HR / ER Series
144 / 288 Watt 10:1 DC-DC Converters
The ER/HR Series of DC-DC converters represents versatile
power supplies ideally suitable for use in transportation and
other advanced electronic systems.
The HR Series converters include a very broad input voltage
range, very high efficiency, high reliability, low output voltage
noise, and excellent dynamic response to load/line changes.
HR converters can be connected to all conventional railway
batteries.
ER Series converters are optimized for connection to 110 V
railway batteries.
111
4.4"
3U
60
2.4"
12 TE
168
6.6"
60
2.4"
12 TE
168
6.6"
111
4.4"
3U
111
4.4"
3U
80
3.2"
16 TE
168
6.6"
80
3.2"
16 TE
168
6.6"
111
4.4"
3U
Features
• Extremely wide input voltage range from 12 to 168 VDC
in the same converter (HR Series)
• RoHS-compliant for all 6 substances
• Class I equipment
• Compliant with EN 50155, EN 50121, EN 45545
• Input over- and programmable undervoltage lockout
• Shutdown function
• Inrush current limitation
• Interruption time 10 ms
• Adjustable output voltages
• 2 isolated outputs: no load, overload, and short-circuit proof
• Rectangular current limiting characteristic
• Parallel operation with active current sharing
• Very high efficiency up to 94%
• Immunity according to IEC 61000-4-2, -3, -4, -5, -6, -8, -9
• All PCB boards protected by lacquer
• Very high reliability
• 5 year warranty
Safety-approved to the latest edition of IEC/EN 62368-1 and
UL/CSA 62368-1.
1
1
on request
Table of Contents
Description........................................................................................1
Model Selection.................................................................................2
Functional Description.......................................................................5
Electrical Input Data..........................................................................7
Electrical Output Data.....................................................................10
Auxiliary Functions..........................................................................16
Electromagnetic Compatibility (EMC)..............................................19
Immunity to Environmental Conditions............................................21
Mechanical Data..............................................................................22
Safety and Installation Instructions..................................................25
Description of Options.....................................................................26
Accessories.....................................................................................27
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BCD.00185 Rev AP, 16 May 2022
ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Description
The converter inputs are protected against surges and transients. An input over- and undervoltage lockout circuitry disables
the outputs, when the input voltage is outside of the specified range. To avoid high input currents at operation with high-voltage
batteries, the inhibit input allows for adjusting the undervoltage lockout to a suitable level, thus allowing the use of an appropriate
external input fuse.
The converters exhibit an inrush current limiter, preventing external circuit breakers and fuses from tripping at switch-on.
The outputs are open- and short-circuit proof.
Full input-to-output, input-to-case, output-to-case, and output to output isolation is provided. The converters are particularly suitable
for railway applications. The HR converters can be supplied by all common railway batteries with 24 V, 36 V, 48 V, 72 V, 96 V, 110 V,
and 120 V nominal voltage. The ER converters can be supplied by all common railway batteries with 96 V, 110 V, and 120 V nominal
voltage. All PCB boards are coated with a protective lacquer.
The case design allows operation at nominal load up to 71 °C with natural cooling. If forced cooling is provided, the ambient
temperature may exceed 71 °C, but the case temperature must remain below 95 °C.
A temperature sensor disables the outputs when the case temperature TC exceeds the limit. The outputs are automatically reenabled, when the temperature drops below the limit.
LED indicators display the status of the converter and allow for visual monitoring of the system at any time.
The converters may either be plugged into a 19 ” rack system according to IEC 60297-3, or be chassis mounted. Two heat sinks
of different size and cooling plates for chassis mounting (option B, B1) are available.
Model Selection
Table 1a: Model Selection of HR models
Output 1
Output 2
Power
Input voltage
Efficiency
η 2 41
Model
Options
η 110 2
Vo nom
[V]
Io nom
[A]
Vo nom
[V]
Io nom
[A]
Po nom
[W]
Vi min3
[V]
Vi cont
[V]
Vi max3
[V]
min
[%]
typ
[%]
min
[%]
typ
[%]
12
12
12
15
15
15
48
48
20
12
24
16
10
19.2
4
5
-
-
240
144
288
240
150
288
192
240
12
12
12
12
12
12
12
12
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
168
168
168
168
168
168
168
168
91
91
91
91
91
91
89.5
89.5
92.5
92.5
92.5
92.5
92.5
92.5
90.5
90.5
92
92
92
92
92
92
92
92
94
94
94
94
94
94
93
93
HR2320-9RG 4
HRL2320-9RG 4
HRP2320-9RG 4
HR2540-9RG 4
HRL2540-9RG 4
HRP2540-9RG 4
HR2880-9RG 4
HRP2880-9RG 4
B, B1
12
12
12
15
15
15
48
48
10
6
12
8
5
9.6
2
2.5
12
12
12
15
15
15
48
48
10
6
12
8
5
9.6
2
2.5
240
144
288
240
150
288
192
240
12
12
12
12
12
12
12
12
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
168
168
168
168
168
168
168
168
91
91
91
91
91
90
89.5
89.5
92.5
92.5
92.5
92.5
92.5
92.5
90.5
90.5
92
92
92
92
92
92
92
92
94
94
94
94
94
94
93
93
HR2320-9RG
HRL2320-9RG
HRP2320-9RG
HR2540-9RG
HRL2540-9RG
HRP2540-9RG
HR2880-9RG
HRP2880-9RG
B, B1
24
24
24
30
30
30
96
96
10
6
12
8
5
9.6
2
2.5
-
-
240
144
288
240
150
288
192
240
12
12
12
12
12
12
12
12
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
16.8 to 150
168
168
168
168
168
168
168
168
91
91
91
91
91
91
89.5
89.5
92.5
92.5
92.5
92.5
92.5
92.5
90.5
90.5
92
92
92
92
92
92
92
92
94
94
94
94
94
94
93
93
HR2320-9RG 5
HRL2320-9RG 5
HRP2320-9RG 5
HR2540-9RG 5
HRL2540-9RG5
HRP2540-9RG 5
HR2880-9RG 5
HRP2880-9RG 5
B, B1
1
2
3
4
5
Efficiency at TA = 25 °C, Vi = 24 V, Io nom, Vo nom
Efficiency at TA = 25 °C, Vi = 110 V, Io nom, Vo nom
Short time; see table 2 for details
Both outputs connected in parallel
Both outputs connected in series
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Table 1b: Model Selection of ER models
Output 1
Output 2
Power
Input voltage
Efficiency
Model
Options
η 110 1
Vo nom
[V]
Io nom
[A]
Vo nom
[V]
Io nom
[A]
Po nom
[W]
Vi min2
[V]
Vi cont
[V]
Vi max2
[V]
min
[%]
typ
[%]
12
12
12
15
15
15
48
48
20
12
24
16
10
19.2
4
5
-
-
240
144
288
240
150
288
192
240
66
66
66
66
66
66
66
66
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
168
168
168
168
168
168
168
168
93
94
91
94
12
12
12
15
15
15
48
48
10
6
12
8
5
9.6
2
2.5
12
12
12
15
15
15
48
48
10
6
12
8
5
9.6
2
2.5
240
144
288
240
150
288
192
240
66
66
66
66
66
66
66
66
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
168
168
168
168
168
168
168
168
24
24
24
30
30
30
96
96
10
6
12
8
5
9.6
2
2.5
-
-
240
144
288
240
150
288
192
240
66
66
66
66
66
66
66
66
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
77 to 150
168
168
168
168
168
168
168
168
1
2
3
4
90.5
92
93
94
91
94
90.5
92
93
94
91
94
90.5
92
ER2320-9RG 3
ERL2320-9RG 3
ERP2320-9RG 3
ER2540-9RG 3
ERL2540-9RG 3
ERP2540-9RG 3
ER2880-9RG 3
ERP2880-9RG 3
B, B1
ER2320-9RG
ERL2320-9RG
ERP2320-9RG
ER2540-9RG
ERL2540-9RG
ERP2540-9RG
ER2880-9RG
ERP2880-9RG
B, B1
ER2320-9RG 4
ERL2320-9RG 4
ERP2320-9RG 4
ER2540-9RG 4
ERL2540-9RG 4
ERP2540-9RG 4
ER2880-9RG 4
ERP2880-9RG 4
B, B1
Efficiency at TA = 25 °C, Vi = 110 V, Io nom, Vo nom
Short time; see table 2 for details
Both outputs connected in parallel
Both outputs connected in series
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Part Number Description
HR 2 5 40 -9 R B1 G
Operating input voltage Vi cont (continuously):
16.8 – 150 VDC ...................................... HR, HRL, HRP
77 – 150 VDC...........................................ER, ERL, ERP
Number of outputs........................................................... 2, 7 2
Nominal voltage of main output Vo1 nom
12 V ..............................................................................3
15 V ..............................................................................5
48 V ..............................................................................8
Other voltages 1 ............................................................9
Nominal voltage of tracking output Vo2 3
12 V..............................................................................20
15 V..............................................................................40
48 V..............................................................................80
Other specifications or additional features 1 ........ 21 – 99
Operational temperature range: TA:
TA = – 40 to 71 °C, TC ≤ 95 °C.......................................-9
Other 1 ................................................................ -0, -5, -6
Auxiliary functions and options:
Output voltage control input ........................................ R
Cooling plate standard case....................................B, B1
Cooling plate for long case 220 mm 2 ........................B2 2
RoHS-compliant for all 6 substances.......................... G 4
Customer-specific models. No safety-relevant changes compared to the respective basic model, e.g. different mechanical details, special
markings, mounted front plates, reduced output voltage, etc.
