t a = C40...71 c ................................................... -9 input filter ......................................................................... l inhibit input ........................................................................ i external output voltage adjustment ................................. r potentiometer ...................................................................p thyristor-crowbar ........................................................... c example:nsr 128-7ip = a negative switching regulator with a C12 v, 8 a output, ambient temperature range of C2571 c, inhibit input and potentiometer. produkt marking main face: family designation, applicable safety approval and recognition marks, warnings, melcher patent nos. and com- pany logo. cover: specific type designation, input voltage range, nominal output voltage and current, pin allocation, identification of led, potentiometers and degree of protection. rear side: label with batch no., serial no. and data code comprising production site, modification status of the main pcb and date of production. european
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