M-Family
DC-DC Converters <100 W
Rugged Environment
50 W DC-DC (AC-DC) Converters
Class I Equipment
Single output: series AM...LM 1000
Dual output:
series AM...LM 2000
Triple output: series AM...LM 3000
Class II Equipment (double insulation)
Single output: series CMZ/DMZ/LMZ 1000
Dual output:
series CMZ/DMZ/LMZ 2000
Triple output: series CMZ/DMZ/LMZ 3000
• Extremely wide input voltage range suitable for
battery (and AC) operation
• Efficient input filter and built-in surge and transient
suppression circuitry
• 4 kV
rms
input to output electric strength test
• Outputs individually isolated and controlled
• Outputs fully protected against overload
Safety according to IEC 950
LGA
C
M-Family
Table of Contents
........................................... Page
Description .................................................................. 7 - 2
Type Survey ................................................................ 7 - 3
Safety and Installation Instructions ............................. 7 - 4
Functional Description ................................................. 7 - 6
Electrical Input Data .................................................... 7 - 7
Electrical Output Data ................................................. 7 - 9
EMC and Immunity to Input Transients ..................... 7 - 13
Supplementary Data ................................................. 7 - 15
Description of Options ............................................... 7 - 16
Immunity to Environmental Conditions ...................... 7 - 22
Mechanical Data ....................................................... 7 - 24
Type Key and Product Marking ................................. 7 - 25
7.1
Description
The M-family of DC-DC (AC-DC) converters represents a
broad and flexible range of power supplies for use in ad-
vanced industrial electronic systems. Features include high
efficiency, reliability, low output voltage noise and excellent
dynamic response to load/line changes due to individual
regulation of each output.
The converter inputs are protected against surges and tran-
sients occuring at the source lines. An input over- and
undervoltage cut-out circuitry disables the outputs if the in-
put voltage is outside the specified range. Certain types in-
clude an inrush current limitation preventing circuit break-
ers and fuses from being damaged at switch-on.
All outputs are open- and short-circuit proof and are pro-
tected against overvoltages by means of built-in suppres-
sor diodes. The outputs can be inhibited by a logic signal
applied to the connector pin 2 (i). If the inhibit function is not
used pin 2 should be connected with pin 23 to enable 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 standard
IEC 950 and have been approved by the safety agencies
LGA (Germany) and UL (USA). The UL Mark for Canada
has been officially recognized be regulatory authorities 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 should 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.
Case: aluminium, black finish, self cooling.
Dimensions: 38.7
×
111.2
×
168.5 mm. Weight: 770 g.
7-2
MELCHER
The Power Partners.
Edition 2/96 - © Melcher AG
Rugged Environment
Type Survey
Options see "Descriptions of Options"
DC-DC Converters <100 W
M-Family
General note
The type survey tables provide an overview of the basic input and output configurations. More than 500 different types
have been manufactured providing different output configurations and customized specialities. Please consult Melcher's
field sales engineers for specific requirements. The best technical solution will carefully be considered and a detailed pro-
posal submitted.
Table 1a: Class I equipment
Output 1
Output 2
Output 3
Input Voltage Range and Efficiency
1
Option
U
o nom
I
o nom
V DC A
5.1
12.0
15.0
24.0
48.0
12.0
15.0
5.1
5.1
8.0
4.0
3.4
2.0
1.0
2.0
1.7
5.0
5.0
U
o nom
I
o nom
V DC A
U
o nom
I
o nom
V DC A
U
i min
...U
i max
8...35 V DC
AM 1001-7R
AM 1301-7R
AM 1501-7R
AM 1601-7R
AM 1901-7R
η
min
%
72
79
79
81
81
77
78
75
75
U
i min
...
U
i max
14...70 V DC
BM 1001-7R
BM 1301-7R
BM 1501-7R
BM 1601-7R
BM 1901-7R
BM 2320-7
BM 2540-7
BM 3020-7
BM 3040-7
η
min
%
74
80
81
83
83
79
80
76
76
U
i min
...