2
Converters with 220 mm case (customer-specific models). Add 5000 to the model number, e.g. HR2540-9RB1G → HR7540-9RB1G.
3
The nominal voltages of both outputs are always equal.
4
G is always placed at the end of the part number.
1
Note: The sequence of options must follow the order above.
Example: HR2540-9RB1G: DC-DC converter, operating input voltage range 16.8 – 150 VDC, 2 isolated outputs, each providing
15 V, 8 A, control input R to adjust the output voltages, cooling plate B1, and RoHS-compliant for all six substances.
Product Marking
Basic type designation, approval marks, CE mark, warnings, pin allocation, patents, MELCHER logo, specific type designation,
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.
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Functional Description
The input voltage is fed via an efficient filter to the interleaved switching boost converter (HR models), which provides the
intermediate circuit voltage on the bulk capacitor C b. The inrush current is limited by the resistor Rinr, which is shorted by Vinr after
the bulk capacitor was charged.
The bulk capacitor sources a single-transistor forward converter with active clamp and provides the power during the interruption
time of 10 ms.
The main transformer exhibits two separate secondary windings for the two outputs. The resultant voltages are rectified by
synchronous rectifiers (not models with Vo = 2 × 48 V) in order to provide the best efficiency. Their ripple voltages are smoothed by
a dual power choke and output filters. The control logic senses the main output voltage Vo1 and generates the control signal for the
forward converter, with respect to the max. output current transferred via magnetic feedback to the control circuit of the forward
converter, located on the primary side.
The second output voltage is tracking the main output, but has its own current limiting circuit. If the main output voltage drops due
to current limitation, the second output voltage will drop as well and vice versa.
The output voltages can be adjusted by external means. Parallel operation of several converters is possible by interconnecting
the T-pins to provide active current sharing. Both outputs can be connected in parallel or in series without any precaution. They
exhibit a rectangular current limitation characteristic. Switchable preloads VPL (Version V101 or later) ensure good regulation even
with no load at one output.
A control output (D) and two LEDs signal correct operation of the converter. In case of an output overvoltage, the converter is
disabled by a latch.
Input over- and undervoltage lockout is provided. The undervoltage trigger level can be adjusted by an external resistor connected
to PUL (pin 24) depending on the nominal voltage of the supplying battery.
Temperature sensors on the primary and secondary side prevent the converter from excessive warm-up.
A cooling plate for chassis-mounting is available (opt. B, B1).
JM080c
30
Vi–
32
PUL 24
22
CY
Primary
control
Cb
Vinr
+
NTC
Isolation
18 T 2
20 D
Synchr.
rect. drive1
12 S1+
+
Synchr.
rect. drive1
Output 1
filter
+
16 R
Secondary
control
logic
CY
CY
+
4 Vo1+
8 Vo1–
14 S1–
VPL
Output 2
filter
NTC
Ci
Rinr
Input filter
Cx
Boost converter
(115 kHz interleaved)
CY
Forward converter
(85 kHz)
26
28
VDR
Vi+
Magnetic
feedback
CY
CY
6 Vo2+
10 Vo2–
VPL
Auxiliary
converter
(80 kHz)
1 models with 2x 48 V have rectifier diodes
2 T-pin is not connected for models HRL / ERL
Fig. 1
Block diagram of HR2320, version V101 (or later)
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
JM157
Vi–
Inrush
current
control
Vinr
30
32
PUL 24
22
NTC
20 D
Synchr.
rect. drive1
12 S1+
+
Synchr.
rect. drive1
CY
CY
Auxiliary
converter
(150 kHz)
4 Vo1+
8 Vo1–
14 S1–
VPL
+
CY
18 T 2
Output 1
filter
+
16 R
Secondary
control
logic
Output 2
filter
NTC
Cb
Rinr
Input filter
Cx
Isolation
CY
Forward converter
(85 kHz)
26
28
VDR
Vi+
Magnetic
feedback
CY
CY
6 Vo2+
10 Vo2–
VPL
1 models with Vo = 2x 48 V have rectifier diodes
2 T-pin is not connected for models HRL / ERL
Fig. 2
Block diagram of ER2320
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Electrical Input Data
General conditions:
- TA = 25 °C, unless TC is specified.
- Pin 24 (PUL) left open-circuit
- Pin 16 (R) and 18 (D) left open-circuit.
Table 2a: Input data of HR models
Model
HR
Characteristics
Conditions
min
Io = 0 – Io max
TC min – TC max
16.8
typ
HRL
max
min
150
16.8
168
12.0
120
24
176
0
15.65
15.65
12.82
1.03
typ
HRP
max
min
150
16.8
168
12.0
120
24
176
0
9.31
2.10
2.10
1.71
typ
Unit
max
Vi
Operating input voltage cont.
