RCM500/1000 Series
500/1000 W DC-DC Converters
The RCM500 and RCM1000 Series converters are
reliable power supplies for railway and transportation
systems. They are optimized for 72 or 110 V railway
batteries. The output delivers 24 V with 500 or 1000 W.
The converters are designed for chassis mounting and
exhibit a closed housing with cooling openings.
Many options are available, such as an output ORing
FET for redundant operation, output voltage adjustment,
interruption time of 10 ms, shutdown input, and a monitoring
relay (change-over contact).
Features
•
•
•
•
•
•
•
Optimized for 72 V or 110 V railway batteries
Output voltage 24 V
Closed housing for chassis mounting
Extremely high efficiency and high power density
Low inrush current
3 connectors: Input, output, auxiliary (option)
Overtemperature, overvoltage, overcurrent, and
short-circuit protection
• Many options available
• Compliant to EN 50155, EN 50121-3-2, AREMA
• RoHS-compatible for all 6 substances
• Fire and smoke: compliant to EN 45545 and NFPA 130
• 5 year warranty
Safety-approved to the latest edition of IEC/EN 60950-1
and UL/CSA 60950-1
1
1
1
pending
Table of Contents
Description........................................................................................1
Model Selection.................................................................................2
Functional Description.......................................................................3
Electrical Input Data..........................................................................4
Electrical Output Data.......................................................................6
Description of Options.......................................................................9
Electromagnetic Compatibility (EMC).............................................. 11
Immunity to Environmental Conditions............................................13
Mechanical Data..............................................................................14
Safety and Installation Instructions..................................................15
Accessories.....................................................................................17
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BCD.00803 Rev AC1, 19-Jun-2018
RCM Series
500 / 1000 W DC-DC Converters
Model Selection
Table 1: Standard models
Input voltage
V
[V]
Vi cont
[V]
1
i min
43.2
66
Output
50.4
77
(72)
(72)
Vi max
[V]
90
137.5
1
110
154
Power
Efficiency 2
η min
Model
Options
η typ
Vo nom
[V]
Io nom
[A]
Po nom
[W]
24
21
500
24
41
1000
24
21
500
96
24
41
1000
96
96.4
110RCM1000-24
[%]
96
72RCM500-24
96
72RCM1000-24
96.4
110RCM500-24
D, M, Q, F, K
Short time; see table 2 for details.
Efficiency at TA = 25 °C, Vi nom, Io nom, Vo nom, only option D fitted.
1
2
Part Number Description
110 RCM 500 -24 D M Q F K
Operating input voltage Vi cont (continuously):
50.4 – 90 VDC ............................................................72
77 – 137.5 VDC ......................................................... 110
Series..............................................................................RCM
Output power:
500 W ......................................................................500
1000 W.....................................................................1000
Nominal output voltage:
24 V............................................................................-24
Auxiliary functions and options:
Out OK, output voltage adjust, shutdown 1 ................... D
Interruption time............................................................M
ORing FET....................................................................Q
Fuse built-in....................................................................F
Pluggable Connectors .................................................. K
1
Opt. D requires the auxiliary connector.
Note: The sequence of options must follow the order above.
Note: All models are RoHS-compliant for all six substances.
Available combinations of options:
72/110RCMxxx-24 (K)
72/110RCMxxx-24D (K)
72/110RCMxxx-24DF (K)
72/110RCMxxx-24DMQ (K)
72/110RCMxxx-24DMQF (K)
Example: 110RCM500-24DMQ: DC-DC converter, input voltage range 77 to 137.5 V continuously, output providing 24 V /21 A, monitoring relay,
output voltage adjust, shutdown input, active current sharing, interruption time 10 ms, integrated ORing FET, RoHS-compliant for
all six substances.
Product Marking
Type designation, applicable safety approval and recognition marks, CE mark, pin allocation, and product logo.
Input voltage range and input current, nominal output voltage and current, degree of protection, batch no., serial no., and data code
including production site, version (modification status) and date of production.
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RCM Series
500 / 1000 W DC-DC Converters
Functional Description
The input voltage is fed via an efficient input filter and a step-up converter (switching with 2 × 110 kHz) to the high-efficient DC-DC
converter operating at a switching frequency of approximately 90 kHz. The built-in overvoltage limiter protects against input
voltage surges.
