10 Watt-Family DC-DC Converters <40 W IBEK DC-DC Converters Rugged Environment 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 6.1 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 appliances. They are also suitable for applications with variable input voltages or with input transients. Input to output isolation test voltage categories up to 5 kVrms are available. The converters feature high efficiency, high reliability, low output 6 - 30 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"x 2" metal, black anodized, IPZ: black colored plastics, self cooling (free air convection). MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Rugged Environment DC-DC Converters <40 W 10 Watt-Family Type Survey General Condition: TA = 25C Table 1a: Type survey IPS 10 Output 1 Uo nom Io nom [V DC] [mA] Output 2 Uo nom Io nom [V DC] [mA] Input Voltage Range Ui [V DC] Group 1 700 V DC/500 Vrms Isolation test voltage Type 2 5 12 15 2000 833 667 - - 24 IPS .. 10...33 (nominal 24) 01 .. IPS 10-05-T.. .. IPS 10-12-T.. .. IPS 10-15-T.. +5 +12 +15 1000 417 333 -5 -12 -15 1000 417 333 48 IPS .. 18...72 (nominal 48) 02 .. IPS 10-0505-T.. .. IPS 10-1212-T.. .. IPS 10-1515-T.. Input Voltage Range Ui [V DC] Group 1 Pin Configuration C, B, G, F Table 1b: Type survey IPW 10 Output 2 Uo nom Io nom [V DC] [mA] 1500 V DC/1060 Vrms Isolation test voltage Type 2 5 12 15 2000 833 667 - - 24 IPW .. 10...33 (nominal 24) 01 .. IPW 10-05-T.. .. IPW 10-12-T.. .. IPW 10-15-T.. +5 +12 +15 1000 417 333 -5 -12 -15 1000 417 333 48 IPW .. 18...72 (nominal 48) 02 .. IPW 10-0505-T.. .. IPW 10-1212-T.. .. IPW 10-1515-T.. Input Voltage Range Ui [V DC] Group 1 Pin Configuration C, G 6.1 Output 1 Uo nom Io nom [V DC] [mA] Table 1c: Type survey IPZ 5 Output 1 Uo nom Io nom [V DC] [mA] 1 2 Output 2 Uo nom Io nom [V DC] [mA] 7070 V DC/5000 Vrms Isolation test voltage Type 2 5 12 15 1000 417 333 - - 24 IPZ .. 10...33 (nominal 24) 01 .. IPZ 5-05-T.. .. IPZ 5-12-T.. .. IPZ 5-15-T.. +5 +12 +15 500 208 167 -5 -12 -15 500 208 167 48 IPZ .. 18...72 (nominal 48) 02 .. IPZ 5-0505-T.. .. IPZ 5-1212-T.. .. IPZ 5-1515-T.. Pin Configuration C See Block Diagrams Nominal 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. Edition 2/96 - (c) Melcher AG MELCHER The Power Partners. 6 - 31 10 Watt-Family DC-DC Converters <40 W Rugged Environment Safety Instructions If the output circuit of a DC-DC converter is operator-accessible 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 insulation, 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). In the following section an interpretation is provided of the IEC 950 safety standard with respect to the safety status of the output circuit. However, 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. Table 2: Insulation concept for SELV circuits Nominal mains supply voltage (AC) Minimum required grade of isolation, to be provided by the AC-DC front end, including mains supplied battery charger 250 V Basic 6.1 Double or reinforced 1 2 3 4 Maximum output voltage from the front end Minimum required safety status of the front end output circuit Minimum required grade of isolation between the input and the output of the DC-DC converter, provided by the converter Resulting safety status of the DC-DC converter output circuit 60 V Earthed SELV circuit 1 Operational SELV circuit 2 72 V Unearthed hazardous voltage secondary circuit 3 Operational Earthed SELV