Vi 2s
For ≤2 s without shutdown
Vi nom
Nominal input voltage range
Vi abs
Input voltage limits
Ii
Input current:
Pi 0
No-load input power
Vi min – Vi max, Io = 0
11
11
11
P i inh
Idle input power
Vi min – Vi max, VPUL = 0 V
2.5
2.5
2.5
Cx
Input capacitance 1
Ri
Input resistance
Iinr p
Peak inrush current 2
tinr r
Time constant of Iinr
ton
Start-up time
24
3 s, without damage
HR2320
HR2540
HR2880
Rise time after inhibit
tr
12.0
(110)
0
Vi max ..(110 V)..Vi min, I o nom
1.76
1.76
1.37
(2.36)
(2.36)
(1.86)
(110)
(1.38)
150
168
(110)
120
V
176
(2.83)
(2.83)
(2.33)
21.40
21.40
16.05
A
W
8.6
8.6
8.6
µF
10
10
10
mΩ
Vi = 150 V, I o nom
30
30
30
A
10
10
10
0 → Vi min, I o nom
400
400
400
40
40
40
Vi ≥ 16.8 V, I o nom,
VPUL = 0 → 5 V
ms
Table 2b: Input data of ER models
Model
ER
Characteristics
Vi
Operating input voltage
Vi 2s
For ≤2 s without shutdown
Vi nom
Nominal input voltage range
Vi abs
Input voltage limits
Conditions
min
Io = 0 – Io max
TC min – TC max
77
66
110
3 s, without damage
ER2320
ER2540
ER2880
typ
0
Vi max ..(110 V)..Vi min, I o nom
1.76
1.76
1.37
ERL
max
min
150
77
168
66
120
176
(2.36)
(2.36)
(1.86)
typ
110
min
150
77
168
66
120
0
1.03
ERP
max
176
(1.38)
typ
150
168
110
0
2.10
2.10
1.71
Unit
max
120
176
(2.83)
(2.83)
(2.33)
Ii
Input current:
Pi 0
No-load input power
Vi min – Vi max, Io = 0
10
10
10
P i inh
Idle input power
Vi min – Vi max, VPUL = 0 V
2.5
2.5
2.5
Cx
Input capacitance 1
Ri
Input resistance
Iinr p
Peak inrush current 2
tinr r
Time constant of Iinr
ton
Start-up time
tr
Rise time after inhibit
1
V
A
W
8.6
8.6
8.6
µF
10
10
10
mΩ
Vi = 150 V, I o nom
30
30
30
A
10
10
10
0 → Vi min, I o nom
400
400
400
40
40
40
Vi ≥ 77 V, I o nom,
VPUL = 0 → 5 V
ms
Not smoothed by the inrush current limiter
According to ETS 300132-2
2
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
PUL Function and Fuse
No fuse is incorporated in the converters. Consequently, an external fuse or a circuit breaker must be installed at system level to
protect against severe defects.
HR converters are designed for an extremely wide input voltage range, allowing for connection to all common railway batteries.
However, the programmable input undervoltage lockout (PUL, pin 24) should be adjusted adequately, in order to limit the input
current at low input voltage.
Table 3 specifies the values of the resistor R PUL, connected between PUL and Vi–, versus the resultant minimum input voltage and
the recommended external input fuse.
Fig. 3 shows more values of R PUL versus start-up voltage. For stationary batteries, a higher start-up voltage might be advantageous.
Vi min [V]
JM101a
80
60
40
20
0
2
6
4
8
10
12
14
16
kΩ
RPUL
Fig. 3
R PUL versus switch-on voltage (HR models)
ER models are designed for the input voltage range of a 110 V railway battery. The input undervoltage lockout (PUL, pin 24) may
be adjusted if requested. The PUL resistors are specified in table 4.
Table 3: PUL Specification (typ.) and recommended external fuses
for HR/HRP models.Smaller fuses are possible for HRL models.
Battery
R PUL
24 V
1
4
Vi min (on / off)
Fuse recommended 4
∞
15 V
12 V 3
25 A fast, Littlefuse 314 1
36 V
16.9 kΩ
20 V
18 V
16 A fast, Schurter / SP
48 V
13.7 kΩ
26 V
20 V
12.5 A fast, Schurter / SP
72 V
9.5 kΩ
38 V
32 V
8 A fast, Schurter / SP 2
96 V
5.2 kΩ
62 V
57 V
6.3 A slow, BEL fuse MRT
110 V
2.9 kΩ
90 V
84 V
5.0 A slow, BEL fuse MRT 2
all
< 100 Ω
2
2
2
Table 4: PUL specification (typ.) and recommended external fuses
for ER/ERP models. Smaller fuses are possible for ERL models.
Battery
R PUL
Vi min (on / off)
Fuse recommended 4
110 V
5.0 kΩ
64.5 V
60.5 V
6.3 A slow, BEL fuse MRT 2
110 V
4.0 kΩ
74.5 V
69 V
6.3 A slow, BEL fuse MRT 2
110 V
3.0 kΩ
87.4 V
81.6 V
6.3 A slow, BEL fuse MRT 2
110 V
2.5 kΩ
96 V
90 V
6.3 A slow, BEL fuse MRT 2
120 V
2.2 kΩ
101.7 V
96 V
5.0 A slow, BEL fuse MRT 2
-
< 100 Ω
Converter disabled
Converter disabled
fuse size 6.3 × 32 mm 2 fuse size 5 × 20 mm 3 for ≤ 2 s
If the converter is not supplied from battery voltage but from other DC source within its operating range, use fuse rating of 25 A fast (e.g. Littlefuse 314)
Note: If PUL (pin 24) is connected to Vi– (pin 30/32), the converter is disabled; see Inhibit Function.
Fig. 4 and 5 show the input current versus the input voltage.
Ii [A]
Ii [A]
JM087
JM167
5
25
4
20
3
15
2
10
1
5
0
0
20
40
60
80
100
120
140
160
Vi [V]
Fig. 4
Typ. input current vs input voltage at nominal load (HR2320)
0
80
100
120
140
Vi [V]
Fig. 5
Typ. input current vs input voltage at nominal load (ER2320)
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Reverse Polarity and Input Transient Protection
Reverse polarity protection of all models is provided by an antiparallel diode across the input, causing the external input fuse or
circuit breaker to trip. ER models exhibit an additional serial diode on the input.
The double stage symmetrical input filter together with a VDR (voltage depending resistor) form an effective protection against
high input transient voltages, which typically occur in battery-driven mobile applications.
At very high input voltage, the overvoltage lockout disables the converter in order to protect it from damage.
Inrush Current Limitation
The converters exhibit an electronic inrush current limiting circuit. This circuit is also functional, when the input voltage is removed
and immediately reapplied.
However, several capacitors are directly connected to the input pins. Consequently, a short current peak is present, when applying
the input voltage.
The inrush current peak value can be determined by following calculation; see also fig. 6:
Vi source
Iinr p = –––––––––
(R ext + Ri )
Iinr [A]
JM086
50
JM001c
Lext
Rext
Vi+
+
Converter
40
Vo+
30
Load
Ri
Ci
Vo–
Vi–
20
10
0
Fig. 6
Equivalent input ciruit
0.1
100
200
300
400 ms
Fig. 7
Inrush current at Vi = 150 V, Io nom (HR2320, ER2320)
Efficiency
η [%]
JM100
100
Vi = 110 V
90
Vi = 150 V
80
Vi = 15.4 V
70
60
0
0.2
0.4
0.6
0.8
Io / Io nom
Fig. 8
Efficiency versus Vi and Io (HR2320, both outputs connected in series)
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Electrical Output Data
General Conditions: – TA = 25 °C, unless TC is specified; Pin 24 (PUL) ≥ 5 V
Table 5a: Output data of HR/ER2320 and HRL/ERL2320
Model
HR2320 / ER2320
HRL2320 / ERL2320
2 × 12 V
2 × 12 V
Nom. output voltage
Characteristics
Conditions
Vo
Output voltage
Vi nom, 0.5 Io nom
V o BR
Output protection
(suppressor diode)
Output 2
Io
Output current nom.