The inrush current is limited by an electronic circuitry. A VDR resistor protects against external surges.
If there is no external circuit breaker, the converter can be ordered with built-in fuse (opt. F). This fuse is not accessible.
The circuitry to provide the interruption time (opt. M) is located after the input filter together with the reverse polarity protection
formed by a FET.
The rectification on the secondary side is provided by synchronous rectifiers, in order to keep the losses as low as possible. The
output voltage control logic is located on the secondary side and controls the FETs of the DC-DC converter via insulated drivers.
An auxiliary converter supplies all circuits with a stable bias voltage.
An output ORing FET is available (opt. Q) and allows for a redundant power supply system.
Opt. D encompasses an additional signal connector to allow for output voltage adjustment, active current sharing, primary
shutdown, and an output voltage monitor activating a relay with change-over contact.
The converter is mounted onto a base plate which acts as cooling plate. An additional heatsink for natural convection cooling is
available as accessory. A thermal protection on the input and output side prevents from overheating.
T T
Primary
control logic
Opt. M
Fuse
(option F)
VDR
Insulated
driver
Isolation
SD
SD0
Vi+
Insulated
driver
1
Ci
Input
filter
2
+
R–
R R
Cy
JM201e
OK1
OK2
Secondary
control logic
OK0
NTC
+
Chu
Opt. Q
Vi–
PE
R+
Auxiliary
converter
Auxiliary connector (only with option D)
Vo+
Output
filter
Vo–
Cy
1
2
Reverse polarity protection (FET) , only fitted with opt. F or M
Bipolar suppressor diode with opt. F or M
Fig. 1
Block diagram
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RCM Series
500 / 1000 W DC-DC Converters
Electrical Input Data
General conditions:
- TA = 25 °C, unless specified.
Table 2a: Input data of RCM500 models
Model
72RCM500-24
Characteristics
110RCM500-24
Unit
Conditions
min
typ
max
min
typ
max
Operating input voltage
Io = 0 – Io max
TA min – TA max
50.4
(72)
90
77
(110)
137.5
Vi 2s
for ≤ 2 s
without shutdown
43.2
100.8
66
Vi nom
Nominal input voltage
Vi abs
Input voltage limits
3 s without damage
Ii
Typical input current
Vi nom, I o nom
7.3
Pi 0
No-load input power
Vi min – Vi max, Io = 0
2.5
4
2.5
4
P i SD
Idle input power
Vi min – Vi max, VSD = 0 V
2
3
2
3
Ci
Input capacitance 1
7
Ri
Input resistance
14
Iinr p
Peak inrush current
tinr d
Duration of inrush current
Vi
Duration of inrush current
ton
Start-up time after removal of shutdown
154
72
0
108
0
165
4.8
Vi min, P o nom
VSD = 0 → 5 V
W
µF
14
mΩ
20
0.5
0 → Vi min, P o nom
A
7
20
Vi = Vi max, P o nom
V
110
A
0.5
300
500
300
500
300
500
300
500
ms
Table 2b: Input data of RCM1000 models
Model
72RCM1000-24
Characteristics
110RCM1000-24
Unit
Conditions
min
typ
max
min
typ
max
(72)
90
77
(110)
137.5
100.8
66
Vi
Operating input voltage
Io = 0 – Io max
TA min – TA max
50.4
Vi 2s
for ≤ 2 s
without shutdown
43.2
Vi nom
Nominal input voltage
Vi abs
Input voltage limits
3 s without damage
Ii
Typical input current
Vi nom, I o nom
15
Pi 0
No-load input power
Vi min – Vi max, Io = 0
3
4
3
4
P i SD
Idle input power
Vi min – Vi max, VSD = 0 V
2.5
3
2.5
3
Ci
Input capacitance 1
7
7
µF
Ri
Input resistance
14
14
mΩ
Iinr p
Peak inrush current
tinr d
Duration of inrush current
Duration of inrush current
ton
1
Start-up time after removal of shutdown
72
0
0 → Vi min, P o nom
Vi min, P o nom
VSD = 0 → 5 V
V
110
108
Vi = Vi max, P o nom
154
0
165
9.5
A
40
40
0.5
0.5
300
500
300
500
300
500
300
500
W
A
ms
Not smoothed by the inrush current limiter at start-up (for inrush current calculation)
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RCM Series
500 / 1000 W DC-DC Converters
Input Transient and Reverse Polarity Protection
A VDR resistor and a symmetrical input filter form an effective protection against input transients, which typically occur in many
installations, but especially in battery-driven mobile applications.
