Industrial Environment
DC-DC Converters <40 W
6 Watt-Family
IBEK DC-DC Converters
Input to output isolation test voltage 500 V
rms
Single output of 5 V DC, 5 W
Single and dual output of 12 V DC & 15 V DC, 6 W
Input voltages of 5, 12, 15, 24, 28 and 48 V DC
•
Efficient Pi input filter
•
Outputs equipped with linear voltage regulation
•
High reliability
•
Optimal dynamic response
•
Continuous no-load and short-circuit proof
•
Operating ambient temperature range up to
–40...85°C (optional)
•
Case height only 10.5 mm
6 Watt-Family
Table of Contents
Page
Description ................................................................ 6 - 43
Type Survey .............................................................. 6 - 44
Safety Instructions ..................................................... 6 - 45
Immunity to Environmental Conditions ...................... 6 - 45
Electrical Input and Output Data ............................... 6 - 46
Installation Instructions .............................................. 6 - 47
Block Diagrams ......................................................... 6 - 47
Mechanical Data ....................................................... 6 - 48
Type Key and Product Marking ................................. 6 - 48
Description
The DC-DC converters have been developed as a re-
sponse to the increasing need for decentralised power sup-
ply systems. They are especially suitable for powering me-
dium loads on PCBs and for realising redundant systems.
The DC-DC converters feature high efficiency, low output
ripple, low module height, high quality and reliability. To
minimise feedback effects in the supply system, the mod-
ules are equipped with an efficient low-pass Pi input filter.
All modules are manufactured according to ISO 9001.
Case: 2"× 2" metal, black anodized, self cooling (free air
convection).
Edition 2/96 - © Melcher AG
MELCHER
The Power Partners.
6 - 43
6.2
6 Watt-Family
Type Survey
General Condition:
T
A
= 25
°C
DC-DC Converters <40 W
Industrial Environment
Table 1: Type survey
Output
U
o nom
[V DC]
5
12
15
±12
±15
5
12
15
±12
±15
5
12
15
5
12
15
±12
±15
I
o nom
[mA]
1000
500
400
±250
±200
1000
500
400
±250
±200
1000
500
400
1000
500
400
±250
±200
1000
500
400
±250
±200
1000
500
400
±250
±200
Input
U
i nom
[V DC]
5
Typ. no load
Input Current
(
U
i nom
,
I
o
= 0) [mA]
32
46
52
125
150
Efficiency
η
(typ.)
[%]
68
72
72
68
70
70
75
75
72
73
72
75
75
72
76
76
74
75
72
76
76
75
75
70
72
72
73
73
Group
1
Type
2
Pin-
Config.
C, B
Option
01
5 ICR 5-05-T..
5 ICR 6-12-T..
5 ICR 6-15-T..
5 ICR 6-1212-T..
5 ICR 6-1515-T..
12 ICR 5-05-T..
12 ICR 6-12-T..
12 ICR 6-15-T..
12 ICR 6-1212-T..
12 ICR 6-1515-T..
15 ICR 5-05-T..
15 ICR 6-12-T..
15 ICR 6-15-T..
24 ICR 5-05-T..
24 ICR 6-12-T..
24 ICR 6-15-T..
S
02
01
12
20
25
30
60
63
02
01
15
18
19
20
18
19
20
37
39
24
02
01
24 ICR 6-1212-T..
24 ICR 6-1515-T..
28 ICR 5-05-T..
28 ICR 6-12-T..
28 ICR 6-15-T..
28 ICR 6-1212-T..
28 ICR 6-1515-T..
48 ICR 5-05-T..
48 ICR 6-12-T..
48 ICR 6-15-T..
48 ICR 6-1212-T..
48 ICR 6-1515-T..
6.2
5
12
15
±12
±15
5
12
15
±12
±15
1
2
28
18
19
20
34
36
02
01
48
12
13
14
28
30
02
See "Block Diagrams"
Pin configuration should be added to the type designation (e.g. 5 ICR 5-05-TC)
6 - 44
MELCHER
The Power Partners.
Edition 2/96 - © Melcher AG
Industrial Environment
Safety Instructions
DC-DC Converters <40 W
6 Watt-Family
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 60 V DC).
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 circuit up to a nomi-
nal output voltage of 30 V (2 x 15 V in series).
Table 2: Insulation concept for SELV circuits
Nominal
mains
supply
voltage
(AC)
≤250
V
Minimum required grade
of isolation, to be
provided by the AC-DC
front end, including mains
supplied battery charger
Basic
Maximum
output
voltage
from the
front end
≤60
V
≤65
V
Double or reinforced
≤60
V
≤65
V
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
Operational
Operational
Operational
Resulting safety
status of the
DC-DC converter
output circuit
SELV circuit
Earthed SELV
circuit
1
SELV circuit
Earthed SELV circuit
1
Unearthed hazardous
voltage secondary circuit
2
SELV circuit
Double or reinforced insu- Operational
lated unearthed hazardous
voltage secondary circuit,
supplying an SELV circuit
3
The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC 950.
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.
3
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.
2
1
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
min
max
71
95
105
Option -S
1
min
–40
–40
–55
max
85
105
105
°C
Unit
T
A
T
C
T
S
1
Ambient temperature
Case temperature
Storage temperature
U
i min
...U
i max
I
o
= 0...