Io1L, Io2L Output current limit
1
Io12L
Output current limit 1, 2
Vo
Output noise incl. spikes
Vo adj
Adjustment by R-input 4
∆Vo u
Static line/load regulation
(total deviation of Vo)
Voltage
deviation 5
tod
Dynamic
load
regulation
αvo
Temperature coefficient of
output voltage
Vo d
Recovery time 5
Vi min – Vi max
TC min – TC max
Output 1
min
typ
max
11.93
12.0
12.07
-
min
typ
Output 1
max
12.0
14.4
10
Output 2
min
typ
max
11.93
12.0
12.07
15.9
-
10
min
14.4
6.0
10.5
6.5
6.5
-
13
-
60
4.8
60
13.8 1
3
±120
3
max
15.9
A
60
4.8
V
6.0
21 2
BW = 20 MHz
typ
12.0
10.5
Vi nom, Io nom
Vi min – Vi max
(0.1 – 1) Io nom
Output 2
Unit
60
13.8 1
3
±120
3
mVpp
V
mV
Vi nom, 0.5 Io2 nom
Io1 nom ↔ 0.5 Io1 nom
and after turn on
Io nom,
TC min – TC max
±200
±200
±150
±150
1
3
1
3
ms
-
±0.01
-
%/K
±0.01
±0.02
±0.02
Table 5b: Output data of HRP/ERP2320 models
Model
HRP2320 / ERP2320
Nom. output voltage
2 × 12 V
Characteristics
Conditions
Vo
Output voltage
Vi nom, 0.5 Io nom
V o BR
Output protection
(suppressor diode)
Output 2
Io
Output current nom.
Io1L, Io2L Output current limit
1
Io12L
Output current limit 1 2
Vo
Output noise incl. spikes
Vo adj
Adjustment by R-input 4
∆Vo u
Static line/load regulation
(total deviation of Vo)
Voltage
deviation 5
tod
Dynamic
load
regulation
αvo
Temperature coefficient of
output voltage
Vo d
Unit
Recovery time 5
Vi min – Vi max
TC min – TC max
Output 1
min
typ
max
11.93
12.0
12.07
-
and after turn on
Io nom,
TC min – TC max
typ
14.4
V
15.9
12
12.3
12.3
-
A
60
4.8
max
12.0
24.6 2
BW = 20 MHz
Vi nom, 0.5 Io2 nom
Io1 nom ↔ 0.5 Io1 nom
min
12
Vi nom, Io nom
Vi min – Vi max
(0.1 – 1) Io nom
Output 2
60
13.8 1
3
±120
3
mVpp
V
mV
±250
±250
1
3
ms
-
%/K
±0.01
±0.02
If Vo is increased above Vo nom through R-, sense, or T-input, the output currents should be reduced so that Po nom is not exceeded.
Both outputs connected in parallel
3
See Output voltage regulation
4
For battery charger application, a defined negative temp. coefficient can be provided by using a temp. sensor (see Accessories)
5
See Dynamic load regulation
6
Measured with a ceramic cap of 1 µF across each output.
1
2
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Table 5c: Output data of HR/ER2540 and HRL/ERL2540. General conditions as per table 5a
Model
HR2540 / ER2540
Nom. output voltage
2 × 15 V
Characteristics
Conditions
Vo
Output voltage
Vi nom, 0.5 Io nom
V o BR
Output protection
(suppressor diode)
Output 2
Io
Output current nom.
Io1L, Io2L Output current limit
1
Io12L
Output current limit 1, 2
Vo
Output noise incl. spikes
Vo adj
Adjustment by R-input 4
∆Vo u
Static line/load regulation
(total deviation of Vo)
Voltage
deviation 5
tod
Dynamic
load
regulation
αvo
Temperature coefficient of
output voltage
Vo d
HRL2540 / ERL2540
Recovery time 5
Vi min – Vi max
TC min – TC max
Output 2
min
typ
max
15.0
15.09
-
min
typ
Output 1
max
15.0
20.9
Output 2
min
typ
max
14.91
15.0
15.09
23.1
8
-
8
min
20.9
5
8.4
5.5
5.5
-
9.8 2
-
75
6.0
75
17.25 1
3
±150
3
23.1
V
A
75
6.0
max
5
8.4
BW = 20 MHz
typ
15.0
16.8 2
Vi nom, Io nom
Vi min – Vi max
(0.1 – 1) Io nom
2 × 15 V
Output 1
14.91
Unit
75
17.25 1
3
±150
3
mVpp
V
mV
Vi nom, 0.5 Io2 nom
Io1 nom ↔ 0.5 Io1 nom
and after turn on
Io nom,
TC min – TC max
±300
±300
±350
±350
1
3
1
3
ms
-
±0.01
-
%/K
±0.01
±0.02
±0.02
Table 5d: Output data of HRP/ERP2540. General conditions as per table 5a
Model
HRP2540 / ERP2540
Nom. output voltage
Characteristics
Conditions
Vo
Output voltage
Vi nom, 0.5 Io nom
V o BR
Output protection
(suppressor diode)
Output 2
Io
Output current nom.
Io1L, Io2L Output current limit 1
Io12L
Output current limit
1, 2
Vo
Output noise incl. spikes
Vo adj
Adjustment by R-input 4
∆Vo u
Static line/load regulation
(total deviation of Vo)
Voltage
deviation 5
tod
Dynamic
load
regulation
αvo
Temperature coefficient of
output voltage
Vo d
Unit
2 × 15 V
Recovery time 5
Vi min – Vi max
TC min – TC max
Output 1
typ
max
14.91
15.0
15.09
-
and after turn on
Io nom,
TC min – TC max
typ
20.9
23.1
V
9.6
10.1
19.7
-
2
A
75
6.0
max
15.0
9.6
BW = 20 MHz
Vi nom, 0.5 Io2 nom
Io1 nom ↔ 0.5 Io1 nom
min
10.1
Vi nom, Io nom
Vi min – Vi max
(0.1 – 1) Io nom
Output 2
min
75
17.25 1
3
±150
3
mVpp
V
mV
±350
±350
1
3
ms
-
%/K
±0.01
±0.02
If the output voltages are increased above Vo nom through R-input control, remote sensing, or option T, the output currents should be
reduced accordingly so that Po nom is not exceeded.
2
Both outputs connected in parallel
3
See Output voltage regulation
4
For battery charger applications, a defined negative temperature coefficient can be provided by using a temperature sensor (see Accessories)
5
See Dynamic load regulation
6
Measured with a ceramic cap of 1 µF across each output.
1
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Table 5e: Output data of HR/ER2880 and HRP/ERP2880. General conditions as per table 5a
Model
HR2880 / ER2880
HRP2880 / ERP2880
2 × 48 V
2 × 48 V
Nom. output voltage
Characteristics
Vo
Output voltage
Vi nom, 0.5 Io nom
V o BR
Output protection
(suppressor diode)
Output 2
Io
Output current nom.
Output current limit
1, 2
Vo
Output noise incl. spikes
Vo adj
Adjustment by R-input 4
∆Vo u
Static line/load regulation
(total deviation of Vo)
Voltage
deviation 5
tod
Dynamic
load
regulation
αvo
Temperature coefficient of
output voltage
Vo d
Recovery time 5
Output 2
min
typ
max
47.7
48.0
48.3
-
min
typ
56.7
Output 2
min
typ
max
47.7
48.0
48.3
62.7
-
2
min
56.7
2.5
2.625
2.625
4.2
-
5.25
-
240
BW = 20 MHz
19.2
2
240
55.2 1
3
±0.5
3
62.7
V
A
240
19.2
max
2.5
2.1
2
typ
48.0
2.1
Vi nom, Io nom
Vi min – Vi max
(0.1 – 1) Io nom
Output 1
max
48.0
2
Vi min – Vi max
TC min – TC max
Io1L, Io2L Output current limit 1
Io12L
Output 1
Conditions
Unit
240
55.2 1
3
±0.5
3
mVpp
V
mV
Vi nom, 0.5 Io2 nom
Io1 nom ↔ 0.5 Io1 nom
and after turn on
Io nom,
TC min – TC max
±0.8
±0.8
±1.0
±1.0
1
3
1
3
ms
-
±0.01
-
%/K
±0.01
±0.02
±0.02
If the output voltages are increased above Vo nom through R-input control, remote sensing, or option T, the output currents should be
reduced accordingly so that Po nom is not exceeded.
