48IPZ5-1515-TC - Power-One

10 Watt-Family DC-DC Converters <40 W Rugged Environment

6 - 30 Edition 2/96 - © Melcher AG

MELCHER

The Power Partners.

6.1

IBEK DC-DC Converters 10 Watt-Family

Input to output isolation test voltage up to 5 kVrms

1 or 2 Outputs: IPS 10, IPW 10, IPZ 5

Input voltage ranges: 10...33 V DC and 18...72 V DC

•Extremely high isolation test voltages

•Wide input voltage ranges of up to 1:4

•Efficient input Pi-filter

•SD-shutdown input (on request)

•High efficiency (typ. 80%)

•High reliability

•Continuous no-load and short-circuit proof

•Case height only 10.5 mm

Table of Contents Page

Description ................................................................6 - 30

Type Survey .............................................................. 6 - 31

Safety Instructions..................................................... 6 - 32

Immunity to Environmental Conditions...................... 6 - 32

Installation Instructions.............................................. 6 - 33

Electrical Input and Output Data ...............................6 - 34

Functional Description and Block Diagrams ............. 6 - 36

Mechanical Data ....................................................... 6 - 36

Type Key and Product Marking ................................. 6 - 38

Description

This series of DC-DC converters has been developed for

powering electronic circuits and systems, e.g. telephone

system components, control modules and small appli-

ances. They are also suitable for applications with var iable

input voltages or with input transients. Input to output isola-

tion test voltage categories up to 5 kVrms are available. The

converters feature high efficiency, high reliability, lo w output

voltage ripple and excellent dynamic response. Efficiency

is high and practically constant over the entire input voltage

range.

All modules are manufactured according to ISO 9001.

Case: IPS/IPW: 2"×2" metal, black anodized, IPZ: black

colored plastics, self cooling (free air convection).

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6.1

Type Survey

General Condition:

A = 25°C

Table 1a: Type survey IPS 10

Output 1 Output 2 Input Voltage Range Group 1 700 V DC/500 Vrms Pin

o nom

iIsolation test voltage Configuration

[V DC] [mA] [V DC] [mA] [V DC] Type 2

5 2000 - - 24 IPS .. 01 .. IPS 10-05-T.. C, B, G, F

12 833 - - 10...33 .. IPS 10-12-T..

15 667 - - (nominal 24) .. IPS 10-15-T..

+5 1000 –5 1000 48 IPS .. 02 .. IPS 10-0505-T..

+12 417 –12 417 18...72 .. IPS 10-1212-T..

+15 333 –15 333 (nominal 48) .. IPS 10-1515-T..

Table 1b: Type survey IPW 10

Output 1 Output 2 Input Voltage Range Group 1 1500 V DC/1060 Vrms Pin

o nom

iIsolation test voltage Configuration

[V DC] [mA] [V DC] [mA] [V DC] Type 2

5 2000 - - 24 IPW .. 01 .. IPW 10-05-T.. C, G

12 833 - - 10...33 .. IPW 10-12-T..

15 667 - - (nominal 24) .. IPW 10-15-T..

+5 1000 –5 1000 48 IPW .. 02 .. IPW 10-0505-T..

+12 417 –12 417 18...72 .. IPW 10-1212-T..

+15 333 –15 333 (nominal 48) .. IPW 10-1515-T..

Table 1c: Type survey IPZ 5

Output 1 Output 2 Input Voltage Range Group 1 7070 V DC/5000 Vrms Pin

o nom

iIsolation test voltage Configuration

[V DC] [mA] [V DC] [mA] [V DC] Type 2

5 1000 - - 24 IPZ .. 01 .. IPZ 5-05-T.. C

12 417 - - 10...33 .. IPZ 5-12-T..

15 333 - - (nominal 24) .. IPZ 5-15-T..

+5 500 –5 500 48 IPZ .. 02 .. IPZ 5-0505-T..

+12 208 –12 208 18...72 .. IPZ 5-1212-T..

+15 167 –15 167 (nominal 48) .. IPZ 5-1515-T..