U
i max
20...100 V DC
FM 1001-7R
FM 1301-7R
FM 1501-7R
FM 1601-7R
FM 1901-7R
FM 2320-7
FM 2540-7
FM 3020-7
FM 3040-7
η
min
%
74
80
81
82
83
80
79
76
76
–9
P
D0...D9
V0,V2,V3
A
H
F
U
12.0
15.0
12.0
15.0
2.0
1.7
0.7
0.6
12.0
15.0
0.7
0.6
AM 2320-7
AM 2540-7
AM 3020-7
AM 3040-7
Table 1b: Class I equipment
Output 1
Output 2
Output 3
Input Voltage Range and Efficiency
1
Option
U
o nom
I
o nom
V DC A
5.1
12.0
15.0
24.0
48.0
12.0
15.0
5.1
5.1
8.0
4.0
3.4
2.0
1.0
2.0
1.7
5.0
5.0
U
o nom
I
o nom
V DC A
U
o nom
I
o nom
V DC A
U
i min
...U
i max
28…140 V DC
CM 1001-7R
CM 1301-7R
CM 1501-7R
CM 1601-7R
CM 1901-7R
η
min
%
74
80
82
82
82
79
80
76
76
U
i min
...
U
i max
44…220 V DC
DM 1001-7R
DM 1301-7R
DM 1501-7R
DM 1601-7R
DM 1901-7R
DM 2320-7
DM 2540-7
DM 3020-7
DM 3040-7
η
min
%
74
81
82
83
83
80
80
77
76
U
i min
...
U
i max
88...372 V DC
(85...264 V AC)
LM 1001-7R
LM 1301-7R
LM 1501-7R
LM 1601-7R
LM 1901-7R
LM 2320-7
LM 2540-7
LM 3020-7
LM 3040-7
η
min
%
73
79
78
81
81
77
78
73
71
–9
E
P
D0...D9
V0,V2,V3
A
H
F
U
12.0
15.0
12.0
15.0
2.0
1.7
0.7
0.6
12.0
15.0
0.7
0.6
CM 2320-7
CM 2540-7
CM 3020-7
CM 3040-7
Table 2: Class II equipment (double insulation)
Output 1
Output 2
Output 3
Input Voltage Range and Efficiency
1
Option
U
o nom
I
o nom
V DC A
5.1
12.0
15.0
24.0
48.0
12.0
15.0
5.1
5.1
1
U
o nom
I
o nom
V DC A
U
o nom
I
o nom
V DC A
U
i min
...U
i max
28...140 V DC
CMZ 1001-7R
CMZ 1301-7R
CMZ 1501-7R
CMZ 1601-7R
CMZ 1901-7R
η
min
%
74
80
82
82
82
79
80
76
76
U
i min
...
U
i max
44...220 V DC
DMZ 1001-7R
DMZ 1301-7R
DMZ 1501-7R
DMZ 1601-7R
DMZ 1901-7R
DMZ 2320-7
DMZ 2540-7
DMZ 3020-7
DMZ 3040-7
η
min
%
74
81
82
83
83
80
80
77
76
U
i min
...
U
i max
88...372 V DC
(85...264 V AC)
LMZ 1001-7R
LMZ 1301-7R
LMZ 1501-7R
LMZ 1601-7R
LMZ 1901-7R
LMZ 2320-7
LMZ 2540-7
LMZ 3020-7
LMZ 3040-7
η
min
%
73
79
78
81
81
77
78
73
71
–9
E
P
D0…D9
V0,V2,V3
A
H
F
U
8.0
4.0
3.4
2.0
1.0
2.0
1.7
5.0
5.0
12.0
15.0
12.0
15.0
2.0
1.7
0.7
0.6
12.0
15.0
0.7
0.6
CMZ 2320-7
CMZ 2540-7
CMZ 3020-7
CMZ 3040-7
Efficiency measured at
U
i nom
and
I
o nom
Notes:
EM types with an input voltage range of 67...385 V DC are available upon request
Remarks: LM types may be operated in AC mode within a frequency range of 47...440 Hz and LMZ types within a fre-
quency range of 47...65 Hz.
Edition 2/96 - © Melcher AG
MELCHER
The Power Partners.