2
Both outputs connected in parallel
3
See Output voltage regulation
4
For battery charger applications, a defined negative temperature coefficient can be provided by using a temperature sensor (see Accessories)
5
See Dynamic load regulation
6
Measured with a ceramic cap of 1 µF across each output.
1
Thermal Considerations
If a converter is located in free, quasi-stationary air (convection cooling) at the indicated maximum ambient temperature TA max
(see table Temperature specifications) and is operated within the specified input voltage range and nominal load, the temperature
measured at the Measuring point of case temperature TC (see Mechanical Data) will approach the indicated value TC max after the
warm-up phase. However, the relationship between TA and TC depends heavily upon the conditions of operation and integration
into a system. The thermal conditions are influenced by input voltage, output current, airflow, and temperature of surrounding
components and surfaces. TA max is therefore, contrary to TC max, an indicative value only; see also fig. 9.
Po [W]
300
240
180
HRP2320
HR2320
Convection
cooling
HRL2320
120
TC max
60
0
JM239
50
60
70
80
90
100
TA [°C]
Fig. 9
Power derating for HRP/HR/HRL2320
Caution: The installer must ensure that under all operating conditions TC remains within the limits stated in the table Temperature specifications.
Notes: Sufficient forced cooling or enhanced cooling with the help of cooling plates (options B, B1) allows for TA to be higher than 71 °C
(e.g. 85 °C), as long as TC max is not exceeded.
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Thermal Protection
Two temperature sensors generate an internal inhibit signal, which disables the converter in the case of overtemperature.
The outputs automatically recover when the temperature drops below the limit.
Interruption Time
The integrated storage capacitor (C b) is loaded to the boost voltage and ensures full output voltage with nominal load during an
interruption time (or ride-through time) of at least 10 ms, provided that V i was ≥ 20 V before the interruption. This complies with
EN 50155:2017 class S 2.
Output Protection
The 2nd output of double-output models is protected by a suppressor diode against overvoltage, which could occur due to a failure
of the internal control circuit. This suppressor diode was not designed to withstand externally applied overvoltages. Overload at
any of the outputs will cause both outputs to shut down.
Note: Vo BR of the suppressor diode is specified in Electrical Output Data. If this voltage is exceeded, the suppressor diode generates losses
and may become a short circuit.
Note: The output voltage of the first output is monitored. If it exceeds typ. 140% of Vo nom for 10 ms, the converter is inhibited. To reactivate,
Vi must be removed or an inhibit signal must be applied to PUL (pin 24).
Each output has its own current limiting circuit, providing a rectangular output characteristic and protecting against short circuit.
There is no limitation for the capacitive load, and battery charging is possible as well.
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Series and Parallel Connection
Both outputs of the same converter can be series-connected or parallel-connected in order to double the output current or the
output voltage respectively.
Outputs of different converters may be series-connected.
In parallel connection of several converters, the T-pins should be interconnected so that all converters share the output current
equally; see fig. 10. HRL and ERL models have no T-pins and should not be operated in parallel connection.
If both outputs of each converter are connected in series, Vo1– of both converters should be connected together and the T-pins
as well. See fig. 11.
JM088a
6
Vo1+
4
T
18
14
4
10
Converter
#1
1
18
14
10
8
Max. 5 converters
in parallel connection
12
Load
6
S1+
10
1
Converter
#2
S1–
Vo2–
T
8
2
T
S1+
Load
Vo2+
12
Vo2–
S1–
14
Vo1–
Vo1–
Vo1+
Vo2+
4 Vo1+
18
Vo2–
8
6
6
1
S1–
10
Converter
#2
2
S1+
12
Converter
#1
JM084a
Vo2+
1
4
12
18
Vo1+
S1+
T
8
1 Lead lines with equal length
Fig. 10
Parallel connection with OR-ing diodes and sense lines
connected at the load
Vo2–
14 S1–
Vo1–
Vo1–
and cross section
2 Diodes for redundant operation only
Vo2+
Max. 5 converters
in parallel connection
T
–
+
Power bus
Fig. 11
Parallel connection of double-output models with the ouputs
of each converter connected in series, using option T.
The signal at the T pins are referenced to Vo1–.
Notes:
– Not more than 5 converters should be connected in parallel.
– If several outputs are connected in series, the resulting voltage can exceed the ES1 level.
– The PUL- pins ( pin 24) should exhibit an individual PUL resistor for each converter. If the shutdown function is used, each PUL-pin must be
controlled individually.
– The R-pins should be left open-circuit. If not, the output voltages must individually be adjusted prior to paralleling within 1 to 2% or the R-pins
should be connected together.
– Series connection of second outputs without involving their main outputs should be avoided, as regulation may be poor.
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Output Voltage Regulation
If both outputs are connected in parallel or in series, the converter exhibits a rectangular output characteristic; see fig. 12.
The typ. dynamic load regulation illustrates fig. 13.
Vo/Vo nom
Vo
0.98
Vod
Vo ±1 %
Vo ±1 %
Vod
td
td
t
0.5
Io /Io nom
Io1
IoL
1
0.5
05098a
0
1.0
0.5
Io/Io nom
Fig. 12
Output characteristic Vo versus Io
(both outputs connected in parallel or in series)
≥ 10 µs
≥ 10 µs
0
05102c
t
Fig. 13
Typical dynamic load regulation of Vo.
Output 1 is under normal conditions regulated to Vo nom, irrespective of the output currents.
However, Vo2 depends upon the load distribution; see fig. 14 a and fig.14b. Converters with version V101 (or later) have incorporated
switchable preloads and do not need a minimum load.
Note: If output 2 is not used, connect it with output 1 ! This ensures good voltage regulation and efficiency.
Vo2 [V]
Vo2 [V]
JM089c
12.3
12.2
12.1
12.0
49
48.5
48
11.8
47.5
11.7
47
0
2
4
6
8
10
12
Fig. 14a
Models HR/ER2320: Vo2 versus Io2 with various Io1
A
Io1 = 2 A
Io1 = 1.5 A
Io1 = 1 A
Io1 = 0.5 A
Io1 = 0.2 A
49.5
11.9
11.6
JM168
50
Io1 = 10 A
Io1 = 7.5 A
Io1 = 5.0 A
Io1 = 2.5 A
Io1 = 1.0 A
Io1 = 0.1 A
Io2
46.5
0
0.4
0.8
1.2
1.6
2
2.4
A
Io2
Fig. 14b
Models HR/ER2880: Vo2 versus Io2 with various Io1
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Auxiliary Functions
Inhibit Function
The PUL input (pin 24) can also be used as inhibit (for the PUL function see table 3 and 4). The response time ton and the rise time tr
are specified in table 2.
The current coming out from pin 24 (PUL) is typ. 1.5 mA (2.875 V may damage the converter.
b) Adjustment by means of an external resistor:
Depending on the value of the required output voltage, the resistor shall be connected
either: between pin 16 (R) and pin 14 (S1–) to adjust the output voltage in the range of approx. 40 – 100% of Vo nom.
