3 Watt-Family
DC-DC Converters <40 W
Rugged Environment
IBEK DC-DC Converters
Input to output and output to output isolation
Test voltage 500 V
rms
or 1 kV
rms
Single, double and dual outputs
Input voltage ranges: 10...33 V DC and 18...72 V DC
•
Wide input voltage ranges of up to 1: 4
•
•
•
•
Efficient current compensated input filter
SD-shutdown input
High efficiency (typ. 80 %)
High reliability
3 Watt-Family
•
No-load and short-circuit proof
•
Operating ambient temperature range up to
–40...85
°C
(optional)
•
No derating
•
DIL 24 package size, height only 10.5 mm
Table of Contents
6.1
Page
Description ................................................................ 6 - 10
Type Survey .............................................................. 6 - 11
Safety Instructions ..................................................... 6 - 12
Immunity to Environmental Conditions ...................... 6 - 12
Electrical Input and Output Data ............................... 6 - 13
Installation Instructions .............................................. 6 - 14
Functional Description and Block Diagrams ............. 6 - 15
Mechanical Data ....................................................... 6 - 16
Type Key and Product Marking ................................. 6 - 16
Description
This series of DC-DC converters has been developed for
powering electronic circuits, e.g. telephone system compo-
nents, control modules and small appliances. They are also
suitable for applications with variable input voltages or with
input transients. The converters feature high efficiency,
high reliability, and good dynamic response to load
changes and at start-up. Efficiency is high and practically
constant over the entire input voltage range. Two input to
output isolation test voltage categories and two tempera-
ture ranges are available.
All modules are manufactured according to ISO 9001.
Case: DIL 24 package, grey coloured plastics, self cooling
(free air convection).
6 - 10
MELCHER
The Power Partners.
Edition 2/96 - © Melcher AG
Rugged Environment
Type Survey
General Condition:
T
A
= 25
°C
DC-DC Converters <40 W
3 Watt-Family
Table 1a: Type survey IPS 3
Output 1
Output 2
U
o nom
[V DC]
5
12
15
+5
+12
+15
5
5
5
12
15
I
o nom
[mA]
500
250
200
250
125
100
250
250
250
125
100
U
o nom
[V DC]
-
-
-
–5
–12
–15
5
12
15
12
15
I
o nom
[mA]
-
-
-
250
125
100
250
125
100
125
100
Input Voltage
U
i
[V DC]
Group
1
700 V DC/500 V
rms
Isolation test voltage
Type
2
.. IPS 3-05-T
.. IPS 3-12-T
.. IPS 3-15-T
.. IPS 3-0505-T
.. IPS 3-1212-T
.. IPS 3-1515-T
.. IPS 3-05-05-T
.. IPS 3-05-12-T
.. IPS 3-05-15-T
.. IPS 3-12-12-T
.. IPS 3-15-15-T
Option
01
24 IPS ..
10...33
(nominal 24)
S
02
48 IPS ..
18...72
(nominal 48)
03
3
Table 1b: Type survey CPS 3
Output 1
Output 2
U
o nom
[V DC]
5
12
15
+5
+12
+15
I
o nom
[mA]
500
250
200
250
125
100
U
o nom
[V DC]
-
-
-
–5
–12
–15
I
o nom
[mA]
-
-
-
250
125
100
Input Voltage
U
i
[V DC]
24 CPS ..
10...33
(nominal 24)
48 CPS ..
18...72
(nominal 48)
Group
1
700 V DC/500 V
rms
Isolation test voltage
Type
2
.. CPS 3-05-T
.. CPS 3-12-T
.. CPS 3-15-T
.. CPS 3-0505-T
.. CPS 3-1212-T
.. CPS 3-1515-T
Option
04
4
S
05
4
Table 1c: Type survey IPW 3
Output 1
Output 2
U
o nom
[V DC]
5
12
15
+5
+12
+15
5
5
5
12
15
1
2
I
o nom
[mA]
500
250
200
250
125
100
250
250
250
125
100
U
o nom
[V DC]
-
-
-
–5
–12
–15
5
12
15
12
15
I
o nom
[mA]
-
-
-
250
125
100
250
125
100
125
100
Input Voltage
U
i
[V DC]
Group
1
1500 V DC/1060 V
rms
Isolation test voltage
Type
2
.. IPW 3-05-T
.. IPW 3-12-T
.. IPW 3-15-T
.. IPW 3-0505-T
.. IPW 3-1212-T
.. IPW 3-1515-T
.. IPW 3-05-05-T
.. IPW 3-05-12-T
.. IPW 3-05-15-T
.. IPW 3-12-12-T
.. IPW 3-15-15-T
Option
01
24 IPW ..
10...33
(nominal 24)
S
02
48 IPW ..
18...72
(nominal 48)
03
3
See "Block Diagrams"
Nominal input voltage should be added to the type designation (e.g. 24 IPS 3-05-T)
3
Group 03 features two independent galvanically isolated outputs. For each unit, the output to output isolation test voltage is identical
to that for input to output isolation.
4
See Mechanical Data: "Alternative Pin Configuration"
Other types with different input and output specifications available upon request.
Edition 2/96 - © Melcher AG
MELCHER
The Power Partners.