7-3
7.1
M-Family
DC-DC Converters <100 W
Rugged Environment
Safety and Installation Instructions
Safety
For safety reasons, the power supply modules must be wired via the female connector H11 (according to DIN 41612,
see section "Accessories") in order to meet national and international safety requirements!
If the output circuit of a DC-DC converter is operator-acces-
sible 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.
Since the M-family DC-DC converters provide double or re-
inforced insulation between input and output, based on an
input voltage of 250 V AC and 400 V DC, only operational
insulation between the AC mains and the input of the DC-
DC converter is needed according to the following table.
If the table below is observed, the output of a DC-DC con-
verter is considered to be an SELV circuit up to a nominal
output voltage of 36 V.
Table 3: Insulation concept
Nominal
mains
supply
voltage
(AC)
≤250V
1
Minimum required grade of
isolation, to be provided by
the AC-DC front end,
including mains supplied
battery charger
Operational
Maximum Minimum required safety
output
status of the front end
voltage
output circuit
from the
front end
≤400
V
1
Primary circuit
Minimum required grade
of isolation between the
input and the output
provided by the
DC-DC converter
Reinforced, based on
AC 250 V and DC 400 V
1
Resulting
safety
status
of the
DC-DC
output
SELV
circuit
With LMZ converters, the maximum rated output voltage of the front end is 250 V according to IEC 950.
7.1
AM...LM types correspond to class I equipment, while the
C/D/LMZ types correspond to class II equipment.
In class I equipment the connector protective earthing pin is
leading while it is omitted in class II equipment (no protec-
tive earthing is required). Class II equipment provides rein-
forced insulation between input and output circuitry and
also between input and case. There are two class II Y-ca-
pacitors connected in series between input and output cir-
cuitry instead of having Y-capacitors connected to the case.
During the production process, all transformers and each of
Important Advice
the fully assembled modules are individually tested for elec-
tric strength and earth continuity (see "Supplementary
Data"). All electric strength tests are performed as factory
tests.
The UL 1950 recognition limits the maximum ambient op-
erational temperature of the standard modules to
T
A
=
T
A max
–15 K. Option U allows the operation in applications
where the full operational temperature range according to
the relevant data sheet and UL 1950 recognition is re-
quired.
Electric strength tests should not be repeated in the field. Improper test methods, for example overshooting or oscillating
test voltages, voltage slopes exceeding 1 kV/µs, internal Y-capacitors not carefully discharged, etc. can cause severe
damage to switching devices and ICs. Melcher AG will not honour any guarantee/warranty claims resulting from high
voltage field tests.
7-4
MELCHER
The Power Partners.
Edition 2/96 - © Melcher AG
Rugged Environment
DC-DC Converters <100 W
M-Family
Installation Instructions
Installation of the power supply must strictly follow the na-
tional safety regulations. To observe the safety require-
ments according to EN 60950/IEC 950, the module shall be
connected via the female connector type H11 (see section
"Accessories"). Other installation methods may not meet
the safety requirements. A second fuse should be installed
in the wiring to pin 29 if:
– Local requirements demand an individual fuse in each
source line
Whenever the inhibit function is not required, pin 2 (i)
should be connected to pin 23 to enable the output(s).
– Input to earth impedance is high or undefined
– Phase and neutral of the mains are not defined (AC-DC
converters)
Reverse polarity at the input of A...D/FM and C/DMZ types
will cause the fuse to blow. In E/LM and LMZ types a series
diode will protect the module. A series diode is not incorpo-
rated in A...D/FM and C/DMZ types to avoid unwanted
power loss.
Table 4: H11 connector pin allocation
Electrical Determination
Inhibit control input
Safe Data or ACFAIL
Output voltage (positive)
Output voltage (negative)
Control input +
1
Control input –
Output voltage (positive)
Output voltage (negative)
Output voltage (positive)
Output voltage (negative)
Protective earthing
2
DC input voltage
3
DC input voltage
AC input voltage
4
AC input voltage
1
2
3
4
A…LM 1000
Pin
Ident
2
5
8
11
14
17
i
D or V
Vo1+
Vo1–
R
G
C/D/LMZ 1000
Pin
Ident
2
5
8
11
14
17
i
D or V
Vo1+
Vo1–
R
G
A…LM 2000
Pin
Ident
2
5
8
11
i
D or V
C/D/LMZ 2000
Pin
Ident
2
5
8
11
i
D or V
A…LM 3000
Pin
Ident
2
5
8
11
i
D or V
Vo3+
Vo3–
C/D/LMZ 3000
Pin
Ident
2
5
8
11
i
D or V
Vo3+
Vo3–
14
17
20
23
26
29
32
29
32
Vi+
Vi–
N
P
29
32
29
32
Vi+
Vi–
N
P
Vo1+
Vo1–
20
23
Vo1+
Vo1–
20
23
26
29
32
29
32
Vo2+
Vo2–
Vo1+
Vo1–
14
17
20
23
Vo2+
Vo2–
Vo1+
Vo1–
14
17
20
23
26
Vo2+
Vo2–
Vo1+
Vo1–
14
17
20
23
Vo2+
Vo2–
Vo1+
Vo1–
Vi+
Vi–
N
P
29
32
29
32
Vi+
Vi–
N
P
29
32
29
32
Vi+
Vi–
N
P
29
32
29
32
Vi+
Vi–
N
P
This function is not simultaneously available with option P
Leading pin (pregrounding)
A/B/C/D/E/FM and C/DMZ types
LM/LMZ types
Degree of Protection
Condition: Female connector fitted to the unit
IP 40:
All units, except those with options P, A, K, D or V with potentiometer adjustment.
IP 30:
All units, except those with option P, D or V with potentiometer adjustment.
IP 20:
All units fitted with options which include potentiometer setting.
Leakage Currents and Insulation
Please refer to "Supplementary Data"
Edition 2/96 - © Melcher AG
MELCHER
The Power Partners.
7-5
7.1
M-Family
Functional Description
DC-DC Converters <100 W
Rugged Environment
The input voltage is fed via an input fuse, an input filter, a
rectifier
3
and an inrush current limiter
4
to the input capaci-
tor. This capacitor sources a single transistor forward con-
verter. Each output is powered by a separate secondary
winding of the main transformer. The resultant voltages are
rectified and their ripples smoothed by a power choke and
an output filter. The control logic senses the main output
voltage
U
o1
and generates, with respect to the maximum
admissible output currents, the control signal for the pri-
mary switching transistor. This signal is fed back via a cou-
pling transformer.
The auxiliary outputs
U
o2
and
U
o3
are individually regulated
by means of secondary switching transistors. Each aux-
iliary output's current is sensed using a current transformer.
If one of the outputs is driven into current limit, the other
outputs will reduce their output voltages as well because all
output currents are controlled by the same control circuit.
P
2
5
Main control circuit
5
5
14
17
Y
29
20
Output 1
filter
23
1
Input filter
2
3
Forward converter
approx. 70 kHz
MKT
14
Control
circuit
MKT
Output 2
filter
17
Fuse
4
32
8
Control
circuit
Output 3
filter
11
26
7.1
Y
Fig. 1a
DC-DC (AC-DC) converter block diagram, class I equipment
P
Y
Y
2
5
Main control circuit
5
5
14
17
20
Output 1
filter
29
23
1
Input filter
2
3
Forward converter
approx. 70 kHz
14
Control
circuit
Output 2
filter
17
Fuse
4
32
8
Control
circuit
Output 3
filter
11
Fig. 1b
DC-DC (AC-DC) converter block diagram,
class II equipment (double insulation)
1
2
Transient suppressor (VDR) in C/D/E/F/LM and C/D/LMZ
Transient suppressor diode in A/B/C/FM and CMZ types
3
Bridge rectifier in LM/LMZ, series diode in EM types
4
Inrush current limiter (NTC) in C/D/E/LM and C/D/LMZ types
(option E: refer to the description of option E)
5
Single output modules A...LM 1000 and C/D/LMZ 1000 with
feature R
7-6
MELCHER
The Power Partners.
Edition 2/96 - © Melcher AG
Electronics Design Contest
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