120 - 192 Watt 10:1 DC-DC Converters
HP Series
These extremely compact DC-DC converters incorporate all
necessary input and output filters, signaling and protection
features, which are required in the majority of applications.
The converters provide important advantages, such as flexible
output power through total current limitation, extremely high
efficiency, excellent reliability, very low ripple and RFI noise
levels, full input-to-output isolation, negligible inrush current,
soft start, over temperature protection, interruption time, and
input over- and undervoltage lockout.
Features
•
Extremely wide input voltage range from 12.5 to 154 VDC
in the same model
•
RoHS-compliant
•
5 year warranty
•
Class I equipment
•
Compliant with EN 50155, EN 50121-3-2, and
IEC/EN 61000-4-2, -3, -4, -5, -6, -8
•
Fire&smoke: Compliant with EN 45545-2
•
Input over- and programmable undervoltage lockout
including inhibit function
•
Low inrush current
•
10 ms interruption time
•
1 to 4 independent, isolated outputs: no load, overload,
and short-circuit proof
•
Rectangular current limiting characteristic
•
Redundant operation (n+1), sense lines, active current
sharing option, output voltage adjust
•
Hipot test voltage 2.8 kVDC
•
Very high reliability and efficiency up to 92.5 %
•
All PCB boards protected by lacquer
•
Extremely slim case (4 TE, 20 mm), fully enclosed
Safety-approved to the latest edition of IEC/EN 60950-1
and UL/CSA 60950-1
1
111
4.4"
3U
20
0.8"
4 TE
164
6.5"
1
pending
Table of Contents
Description........................................................................................2
Model Selection ................................................................................2
Functional Description ......................................................................5
Electrical Input Data .........................................................................8
Electrical Output Data.....................................................................
11
Auxiliary Functions .........................................................................17
Electromagnetic Compatibility (EMC) .............................................19
Immunity to Environmental Conditions ...........................................21
Mechanical Data
.............................................................................23
Safety and Installation Instructions .................................................24
Description of Options
....................................................................26
Accessories
....................................................................................27
belfuse.com/power-solutions
BCD.00316 Rev AM, 25-Feb-2019
HP Series
Description
120 - 192 W 10:1 DC-DC Converters
The converters are particularly suitable for rugged environments, such as railway applications. They have been designed in
accordance with the European railway standards EN 50155 and EN 50121-3-2. All printed circuit boards are coated with a protective
lacquer. The converter covers a total input voltage range from 12.5 to 154 VDC in the same model. The input is protected against
surges and transients occurring on the source lines. The outputs are continuously open- and short-circuit proof.
Full system flexibility and n+1 redundant operating mode are possible due to series or parallel connection capabilities of the outputs
under the specified conditions. When several converters with T option are connected in parallel, a single-wire connection between
these converters ensures good current sharing. LEDs at the front panel and an isolated output OK signal indicate the status of the
converter. Voltage suppressor diodes and an independent overvoltage monitor protect the outputs against an internally generated
over voltage.
The converters are designed using transformers with planar technology. The input voltage is fed to a booster, which generates
approximately 70 V. If
V
i
is higher, the booster becomes simply a diode. The resulting intermediate voltage supplies the powertrains.
There are two powertrains fitted to a converter, each consisting either of a regulated single output with synchronous rectifier or of a
regulated main output with a tracking second output. The output power may be flexibly distributed among the main and the tracking
output of each powertrain. Close magnetic coupling in the transformers and output inductors together with circuit symmetry ensure
a small deviation between main and tracking output.
A storage capacitor charged to approx. 70 V enables the powertrains to operate during the specified interruption time.
As part of a distributed power supply system, the low-profile design significantly reduces the required volume without sacrificing
high reliability. The converters are particularly suitable for 19” rack systems occupying 3 U /4 TE only, but they can also be chassis-
mounted by screws or fitted with a heat sink. The connector type is H15. The fully enclosed black-coated aluminum case acts as
heat sink and RFI shield, such protecting the converter together with the coating of all components against environmental impacts.
Model Selection
Note:
Only standard models are listed. Other voltage configurations are possible on request.