Vo
___________
Rext1 ≈ 4 kΩ •
Vo nom – Vo
or: between pin 16 (R) and pin 12 (S1+) to adjust the output voltage in the range of 100 – 115% of Vo nom.
(Vo – 2.5 V)
Rext2 ≈ 4 kΩ • ___________________
2.5 V • (Vo/Vo nom – 1)
Caution: To prevent the converter from damage, the value of R ’ext shall never be less than the value for increasing Vo1 to 115% !
JM091a
Vi+
12
Vref = 2.5 V
+
4 kΩ
16
S1+
Rext2
R
+
Control
logic
Vi–
Rext1
14
S1–
Vext
–
Fig. 17
Output voltage adjustment
Notes:
– If the output voltages are increased above Vo nom via R-input control, sense lines, or option T, the output currents should be reduced, so that
Po nom is not exceeded.
– The second output of double-output models follows the voltage of the controlled main output.
Output Voltage Monitor
The output voltage monitor generates a logic “low” signal (NPN open-collector output) at the D-output (pin 20), when Vo1 ≥ 0.96 Vo nom.
For converters with version V101 (or later), the voltage at S1+ (corresponding to Vo1) must be ≥ 0.96 Vo nom and ≤1.04 Vo nom (typ.
values). Then, a green LED (Out OK) at the frontplate is illuminated. If the output voltage is adjusted by the R-input, the trigger
levels are corrected accordingly.
At low D-output, the current is limited by a 10 Ω protective resistor; for converters with Version V102 (or later) I D should be ≤ 100 mA.
If the D-output is high (open collector), VD should be ≤ 75 V. For previous converters: ≤50 mA and 50 V.
Note: Output overvoltage activates a latch; see Output Protection.
JM090
Input
12
NPN open
collector
10 Ω
20
14
S1+
D
S1–
ID
Rp
VD
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Fig. 18
Output voltage monitor
Indicators
Two green LED indicators are visible at the front plate:
- Out OK; see Output Voltage Monitor
- In OK. This signal is activated when Vi is below 158 V and greater than Vi min, whereas Vi min is defined by the adjust resistor
connected to the PUL input (pin 24).
Battery Charging / Temperature Sensor
All converters with an R-input are suitable for battery charger application. For optimal battery charging and life expectancy of the
battery an external temperature sensor can be connected to the R-input. The sensor is mounted as close as possible to the battery
and adjusts the output voltage according to the battery temperature.
Depending upon cell voltage and the temperature coefficient of the battery, different sensor types are available; see Accessories.
Cell voltage [V]
2.45
Input
Power
supply
03099d
Vo+
Vo–
Load
R
06139b
2.40
2.35
2.30
2.25
+
–
Temperature sensor
+
Battery
2.20
2.15 Vo safe
2.10
–20
–10
0
10
VC = 2.27 V, –3 mV/K
VC = 2.23 V, –3 mV/K
Fig. 19
Connection of a temperature sensor
20
30
40
50 °C
VC = 2.27 V, –3.5 mV/K
VC = 2.23 V, –3.5 mV/K
Fig. 20
Trickle charge voltage versus temperature for defined temp.
coefficient. Vo nom is the output voltage with open R-input.
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Electromagnetic Compatibility (EMC)
A metal oxide VDR together and an efficient input filter form an effective protection against high input transient voltages, which
typically occur in most installations. The converters have been successfully tested to the following specifications:
Electromagnetic Immunity
Table 7: Electromagnetic immunity (type tests)
Phenomenon
Standard
Level
Electrostatic
discharge (to case)
IEC/EN
61000-4-2
43
Electromagnetic
field
IEC/EN
61000-4-3
x4
Coupling mode 1
Value
applied
contact discharge
8000 Vp
air discharge
15000 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
5
antenna
10 V/m
5 V/m
Electrical fast
transients / burst
Surges
Supply related
surge
IEC/EN
61000-4-4
IEC/EN
61000-4-5
RIA12
3
antenna
36
capacitive, o/c 1
±2000 Vp
4
i/c, +i/–i 1
direct
±4000 Vp
i/c 1
±2000 Vp
+i/– i 1
±1000 Vp
37
A
+i/– i
B
Conducted
disturbances
IEC/EN
61000-4-6
38
i, o, signal wires
Power frequency
magnetic field
IEC/EN
61000-4-8
39
-
Pulse magnetic
field
IEC/EN
61000-4-9
-
-
Perf.
crit. 2
10 pos. & 10 neg.
discharges
yes
A
80 – 1000 MHz
yes
A
yes
A
800 – 1000 MHz
AM 80% / 1 kHz
N/A
3 V/m
10 V/m
In
oper.
1400 – 2000 MHz
2000 – 2500 MHz
5100 – 6000 MHz
50% duty cycle,
200 Hz rep. rate
bursts of 5/50 ns;
2.5 / 5 kHz over 15 ms;
burst period: 300 ms
1.2 / 50 µs
3.5 x Ubatt
max.
182 VDC
2/20/2 ms
1.5 x Ubatt
max.
168 VDC
0.1/1/0.1 s
10 VAC
(140 dBµV)
AM 80% / 1 kHz
N/A
900 ±5 MHz
pulse modul.
yes
A
50 Ω
60 s positive
60 s negative
transients per
coupling mode
yes
A
5 pos. & 5 neg.
surges per
coupling mode
yes
A
42 Ω
0.5 μF
B
2Ω
1 positive surge
yes
A
150 Ω
0.15 – 80 MHz
yes
A
300 A/m
60 s in all 3 axes
yes
A
±300 A/m
5 pulses per axis
repetit. rate 10 s
yes
A
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
3
Exceeds EN 50121-3-2:2016 table 5.3 and EN 50121-4:2016 table 2.4.
4
Corresponds to EN 50121-3-2:2016 table 5.1 and exceeds EN 50121-4:2016 table 2.1.
5
Corresponds to EN 50121-3-2:2016 table 5.2 and EN 50121-4:2016 table 2.2 (compliance with digital communication devices).
6
Corresponds/exceeds EN 50121-3-2:2016 table 3.2 and EN 50121-4:2016 table 4.2.
7
Covers EN 50121-3-2:2016 table 5.3 and EN 50121-4:2016 table 4.3.
8
Corresponds to EN 50121-3-2:2016 table 3.1 and EN 50121-4:2016 table 4.1 (radio frequency common mode).
9
Corresponds to EN 50121-4:2016 table 2.3.
1
2
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Electromagnetic Emissions
All conducted emissions (fig. 21 and 22) have been tested according to EN 55011, group 1, class A. These limits are much
stronger than requested in EN 50121-3-2:2016, table 2.1, and coincide with EN 50121-4:2016, table 1.1. The limits in fig. 21 and
22 apply to quasipeak values, which are always lower then peak values.
In addition, the values for average must hold a limit 10 dBµV below the limits in fig. 21 and 22 (not shown).
Radiated emissions have been tested according to EN 55011, group 1, class A . These limits are similar to the requirements of
EN 50121-3-2:2016 and EN 50121-4:2016, both calling up EN 61000-6-4+A1:2011, table 1. The tests were executed with hori
zontal and vertical polarization. The worse result is shown in fig. 22 and 23.
dBµV
dBµV
VUS EMC Labatory, Vin = 24 VDC, Iout = 2x 10 A, C115.
Testdistance 10 m, Class A, HR2320-9RG, B01932739, U00004, 26.07.2012
80
80
EN 55011 A qp
40
20
20
0.2
0.5
1
2
5
10
20 MHz
Fig. 21
Typ. conducted emissions (peak/quasipeak and average) at
the input, measured at Vi = 24 V and Io nom (HR2320-9RG).
dBµV/m
0.2
30
30
20
20
10
10
500
1000 MHz
Fig. 23
Typ. radiated emissions in 10 m distance, measured at Vi = 24 V
and Io nom (HR2320-9RG).
