ddb converter 50w - functional description · rau elektronic mbh 09/2014 print errors and mistakes...

Grau Elektronik GmbH ▪ Badhausweg 14 ▪ 76307 Karlsbad ▪ GermanyTel.: +49 (0) 7248 - 92580 ▪ Fax: +49 (0) 7248 - 925810 ▪ www.grau-elektronik.de ▪ [email protected] Elektronic GmbH © ▪ 09/2014 - Print errors and mistakes reserved 1/9

Pout = 50WVIn VOut IOut

Nom Min Max24V 8V 36V 12V 4A

24V 2A

24V, 36V 14.4V 50.4V 12V 4A24V 2A

72V, 110V 43.2V 154V 12V 4A24V 2A

Table 1

The DDB voltage converter series is well suited for Railway Applications. Particularly the design requirements of IEC 60571 and EN 50121-3-2 are considered. A 100kHz fly back technology with low Q-, Rds,on – MOSFET transistor, cur-rent mode PWM circuit, low loss ferrite magnetic transformer, schottky diode output rectifier are the basis for high efficiency transfer processes. The converters have three wide input voltage ranges: 8V – 40V, 14.4V – 50.4V and 43.2V – 154V. For railway applications 2 standard bat-tery ranges (24V/36V and 72V/110V) are cov-ered with same unit, minimizing count and cost of converter types. Input reverse protection, En-able and Power Fail signaling, no load & short circuit proofed, 10ms hold up circuit stage, input and output voltage monitoring make it perfect for railway application uses. Through a special input voltage circuit, the converter can be brought into a Stand –by mode (Enable = Low), max input current at Vin ≤ 2mA.

+Vin, -Vin: DC input voltage terminals

+Vout, -Vout: DC output voltage terminals

ENABLE: this pin may be used to start the converter with an external signal.

High: converter ON, Low Converter OFF

High voltage levels converter type dependent, see data sheets

Power Fail: open collector output NPN transistor

NC: this pin is internal not connected to any potential (free)

Pin DescriptionPin Assignment XP10Pin Recommended wire gauge7 + VIn 2.5mm²6 - VIn 2.5mm²5 ENABLE 1.0mm²4 N.C. -3 PowerFail -2 - VOut 1.5mm²1 + VOut 1.5mm²

Table 2

DDB Converter 50W - Functional Description

DC/DC ConvertersDDB Series 50W

Chassis Mountable


ENABLE Function

The DDB dc/dc voltage converters are starting under following conditions:

Vin must be inside specified input voltage range Vin,min ≤ Vin ≤ Vin,max. With an external voltage at the ENABLE pin, converters can be started or switched OFF.

Vin [V] ENABLE level [V] ConverterMin Max

12.0 – 36.0 9.0 36.0 ON

0 6.0 OFF

16.8 – 50.4 16.8 50.4 ON

0 6.0 OFF

50.4 – 154 50.4 154.0 ON

0 6.0 OFF

Table 3

Figure 1

+ Vin

- Vin

EN

S

Converters will be started with the Enable sig-nal (switch S must be closed). There is a choica-ble time delay converter continues its operation (10sec, 15min, 30min, 60min) after Enable pin (5) is connected either to + Vin or to another Voltage sour-ce. 60 minutes is the default value at factory adjust, other values see select table. If there is no use to start with ENABLE function connect pin 5 with pin 7. When pin 5 is left open (Enable pin has no re-ference voltage converter is not working, even when Vin is inside its specified voltage range). Maxi-mum voltage levels, current source see data sheet.

EN

t

Selected Duration e.g. 60 min.

Voltage tolerances of Enable signal. See data sheet.

Reverse Input Protection at + Vin, - Vin

A MOSFET transistor in the minus input line prevents an internal short circuit condition when +/- input lines are inadvertently exchanged. The internal fuse does not blow under this condition, until Vin < Vin, max.

This transistor is also necessary to prevent energy flowing back from the converter inter-nal 10 ms hold up stage, back into the bat-tery circuit when an external voltage dip occurs.Max. negative input value see resp. data sheet.

Input Voltage Monitor

Avoiding overstressing the converter input stage, either from too high input currents (Vin < Vin,min) or too high voltage between +/- Vin the converters switches ON / OFF inside safe operating defined voltage levels (see data sheet).

EN

t

Rise time Vout = f(load), see also data sheet declaration.

