10 Watt-Family
DC-DC Converters <40 W
Rugged Environment
IBEK DC-DC Converters
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
10 Watt-Family
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
6.1
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).
6 - 30
MELCHER
The Power Partners.
Edition 2/96 - © Melcher AG
Rugged Environment
Type Survey
General Condition:
T
A
= 25°C
DC-DC Converters <40 W
10 Watt-Family
Table 1a: Type survey IPS 10
Output 1
Output 2
U
o nom
[V DC]
5
12
15
+5
+12
+15
I
o nom
[mA]
2000
833
667
1000
417
333
U
o nom
[V DC]
-
-
-
–5
–12
–15
I
o nom
[mA]
-
-
-
1000
417
333
Input Voltage Range
U
i
[V DC]
24 IPS ..
10...33
(nominal 24)
48 IPS ..
18...72
(nominal 48)
Group
1
700 V DC/500 V
rms
Isolation test voltage
Type
2
.. IPS 10-05-T..
.. IPS 10-12-T..
.. IPS 10-15-T..
.. IPS 10-0505-T..
.. IPS 10-1212-T..
.. IPS 10-1515-T..
Pin
Configuration
C, B, G, F
01
02
Table 1b: Type survey IPW 10
Output 1
Output 2
U
o nom
[V DC]
5
12
15
+5
+12
+15
I
o nom
[mA]
2000
833
667
1000
417
333
U
o nom
[V DC]
-
-
-
–5
–12
–15
I
o nom
[mA]
-
-
-
1000
417
333
Input Voltage Range
U
i
[V DC]
24 IPW ..
10...33
(nominal 24)
48 IPW ..
18...72
(nominal 48)
Group
1
1500 V DC/1060 V
rms
Isolation test voltage
Type
2
.. IPW 10-05-T..
.. IPW 10-12-T..
.. IPW 10-15-T..
.. IPW 10-0505-T..
.. IPW 10-1212-T..
.. IPW 10-1515-T..
Pin
Configuration
C, G
01
02
Table 1c: Type survey IPZ 5
Output 1
Output 2
U
o nom
[V DC]
5
12
15
+5
+12
+15
1
2
I
o nom
[mA]
1000
417
333
500
208
167
U
o nom
[V DC]
-
-
-
–5
–12
–15
I
o nom
[mA]
-
-
-
500
208
167
Input Voltage Range
U
i
[V DC]
24 IPZ ..
10...33
(nominal 24)
48 IPZ ..
18...72
(nominal 48)
Group
1
7070 V DC/5000 V
rms
Isolation test voltage
Type
2
.. IPZ 5-05-T..
.. IPZ 5-12-T..
.. IPZ 5-15-T..
.. IPZ 5-0505-T..
.. IPZ 5-1212-T..
.. IPZ 5-1515-T..
Pin
Configuration
C
01
02
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 - © Melcher AG
MELCHER
The Power Partners.
6 - 31
6.1
10 Watt-Family
Safety Instructions
DC-DC Converters <40 W
Rugged Environment
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).
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)
≤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
≤72
V
Double or reinforced
≤60
V
≤72
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
2
Earthed SELV
circuit
1 2
SELV circuit
2
Earthed SELV circuit
1
Unearthed hazardous
voltage secondary circuit
3
SELV circuit
Double or reinforced insu- Operational
lated unearthed hazardous
voltage secondary circuit,
supplying an SELV circuit
4
6.1
1
2
3
4
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 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
min
max
71
95
105
on request
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
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
Case Temperature
MTBF according to
MIL-HDBK-217F
Modules Types
Ground Benign
40°C
Single output
Double outputs
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
6 - 32
MELCHER
The Power Partners.