circuit 1 2 60 V SELV circuit Operational SELV circuit 72 V Double or reinforced insu- Operational lated unearthed hazardous voltage secondary circuit, supplying an SELV circuit 4 2 The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC 950. The output has to be protected against overvoltages higher than 60 V by external means, e.g. an overvoltage suppressor diode. Has 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. Has to be insulated from earth by double or reinforced insulation according to the relevant safety standard, based on the maximum input 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) 1 on request 1 Characteristics Conditions Standard -T min max min max TA Ambient temperature -25 71 -40 85 TC Case temperature Ui min...Ui max Io = 0... Io nom -25 95 -40 105 TS Storage temperature not operational -55 105 -55 105 Unit C Available on request as special types (custom designed units) with reduced output power The case temperature TC 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 TC max ! Table 4: MTBF Values at specified Case Temperature Modules Types 40C 40 C 70C 40C 70C MTBF according to MIL-HDBK-217F Single output 2'150'000 570'000 270'000 190'000 90'000 Double outputs 1'850'000 510'000 250'000 150'000 70'000 6 - 32 Ground Benign Ground Fixed MELCHER The Power Partners. Ground Mobile Unit h Edition 2/96 - (c) Melcher AG Rugged Environment DC-DC Converters <40 W 10 Watt-Family 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 1 IPZ Unit Uis io AC: 50 Hz, 1 minute 500 1060 5000 Vrms 1400 3000 14100 Vpp 700 1500 7070 V 800 1700 8000 1000 1000 40 Isolation test voltage Input to output DC: 1 second 2 DC: 1 second Cio Coupling capacitance Ris Insulation resistance 3 typ pF 1000 at 100 V DC after 1 minute M 1 According to EN 41003 (1993) For production test purposes in accordance with IEC 950/EN 60950 3 Factory test procedure 2 Connection in Series Unit 1 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. Edition 2/96 - (c) Melcher AG +Vo +Uo 6.1 Go -Vo +Vo Unit 2 Go -Vo - Uo Fig. 1 Outputs connected in series Shutdown Description The shutdown terminal is used to switch the converter output voltage Uo 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 terminal 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. MELCHER The Power Partners. 6 - 33 10 Watt-Family DC-DC Converters <40 W Rugged Environment Electrical Input and Output Data General Conditions: TA = 25 C, unless otherwise specified Table 5a: Input Data Input .. IPS/IPW 10-05 .. .. IPS/IPW 10-12 .. .. IPS/IPW 10-15 .. Characteristics Ui Input voltage range 24 IPS 48 IPS Ui abs Input voltage limits without any damage 24 IPS 1 48 IPS 2 Ii o No load input current Group 01 Group 02 I i SD 3 Ii L min max min max min max Unit TA min...TA max I o = 0... Io nom 10 18 typ 33 72 10 18 typ 33 72 10 18 typ 33 72 V DC 0 0 45 75 0 0 45 75 0 0 45 75 Ui nom, I o = 0 25 25 25 45 25 45 Input current in shutdown condition Ui min...Ui max TA min...TA max 3 3 3 Input current limitation response 1.2 I i 1.2 I i 1.2 I i RFI current at the input Ui min...Ui max TA min...TA max I o = 0... Io nom 30 30 30 mApp Shutdown voltage for converter operating not operating open circuit -0.3...+2 open circuit -0.3...+2 open circuit -0.3...