1See Block Diagrams

2Nominal input voltage and pin configuration should be added to the type designation (e.g. 24 IPS 10-05-TC)

Other types with different input and output specifications available upon request.

10 Watt-Family DC-DC Converters <40 W Rugged Environment

6 - 32 Edition 2/96 - © Melcher AG

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6.1

Safety Instructions

If the output circuit of a DC-DC converter is operator-acces-

sible according to the IEC 950 related safety standards, it

shall be an SELV circuit (Safety Extra Low Voltage circuit,

i.e. a circuit, separated from mains by at least basic insula-

tion, that is so designed and protected that under normal

and single fault conditions, the voltage between any two

conductors and between any conductor and earth does not

exceed DC 60 V).

Table 2: Insulation concept for SELV circuits

Nominal Minimum required grade Maximum Minimum required Minimum required grade of Resulting safety

mains of isolation, to be output safety status of the isolation between the input status of the

supply provided by the AC-DC voltage front end output circuit and the output of the DC-DC DC-DC converter

voltage front end, including mains from the converter, provided by output circuit

(AC) supplied battery charger front end the converter

≤250 V Basic ≤60 V Earthed SELV circuit 1 Operational SELV circuit 2

≤72 V Unearthed hazardous Operational Earthed SELV

voltage secondary circuit 3 circuit 1 2

Double or reinforced ≤60 V SELV circuit Operational SELV circuit 2

≤72 V Double or reinforced insu- Operational

lated unearthed hazardous

voltage secondary circuit,

supplying an SELV circuit 4

1The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC 950.

2The output has to be protected against overvoltages higher than 60 V by external means, e.g. an overvoltage suppressor diode.

3Has to be insulated from earth by at least basic insulation according to the relevant safety standard, based on the maximum input

voltage of the DC-DC converter.

4Has to be insulated from earth by double or reinforced insulation according to the relevant safety standard, based on the maximum in-

put voltage of the DC-DC converter.

Immunity to Environmental Conditions

Thermal Considerations

Table 3: Temp. specification values given are valid for air pressures in the range 800...1200 hPa (800...1200 mbar)

Characteristics Conditions Standard -T on request 1 Unit

min max min max

AAmbient temperature

i min...

i max –25 71 –40 85 °C

CCase temperature

o = 0...

o nom –25 95 –40 105

SStorage temperature not operational –55 105 –55 105

1Availab le on request as special types (custom designed units) with reduced output power

The case temperature

C should not exceed the maximum value. In applications with limited air circulation, additional

measures must be taken (either larger spacing or a fan) to avoid case temperatures higher than

C max!

Table 4: MTBF

Values at specified Modules Types Ground Benign Ground Fixed Ground Mobile Unit

Case Temperature 40°C40°C70°C40°C70°C

MTBF according to Single output 2'150'000 570'000 270'000 190'000 90'000 h

MIL-HDBK-217F Double outputs 1'850'000 510'000 250'000 150'000 70'000

In the following section an interpretation is provided of the

IEC 950 safety standard with respect to the safety status of

the output circuit. Ho w ev er, it is the sole responsibility of the

installer or user to assure the compliance with the relevant

and applicable safety standards.

If the following table is observed, the output of any DC-DC

converter is considered to be an SELV.

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6.1

Installation Instructions

Isolation Tests

Input to output isolation voltage tests are performed as factory tests (100%) and should not be repeated in the field.

Melcher will not honour any guarantee/warranty claims resulting from high voltage field tests.

Table 8: Isolation test voltage coupling capacitance and insulation resistance

Characteristic Conditions IPS IPW 1IPZ Unit

is io Isolation test voltage AC: 50 Hz, 500 1060 5000 Vrms

Input to output 1 minute 1400 3000 14100 Vpp

DC: 1 second 2700 1500 7070 V

DC: 1 second 3800 1700 8000

io Coupling capacitance typ 1000 1000 40 pF

is Insulation resistance at 100 V DC ≥1000 MΩ

after 1 minute

1According to EN 41003 (1993)

2For production test purposes in accordance with IEC 950/EN 60950

3Factory test procedure

Connection in Series

If the outputs of one or more units are connected in series

each individual output should be protected by a zener diode

or preferably by a suppressor diode to avoid overvoltages

or reverse polarity at the individual outputs, e.g.: 1N5908

(5 V), BZW04-11 (12 V), BZW04-14 (15 V) or equivalent

types.