6 - 11
6.1
3 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
Option -S
min
–40
–40
–55
max
85
105
105
°C
Unit
T
A
T
C
T
S
Ambient temperature
Case temperature
Storage temperature
U
i min
...
U
i max
I
o
= 0...I
o nom
not operational
–25
–25
–55
The case temperature
T
C
should not exceed the maximum value. In applications with limited air circulation, additional
measures should 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
Group 01
Group 02/03
2'900'000
2'300'000
Ground Fixed
40°C
70°C
Ground Mobile
40°C
430'000
310'000
70
°C
150'000
110'000
h
Unit
1'400'000 310'000
1'000'000 270'000
6 - 12
MELCHER
The Power Partners.
Edition 2/96 - © Melcher AG
Rugged Environment
DC-DC Converters <40 W
3 Watt-Family
Electrical Input and Output Data
General Conditions:
T
A
= 25°C, unless otherwise specified
Table 5: Input Data
Input
Characteristics
Conditions
24 IPS/IPW
48 IPS/IPW
24 IPS/IPW
1
48 IPS/IPW
2
.. IPS/IPW 3-05 ..
min
10
18
0
0
typ
max
33
72
45
75
5
3
1.3
1.25
I
i
30
open or 8...10
–0.3...+2
+1...+5
–25...–35
130
.. IPS/IPW 3-12 ..
min
10
18
0
0
5
3
1.3
1.25
I
i
30
open or 8...10
–0.3...+2
+1...+5
–25...–35
130
typ
max
33
72
45
75
.. IPS/IPW 3-15 ..
min
10
18
0
0
5
3
1.3
1.25
I
i
30
open or 8...10
–0.3...+2
+1...+5
–25...–35
130
mA
pp
V DC
µA
typ
max
33
72
45
75
mA
Unit
V DC
U
i
U
i abs
Input voltage
range
Input voltage
limits without
any damage
T
A min
...T
A max
I
o
= 0...I
o nom
I
i o
I
i SD
I
i L
i
i rfi
U
SD
I
SD
f
s
1
2
No load input current
Input current in
shutdown condition
Input current limitation
response
RFI current at the input
Shutdown voltage
for converter
Shutdown current
for converter
Switching frequency
U
i nom
= 24 V,
I
o
= 0
U
i nom
= 48 V,
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
U
i min
...
max,
I
o nom
T
A min
...T
A max
35 V DC 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 25% between 72.0...75.0 V DC
Table 6: Output Data
Output
Characteristics
Conditions
.. IPS/IPW 3-05 ..
min
4.90
500
250
100
±10
typ
max
5.10
.. IPS/IPW 3-12 ..
min
11.76
250
125
100
±12
0...2
1
±0.02
13
+5/–0 %
15
typ
max
12.24
.. IPS/IPW 3-15 ..
min
14.70
200
100
100
±15
0...2
1
±0.02
16
+5 /–0%
15
typ
max
15.30
Unit
V DC
mA
mV
pp
mV
%
%/K
V
µF
U
o
I
o nom
u
o
∆
U
o U
∆
U
o I
α
Uo
Output voltage
Nominal output
current
Group 01
Group 02/03
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
Output voltage noise
(BW = 20 MHz)
Static line regulation
Static load regulation
Temperature coefficient
Output overvoltage clamping
U
i min
...
U
i max
I
o nom
...0.25
I
o nom
U
i nom
,
I
o nom
0...5
±0.02
5.6
+5/–0%
33
C
o ext
1
Maximum admissible
capacitive load
0...5% for the galvanically isolated second output of the types ..05-12.. and ..05-15..
Double and dual output units should have the same (%) load conditions at both outputs to comply with above specifications
Table 7: Efficiency
Efficiency
Characteristics
Conditions
.. IPS/IPW 3-05 ..
min
78
80
typ
80
82
max
.. IPS/IPW 3-12 ..
min
78
80
typ
80
82
max
.. IPS/IPW 3-15 ..
min
78
80
typ
80
82
max
Unit
%
η
Efficiency
U
i nom
= 24 V
I
o nom
,
U
i nom
= 48 V
I
o nom
,
Edition 2/96 - © Melcher AG
MELCHER
The Power Partners.
6 - 13
6.1
kHz
3 Watt-Family
Installation Instructions
DC-DC Converters <40 W
Rugged Environment
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
Characteristics
Conditions
AC: 50 Hz,
1 minute
DC: 1 second
2
DC: 1 second
3
IPS
500
1400
700
800
500
1400
700
800
300
at 100 V DC
after 1 minute
≥2000
IPW
1
1060
3000
1500
1700
1060
3000
1500
1700
external
5
pF
MΩ
V
rms
V
pp
V
Unit
V
rms
V
pp
V
U
is io
Isolation test voltage
Input to output
U
is oo
Isolation test voltage
output to output
4
AC: 50 Hz,
1 minute
DC: 1 second
2
DC: 1 second
3
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
4
Group 03
5
Important: All IPW types need (an) external coupling capacitor(s)
C
of min. 220 pF, 1 kV
io
rms
6.1
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 the air.
Unit 1
+Vo
+U
o
Go
–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 via a control signal (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 or +8...+10 V. 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.
6 - 14
MELCHER
The Power Partners.
Edition 2/96 - © Melcher AG
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