+2 V DC I SD 3 Shutdown current for converter operating not operating 3 3 3 A fs Switching frequency Ui min...max, I o nom TA min...TA max 145 145 145 kHz ii rfi USD 6.1 Conditions 3 mA 1 35 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 The applied minimum load must be 10% between 72.0...75.0 V DC 3 With shutdown facility: Pin configuration F and G for IPS-types, pin configuration G for IPW-types 2 Table 6a: Output Data Output .. IPS/IPW 10-05 .. Characteristics Conditions min Uo Output voltage Ui nom , Io nom 4.95 Io nom Nominal output current uo Output voltage noise (BW = 20 MHz) Uo U Static line regulation Uo I Uo typ max min 5.05 11.88 Ui min...Ui max TA min... TA max 2000 1000 Ui min...Ui max Io nom 50 100 5 10 Static load regulation Ui min...Ui max Io nom...0 0...50 Temperature coefficient Ui nom , Io nom Group 01 Group 02 .. IPS/IPW 10-12 .. typ max min 12.12 14.85 typ Unit V DC 667 333 120 240 150 300 mVpp 15 30 mV 0.02 %/K 12 0.02 24 mA 0...50 0.02 13 max 15.15 833 417 0...50 5.6 +10/-0 % Output overvoltage clamping .. IPS/IPW 10-15 .. +10/-0% 16 +10/-0% V Table 7a: Efficiency Efficiency .. IPS/IPW 10-05 .. Characteristics Conditions min typ Ui nom = 24 V, I o nom Ui nom = 48 V, Io nom 77 77 80 80 Efficiency max .. IPS/IPW 10-12 .. min typ 77 77 80 80 max .. IPS/IPW 10-15 .. min typ 77 77 80 80 max Unit % Dual output units should have the same (%) load conditions at both outputs to comply with above specifications. 6 - 34 MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Rugged Environment DC-DC Converters <40 W 10 Watt-Family Table 5b: Input Data Input .. IPZ 5-05 .. Characteristics 1 2 Ui Input voltage range Ui abs Input voltage limits without any damage 24 IPS 1 48 IPS 2 Ii o No load input current Group 01 Group 02 Ii L Input current limitation response ii rfi RFI current at the input fs Switching frequency 24 IPS 48 IPS Conditions min TA min... TA max Io = 0...I o nom typ .. IPZ 5-12 .. max min 10 18 33 72 0 0 45 75 typ .. IPZ 5-15 .. max min 10 18 33 72 0 0 45 75 typ max Unit 10 18 33 72 V DC 0 0 45 75 Ui nom, Io = 0 25 25 25 45 25 45 Ui min... Ui max TA min... TA max Io = 0...I o nom 1.2 I i 1.2 I i 1.2 I i Ui min... max, Io nom TA min... TA max mA 30 30 30 mApp 145 145 145 kHz 35 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 The applied minimum load must be 10% between 72.0...75.0 V DC Output .. IPZ 5-05 .. Characteristics Conditions min Uo Output voltage Ui nom , I o nom 4.95 Io nom Nominal output current uo Output voltage noise (BW = 20 MHz) Uo U Static line regulation Uo I Static load regulation Ui min...Ui max Io nom...0 Temperature coefficient Ui nom , I o nom Uo Group 01 Group 02 typ Ui min...Ui max TA min...TA max 1000 500 Ui min...Ui max Io nom 50 5 .. IPZ 5-12 .. max min 5.05 11.88 typ max min 12.12 14.85 typ max Unit 15.15 V DC 333 167 100 120 240 150 300 10 12 15 24 0...50 0.02 mA mVpp 30 mV 0.02 %/K 0...50 0.02 5.6 +10/-0% Output overvoltage clamping .. IPZ 5-15 .. 417 208 0...50 6.1 Table 6b: Output Data 13 +10/-0 % 16 +10/ -0% .. IPZ 5-12 .. .. IPZ 5-15 .. V Table 7b: Efficiency Efficiency .. IPZ 5-05 .. Characteristics Conditions min typ Ui nom = 24 V, Io nom Ui nom = 48 V, I o nom 77 77 80 80 Efficiency max min typ 77 77 80 80 max min typ 77 77 80 80 max Unit % Dual output units should have the same (%) load conditions at both outputs to comply with above specifications. Edition 2/96 - (c) Melcher AG MELCHER The Power Partners. 