5
10
20 MHz
VUS EMC Labatory, Vin = 110 VDC, Iout=2x10A, C115.
Testdistance 10 m, Class A, HR2320-9RG, B01932739, U00004, 26.07.2012
50
40
200
2
Fig. 22
Typ. conducted emissions (peak/quasipeak and average) at
the input, measured at Vi = 110 V and Io nom (HR2320-9RG,
ER2320-9RG).
40
100
1
0
30
EN 55011AA
EN
EN 55011
55011 A
50
100
200
500
JM109
EN55011
55011AA
EN
50
0.5
60
JM108
50
0
dBµV/m
VUS EMC Labatory, Vin = 24 VDC, Iout=2x10A, C115.
Testdistance 10 m, Class A, HR2320-9RG, B01932739, U00004, 26.07.2012
60
0
30
EN 55011 A av
60
JM107
40
0
EN 55011 A qp
JM106
EN 55011 A av
60
VUS EMC Labatory, Vin = 110 VDC, Iout = 2x 10 A, C115.
Testdistance 10 m, Class A, HR2320-9RG, B01932739, U00004, 26.07.2012
1000 MHz
Fig. 24
Typ. radiated emissions in 10 m distance, measured at Vi = 110 V
and Io nom (HR2320-9RG, ER2320-9RG).
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Immunity to Environmental Conditions
Table 8: Mechanical and climatic stress
Test method
Standard
Test Conditions
Cab
Damp heat
steady state
IEC/EN 60068-2-78
MIL-STD-810D section 507.2
Temperature:
40 °C
Relative humidity:
93 +2/-3 %
Duration:
56 days
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
Db 2
Be
Ad
Ka
Fc
Fh
Ea
-
-
Converter
not operating
Converter
not operating
Dry heat test
steady state
EN 50155:2017, clause 13.4.5
IEC/EN 60068-2-2
Temperature:
70 °C
Duration:
6h
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
Salt mist test
sodium chloride
(NaCl) solution
EN 50155:2017, clause 13.4.10
Temperature:
35 ±2 °C
Duration:
48 h
Vibration
(sinusoidal)
IEC/EN 60068-2-6
MIL-STD-810D section 514.3
Acceleration amplitude:
0.35 mm (10 – 60 Hz)
Random vibration
broad band (digital
control) & guidance
Converter
operating
Converter
not operating
Converter
not operating
5 gn = 49 m/s2 (60 - 2000 Hz)
IEC/EN 60068-2-64
Frequency (1 Oct/min):
10 – 2000 Hz
Test duration:
7.5 h (2.5 h in each axis)
Acceleration spectral density:
0.05 gn2/Hz
Frequency band:
8 – 500 Hz
Acceleration magnitude:
4.9 gn rms
Test duration:
1.5 h (0.5 h in each axis)
Converter
operating
Converter
operating
Shock
(half-sinusoidal)
IEC/EN 60068-2-27
MIL-STD-810D section 516.3
Acceleration amplitude:
50 gn = 490 m/s2
Bump duration:
11 ms
Number of bumps:
18 (3 in each direction)
Shock
EN 50155:2017 clause 13.4.11,
EN 61373:2010 sect. 10,
class B, body mounted 1
Acceleration amplitude:
5.1 gn
Bump duration:
30 ms
Number of bumps:
18 (3 in each direction)
EN 50155:2017 clause 13.4.11.2,
EN 61373:2010 sect. 8 and 9,
class B, body mounted 1
Acceleration spectral density:
0.02 g n2/Hz
Frequency band:
5 – 150 Hz
Acceleration magnitude:
0.8 g n r ms
Test duration:
15 h (5 h in each axis)
Simulated long life
testing at increased
random vibration
levels
1
Status
±2
Converter
operating
Converter
operating
crit. A
Converter
operating
crit. A
Body mounted = chassis of a railway coach
Temperatures
Table 9: Temperature specifications, valid for an air pressure of 800 – 1200 hPa (800 – 1200 mbar)
Model
-9
Characteristics
TA
Ambient temperature
TC
Case temperature
TS
Storage temperature
1
2
Conditions
min
Converter operating
- 40
71 1
- 40
95 1 2
- 55
85
Not operational
typ
Unit
max
°C
See Thermal Considerations.
Overtemperature lockout at TC >95 °C (An NTC resistor on primary and secondary heatsink).
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Reliability
Table 10: MTBF and device hours
Ratings at specified
Model
case temperature
Bellcore SR332
1
2
HR2320
Ground benign
Ground fixed
Ground mobile
Life test 1
40 °C
40 °C
70 °C
50 °C
25 °C
352 000
176 000
49 000
38 000
500 000
Device hours 2
Unit
h
Life test with 32 converters during 26 days, cycling at 60 °C; confidence level 60%.
Statistical values, based on an average of 4300 working hours per year and in general field use over 5 years; upgrades and customerinduced errors are excluded.
Mechanical Data
Dimensions in mm. The converters are designed to be inserted into a 19” rack, 160 mm long, according to IEC 60297-3.
Fig. 25
Case S03 for HR / ER and HRL / ERL models with heat sink;
Aluminum, black finish (EP powder coated);
weight approx. 1.5 kg
Notes:
– d ≥ 15 mm, recommended minimum distance to next part in order to ensure proper air circulation at full output power and free convection cooling.
– free air location: the converter should be mounted with fins in a vertical position to achieve maximum airflow through the heat sink.
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Dimensions in mm. The converters are designed to be inserted into a 19” rack, 160 mm long, according to IEC 60297-3.
7 TE
9 TE
3.27
159
4.5
30.3
52
Out OK
In OK
d
50
51.5
Measuring point of
case temperature TC
6.5
89
111 (3U)
5
26.4
11.3
JM093
27.38
(171.0 .... 171.9)
80
168.5
Back plate
25.9
Ø 5 x 90°
Ø 2.8
0.2
Main face
11.8
Front plate
Screw holes of the
frontplate
European
Projection
Mounting slots for chassis or wall mounting
Fig. 26
Case K03 for HRP and ERP models with heat sink;
Aluminum, black finish (EP powder coated);
weight approx. 1.8 kg
Notes:
– d ≥ 15 mm, recommended minimum distance to next part in order to ensure proper air circulation at full output power and free convection cooling.
– free air location: the converter should be mounted with fins in a vertical position to achieve maximum airflow through the heat sink.
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ER / HR Series
47.2
6.5
6.5
5
38.5
11027
11.2
144 / 288 W 10:1 DC-DC Converters
13
140
127
11.8
133.4 ±0.2
17.3
30
168
Fig. 27
Option B: Aluminum case S03 with large cooling plate; black finish (EP powder coated).
Suitable for front mounting.
Total weight approx. 1.5 kg
Note: Long case with option B2, elongated by 60 mm for 220 mm rack depth, is available on request. (No LEDs)
7 TE
50
38.5
5
11.8
5
158
4 TE
3.27
JM094
M4
101
111 (3U)
Out OK
In OK
Measuring point of
case temperature TC
17.3
133.4
47.2
5
168
(171.0 ... 171.9)
Fig. 28
Option B1: Aluminum case S03 with small cooling plate; black finish (EP powder coated).
Suitable for mounting with access from the backside.
Total weight approx. 1.4 kg.
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Safety and Installation Instructions
Connector Pin Allocation
The connector pin allocation table defines the electrical potentials and the physical pin positions on the H15 connector. The
protective earth is connected by a leading pin (no. 24), ensuring that it makes contact with the female connector first.