Such destructive voltages may occur at switch-on cycle of

the converters, if the output voltages do not rise at the same

time. The "slower" output(s) could be supplied and, as a

result, destroyed by the "faster" output(s) via the load. The

maximum output current is limited by the lowest current

limitation.

Connection in Parallel

Connection of the outputs of one or more units in parallel is

not permitted. The load distribution and the ripple values

could not be controlled.

Cleaning

Two CFC free cleaning solvents have been tested and can

be recommended:

– Prozone from BP

– Zestron from Dr. O. K. Wack Chemie GmbH (Germany)

Submersion of the units in water for rinsing is permitted.

Drying should be done in air only.

Unit 1

Unit 2

–

+Vo

–Vo

+Vo

–Vo

Fig. 1

Outputs connected in series

Shutdown Description

The shutdown terminal is used to switch the converter out-

put voltage

o on and off (e.g. using an open collector

drive). See "Electrical Input and Output Data".

The output voltage is switched on when the shutdown ter-

minal is open circuit. The output voltage is switched off

when a voltage of –0.3...+2 V is applied to the shutdown

terminal. At the open shutdown pin 10...12 V will appear.

10 Watt-Family DC-DC Converters <40 W Rugged Environment

6 - 34 Edition 2/96 - © Melcher AG

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The Power Partners.

6.1

Electrical Input and Output Data

General Conditions:

A = 25°C, unless otherwise specified

Table 5a: Input Data

Input .. IP S/IPW 10-05 .. .. IPS/IPW 10-12 .. .. IP S/IPW 10-15 ..

Characteristics Conditions min typ max min typ max min typ max Unit

iInput voltage range 24 IPS

A min...

A max 10 33 10 33 10 33 V DC

48 IPS

o = 0...

o nom 18 72 18 72 18 72

i abs Input voltage 24 IPS 1 045045045

limits without 48 IPS 2 075075075

any damage

i o No load input Group 01

i nom,

o = 0 25 25 25 mA

current Group 02 25 45 45

i SD 3 Input current in

i min...

i max 333

shutdown condition

A min...

A max

i L Input current limitation

i min...

i max 1.2

i1.2

response

A min...

A max

i rfi RFI current at the input

o = 0...

o nom 30 30 30 mApp

SD 3 Shutdown voltage operating open circuit open circuit open circuit V DC

for converter not operating –0.3...+2 –0.3...+2 –0.3...+2

SD 3 Shutdown current operating - - - µA

for converter not operating 3 3 3

sSwitching frequency

i min...max,

o nom 145 145 145 kHz

A min...

A max

135 V for 500 ms, repetition rate 50 s; 45 V DC for 10 ms repetition rate 10 s; according to Siemens standard SN 26555, section 9

2The applied minimum load must be 10% between 72.0...75.0 V DC

3With shutdown facility: Pin configuration F and G for IPS-types, pin configuration G for IPW-types

Table 6a: Output Data

Output .. IP S/IPW 10-05 .. .. IPS/IPW 10-12 .. .. IPS/IPW 10-15 ..

Characteristics Conditions min typ max min typ max min typ max Unit

oOutput voltage

i nom,

o nom 4.95 5.05 11.88 12.12 14.85 15.15 V DC

o nom Nominal output Group 01

i min…

i max 2000 833 667 mA

current Group 02

A min...

A max 1000 417 333

oOutput voltage noise

i min...

i max 50 100 120 240 150 300 mVpp

(BW = 20 MHz)

o nom

∆

o U Static line regulation 5 10 12 24 15 30 mV

∆

o I Static load regulation

i min...

i max 0...50 0...50 0...50

o nom...0

αUo Temperature coefficient

i nom,

o nom ±0.02 ±0.02 ±0.02 %/K

Output overvoltage clamping 5.6 +10/–0% 13 +10/–0% 16 +10/–0% V

Table 7a: Efficiency

Efficiency .. IP S/IPW 10-05 .. .. IPS/IPW 10-12 .. .. IPS/IPW 10-15 ..