Table 1: Model Selection
Output 1, 4
V
o nom
[V]
5.1
12
15
24
5.1
5.1
5.1
12
15
24
5.1
5.1
5.1
12, 12
4
15, 15
4
15, 15
4
24, 24
4
1
2
3
4
5
6
7
Output 2, 3
P
o 50
6
[W]
184
192
192
192
92
92
92
96
96
96
92
92
92
96
96
96
96
V
o nom
[V]
-
-
-
-
5.1
12
15
12
15
24
12, 12
4
15, 15
4
24, 24
4
12, 12
4
15, 15
4
24, 24
4
24, 24
4
P
o nom
5
[W]
-
-
-
-
61
61
61
61
61
60
60
60
60
60
60
60
60
P
o 50
6
[W]
-
-
-
-
92
96
96
96
96
96
96
96
96
96
96
96
96
V
o min
3
[V]
12.5
Input voltage
V
o cont
[V]
16.8 - 137.5
V
o max
3
[V]
154
min
[%]
86.5
Efficiency
η
2 41
η
110 2
min
[%]
87
typ
[%]
90.5
92.5
91
90
90.5
-
-
92.5
91
89.5
90
90
90
90
-
-
89.5
typ
[%]
89
91
89.5
89
89
-
-
91
89.5
88
88.5
88
89
88
-
-
88
Model
Options
P
o nom
5
[W]
122
122
122
122
61
61
61
61
61
60
61
61
61
60
60
60
60
HP1001-9RTG
HP1301-9RTG
HP1501-9RTG
HP1601-9RTG
HP2001-9RG
HP2020-9RG
HP2040-9RG
HP2320-9RG
HP2540-9RG
HP2660-9RG
HP3020-9RG
HP3040-9RG
HP3060-9RG
HP4320-9RG
HP4540-9RG
HP4560-9RG
HP4660-9RG
U, V, B
12.5
16.8 - 137.5
154
86.5
87
U, V, T
7
, B
12.5
12.5
16.8 - 137.5
16.8 - 137.5
154
154
86.5
86.5
87
87
U, V, B
U, V, T
7
, B
12.5
16.8 - 137.5
154
86.5
87
U, V, B
Efficiency at
T
A
= 25 °C,
V
i
= 24 V,
I
o nom
,
V
o nom
Efficiency at
T
A
= 25 °C,
V
i
= 110 V,
I
o nom
,
V
o nom
Short time; see table 2 for details!
Isolated tracking output
P
o nom
is specified at
T
amb
= 70 °C
P
o 50
is specified at
T
amb
= 50 °C and
V
i
=
≥
22 V. For
V
i
=
≤
22, only 90% of
P
o 50
are continuously possible
T replaces R
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HP Series
120 - 192 W 10:1 DC-DC Converters
Part Number Description
Continuous operating input voltage
V
i
:
Series
H P 4 6 60 -9 R B1 G
16.8 to 137.5 VDC ............................................... H
..............................................................................
P
Number of outputs:
Single output (160 mm case)
4
.............................. 1
Double output (160 mm case)
4
............................ 2
Triple output (160 mm case)
4
............................... 3
Quadruple output (160 mm case)
4
....................... 4
Nominal voltage output 1 /output 4,
V
o1/4 nom
:
5.1 V ..................................................................... 0
12 V ...................................................................... 3
15 V ...................................................................... 5
24 V ...................................................................... 6
other voltages
1
................................................. 7, 8
Other specifications and additional features
1
............. 01, ... 99
Nominal voltage output 2 /output 3,
V
o2/3 nom
:
5.1 V ................................................................... 01
12 V .................................................................... 20
15 V .................................................................... 40
24 V .................................................................... 60
other voltages and features
1
.................... 80, ... 99
Operational ambient temperature range
T
A
:
– 40 to 71 °C ........................................................ -9
other
1
.................................................................. 0
Output voltage adjust (auxiliary function) .............................. R
3
Options:
Current sharing ...................................................
T
2
UVL (preadjusted
V
i min
) ...................................
Uxx
5
V (rotary switch to adjust
V
i min
) ............................V
6
Heatsink 10, 20, 30 mm .........................B0, B1, B3
RoHS-compliant for all 6 substances ......................................G
1
2
3
4
5
6
Customer-specific models.
Only available for single-output powertrains. Option T excludes option R, except for single-output models; refer to table 12.
T is standard for single-output models
The R-input influences the first power train only; refer to table 12.
Models with 220 mm case length. Just add 5000 to the standard model number, e.g. HP3020-9RG
→
HP8020-9RG.
For full compatibility with former P Series, the start voltage can be preadjusted depending on the nominal battery voltage. Excludes opt. V.
Excludes opt. U.
Note:
The sequence of options must follow the order above.
Example:
HP4660-9RB1G: DC-DC converter, input voltage 16.8 to 137.5 V, 4 outputs providing 24 V each, heatsink B1,
ambient temperature of – 40 to 71 °C, RoHS-compliant.
Note:
All models exhibit the following auxiliary functions, which are not reflected in the type designation: input and output filters, primary referenced
PUL (programmable undervoltage shutdown with inhibit function), sense lines (single-, double-, triple-output models only), and LED indicators.
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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HP Series
120 - 192 W 10:1 DC-DC Converters
Output Configuration
The HP Series allows high flexibility in output configuration to cover almost every individual requirement, by simply wiring outputs
in parallel, in series, or in independent configuration, as shown in the following diagrams.
Parallel or serial operation of several converters with equal output voltage is possible, using the current share option T to provide
reasonable current sharing. Choose suitable single-output models, if available.