Edition 2/96 - © Melcher AG
Rugged Environment
Installation Instructions
DC-DC Converters <40 W
10 Watt-Family
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
AC: 50 Hz,
1 minute
DC: 1 second
2
DC: 1 second
3
IPS
500
1400
700
800
1000
at 100 V DC
after 1 minute
IPW
1
1060
3000
1500
1700
1000
≥1000
IPZ
5000
14100
7070
8000
40
pF
MΩ
Unit
V
rms
V
pp
V
U
is io
Isolation test voltage
Input to output
C
io
R
is
1
2
Coupling capacitance
Insulation resistance
typ
According to EN 41003 (1993)
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:
– 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
+Vo
+U
o
–Vo
+Vo
Unit 2
Go
–Vo
–
U
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 –0.3...+2 V is applied to the shutdown
terminal. At the open shutdown pin 10...12 V will appear.
Edition 2/96 - © Melcher AG
MELCHER
The Power Partners.
6 - 33
6.1
Go
10 Watt-Family
DC-DC Converters <40 W
Rugged Environment
Electrical Input and Output Data
General Conditions:
T
A
= 25
°C,
unless otherwise specified
Table 5a: Input Data
Input
Characteristics
Conditions
24 IPS
48 IPS
24 IPS
1
48 IPS
2
Group 01
Group 02
.. IPS/IPW 10-05 .. .. IPS/IPW 10-12 .. .. IPS/IPW 10-15 ..
min
10
18
0
0
typ
max
33
72
45
75
25
25
3
1.2
I
i
30
open circuit
–0.3...+2
-
3
145
min
10
18
0
0
25
45
3
1.2
I
i
30
open circuit
–0.3...+2
-
3
145
typ
max
33
72
45
75
min
10
18
0
0
25
45
3
1.2
I
i
30
open circuit
–0.3...+2
-
3
145
mA
pp
V DC
µA
kHz
typ
max
33
72
45
75
mA
Unit
V DC
U
i
U
i abs
Input voltage range
Input voltage
limits without
any damage
No load input
current
Input current in
shutdown condition
T
A min
...T
A max
I
o
= 0...
I
o nom
I
i o
I
i SD 3
I
i L
i
i rfi
U
SD 3
I
SD 3
U
i nom
,
I
o
= 0
U
i min
...U
i max
T
A min
...T
A max
U
i min
...U
i max
T
A min
...T
A max
I
o
= 0...
I
o nom
operating
not operating
operating
not operating
Input current limitation
response
RFI current at the input
Shutdown voltage
for converter
Shutdown current
for converter
Switching frequency
6.1
f
s
1
U
i min
...
max,
I
o nom
T
A min
...T
A max
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
Characteristics
Conditions
.. IPS/IPW 10-05 ..
min
4.95
2000
1000
50
5
100
10
typ
max
5.05
.. IPS/IPW 10-12 ..
min
11.88
833
417
120 240
12
0...50
±0.02
5.6
+10/–0 %
±0.02
13
+10/–0%
24
typ
max
12.12
.. IPS/IPW 10-15 ..
min
14.85
667
333
150
15
0...50
±0.02
16
+10/–0%
%/K
V
300
30
typ
max
15.15
Unit
V DC
mA
mV
pp
mV
U
o
I
o nom
u
o
∆
U
o U
∆
U
o I
α
Uo
Output voltage
Nominal output
current
Output voltage noise
(BW = 20 MHz)
Static line regulation
Static load regulation
Temperature coefficient
Output overvoltage clamping
Group 01
Group 02
U
i nom
,
I
o nom
U
i min
…U
i max
T
A min
...
T
A max
U
i min
...U
i max
I
o nom
U
i min
...U
i max
I
o nom
...0
U
i nom
,
I
o nom
0...50
Table 7a: Efficiency
Efficiency
Characteristics
Conditions
.. IPS/IPW 10-05 ..
min
77
77
typ
80
80
max
.. IPS/IPW 10-12 ..
min
77
77
typ
80
80
max
.. IPS/IPW 10-15 ..
min
77
77
typ
80
80
max
Unit
%
η
Efficiency
U
i nom
= 24 V
I
o nom
,
U
i nom
= 48 V
I
o nom
,
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 - © Melcher AG
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