Characteristics Conditions min typ max min typ max min typ max Unit

Efficiency

i nom = 24 V,

o nom 77 80 77 80 77 80 %

i nom = 48 V,

o nom 77 80 77 80 77 80

Dual output units should have the same (%) load conditions at both outputs to comply with above specifications.

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6.1

Table 5b: Input Data

Input .. IPZ 5-05 .. .. IPZ 5-12 .. .. IPZ 5-15 ..

Characteristics Conditions min typ max min typ max min typ max Unit

iInput voltage range 24 IPS

A min...

A max 10 33 10 33 10 33 V DC

48 IPS

o = 0...

o nom 18 72 18 72 18 72

i abs Input voltage 24 IPS 1 045045045

limits without 48 IPS 2 075075075

any damage

i o No load input Group 01

i nom,

o = 0 25 25 25 mA

current Group 02 25 45 45

i L Input current limitation

i min...

i max 1.2

i1.2

response

A min...

A max

i rfi RFI current at the input

o = 0...

o nom 30 30 30 mApp

sSwitching frequency

i min...max,

o nom 145 145 145 kHz

A min...

A max

135 V for 500 ms, repetition rate 50 s; 45 V DC for 10 ms repetition rate 10 s; according to Siemens standard SN 26555, section 9

2The applied minimum load must be 10% between 72.0...75.0 V DC

Table 7b: Efficiency

Efficiency .. IPZ 5-05 .. .. IPZ 5-12 .. .. IPZ 5-15 ..

Characteristics Conditions min typ max min typ max min typ max Unit

Efficiency

i nom = 24 V,

o nom 77 80 77 80 77 80 %

i nom = 48 V,

o nom 77 80 77 80 77 80

Dual output units should have the same (%) load conditions at both outputs to comply with above specifications.

Table 6b: Output Data

Output .. IPZ 5-05 .. .. IPZ 5-12 .. .. IPZ 5-15 ..

Characteristics Conditions min typ max min typ max min typ max Unit

oOutput voltage

i nom,

o nom 4.95 5.05 11.88 12.12 14.85 15.15 V DC

o nom Nominal output Group 01

i min…

i max 1000 417 333 mA

current Group 02

A min...

A max 500 208 167

oOutput voltage noise

i min...

i max 50 100 120 240 150 300 mVpp

(BW = 20 MHz)

o nom

∆

o U Static line regulation 5 10 12 24 15 30 mV

∆

o I Static load regulation

i min...

i max 0...50 0...50 0...50

o nom...0

αUo Temperature coefficient

i nom,

o nom ±0.02 ±0.02 ±0.02 %/K

Output overvoltage clamping 5.6 +10/–0% 13 +10/–0% 16 +10/–0% V

10 Watt-Family DC-DC Converters <40 W Rugged Environment

6 - 36 Edition 2/96 - © Melcher AG

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The Power Partners.

6.1

Functional Description and Block Diagrams

These converters are primary controlled single transistor

forward converters using Pulse With Modulation (PWM).

The output voltage is fed back to the primary control circuit

via a signal transformer. The second output voltage regula-

tion relies on the close magnetic coupling of the output

inductor together with the circuit symmetry. Therefore out-

put 2 should have the same (%) load condition as output 1

to comply with the specified data. The current limitation is

located on the primary side, limiting the total output current.

PWM Go

PWM

–Vo

+Vo

Fig. 2

Group 01, single output Fig. 3

Group 02, dual output

Mechanical Data

Dimensions in mm. Tolerances ±0.2 mm, unless otherwise specified. European

Projection

Fig. 4

2" metal case, single output without shutdown

Pin configuration C, available for IPS and IPW-types

Fig. 5

2" metal case, dual output without shutdown

Pin configuration C, available for IPS and IPW-types

10.5

min. 5

ø 1

51.3

23.2 ±0.5

20.3

15.5 ±0.5

Go Vo

Bottom view

Output

51.3 5.1

Input

20.3

15.5 ±0.5

10.5

min. 5

ø 1

51.3

23.2 ±0.5

15.5 ±0.5

–Vo +Vo

Bottom view

Output

51.3 5.1

Input

20.3

10.210.2

Gi Vi

15.5 ±0.5

Fig. 6

Plastic case, single output without shutdown

Pin configuration C, available for IPZ-types

Fig. 7

Plastic case, dual output without shutdown

Pin configuration C, available for IPZ-types

10.5

min. 5

ø 1

50.8

±0.5

20.3

15.3

±0.5

Go Vo

Bottom view

±0.5

+0.0

-0.2

Output

50.8 5.1

Input

20.3

15.3

±0.5

10.5

min. 5

ø 1

50.8

23 ±0.5

15.3 ±0.5

–Vo +Vo

Bottom view

3 ±0.5

9 ±0.5

+0.0

-0.2

Output

50.8 5.1

Input

20.3

10.210.2

Gi Vi

15.3 ±0.5

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6.1

10.5

min. 5

ø 1

50.8

23 ±0.5

20.3

15.3 ±0.5

Go Vo

Bottom view

3 ±0.5

9 ±0.5

+0.0

-0.2

Output

50.8 5.1

Input

20.3

10.8

27.3

15.3 ±0.5

10.5

min. 5

ø 1

50.8

23 ±0.5

15.3 ±0.5

–Vo +Vo

Bottom view

3 ±0.5

9 ±0.5

+0.0

-0.2

Output

50.8 5.1

Input

20.3

10.210.2

Gi Vi

10.8

27.3

15.3 ±0.5

Fig. 8

2" metal case, single output with shutdown

Pin configuration G, available for IPS and IPW-types

Fig. 9

2" metal case, dual output with shutdown

Pin configuration G, available for IPS and IPW-types

Fig. 10

2" metal case, single output without shutdown

Pin configuration B, available for IPS-types

Bottom view

10.5

min. 5

ø 1

3 ±0.5

9 ±0.5

+0.0

-0.2

50.8

4.5 ±0.5

43.2

Go Vo

50.8

43.2

Input

Output

3.9 ±0.5

Gi Vi

3.9 ±0.5

38.7

Bottom view

10.5

min. 5

ø1

3 ±0.5

9 ±0.5

+0.0

-0.2

50.8

4.5 ±0.5

–Vo +Vo

50.8

43.2

Input

Output

21.6 21.6

3.9 ±0.5

Gi Vi

3.9 ±0.5

38.7

Fig. 12

2" metal case, single output with shutdown

Pin configuration F, available for IPS-types

Bottom view

10.5

min. 5

ø 1

3 ±0.5

9 ±0.5

+0.0

-0.2

50.8

4.5 ±0.5

43.2

Go Vo

50.8

43.2

Input

Output

3.9 ±0.5

Gi Vi

3.9 ±0.5

Bottom view

10.5

min. 5

ø1

3 ±0.5

9 ±0.5

+0.0

-0.2

50.8

4.5 ±0.5

-Vo +Vo

50.8

43.2

Input

Output

21.6 21.6

3.9 ±0.5

Gi Vi

3.9 ±0.5

Fig. 11

2" metal case, dual output without shutdown

Pin configuration B, available for IPS-types

Fig. 13

2" metal case, dual output with shutdown

Pin configuration F, available for IPS-types

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6.1

Type Key and Product Marking

Type Key: 24 IPS 10 - 12 12 - T C

Nominal input voltage in volt .................................... 24, 48

Family .......................................................... IPS, IPW, IPZ

Nominal output power in watts ................................... 5, 10

Nominal output voltage for output 1 in volt ......... 05, 12, 15

Nominal output voltage for output 2 in volt ......... 05, 12, 15

Operating ambient temperature range

A = –25...71°C ..................................................... T

Pin configuration ................................................ C, B, G, F

Product Marking:

Main face: Manufacturer's name (IBEK), specific type designation, input voltage range, input and output pin allocation.

Bottom: Date code.