I
o nom
not operational
–25
–25
–55
ICR 6: Linear derating of the output power from 6 to 5 watts for
T
A
= 71°C to 85°C.
The case temperature
T
C
must not exceed the maximum value. In applications with limited air circulation, additional meas-
ures must be taken (either larger spacing or a fan) to avoid case temperatures higher than
T
C max
!
Table 4: MTBF
Values at specified
Case Temperature
MTBF according to
MIL-HDBK-217F
Modules Types
Ground Benign
40°C
Single output
Double output
2'150'000
1'850'000
Ground Fixed
40
°C
570'000
510'000
70°C
270'000
250'000
Ground Mobile
40°C
190'000
150'000
70°C
90'000
70'000
h
Unit
Edition 2/96 - © Melcher AG
MELCHER
The Power Partners.
6 - 45
6.2
6 Watt-Family
DC-DC Converters <40 W
Industrial Environment
Electrical Input and Output Data
General Conditions:
T
A
= 25°C
Table 5: Input Data
Input
Characteristics
Conditions
min
max
min
max
min
max
typ
max
max
min
max
DC
4.40
6.50
4.50
6.00
4.65
5.50
10.56
15.60
10.80
14.40
11.16
13.20
13.20
19.50
13.50
18.00
13.95
16.50
21.12
31.20
21.60
28.80
22.32
26.40
24.64
36.40
25.20
33.60
26.04
30.80
42.24
62.40
43.20
57.60
44.64
52.80
5V
12 V
15 V
24 V
28 V
48 V
Unit
V
U
i
Input voltage range
at 60% load
Input voltage range
at 80% load
Input voltage range
at 100% load
i
i rfi
U
i abs
f
s
RFI current at
the input
Input voltage limits
without any damage
Switching frequency
U
i nom
,
I
o nom
L
source
= 1
µH
max 60 s
6.75
6.20
1%
pp
of
I
i
3%
pp
of
I
i
V
20.25
20
40
32.40
37.80
64.80
kHz
U
i nom
,
I
o nom
Table 6: Output Data
Output
Characteristics
Conditions
5V
12 V
15 V
Unit
5
12
±0.5
15
V
%
6.2
U
o
∆
U
o a
Output voltage
Output voltage accuracy max
Output current
limitation response
Short-circuit current
of the output
Output voltage noise
typ
typ
max
max
U
i nom
,
I
o nom
I
oL
I
oS
u
o
∆
U
o U
∆
U
o I
U
i nom
U
i nom
,
U
o
= 0
U
i nom
,
I
o nom
(BW = 20 MHz)
U
i min
…U
i max
I
o nom
U
i nom
I
o
= 0…I
o nom
1.25
I
o nom
1.4
I
o nom
2.0
I
o nom
1
35
±0.05
±0.1
50
20
mV
µs
%/K
mV
rms
mV
pp
%
Static line regulation
Static Load regulation
typ
typ
u
od
t
rr
α
Uo
Dynamic load regulation max
Load transient
recovery time
Temperature coefficient
typ
typ
max
U
i nom
,
I
o nom
±0.01
±0.03
Table 7: Efficiency
Efficiency
Characteristics
Conditions
min
typ
5V
12 V
15 V
Unit
68
75
%
η
Efficiency
U
i nom
,
I
o nom
6 - 46
MELCHER
The Power Partners.
Edition 2/96 - © Melcher AG
Industrial Environment
Installation Instructions
DC-DC Converters <40 W
6 Watt-Family
Isolation Tests
Input to output isolation voltage tests are performed as fac-
tory tests (100%) and should not be repeated in the field.
Melcher will not honour any guarantee/warranty claims re-
sulting from high voltage field tests.
Table 8: Isolation test voltage, coupling capacitance and
insulation resistance
Characteristics
Conditions
AC: 50 Hz,
1 minute
DC: 1 second
DC: 1 second
1
2
ICR
500
1400
700
800
70
Unit
V
rms
V
pp
V
U
is io
Isolation test voltage
Input to output
C
io
R
is
1
Coupling capacitance typ
Insulation resistance
at 100 V DC
after 1 minute
pF
MΩ
≥1000
For production test purposes in accordance with IEC 950/
EN 60950
2
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 to protect 5 V outputs
– BZW04-11 to protect 12 V outputs
– BZW04-14 to protect 15 V outputs
(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.
Exception: .. ICR 5-05 (all 5 V single output units)
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 the air.
Unit 1
+Vo
+U
o
Go
–Vo
+Vo
Unit 2
Go
–Vo
–
U
o
Fig. 1
Outputs connected in series
Block Diagrams
Push-pull
converter 20 kHz
Push-pull
converter 20 kHz
Filter
Filter
Vi
Gi
Linear
regulator
Linear
regulator
+Vo
Go
Vo
Go
Vi
Gi
Linear
regulator
–Vo
Fig. 2
ICR 5/6, group 01 (single output)
Edition 2/96 - © Melcher AG
Fig. 3
ICR 5/6, group 02 (dual output)
MELCHER
The Power Partners.
6 - 47
6.2
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