Figure 2

Figure 3


Fuse

An internal fuse protects external lines and internal electronics at any failure mode conditions inside converter (e.g. overvoltage transil diode fires and leads to a short condition between +/- Vin or Power switch transistor failed).

Output Vout

Depending from converter type 12V or 24V is avai-lable between +Vout and – Vout pins (pin1, pin2 res-pectively). The output is protected against current overloading. An internal protection circuit prevents and overvoltage condition, which could be severe for connected loads. Switch levels are converter type dependent, see data sheet). The output voltage is adjusted to its nominal value (see data sheet) and an internal voltage regulation circuit keeps the output voltage stable as long as output is not in overload condition. All converters are also protected against short circuit conditions at the output pins. Output current is therefore limited and in-put current is decreased via the internal primary side PWM stage. This condition is absolutely uncritical for the converter itself. After removal of an external short circuit, the output voltage rises up again to its nomi-nal specified value (12V or 24V). The converters may be used for several kind of loads: R-load, C-Load (Cmax, ask manufacturer), R-L-load (L must be defined, here fore ask manufacturer), Step Down, Step up converters, dc/dc converters. Due to continuously working current limitation sta-ge (no hiccup mode), charging high capacitor input loads is possible.

Voutmax Overvoltage Protection

The dc/dc converter is protected against output over-voltage by a separate reference. If Vout increases, e.g. due of a malfunction of the regulation stage, conver-ter is switched OFF. Treshold value for 12V output is 15V (± 1V) for the 24V output it is 30V (± 1V). Beside this, an additional transil diode serves as protection against external voltage spikes/transients and also as a further Vo,max limit element (1.5KE 15A, 1.5KE30A). Vbr,max is f(I).

10 ms Hold Up Circuit

An internal sophisticated capacitor storage circuit allows overcoming input voltage dips up to 10 ms (meets class S2 IEC 60571) inside the whole spe-cified operating temperature range. Recharge times see data sheet values.When battery voltage (Vin) dips down to 0V, e.g. cau-sed by switching actions of big loads, short circuits in a neighbored electronic unit, the dc/dc conver-ters switches OFF when reaching its Vin,min threshold value. Depending on output load, the output voltage decreases more or less fast:

Vout(t) = Vout * e – t/RC

R = load resistance, C = Cint + Cext

In certain cases small input voltage dips can cau-se large system disturbances, due of a RESET and Restart (booting) process. This can be avoided by a converter hold up circuit, which is able to sustain energy for 10ms providing the output load with cur-rent during typical battery voltage dips.

Power Fail Signal (Pin 3)

With an open collector NPN transistor it is possible to deactivate some external loads, when output voltage fall under specified value (Vout nom value – 5%). Voltage and current limits see data sheet. External Pull up resistance necessary.

- Vout (pin 2)

PF (pin 3)

Vext

Recommended values

5V ≤ Vext ≤ 60V

I ≤ 20mA

R = Vext / I

Figure 4


Common Information

EMC

The converters met EN 50121-3-2 Railway Vehic-le, unit requirements. The dc/dc converters shall work at Port 10 “behind” the battery charger unit. Noadditional parts for bypassing in- or output linesare necessary to fulfill the EN requirements. The con-verter must be connected to Earth potential during all operations or tests for reasons of safety and emc behavior.

Safety

In case of malfunction, e.g. loss of isolation between a semiconductor and metal housing, grounding the metal chassis with ≥ 2.5mm² line (green/yellow earth potential is necessary preventing hazardous voltage at the metal housing!)

Don’t use the converter without grounding the metal housing see mechanical drawing for connecting point!

Vibration & Shock

The converters meets the requirements acc. EN 50155, EN 61373 requirements

Test levels acc. EN 61373: 1999functional tests:continuosly: 10 minutes each axixdimensions: Longitudinal -, tranvers-, vertical

axisFrequency range: ASD level Effective value

m/s²5 Hz – 20 Hz 0,0298 [m/s²]²

/ Hz1.0

20 Hz – 150 Hz - 6dB / Octave 1.0continuously: long time test

5h each axis

5 Hz – 20 Hz 1,857 [m/s²]² / Hz

7.9

2 Hz – 150 Hz - 6dB / Octave 7.9Table 4

Operating Temperature Range

The converters are designed for operating from TA = – 40°C up to + 85°C without any power derating limitation.