Note:
Unused tracking outputs should be connected in parallel to the respective regulated outputs.
JM144a
JM145a
Single-output
model
R
Vo+
Vo+
S+
16
4
6
12
22
24
14
8
10
Double-output
model
Vo2+
S2+
i
Load
R
PUL
30
32
28
6
18
20
10
4
12
14
8
i
R
PUL
28
PUL
OK+
OK–
S–
Vo–
Vo–
PUL
S2–
Vo2–
Vo1+
S1+
S1–
Vo1–
Load
30
32
Vi+
Vi–
Vi+
Vi–
Fig. 1a
Standard configuration (single-output model)
JM146a
Fig. 1b
Series output configuration of a double-output model.
The second output is fully regulated.
JM147a
Double-output
model
Vo1+
S1+
i
R
PUL
30
32
28
4
12
14
8
6
18
20
10
Triple-output
model
Vo1+
Load 1
4
12
14
8
6
10
18
20
S1+
i
R
PUL
28
PUL
S1–
Vo1–
Vo2+
S2+
S2–
Vo2–
PUL
S1–
Vo1–
Vo2+
Vo2–
Vo3+
Vo3–
Load 1
Vi+
Vi–
Load 2
30
32
Vi+
Vi–
Load 2
Load 3
Fig. 1c
Independent double-output configuration. Both outputs are
fully regulated
JM148b
Fig. 1d
Independent triple-output configuration. Output 3 is tracking
Quadruple- Vo3+
output
Vo3–
model
Vo2+
i
R
PUL
30
32
28
JM149b
Quadruple-
output
Vo1+
model
Vo1–
i
R
PUL
30
32
18
20
6
10
12
14
4
16
8
R
2
R
1
4
8
12
14
6
10
18
20
Load 1
Load 4
Vo4+
28
PUL
Vo4–
Vo2+
Vo2–
Vo3+
Vo3–
PUL
Vo2–
Vo4+
Vo4–
Vo1+
R
Vo1–
Load
Vi+
Vi–
Load 2
Load 3
Vi+
Vi–
Fig. 1e
Common ground configuration of output 1 with 4 and
independent configuration of output 2 and 3
Fig. 1f
Series configuration of all outputs (V
o
= 96 V for HP4660).
The R-input influences only outputs 1 and 4. For the values
of R1 and R2 see Output Voltage Adjust.
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HP Series
120 - 192 W 10:1 DC-DC Converters
Functional Description
The converters are designed using transformers with planar technology. The input voltage is fed to a booster, which generates
a voltage of approx. 70 V. If
V
i
is higher, the booster becomes simply a diode. The storage capacitor
C
hu
is charged by a current
source to max. 70 V and enables the powertrains to operate during the specified interruption time. The resulting intermediate
voltage, between 45 V (during interruption time) and 154 V, supplies the powertrains.
There are two powertrains fitted to a converter, each consisting either of a regulated single output with synchronous rectifier or of
a regulated main output with a tracking 2
nd
output.
As part of a distributed power supply system, the low-profile design significantly reduces the required volume without sacrificing
high reliability. The converters are particularly suitable for 19” rack systems occupying 3 U / 4 TE only, but they can also be chassis-
mounted by screws or fitted with a heat sink. Connector type is H15. The fully enclosed Aluminum case acts as heat sink and RFI
shield, such protecting the converter together with the coating of all components against environmental impacts. The converters
are equipped with two independent forward converters, switching 180° phase-shifted to minimize the input ripple current. These
two forward converters are called “powertrains” (PT), exhibiting either a single output with synchronous rectifier or two isolated
outputs, one fully regulated and the other one tracking (semi-regulated), thus providing up to four output voltages. The output
power may be flexibly distributed among the main and the tracking output of a double-output powertrain. Close magnetic coupling
in the transformers and output inductors together with circuit symmetry ensure small deviation between main and tracking output.
The low input capacitance results in low and short inrush current. After the isolating transformer and rectification, the output filter
reduces ripple and noise to a minimum without affecting the dynamic response. Outputs 3 and 4, if available, are tracking (semi-
regulated). An individual current limiter built in to of each powertrain limits the total output current of that powertrain in an overload
condition. This allows flexible power distribution of the outputs of each powertrain. All outputs can either be connected in series or
in parallel; see
Electrical Output Data.
An auxiliary converter provides the bias voltages for the primary and secondary referenced control logic and auxiliary circuits. The
converter is only enabled, if the input voltage is within the operating voltage range and above the programmable undervoltage
lockout threshold (PUL) – such limiting the input current dependent on the nominal battery voltage.
All output are equipped with a suppressor diode and an independent monitor sensing the output voltage of the main output. In the
case of an overvoltage, it influences the control logic respectively.
The temperature is monitored and induces the converter to disable the outputs. After the temperature has dropped, the converter
automatically resumes.
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