S10002b
30 26 22 18 14 10
32 28 24 20 16 12
6
8
4
Fixtures for retention clips
Fig. 29
View of module’s male connectors
Table 11: Pin allocation
Pin
Name
Function
4
Vo1+
Output 1 positive
6
Vo2+
Output 2 positive
8
Vo1-
Output 1 negative
10
Vo2-
Output 2 negative
12
S1+
Sense line positive
14
S1-
Sense line negative
16
R
Output voltage adjust
18 2
T
Current share
20
D
Out OK
PE
Protection earth
22
1
2
1
24
PUL
Programmable undervoltage lockout
26 + 28
Vi+
Input positive
30 + 32
Vi-
Input negative
Leading pin (pre-connecting)
Not connected for HRL / ERL models
Installation Instructions
The converters are components, intended exclusively for inclusion within other equipment by an industrial assembly operation
or by professional installers. Installation must strictly follow the national safety regulations in compliance with the enclosure,
mounting, creepage, clearance, casualty, markings, and segregation requirements of the end-use application.
Connection to the system shall be made via the female connector H15; see Accessories. Other installation methods may not meet
the safety requirements.
Pin no. 22 (
) is connected with the case. For safety reasons it is essential to connect this pin reliably to protective earth.
Notes:
– The PUL function (pin 24) must be programmed to enable the outputs. PUL should be connected to Vi– (pins 30 + 32) by a resistor to adjust
the start-up voltage; see table 3. Otherwise, the input current may become too high at low input voltage.
– Do not open the converter, or warranty will be invalidated.
– If the second output is not used, connect it in parallel with the main output.
Make sure that there is sufficient airflow available for convection cooling and verify it by measuring the case temperature TC, when
the converter is installed and operated in the end-use application; see Thermal Considerations.
Ensure that a converter failure (e.g. an internal short-circuit) does not result in a hazardous condition.
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Standards and Approvals
The converters are safety-approved to UL/CSA 62368-1 3rd edition and IEC/EN 62368-1 3rd edition.
The converters correspond to Class I equipment (with case connected to ground). They have been evaluated for:
• Building-in
• Basic insulation between input and case based on 250 VA. Double or reinforced insulation between input and outputs
• Functional insulation between outputs
• Overvoltage category II
• Pollution degree 2 environment
• Max. altitude: 2000 m
• The converters fulfill the requirements of a fire enclosure.
The output voltage is considered as ES1, except HR/HRP/ER/ERP2880 with both outputs in series connection.
The converters are subject to manufacturing surveillance in accordance with the above mentioned safety standards and with ISO 9001:2015,
IRIS ISO/TS 22163:2017 certified quality and business management system. CB-scheme is available on request.
Protection Degree and Cleaning Liquids
The protection degree is IP 40, provided that the female connector is fitted to the converter.
In order to avoid possible damage, any penetration of cleaning fluids has to be prevented, since the power supplies are not
hermetically sealed.
Railway Application and Fire Protection
The converters have been designed by observing the railway standards EN 50155, EN 50121-3-2, and EN 50121-4. All boards
are coated with a protective lacquer.
The converters comply with NF-F16 (I2/F1). They also comply with EN 45545-1, EN 45545-2, if installed in a technical compartment
or cabinet.
Isolation and Protective Earth
The electric strength test is performed in the factory as routine test according to EN 62911 and IEC/EN 62368-1 and should not be
repeated in the field. The Company will not honor warranty claims resulting from incorrectly executed electric strength tests. The
resistance case to the earth pin (< 0.1 Ω) is tested with 25 A for 1 s.
Table 12: Isolation
Characteristics
Input to
Case + Outputs
Output(s)
to Case
2.8 1
2.0
Insulation resistance
>300
>300
Creepage distances
≥ 2.8 3
≥ 2.5
Electric strength test
Factory test 10 s
AC test voltage equivalent to factory test
Output 1 to
Output 2
Unit
1.4
0.3
kVDC
1.0
0.21
>100
-
kVAC
2
MΩ
mm
Subassemblies connecting input to output are pre-tested with 5.0 kVDC or 3.5 kVAC.
Tested at 150 VDC
3
Input to outputs: 5.0 mm
1
2
Description of Options
B, B1 Cooling Plates
Where a cooling surface is available, we recommend the use of a cooling plate instead of the standard heat sink. The mounting
system should ensure that the maximum case temperature TC max is not exceeded. The cooling capacity is calculated by (η see
Model Selection):
(100% – η)
PLoss = –––––––––– • Vo • Io
η
For the dimensions of the cooling plates; see Mechanical Data.
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Accessories
A variety of electrical and mechanical accessories are available including:
– Front panels for 19” DIN-rack: Schroff or Intermas, 12 or 16TE / 3U; see fig. 30 and the data sheet BCD.00495.
– Mating H15 connectors with screw, solder, faston, or press-fit terminals; see fig. 31
– Coding clips for connector coding HZZ00202
– Pair of connector retention clips HZZ01209-G; see fig. 32
– Connector retention brackets HZZ01216-G; see fig. 33
– Cage clamp adapter HZZ00144-G; see fig. 34
– Cable hood for H15 connectors (fig 35):
- HZZ00141-G, screw version
- HZZ00142-G, use with retention brackets HZZ01218-G
- HZZ00143-G, metallic version providing fire protection
– Wall-mounting plate K02 (HZZ01213-G) for models with option B1; see fig. 36
– DIN-rail mounting assembly HZZ0615-G (DMB-K/S); see fig. 37
– Additional external input and output filters
– Different battery sensors S-KSMH... for using the converter as a battery charger. Different cell characteristics can be selected;
see fig. 38, table 13, and Battery Charging / Temperature Sensors.
For additional accessory product information, see the accessory data sheets listed with each product series or individual
model at our web site belfuse.com/power-solutions.
Fig. 31
Different mating connectors
Fig. 30
Different front panels
Fig.32
Connector retention clips to fasten the H15 connector to the
rear plate; see fig. 29. HZZ01209-G consists of 2 clips.
20 to 30 Ncm
Fig. 33
Connector retention brackets HZZ01216-G
Fig. 34
Cage clamp adapter HZZ00144-G
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ER / HR Series
144 / 288 W 10:1 DC-DC Converters
Fig. 35
Different cable hoods
Fig. 36
Chassis- or wall-mounting plate HZZ01213-G (Mounting
plate K02)
European
Projection
9.8 (0.4")
26 (1.02")
09125a
L
56 (2.2")
L = 2 m (standard length)
other cable lengths on request
Fig. 37
DIN-rail mounting assembly HZZ00615-G (DMB-K/S)
adhesive tape
Fig. 38
Battery temperature sensor
Table 13: Battery temperature sensors
Battery
voltage nom.
[V]
Sensor type
Cell
voltage
[V]
Cell temp.
coefficient
[mV/K]
Cable
length
[m]
12
S-KSMH12-2.27-30-2
2.27
–3.0
2
12
S-KSMH12-2.27-35-2
2.27
–3.5
2
24
S-KSMH24-2.27-30-2
2.27
–3.0
2
24
S-KSMH24-2.27-35-2
2.27
–3.5
2
24
S-KSMH24-2.31-35-0
2.31
–3.5
4.5
24
S-KSMH24-2.31-35-2
2.31
–3.5
2
24
S-KSMH24-2.35-35-2
2.35
–3.5
2
48
S-KSMH48-2.27-30-2
2.27
–3.0
2
48
S-KSMH48-2-27-35-2
2.27
–3.5
2
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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