Continuous operation: – 40°C ≤ TA ≤ + 70°C @ Pout = 0 … 50W

10 minutes class Tx EN 50155/IEC60571:

Operation: + 70°C ≤ TA ≤ + 85°C @ Pout = 0 … 50W

Depending on mounting conditions, converter to any chassis or heatsink, it is possible to extend time duration operating also in the higher temperature range between + 70°C to + 85°C continuously. Plea-se, ask manufacturer.

Converter OFF Converter ON

Vin

t

Min

Vout

t

Class S1 converter, no 10ms hold up

10ms class S2 EN 50155

Figure 5

Figure 6


Creepage and clearance distances

acc. OV. 2, PD2, EN 50124-1

validation by type test acc. EN 60571 ff

Isolation Voltage Test, Isolations resistance test

Galvanic isolation between input- and output circuit, input housing and output housing is piece tested at factory. Values see data sheet.

Isolation resistance is only type test measurement between in- and output potential. Values on request.

Piece test is a ramp test 2sec – 2sec – 2sec

Type test time duration: 1 minute

Prefered test voltage is dc. AC testing on request. Repetition testing from customer recommend with decreased voltage levels (80% dc voltage). Further information ask manufacturer.

Protection Degree

The converter is designed acc. protection degree class I and IP 30.

Burn In

Avoiding early failures in the field operation, all con-verters are running for at least 12h at TA = + 60°C, Vin,nom with 50% load before leaving factory.

Efficiency, MTBF

Due to its excellent efficiency η ≥ 0.87 … 0.92, its compact design, converter operating temperature range lies between – 40°C ≤ TA ≤ + 85°C. No ex-ternal heat-sinks are necessary to meet IEC 60571 Tx class requirement. The converters are no load proofed and have a calculated MTBF of 500’000h referenced at TA = + 40°C, nominal power conditions acc. SN 29500 standard (Siemens).

RAM, LCC

The converters are designed for long time reliabili-ty and availability. There are no parts that must be exchanged during operation life time. For more infor-mation ask manufacturer.

Oscillograms, diagrams switch ON, 10ms dip, load change 20% - 80% - 20%, ripple and spikes, emc line conducted and radiated on request.

continuouslyr: 10 minutes each axisdimensions: Longitudinal -, tranvers-,

vertical axisFrequency range:5 Hz – 8,4 Hz 3,5mm peak-peak ampli-

tude8,4 Hz – 150 Hz 1g accelarationType of vibrationFrequency procedures with following velocity deviation 1 Octave/Min. (± 10%)10 Frequency steps (procedures) each axis in each to the other of three vertical standing axis Validation of correct operation during and after tests procedure

Table 5


Converter Selection, Output power = 50W

Type Vin [V] Vout [V] Extension Converter On Time Article number W□□ After Enable is switched OFF or

LOW50 DDB 024 M12 W00 9 … 36 12 0 0 0 sec

1 0 15 min

2 0 30 min

3 0 60 min

50 DDB 024 M24 W00 9 … 36 24 0 0 0 sec

1 0 15 min

2 0 30 min

3 0 60 min 1306 - 01

50 DDB 036 M12 W00 14.4 … 50.4 12 0 0 0 sec

1 0 15 min

2 0 30 min

3 0 60 min

50 DDB 036 M24 W00 14.4 … 50.4 24 0 0 0 sec

1 0 15 min

2 0 30 min

3 0 60 min

50 DDB 110 M12 W00 14.4 … 50.4 12 0 0 0 sec

1 0 15 min

2 0 30 min

3 0 60 min

50 DDB 110 M24 W00 14.4 … 50.4 24 0 0 0 sec

1 0 15 min

2 0 30 min

3 0 60 min

W□□Choice delivery without PHOENIX counter connector. Select 0 no counter connector required Select 1 delivery with external connector required

Selection of time duration how long converter is operating after Enable signal is removed (switched OFF HIGH to LOW voltage condition at pin 5.

024 / 036 / 110 = nominal input voltage range M12 / M24 = nominal output voltage

M = mono / single output

W = wall mounting


Mechanic Design


01 02

03 04

Mount the device to a prefered place using four M4 screws.

Connect a grounded wire ( ≥ 2.5mm²) to the Torx screw on the metal chassis.

Plug a counter connector into the device (make sure that the counter connector don´t run any vol-tage while installation).

Use the slotted screws to secure the counter connector.

DDB Converter installation guide

ddb converter 50w - functional description · rau elektronic mbh 09/2014 print errors and mistakes...

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