Industrial Environment
AC-DC Converters >100 Watt
PC Series
190/230 Watt AC-DC Front End with PFC
Universal AC-input range
Single outputs for 70 and 85 V DC loads
No electrical isolation input to output
• Step-down converter with single stage AC to DC
conversion and PFC
• Immunity to IEC/EN 61000-4-2, -3, -4, -5, -6
• Harmonics below IEC/EN 61000-3-2
• No electrical isolation input to output
• Complete solution with input and output filters
• Input over- and undervoltage protection
• Very high efficiency up to 95%
• Output no load, overload and short-circuit proof
• Output overvoltage protection
• Thermal protection with automatic restart
• Ambient operating temperature range –40...71°C
• Plug-in type for 19" rack systems with H15 connector
• Extremely slim case (4TE wide) fully enclosed
• Very high reliability
Safety according to IEC/EN 60950, UL 1950
LGA
C
PC Series
111
4.4"
3U
20
0.8"
4 TE
164
6.5"
LGA approval pending
Summary
The LPC series is a range of non isolated AC-DC convert-
ers for use as power factor corrected front ends capable of
delivering up to 230 Watt at nominal output voltages of up to
85V. For higher power requirements, several units may be
connected in parallel.
The AC-DC converters are ideally adapted to mains opera-
tion due to their universal input voltage range. Key features
are: Power factor correction, low input harmonic distortion,
no inrush current, low RFI, high immunity to electrical dis-
turbances and high efficiency over the entire input voltage
range.
The outputs are no load, overload and short-circuit proof
and are protected against overvoltages by means of a built-
in suppressor diode.
The converters are especially suited to powering Melcher
DC-DC converters of the P and Q series which, depending
on the mains input voltage level, provide the necessary
electrical isolation for SELV (Safety Extra Low Voltage) out-
puts.
The OK LED displays the status of the converter and allows
visual monitoring of the system at any time.
The AC-DC converters are designed and built according to
the international safety standards IEC/EN 60950, UL 1950,
CAN/CSA C22.2 No.950-95, LGA , UL and cUL. Approvals
are in progress.
The converters are based on a single PCB with high power
density. The thermal concept allows operation at full load
up to an ambient temperature of 71°C in free air without
forced cooling. If forced air cooling is provided the ambient
temperature may exceed 71°C but the case temperature
T
C
must remain below 95°C under all operating conditions.
Semiconductors and other heat generating components
are mounted in such a way that the generated heat is
transfered directly to the rugged metallic case. High effi-
ciency, low heat dissipation and careful consideration of
possible thermal stresses ensure no hot spots and high re-
liability. A built-in temperature sensor generates an inhibit
signal which disables the output if the case temperature
T
C
exceeds 95°C. The output is automatically re-enabled
when the temperature returns below this limit.
A special feature of the LPC front end is the extremely slim
case, just 4TE wide.
The modules are plug-in types fitted with an H15 connector
for use in 19" rack systems according to DIN 41494.
Table of Contents
Page
Page
Mechanical Data .............................................................. 3
Safety and Installation Instructions .................................. 4
Description of Options ...................................................... 5
Summary .......................................................................... 1
Type Survey and Key Data .............................................. 2
Type Key and Product Marking ........................................ 2
MELCHER
The Power Partners.
Edition 4/7.99
1/5
Preliminary
PC Series
AC-DC Converters >100 Watt
Industrial Environment
Preliminary
Type Survey and Key Data
Table 1: Type survey
Nominal
1
output
voltage
U
o nom
[V]
72
85
1
2
3
4
Output
current
Output
power
I
o nom
[A]
2.7
2.7
P
o nom
[W]
190
230
Input voltage
range
47...63 Hz
U
i min
...U
i max
[V AC]
85...255
95...255
Efficiency
Type
designation
Options
h
[%]
2
94
94
LPC 1901-7
3
LPC 1902-7
4
-9
D
No electrical isolation input to output.
Measured at
U
i nom
.
For use with Melcher P units and Q units based on an AC input voltage of up to 150 V.
For use with Melcher P units based on an AC input voltage of up to 250 V.
Type Key and Product Marking
Type Key
L PC 1 901 -7 D
Input voltage range
U
i
85/95...255 V AC, 47...63 Hz ....................... L
Series ............................................................................ PC
Number of outputs ............................................................ 1
Nominal voltage output 1
72 V ......................................................... 901
85 V ......................................................... 902
Ambient temperature range
T
A
:
–25...71°C .................................................. -7
–40...71°C .................................................. -9
Customer specific ................................. -0...-6
Option:
Example:
Converter OK signal ................................... D
LPC 1901-7: Power factor corrected AC-DC converter, input voltage range 85...255 V AC, non isolated out-
put providing 72 V DC, 2.7 A.