If the input voltage has the wrong polarity, the incorporated reverse diode will cause the external input circuit breaker or fuse to
trip. With option M or F (incorporated fuse), an active reverse-polarity protection circuit prevents from any damage.
Input Under- / Overvoltage Lockout
If the input voltage is out of range, an internally generated signal disables the converter to avoid any damage.
Efficiency
See fig. 2.
η [%]
η [%]
110RCM500-24DMQ
JM216
100
110RCM1000-24DMQ
JM215
100
Vi = 110 V
Vi = 137 V
90
90
Vi = 77 V
Vi = 137 V
80
80
70
70
60
0
0.2
0.4
0.6
0.8
Fig. 2a
Efficiency versus Vi and Po (110RCM500-24DMQ)
Po / Po nom
60
0
0.2
0.4
0.6
Vi = 77 V
Po / Po nom
0.8
Fig. 2b
Efficiency versus Vi and Po (110RCM1000-24DMQ)
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RCM Series
500 / 1000 W DC-DC Converters
Electrical Output Data
General conditions:
- TA = 25 °C, unless TC is specified
- R input not connected
Table 3: Output data
Model
72/110RCM500-24
Characteristics
Unit
min
typ
max
min
typ
max
Vo
Output voltage 1
V i nom, 0.5 Io nom
23.76
24
24.24
23.76
24
24.24
V ow
Worst case output voltage
Vi min – Vi max
TC min – TC max, 0 - Io nom
23.28
24.72
23.28
V o droop
Output voltage droop
Vo L
Overvoltage shutdown
Vo P
Overvoltage protection 2
Io nom
Nominal output current
Io L
Output current limit
vo
Output noise 3
vod
Conditions
72/110RCM1000-24
- 10
-5
28
6
28.5
Total incl. spikes
Voltage deviation 5
td 4
Dynamic load
regulation
α vo
Temperature coefficient of vo (NTC)
Recovery time
28.5
30
31.5
42
45
V i nom, Io nom
BW = 20 MHz
240
240
480
480
Vi nom ,
0.1 ↔ 0.9 Io nom
1000
1000
5
- 0.02
0
- 0.02
V
A
23
0 - Io nom, TC min – TC max
V
mV/A
28
31.5
21
TC min – TC max
Switching frequency
30
24.72
mVpp
5
ms
0
%/K
If the output voltage is increased above Vo nom through R-input control, the output power should be reduced accordingly, so that Po max and
TC max are not exceeded.
2
Breakdown voltage of the incorporated suppressor diode at 1 mA . Exceeding this value might damage the suppressor diode.
3
Measured according to IEC/EN 61204 with a probe described in annex A
4
Recovery time until Vo returns to ±1% of Vo; see fig. 3.
5
No overshoot at switch on.
6
Output overvoltage shutdown by an electronic circuitry, with automatic recovery.
1
Output Voltage Regulation
Vo
Vod
Vo ±1 %
td
Vod
Vo ±1 %
td
t
Io /Io nom
1
0.5
0
≥ 10 µs
≥ 10 µs
05102c
t
Fig. 3
Typical dynamic load regulation of output voltage
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RCM Series
500 / 1000 W DC-DC Converters
Output Current Limitation
The output is continuously protected against open-circuit (no load) and short-circuit by an electronic current limitation with
rectangular characteristic; see fig. 4.
Vo
Vo nom
0.98
0.5
JM097
0
IoL
1.0
0.5
Io
Io nom
Fig. 4
Rectangular current limitation
Series, Parallel Connection, Redundancy
The outputs of several RCM Series converters may be connected in series.
Note: If the sum of the output voltages is greater than 60 V, it cannot be considered being SELV (Safety Extra Low Voltage) according to the
safety standards. but the voltage may exceed the SELV level.
The outputs RCM Series converters may be connected in parallel. In order to ensures proper current sharing, the load lines
should have equal length and section. The output voltage exhibits a slight droop characteristic, which facilitates current sharing.