6 - 35 10 Watt-Family DC-DC Converters <40 W Rugged Environment 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 regulation relies on the close magnetic coupling of the output Vi Vo PWM inductor together with the circuit symmetry. Therefore output 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. +Vo Vi Go PWM Go -Vo Cio Gi Gi SD SD Fig. 3 Group 02, dual output Mechanical Data Dimensions in mm. Tolerances 0.2 mm, unless otherwise specified. Output 15.3 0.5 15.3 0.5 50.8 3 0.5 Vo C Bottom view Fig. 4 2" x 2" metal case, single output without shutdown Pin configuration C, available for IPS and IPW-types 15.3 0.5 15.3 0.5 10.210.2 Bottom view Fig. 5 2" x 2" metal case, dual output without shutdown Pin configuration C, available for IPS and IPW-types 51.3 51.3 5.1 Gi Vi Go 23.2 0.5 10.5 Vo Bottom view 6 - 36 15.5 0.5 15.5 0.5 20.3 Fig. 6 Plastic case, single output without shutdown Pin configuration C, available for IPZ-types C Gi Vi -Vo Go +Vo Output Output 15.5 0.5 15.5 0.5 5.1 Input 51.3 20.3 51.3 Input C min. 5 20.3 23.2 0.5 10.5 o1 min. 5 Gi Vi -Vo Go +Vo Output 10 20.3 5.1 Input Gi Vi Go 23 0.5 10.5 -0.2 9 0.5 20.3 50.8 9 0.5 3 0.5 C 50.8 +0.0 min. 5 o1 o1 5.1 20.3 23 0.5 Input 10 European Projection 50.8 +0.0 10.5 -0.2 min. 5 o1 6.1 Fig. 2 Group 01, single output Cio 10.210.2 Bottom view Fig. 7 Plastic case, dual output without shutdown Pin configuration C, available for IPZ-types MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG 50.8 Gi Vi Output 10 15.3 0.5 15.3 0.5 20.3 10 Bottom view Gi Vi -Vo Go +Vo 15.3 0.5 15.3 0.5 10.210.2 10.8 Bottom view Fig. 9 2" x 2" metal case, dual output with shutdown Pin configuration G, available for IPS and IPW-types 50.8 +0.0 10.5 -0.2 4.5 0.5 G Output 10.8 Fig. 8 2" x 2" metal case, single output with shutdown Pin configuration G, available for IPS and IPW-types 50.8 +0.0 10.5 -0.2 4.5 0.5 min. 5 42 42 Gi Output Go 10 3.9 0.5 3.9 0.5 Vo Bottom view 21.6 +Vo 21.6 Fig. 11 2" x 2" metal case, dual output without shutdown Pin configuration B, available for IPS-types 50.8 +0.0 10.5 -0.2 4.5 0.5 3.9 0.5 3.9 0.5 Output Go Bottom view Fig. 10 2"x 2" metal case, single output without shutdown Pin configuration B, available for IPS-types 50.8 +0.0 10.5 -0.2 4.5 0.5 min. 5 42 42 Vi Output 3.9 0.5 3.9 0.5 Vo Bottom view Fig. 12 2"x 2" metal case, single output with shutdown Pin configuration F, available for IPS-types Edition 2/96 - (c) Melcher AG 3.9 0.5 3.9 0.5 Vi Input SD 38.7 F -Vo 10 43.2 43.2 F Go 10 Gi SD 50.8 Input 9 0.5 3 0.5 43.2 9 0.5 3 0.5 50.8 Gi 38.7 o1 o1 min. 5 B -Vo 10 43.2 Vi Input 6.1 B 43.2 Vi Input 50.8 43.2 9 0.5 3 0.5 50.8 Gi 9 0.5 3 0.5 o1 o1 min. 5 SD 9 0.5 Vo 5.1 Input 3 0.5 27.3 20.3 9 0.5 3 0.5 50.8 SD Go 23 0.5 10.5 -0.2 27.3 o1 Input G 50.8 +0.0 min. 5 5.1 50.8 23 0.5 10 Watt-Family o1 +0.0 10.5 -0.2 min. 5 DC-DC Converters <40 W 20.3 Rugged Environment Output Go 21.6 +Vo 21.6 Bottom view Fig. 13 2"x 2" metal case, dual output with shutdown Pin configuration F, available for IPS-types MELCHER The Power Partners. 6 - 37 10 Watt-Family DC-DC Converters <40 W Rugged Environment 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 TA = -25...71C ..................................................... T Pin configuration ................................................ C, B, G, F 6.1 Product Marking: Main face: Manufacturer's name (IBEK), specific type designation, input voltage range, input and output pin allocation. Bottom: Date code. 6 - 38 MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG