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 kv rms 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 variable input voltages or with input transients. input to output isola- tion test voltage categories up to 5 kv rms are available. the converters feature high efficiency, high reliability, low 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).
rugged environment dc-dc converters <40 w 10 watt-family edition 2/96 - ? melcher ag 6 - 31 melcher
the power partners. 6.1 type survey general condition: t a = 25 c table 1a: type survey ips 10 output 1 output 2 input voltage range group 1 700 v dc/500 v rms pin u o nom i o nom u o nom i o nom u i isolation 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 C5 1000 48 ips .. 02 .. ips 10-0505-t.. +12 417 C12 417 18...72 .. ips 10-1212-t.. +15 333 C15 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 v rms pin u o nom i o nom u o nom i o nom u i isolation 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 C5 1000 48 ipw .. 02 .. ipw 10-0505-t.. +12 417 C12 417 18...72 .. ipw 10-1212-t.. +15 333 C15 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 v rms pin u o nom i o nom u o nom i o nom u i isolation 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 C5 500 48 ipz .. 02 .. ipz 5-0505-t.. +12 208 C12 208 18...72 .. ipz 5-1212-t.. +15 167 C15 167 (nominal 48) .. ipz 5-1515-t.. 1 see block diagrams 2 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.
10 watt-family dc-dc converters <40 w rugged environment 6 - 32 edition 2/96 - ? melcher ag melcher
the power partners. 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 1 the earth connection has to be provided by the installer according to the relevant safety standard, e.g. iec 950. 2 the output has to be protected against overvoltages higher than 60 v by external means, e.g. an overvoltage suppressor diode. 3 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. 4 has 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 t a ambient temperature u i min ... u i max C25 71 C40 85 c t c case temperature i o = 0... i o nom C25 95 C40 105 t s storage temperature not operational C55 105 C55 105 1 available on request as special types (custom designed units) with reduced output power the case temperature t 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 t 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. 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.
rugged environment dc-dc converters <40 w 10 watt-family edition 2/96 - ? melcher ag 6 - 33 melcher
the power partners. 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 1 ipz unit u is io isolation test voltage ac: 50 hz, 500 1060 5000 v rms input to output 1 minute 1400 3000 14100 v pp dc: 1 second 2 700 1500 7070 v dc: 1 second 3 800 1700 8000 c io coupling capacitance typ 1000 1000 40 pf r is insulation resistance at 100 v dc 3 1000 m w after 1 minute 1 according to en 41003 (1993) 2 for production test purposes in accordance with iec 950/en 60950 3 factory 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: C prozone from bp C 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 + u o u o +vo go ?o +vo go ?o fig. 1 outputs connected in series shutdown description the shutdown terminal is used to switch the converter out- put voltage u 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 C0.3...+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 melcher
the power partners. 6.1 electrical input and output data general conditions: t a = 25 c, unless otherwise specified table 5a: input data input .. ips/ipw 10-05 .. .. ips/ipw 10-12 .. .. ips/ipw 10-15 .. characteristics conditions min typ max min typ max min typ max unit u i input voltage range 24 ips t a min ... t a max 10 33 10 33 10 33 v dc 48 ips i o = 0... i o nom 18 72 18 72 18 72 u i abs input voltage 24 ips 1 045045045 limits without 48 ips 2 075075075 any damage i i o no load input group 01 u i nom , i o = 0 25 25 25 ma current group 02 25 45 45 i i sd 3 input current in u i min ... u i max 333 shutdown condition t a min ... t a max i i l input current limitation u i min ... u i max 1.2 i i 1.2 i i 1.2 i i response t a min ... t a max i i rfi rfi current at the input i o = 0... i o nom 30 30 30 ma pp u sd 3 shutdown voltage operating open circuit open circuit open circuit v dc for converter not operating C0.3...+2 C0.3...+2 C0.3...+2 i sd 3 shutdown current operating - - - m a for converter not operating 3 3 3 f s switching frequency u i min ... max, i o nom 145 145 145 khz t a min ... t a max 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 2 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 table 6a: output data output .. ips/ipw 10-05 .. .. ips/ipw 10-12 .. .. ips/ipw 10-15 .. characteristics conditions min typ max min typ max min typ max unit u o output voltage u i nom , i o nom 4.95 5.05 11.88 12.12 14.85 15.15 v dc i o nom nominal output group 01 u i min u i max 2000 833 667 ma current group 02 t a min ... t a max 1000 417 333 u o output voltage noise u i min ... u i max 50 100 120 240 150 300 mv pp (bw = 20 mhz) i o nom d u o u static line regulation 5 10 12 24 15 30 mv d u o i static load regulation u i min ... u i max 0...50 0...50 0...50 i o nom ...0 a uo temperature coefficient u i nom , i o nom 0.02 0.02 0.02 %/k output overvoltage clamping 5.6 +10/C0 % 13 +10/C0% 16 +10/C0% v table 7a: efficiency efficiency .. ips/ipw 10-05 .. .. ips/ipw 10-12 .. .. ips/ipw 10-15 .. characteristics conditions min typ max min typ max min typ max unit h efficiency u i nom = 24 v, i o nom 77 80 77 80 77 80 % u i nom = 48 v, i 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.
rugged environment dc-dc converters <40 w 10 watt-family edition 2/96 - ? melcher ag 6 - 35 melcher
the power partners. 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 u i input voltage range 24 ips t a min ... t a max 10 33 10 33 10 33 v dc 48 ips i o = 0... i o nom 18 72 18 72 18 72 u i abs input voltage 24 ips 1 045045045 limits without 48 ips 2 075075075 any damage i i o no load input group 01 u i nom , i o = 0 25 25 25 ma current group 02 25 45 45 i i l input current limitation u i min ... u i max 1.2 i i 1.2 i i 1.2 i i response t a min ... t a max i i rfi rfi current at the input i o = 0... i o nom 30 30 30 ma pp f s switching frequency u i min ... max, i o nom 145 145 145 khz t a min ... t a max 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 2 the 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 h efficiency u i nom = 24 v, i o nom 77 80 77 80 77 80 % u i nom = 48 v, i 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 u o output voltage u i nom , i o nom 4.95 5.05 11.88 12.12 14.85 15.15 v dc i o nom nominal output group 01 u i min u i max 1000 417 333 ma current group 02 t a min ... t a max 500 208 167 u o output voltage noise u i min ... u i max 50 100 120 240 150 300 mv pp (bw = 20 mhz) i o nom d u o u static line regulation 5 10 12 24 15 30 mv d u o i static load regulation u i min ... u i max 0...50 0...50 0...50 i o nom ...0 a uo temperature coefficient u i nom , i o nom 0.02 0.02 0.02 %/k output overvoltage clamping 5.6 +10/C0% 13 +10/C0 % 16 +10/ C0% v
10 watt-family dc-dc converters <40 w rugged environment 6 - 36 edition 2/96 - ? melcher ag melcher
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 vo vi gi sd c io pwm ?o go +vo vi gi sd c io 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" 2" metal case, single output without shutdown pin configuration c, available for ips and ipw-types fig. 5 2" 2" metal case, dual output without shutdown pin configuration c, available for ips and ipw-types 10.5 min. 5 ?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 vi gi c 15.5 0.5 10.5 min. 5 ?1 51.3 23.2 0.5 15.5 0.5 ?o +vo bottom view output 51.3 5.1 input 20.3 10.2 10.2 gi vi go c 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 ?1 50.8 23 0.5 20.3 15.3 0.5 go vo bottom view 10 3 0.5 9 0.5 +0.0
-0.2 output 50.8 5.1 input 20.3 vi gi c 15.3 0.5 10.5 min. 5 ?1 50.8 23 0.5 15.3 0.5 ?o +vo bottom view 10 3 0.5 9 0.5 +0.0
-0.2 output 50.8 5.1 input 20.3 10.2 10.2 gi vi go c 15.3 0.5
rugged environment dc-dc converters <40 w 10 watt-family edition 2/96 - ? melcher ag 6 - 37 melcher
the power partners. 6.1 10.5 min. 5 ? 1 50.8 23 0.5 20.3 15.3 0.5 go vo bottom view 10 3 0.5 9 0.5 +0.0
-0.2 output 50.8 5.1 input 20.3 vi gi g 10.8 27.3 sd 15.3 0.5 10.5 min. 5 ? 1 50.8 23 0.5 15.3 0.5 evo +vo bottom view 10 3 0.5 9 0.5 +0.0
-0.2 output 50.8 5.1 input 20.3 10.2 10.2 gi vi go g 10.8 27.3 sd 15.3 0.5 fig. 8 2" 2" metal case, single output with shutdown pin configuration g, available for ips and ipw-types fig. 9 2" 2" metal case, dual output with shutdown pin configuration g, available for ips and ipw-types fig. 10 2" 2" metal case, single output without shutdown pin configuration b, available for ips-types bottom view 10.5 min. 5 ? 1 10 3 0.5 9 0.5 +0.0 -0.2 50.8 4.5 0.5 43.2 go vo 50.8 42 43.2 input output 3.9 0.5 gi vi f 3.9 0.5 38.7 sd bottom view 10.5 min. 5 ?1 10 3 0.5 9 0.5 +0.0 -0.2 50.8 4.5 0.5 evo +vo 50.8 42 43.2 input output 21.6 21.6 go 3.9 0.5 gi vi f 3.9 0.5 sd 38.7 fig. 12 2" 2" metal case, single output with shutdown pin configuration f, available for ips-types bottom view 10.5 min. 5 ? 1 10 3 0.5 9 0.5 +0.0 -0.2 50.8 4.5 0.5 43.2 go vo 50.8 42 43.2 input output 3.9 0.5 gi vi b 3.9 0.5 bottom view 10.5 min. 5 ?1 10 3 0.5 9 0.5 +0.0 -0.2 50.8 4.5 0.5 -vo +vo 50.8 42 43.2 input output 21.6 21.6 go 3.9 0.5 gi vi b 3.9 0.5 fig. 11 2" 2" metal case, dual output without shutdown pin configuration b, available for ips-types fig. 13 2" 2" metal case, dual output with shutdown pin configuration f, available for ips-types
10 watt-family dc-dc converters <40 w rugged environment 6 - 38 edition 2/96 - ? melcher ag melcher
the power partners. 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 t a = C25...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.
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