In addition, the output voltage tends to be lowered with increasing temperature.
Converters with option D exhibit an additional pin T to provide active current sharing by simply interconnecting all T- pins. For
redundant systems, we recommend option Q, which exhibits ORing diodes built by FETs, in order to keep the losses to a minimum.
Figure 5 shows a system with 3 parallel-connected converters forming a redundant system. The output voltage is increased by the
resistor R ext2 (as an example). The OK signals, connected in series, allow for monitoring all 3 converters.
Input
SD
OK
OK2
OK1
OK0
SD
SD0
Vi+
110RCM1000-24DQ
Vi–
OK2
OK1
OK0
SD
SD0
Vi+
110RCM1000-24DQ
JM237
Vo+
T
R+
R
R–
Vo–
Vo+
T
R+
R
R–
Vo–
Vo+
T
R+
R
R–
Vo–
Rext2
Vi–
OK2
OK1
OK0
Vi+
SD
+
Vi–
SD0
–
110RCM1000-24DQ
Rext2
Rext2
Load
Fig. 5
Parallel connection of 3 converters
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RCM Series
500 / 1000 W DC-DC Converters
Thermal Considerations and Protection
A temperature protection is incorporated in the primary and secondary control logic each. It generates an internal inhibit signal,
which disables the converter in case of overtemperature. The converter automatically recovers, when the temperature drops below
the limit; see fig. 6. The relationship between TA and TC depends heavily upon the conditions of operation and the integration into
a system.
Caution: The installer must ensure that under all operating conditions TC remains within the limits stated in table 7.
Po [W]
1000
RCM1000
800
600
with heatsink
(dotted lines)
RCM500
400
convection
cooling
200
0
TC max
TA [°C]
JM252
40
50
60
70
80
90
100
Fig. 6
Typical output power derating versus temperature;
vertical mounting position, free convection cooling.
LED Indicator
Each converter exhibits a green LED “Out OK”, signaling that the output voltage is inside the specified range.
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RCM Series
500 / 1000 W DC-DC Converters
Description of Options
Option D: Output Monitor, Output Adjust, Shutdown
Option D consists of several auxiliary functions (R, OK, SD, T) and encompasses an additional auxiliary connector.
Output Voltage Adjust (R)
Note: With open R-input, Vo = Vo nom.
The converter allows for adjusting the output voltage in the range of 80 to 105% of Vo nom. The adjust is accomplished by an external
resistor Rext1 or Rext2, connected to input R; see fig. 7.
Depending on the value of the required output voltage, the resistor shall be connected:
either: Between the pins R and R– to adjust the output voltage to a value below Vo nom :
Vo
Rext1 ≈ 4 kΩ • __________ – 15.8 kΩ
Vo nom – Vo
Note: Rext1 = 0 Ω reduces Vo to 80%.
or: Between the pins R and R+ to adjust the output voltage to a value greater than Vo nom :
(V – 2.5 V)
o
Rext2 ≈ 4 kΩ • __________________
– 682 kΩ
2.5 V • (Vo /Vo nom – 1)
Note: Rext2 = 0 Ω increases Vo to 105%.
JM191
Vi+
628 kΩ
Bias
Vref = 2.5 V
+
R+
Rext2
4 kΩ
R
Control
logic
15.8 kΩ
Vi–
Rext1
R–
Vo–
Fig. 7
Output voltage control via R-input
Output Voltage Monitor (OK)
The output voltage Vo is monitored. When Vo is in range, a relay with a changeover contact connected to the auxiliary connector
is activated, and OK0 is connected with OK1.
Note: The trigger levels are typ. ±5 % of Vonom (with open R-input).
Data of relay contacts: 0.4 A /150 VDC.
Primary Shutdown (SD)
The output of the converter may be enabled or disabled by a logic signal (e.g. CMOS) applied between the shutdown pin SD and
SD0 (= Vi–). If the shutdown function is not required, pin SD can be left open-circuit. Voltage on pin SD:
Converter operating:
Converter disabled:
12 V to Vi max or open-circuit
– 2 to +2 V
The output response is shown in fig.8
Note: In systems consisting of several converters, this feature may be used to control the activation sequence by logic signals or to enable the
power source to start up, before full load is applied.
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RCM Series
500 / 1000 W DC-DC Converters
Current Share Function in Parallel Operation (T)
Just interconnect the T-pins of all converters to balance their output currents. Only a single-wire connection is needed.
Vo /Vo nom
1
tr
thu
tf
td on
0.1
0
t off
ton
SD
1
JM193a
0
t
Fig. 8
Typical output response to the SD-signal. If option M is not fitted, thu = 0 ms.
Option Q: ORing FET for Redundant Systems
Two parallel connected converters are separated with ORing diodes (built by FETs). If one converter fails, the remaining one still
delivers the full power to the loads. If more power is needed, the system may be extended to more parallel converters (n+1 re
dundancy).
Current sharing must be ensured by load lines of equal section and length. In addition, a slight droop characteristic of the outputs
and a negative temperature coefficient are helpful as well.
To keep the losses as small as possible, the ORing diode is replaced by a FET.
Note: In the case of a failing converter, the output voltage is maintained by the redundant converters. However, the failing item should be
identified and replaced. We recommend the Out OK function (option D).
Option M: Interruption Time
The interruption time t hu is specified in the railway standard EN 50155:2017 clause 5.1.1.4: Class S2 is 10 ms. It is measured at
VB nom (nominal battery voltage) for interruption and short-circuit of the input. After such an event, the system is ready for the next
event after 10 s. Fig. 6 shows the output voltage Vo, if option M is fitted. Option M encompasses a backrush protection formed by
a FET device.
For less critical applications, option M is not required (class S1). Such units have a slightly better efficiency.
Option F: Incorporated Fuse
The railway standard EN 50155 does not recommend fuses in converters. Consequently, the installer should preview an external
fuse or circuit breaker.
However, when this is not possible, we offer an incorporated fuse (option F) with active reverse polarity protection formed by a
FET device. The fuse is not accessible and will not trip, unless the converter is really defect. The type of the incorporated fuses is
specified in table 4. Such fuses are also recommended for external fuses.
Table 4: Recommended external fuses (same as with option F)
Converter
Specification
Ordering number
72RCM500-24
15 A fast acting
Littlefuse 0505015.MX52 LEP
110RCM500-24
15 A fast acting
Littlefuse 0505015.MX52 LEP
25 A fast acting
Littlefuse 0505025.MX52 LEP
72RCM1000-24
110RCM1000-24
Option K: Pluggable Connectors
This option allows the use of preassembled pluggabale connectors; for details see Accessories.
Note: Female connectors must be ordered separately.
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RCM Series
500 / 1000 W DC-DC Converters
Electromagnetic Compatibility (EMC)
Electromagnetic Immunity
Table 5: Electromagnetic immunity (type tests). Corresponds or Exceeds EN50121-3-2:2016 and AREMA.
Phenomenon
Standard
Level
Electrostatic
discharge (to case)
IEC/EN
61000-4-2
4
Electromagnetic
field
IEC/EN
61000-4-3
x
Coupling mode 1
Value
applied
contact discharge
6000 Vp
air discharge
8000 Vp
antenna
20 V/m
Waveform
1/50 ns
AM 80% / 1 kHz
Source
imped.
Test procedure
330 Ω
150 pF
N/A
20 V/m
antenna
20 V/m
5 V/m
IEC/EN
61000-4-4
3
3
Surges
IEC/EN
61000-4-5
3
Conducted
disturbances
IEC/EN
61000-4-6
3
Power frequency
magnetic field
IEC/EN
61000-4-8
3
1
capacitive, o/c
i/c, +i/–i
direct
±2000 Vp
i/c
±2000 Vp
+i/– i
±1000 Vp
i/c, +i/–i
±2000 Vp
i, o, signal wires
10 VAC
(140 dBµV)
Perf.
crit. 2
10 pos. & 10 neg.
discharges
yes
A
80 – 800 MHz
yes
A
yes
A
60 s positive
60 s negative
transients per
coupling mode
yes
A
5 pos. & 5 neg.
surges per
coupling mode
yes
0.15 – 80 MHz
yes
A
yes
A
800 – 1000 MHz
AM 80% / 1 kHz
N/A
3 V/m
Electrical fast
transients/burst
In
oper.
1400 – 2000 MHz
2000 – 2700 MHz
5100 – 6000 MHz
bursts of 5/50 ns;
2.5/5 kHz over 15 ms;
burst period: 300 ms
1.2 / 50 µs
AM 80% / 1 kHz
50 Ω
42 Ω
0.5 μF
12 Ω
9 μF
150 Ω
300 A/m
60 s in all 3 axis
A
B
i = input, o = output, c = case
A = normal operation, no deviation from specs.; B = normal operation, temporary loss of function or deviation from specs possible
2
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RCM Series
500 / 1000 W DC-DC Converters
Electromagnetic Emissions
The conducted emissions (fig. 9) have been tested according to EN 55011, group 1, class A (similar to EN 55032), much better
values than requested by EN 50121-3-2:2016, table 2.1. The limits in fig. 9 apply to quasipeak values, which are always lower
then peak values.
Radiated emissions have been tested as per EN 55011, group 1, class A, similar to EN 61000-6-4+A1:2011, table 1. The test was
executed with horizontal and vertical polarization; the worse result is shown in fig. 10.
dBµV
110RCM500-24DMQF; Vi = 110 V, Vo = 24 V; Io = 21 A
Class A, 25-May-2017
dBµV
EN 55011 A av
60
80
40
20
20
0.2
0.5
1
2
5
10
20 MHz
Fig. 9a
110RCM500 -24: Typ. conducted disturbances at the input
(Vi =110 V, Ii nom, resistive load, quasi peak and average).
dBµV/m
60
0
0.2
0.2
60
JM226
0.5
0.5
11
22
55
10
10
20
20 MHz
MHz
Fig. 9b
110RCM1000 -24: Typ. conducted disturbances at the input
(Vi =110 V, I i nom, resistive load, quasi peak and average).
dBµV/m
EMC Labatory, 110RCM500-24DMQF; Vi = 110 VDC, Vo = 24 V / 21 A
ETS-3143B Testdistance 3 m, Class A, 25-May-2017
EMC Labatory, 110RCM500-24DMQF; Vi = 110 VDC, Vo = 24 V / 42 A
ETS-3143B Testdistance 3 m, Class A, 25-May-2017
JM228
QP Limit EN 55011, Group 1, Class A, 3 m
QP Limit EN 55011, Group 1, Class A, 3 m
50
50
40
40
30
30
20
20
10
10
0
EN 55011 A av
av
60
40
0
qp
EN 55011 A qp
JM225
JM227
EN 55011 A qp
JM225
80
110RCM500-24DMQF;
110RCM1000-24DMQF; ViVi==110
110V,V,Vo
Vo==24
24V;V;IoIo==21
42AA
Class A, 25-May-2017
30
50
100
200
500
1000 MHz
Fig. 10a
110RCM500 -24: Typ. radiated disturbances in 3 m distance
(Vi = 110 V, I i nom, resistive load, quasi peak).
0
30
50
100
200
500
1000 MHz
Fig. 10b
110RCM1000 -24: Typ. radiated disturbances in 3 m
distance (Vi = 110 V, I i nom, resistive load, quasi peak).
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RCM Series
500 / 1000 W DC-DC Converters
Immunity to Environmental Conditions
Table 6: Mechanical and climatic stress. Air pressure 800 – 1200 hPa
Test method
Standard
Test Conditions
Ad
Low temperature
start-up test
EN 50155:2017, clause 13.4.4
IEC/EN 60068-2-1
Temperature, duration:
- 40 °C, 2 h
Performance test:
+25 °C
Dry heat test,
cycle A
EN 50155:2017, clause 13.4.5
IEC/EN 60068-2-2
Temperature:
70 °C
Duration:
6h
Cyclic damp heat
test
EN 50155:2017, clause 13.4.7
IEC/EN 60068-2-30
Temperature:
55 °C and 25 °C
Cycles (respiration effect):
2
Duration:
2x 24 h
Be
Db 2
Ka
Not operating
Operating
perf. crit. A
Not operating
Salt mist test
sodium chloride
(NaCl) solution
EN 50155:2017, clause 13.4.10
IEC/EN 60068-2-11
Temperature:
35 ±2 °C
Duration:
48 h
Functional random
vibration test
EN 50155:2017 clause 13.4.11.4
EN 61373:2010 clause 8,
class B, body mounted 1
Acceleration amplitude:
0.1 gn = 1.01 m/s2
Frequency band:
5 – 150 Hz
Test duration:
30 min (10 min in each axis)
Simulated long life
testing
EN 50155:2017 clause 13.4.11.2
EN 61373:2010 clause 9,
class B, body mounted 1
Acceleration amplitude:
0.58 gn = 5.72 m/s2
Frequency band:
5 – 150 Hz
Test duration:
15 h (5 h in each axis)
Shock test
EN 50155:2017 clause 13.4.11.3
EN 61373:2010 clause 10,
class B, body mounted 1
Acceleration amplitude:
5.1 g n
Bump duration:
30 ms
Number of bumps:
18 (3 in each direction)
AREMA Part. 11.5.1
class C, D, E, I, J
Acceleration amplitude:
0.3” (5 – 20 Hz)
1.5 gn = 14.7 m/s2
Frequency:
10 – 200 Hz
Test duration:
12 h (4 h in each axis)
Acceleration amplitude:
10 g n = 98 m/s2
Bump duration:
11 ms
Number of bumps:
18 (3 in each direction)
Vibration sinusoidal
Mechanical shock
1
Status
AREMA Part. 11.5.1
class C, D, E, I, J
Converter not
operating
Operating
perf. crit. A
Not operating
Operating
perf. crit. A
Operating
perf. crit. A
Operating
perf. crit. A
Body mounted = chassis of a railway coach
Temperatures
Table 7: Temperature specifications, valid for an air pressure of 800 – 1200 hPa (800 – 1200 mbar)
Model
RCM500
RCM1000
EN 50155:2017 Class OT4
Characteristics
TA
Ambient temperature
TC
Case temperature 1
TS
Storage temperature
1
Unit
EN 50155:2017 Class OT2
Conditions
min
max
10 min
min
max
10 min
Converter operating
- 40
70
85
- 40
55
70
- 40
90
- 55
85
Not operational
2
90
- 55
°C
85
Measured at the measurement point TC ; see Mechanical Data.
RCM1000 can be operated at higher temperature with reduced output power.
2
Reliability
Table 8: MTBF and device hours
Ratings at specified case temperature between failures
Accord. to IEC 62380
Model
MTBF
110RCM500-24DMQF
1 120 000 h
110RCM1000-24DMQF
1 110 000 h
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RCM Series
500 / 1000 W DC-DC Converters
Mechanical Data
Dimensions in mm.
92.75
92.75
70.5
(4
x)
70.5
JM204e
6
JM206d
6
Heatsink fixation
2x M3
197
209
Heatsink fixation
2x M3
123
141
123
9.0
99.65
53.65
53.65
40
7
Vo+ Vo–
46
10.95
RCM500/1000
standard
53.7
9.0
141
99.65
10.95
197
147.05
71.5
66
6
Measuring
point of case
temperatureTC
147.05
66
71.5
Measuring
point of case
temperatureTC
209
.5
6
4
Vi– Vi+ PE
Vo+ Vo–
99.4
53.7
13.9
Vi– Vi+ PE
99.4
13.9
7
7
RCM500/1000
with option K
Vo+ Vo–
Vi– Vi+ PE
Vo+ Vo–
Fig. 11
Case for RCM500 (RCM03),
Aluminum, EP powder-coated; 1160 g.
pluggable
connector
European
Projection
6
JM246
Vi– Vi+ PE
Fig. 12
Case for RCM1000 (RCM04),
Aluminum, EP powder-coated; 1250 g.
17.7
Fig. 13
Case detail for RCM500/1000 with option K
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RCM Series
500 / 1000 W DC-DC Converters
Safety and Installation Instruction
Connectors and Pin Allocation
- Input connector, 3 pins: Wago 745-353: Vi+, Vi–, PE;
wire sections:
RCM500 /1000: 0.2 – 6 mm 2, 24 – 10 AWG;
with option K: Weidmüller 1048500000
- Output connector, 2 pins: Wago 745-652/006-000: Vo+, Vo;
wire sections:
RCM500/1000: 0.2 – 16 mm2, 24 – 06 AWG
with option K: Weidmüller 1048390000
n.c.
SD
n.c.
n.c.
n.c.
SD0
T
T
OK0 OK2
R–
R
OK0 OK1
R+
R
- Auxiliary connector: Phoenix Contact 1874043, pin allocation see fig. 14.
Fig. 14
Auxiliary connector pin allocation
Installation Instruction
These converters are components, intended exclusively for inclusion by an industrial assembly process or by a professionally
competent person. Installation must strictly follow the national safety regulations in respect of the enclosure, mounting, creepage
distances, clearances, markings and segregation requirements of the end-use application.
Connection to the system shall only be effected with cables with suitable section (primary and secondary connector in cage clamp
technique).
The auxiliary connector shall be connected via the suitable female connector; see Accessories.
Other installation methods may not meet the safety requirements. Check that PE is safely connected to protective earth.
No fuse is incorporated in the converter (except for option F). An external circuit breaker or a fuse in the wiring to one or both
input pins.
Do not open the converters, or the warranty will be invalidated. Make sure that there is sufficient airflow available for convection
cooling and that the temperature of the bottom plate is within the specified range. This should be verified by measuring the case
temperature at the specified measuring point, when the converter is operated in the end-use application. TC max should not be
exceeded. Ensure that a failure of the converter does not result in a hazardous condition.
Standards and Approvals
The RCM Series converters are approved according to the last edition of IEC/EN 60950-1 and UL/CSA 60950-1.
They have been evaluated for:
• Class I equipment
• Building in
• Double or reinforced insulation based on 250 VAC or 240 VDC between input and output, and between input and OK signals
(relay contacts)
• Pollution degree 2 environment
The converters are subject to manufacturing surveillance in accordance with the above mentioned UL standards and with ISO 9001:2015.
Cleaning Liquids and Protection Degree
The converters are not hermetically sealed. In order to avoid possible damage, any penetration of liquids shall be avoided.
The converters correspond to protection degree IP 30.
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RCM Series
500 / 1000 W DC-DC Converters
Railway Applications
The RCM Series converters have been designed observing the railway standards EN 50155:2017, EN 50121-3-2:2016, and AREMA.
All boards are coated with a protective lacquer. The converters comply with the fire & smoke standard EN 45545-2, HL1 to HL3.
Insulation Test
The electric strength test is performed in the factory as routine test in accordance with EN 50514 and IEC/EN 60950 and AREMA.
It should not be repeated in the field. The Company will not honor warranty claims resulting from incorrectly executed electric
strength tests.
Table 9: Isolation
Characteristics
Input to
Output to Case
Output 1
Case + Output
Factory test 10 s
4.2
2.86
AC test voltage equivalent
to factory test
3.0
Insulation resistance
Creepage distances
Electric strength test
1
2
OK contacts to
Unit
Input
Case
Outputs
2.86
2.86
2.86
2.86
kVDC
2.0
2.0
2.0
2.0
2.0
kVAC
>300 2
>300 2
>300
>300
>300
>300
MΩ
5.0
3.5
3.5
3.5
3.5
3.5
mm
Pretest of subassemblies in accordance with IEC/EN 60950
Tested at 500 VDC
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RCM Series
500 / 1000 W DC-DC Converters
Accessories
Female Connector
A suitable 16 pin female connector is available; see fig. 15.
For converters RCM500/1000 with option K, use (see fig. 16):
• HZZ00303-G (3 poles, Weidmüller 1060580000)
• HZZ00302-G (2 poles, Weidmüller 1060550000).
Wire section: 0.5 – 10 mm 2, 24 – 8 AWG
Fig. 15
Female connector 16 pins, HZZ00146-G
(Phoenix Contact 1790357)
Fig. 16
Female connectors for RCM500/1000 with option K
Additional Heatsink
A suitable heat sink (HZZ00149-G) for free air cooling is available, if cooling by wall or a chassis mounting is not possible; see fig. 17.
6
Visible surface
A-A
6
C
71.5±0.2
D
66 ±0.1
B
135
67.5±0.2
JM224a
A
A
(209)
90°
Ø6
R
>6
8 ±1
6
M4
0.2
Ø 3.4
B (4x)
D (2x)
C (2x)
.5
Ø4
6
6
Fig. 17
Additional heatsink for RCM500 and
RCM1000 (HZZ00149-G)
Weight 530 g
Content: Heatsink + 2 screws
(M3 x 6 mm)
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.
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