Product Marking
Basic type designation, applicable safety approval and recognition marks, CE mark, warnings, pin allocations of inputs and
outputs, Melcher patents and company logo.
Identification of LED
Specific type designation, operating input voltage range, maximum input current, nominal output voltage and output cur-
rent, degree of protection and pin allocations of auxiliary functions.
Batch no., serial no. and data code including production site, modification status and date of production.
MELCHER
The Power Partners.
Edition 4/7.99
2/5
Industrial Environment
Mechanical Data
AC-DC Converters >100 Watt
PC Series
Dimensions in mm. Tolerances
±0.3
mm unless otherwise indicated.
09106
European
Projection
104
±0.15
Front plate
35
Measuring point of
case temperature
T
C
M3; through
20
Rear
face
171.93 (DIN 41494)
164
±0.5
127
±0.15
Main
face
8
±0.5
65
111
Back plate
100
95
20.32 (4 TE)
13.43
Fig. 1
Case Q03, weight 480 g
Aluminium, fully enclosed,
black finish and self cooling
LED "OK" green
Note:
Long case, elongated by 60 mm for 220 mm rack
depth, available on request.
MELCHER
The Power Partners.
Edition 4/7.99
3/5
19.8
Preliminary
5.5
PC Series
AC-DC Converters >100 Watt
Industrial Environment
Preliminary
Safety and Installation Instructions
Connector Pin Allocation
The connector pin allocation table defines the electrical
potentials and the physical pin positions on the H15 con-
nector. The protective earth pins (pins 12 and 14) present
on all PC series converters are leading pins, ensuring that
they make contact with the female connector first.
30
26
22
18
14
10
6
10025
Connection to the system shall be made via the female con-
nector H15 (see:
Accessories).
Other installation methods
may not meet the safety requirements.
The AC-DC converters are provided with pins 12 and 14
( ), which are reliably connected to the case. For safety
reasons it is essential to connect at least one of these pins
to the protective earth of the supply system.
The P and N inputs (pins 8 and 10) are both internally
fused. These fuses are designed to protect the unit in case
of overcurrent and may not be able to satisfy all customer
requirements. External fuses in the wiring to one or both
input pins may therefore be necessary to ensure compli-
ance with local requirements.
Ensure that a unit failure (e.g. by an internal short-circuit)
does not result in a hazardous condition.
Important:
Do not open the modules, or guarantee will
be invalidated.
Make sure that there is sufficient air flow available for con-
vection cooling. This should be verified by measuring the
case temperature when the unit is installed and operated in
the user’s application. The maximum specified case tem-
perature
T
C
max shall not be exceeded. See also:
Thermal
Considerations.
Caution:
Check for hazardous voltages before and after
altering any connections. Hazardous voltages may be
present at the output terminals for 1 minute even after
the mains input voltage has been disconnected from the
unit.
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.
Standards and approvals
All PC series AC-DC converters correspond to class I
equipment.
They are UL recognized according to UL 1950, UL recog-
nized for Canada to CAN/CSA C22.2 No. 950-95. LGA ap-
proval to IEC/EN 60950 standards pending. The units for:
• Building in
• Basic insulation between input and case based on their
maximum rated input voltage
• Operational insulation between input and output (Opera-
tional insulation according to the standards includes the
case where only rectification and voltage/current regula-
tion by diodes and transistors is provided, as is the case
for PC series AC-DC converters. If the input circuit is a
primary circuit, the output is a primary circuit, too.)
• Use in a pollution degree 2 environment.
The AC-DC converters are subject to manufacturing sur-
veillance in accordance with the above mentioned UL,
CSA, EN and with ISO 9001 standards.
Protection Degree
Condition: Female connector fitted to the unit.
IP 40: All units.
32
28
24
20
16
12
8
4
Fig. 2
View of male H15 connector
Table 2: Pin allocation of the H15 connector
Pin no.
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
1
Electrical determination
Output voltage negative
Output voltage positive
Phase
Neutral
Protective earth
1
Protective earth
1
-
-
OK positive
OK negative
-
Output voltage positive
Output voltage negative
Output voltage positive
Output voltage negative
2
Pin designation
Vo–
Vo+
P
N
Pin not connected
Pin not connected
OK+
2
OK–
2
Pin not connected
Vo+
Vo–
Vo+
Vo–
Leading pin (pre-connecting).
Optional
Installation Instructions
The PC series AC-DC converters are components, in-
tended exclusively for inclusion within other equipment by
an industrial assembly operation or by professional install-
ers. Installation must strictly follow the national safety regu-
lations in compliance with the enclosure, mounting, creep-
age, clearance, casualty, markings and segregation requi-
rements of the end-use application.
Important:
Since the PC series AC-DC converters do
not provide electrical input to output isolation, their out-
put circuit is a Hazardous Voltage Primary Circuit which
must not be user accessible.
DC-DC converters with accessible output circuits, pow-
ered by a PC series AC-DC converter must provide dou-
ble or reinforced insulation, based on the mains input
voltage of the PC series AC-DC converter. Refer to:
Safety of operator accessible output circuit
of the H, K,
M, P, Q and S series data to determine safe installation if
such DC-DC converters are powered by a PC series
unit.
MELCHER
The Power Partners.
Edition 4/7.99
4/5
Industrial Environment
Temperature
Characteristics
Conditions
Operational
AC-DC Converters >100 Watt
Standard -7
min
–25
–25
Not operational
–40
max
71
95
100
Option -9
min
–40
–40
–55
max
71
95
100
PC Series
Table 3: Temperature specifications, valid for air pressure of 800...1200 hPa (800...1200 mbar)
Unit
°C
T
A
T
C
T
S
Ambient temperature
Case temperature
Storage temperature
Isolation
The electric strength test is performed as a factory test in
accordance with IEC/EN 60950 and UL 1950 and should
not be repeated in the field. Melcher will not honour any
guarantee claims resulting from electric strength field tests.
Leakage Currents
Leakage currents flow due to internal leakage capacitance
and RFI suppression Y-capacitors. The current values are
proportional to the mains voltage and nearly proportional to
the mains frequency. They are specified at maximum oper-
ating input voltage where phase, neutral and protective
earth are correctly connected as required for class I equip-
ment.
Table 5: Leakage currents
Characteristic
Earth
leakage
current
1
Table 4: Isolation
Characteristic
Electric
strength
test
voltage
Required according to
IEC/EN 60950
Actual factory test 1 s
AC test voltage equivalent
to actual factory test
Insulation resistance at 500 V DC
Input to
case
1.0
1.4
2.1
1.5
>300
kV
rms
MΩ
Unit
kV
rms
kV DC
Unit
3.5
1.1
1
mA
Permissible according to
IEC/EN 60950
Specified value at 255 V, 50 Hz
For creepage distances and clearances refer to:
Technical
Information: Safety.
Leakage current of one LPC unit operating alone. This value will
increase when powering DC-DC converters of the P or Q series
or any other load with an internal capacitance between its in-
puts and earth. When LPC units are operated in parallel, the
leakage current of the system will increase linearly with the
number of paralleled units.
Safety of operator accessible output circuit
If the output circuit of a power supply system is operator
accessible, it shall be an SELV circuit according to the IEC/
EN 60950 related safety standards.
Since the output circuit of a PC series AC-DC converter is a
primary circuit, it must be non user accessible. In order to
generate an accessible SELV output circuit, a DC-DC con-
verter, with double or reinforced insulation between input
and output must be connected to the output of a PC series
AC-DC converter. See:
Schematic safety concept.
Fuse
LPC
AC-DC
front
end
Earth
connection
Fuse
DC-DC converter with
double or reinforced
insulation input to
output
Earth
connection
Refer to the:
Safety concept leading to an SELV output cir-
cuit
tables of the H, K, M, P, Q and S series DC-DC con-
verter data in order to ensure that the output of the DC-DC
converter, which is supplied by the PC series AC-DC con-
verter, is an SELV circuit according to IEC/EN 60950.
It is the sole responsibility of the installer to ensure the com-
pliance with the relevant and applicable safety regulations.
More information is given in:
Technical Information: Safety.
~
Mains
10063
~
Fuse
Fuse
Suppressor
diode
SELV
+
–
Earth
connection
Fig. 3
Schematic safety concept
Use input fuses and earthing of the AC-DC converter as per:
Installation Instructions
of this data sheet.
Use input fuses, earth connection of the DC-DC converter and suppressor diode as per:
Installation Instructions
and per
table:
Safety concept leading to an SELV output circuit
of the data sheet of the corresponding DC-DC converter.
Description of Options
Option D
Converter OK Signal
Option D indicates the status of the converter. When the in-
put voltage is within the upper and lower limit and the output
is above the lower limit the converter delivers an electrically
isolated logic Low. Available hold-up time minimum 4 ms.
MELCHER
The Power Partners.
Edition 4/7.99
5/5
Preliminary
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