1 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:
ICR 1, IXR 1, IYR 1, IZR 1
1, 2 or 4 Outputs: IWR 1
•
Extremely high isolation test voltages
•
Efficient Pi input filter
•
Aluminium solid electrolytic capacitors
(OS-CON)
•
Outputs equipped with linear voltage regulators
•
High reliability
•
Optimal dynamic response
•
Operating ambient temperature range up to
–40...85
°C
(optional)
•
Case height only 10.5 mm
1 Watt-Family
Table of Contents
6.1
Page
Description .................................................................. 6 - 2
Type Survey ................................................................ 6 - 3
Safety Instructions ....................................................... 6 - 4
Immunity to Environmental Conditions ........................ 6 - 4
Electrical Input and Output Data ................................. 6 - 5
Installation Instructions ................................................ 6 - 6
Block Diagrams ........................................................... 6 - 7
Mechanical Data ......................................................... 6 - 8
Type Key and Product Marking ................................... 6 - 9
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
small loads on PCBs and for realising redundant systems.
Five input to output isolation test voltage categories and
three temperature ranges are available. The DC-DC con-
verters feature low output ripple, low module height, high
quality and reliability. To minimize feedback effects in the
supply system, the modules are equipped with an efficient
low-pass Pi input filter.
All modules are manufactured according to ISO 9001.
Case: DIL 24 package, grey colored plastic material, self
cooling (free air convection).
6-2
MELCHER
The Power Partners.
Edition 2/96 - © Melcher AG
Rugged Environment
Type Survey
General Condition:
T
A
= 25°C
DC-DC Converters <40 W
1 Watt-Family
Table 1a: Type survey ICR 1 and IWR 1
Output 1
Output 2
Input Voltage
1
Group
2
U
o nom
I
o nom
U
o nom
I
o nom
U
i
[V DC] [mA] [V DC] [mA]
[V DC]
5
12
15
±5
±12
±15
5
5
5
12
15
±5
±12
±15
200
80
66
±50
±40
±33
100
100
100
40
33
±50
±20
±17
-
-
-
-
-
-
5
12
15
12
15
±5
±12
±15
-
-
-
-
-
-
100
40
33
40
33
±50
±20
±17
5 (±5%)
or
12 (±10%)
or
15 (±10%)
or
24 (±10%)
or
28 (±10%)
or
48 (±10%)
5
06
700 V DC/500 V
rms
I
solation test voltage
Type
1
.. ICR 1-05-N
.. ICR 1-12-N
.. ICR 1-15-N
-
.. ICR 1-1212-N
3 4
.. ICR 1-1515-N
3 4
-
-
-
.. ICR 1-12-12-N
3 4
.. ICR 1-15-15-N
3 4
-
-
-
Group
2
1500 V DC/1060 V
rms
I
solation test voltage
Type
1
01
.. IWR 1-05-N
.. IWR 1-12-N
.. IWR 1-15-N
.. IWR 1-0505-N
.. IWR 1-1212-N
3 4
.. IWR 1-1515-N
3 4
.. IWR 1-05-05-N
.. IWR 1-05-12-N
.. IWR 1-05-15-N
.. IWR 1-12-12-N
.. IWR 1-15-15-N
Option
T, S
-
07
-
-
-
08
-
-
-
02
03
34
34
05
.. IWR 1-2×0505-N
.. IWR 1-2×1212-N
3 4
.. IWR 1-2×1515-N
3 4
T
Table 1b: Type survey IXR 1 and IYR 1
Output 1
Output 2
Input Voltage
1
Group
2
U
o nom
I
o nom
U
o nom
I
o nom
U
i
[V DC] [mA] [V DC] [mA]
[V DC]
5
12
15
±5
±12
±15
5
5
5
12
15
200
80
66
±50
±40
±33
100
100
100
40
33
-
-
-
-
-
-
5
12
15
12
15
-
-
-
-
-
-
100
40
33
40
33
5 (±5%)
or
12 (±10%)
or
15 (±10%)
or
24 (±10%)
or
28 (±10%)
or
48 (±10%)
5
11
3530 V DC/2500 V
rms
I
solation test voltage
Type
1
.. IXR 1-05-N
.. IXR 1-12-N
.. IXR 1-15-N
.. IXR 1-0505-N
.. IXR 1-1212-N
.. IXR 1-1515-N
34
34
Group
2
5300 V DC/3750 V
rms
I
solation test voltage
Type
1
11
.. IYR 1-05-N
.. IYR 1-12-N
.. IYR 1-15-N
.. IYR 1-0505-N
.. IYR 1-1212-N
3 4
.. IYR 1-1515-N
3 4
.. IYR 1-05-05-N
.. IYR 1-05-12-N
.. IYR 1-05-15-N
.. IYR 1-12-12-N
3 4
.. IYR 1-15-15-N
3 4
T, S
12
12
13
13
.. IXR 1-05-05-N
.. IXR 1-05-12-N
.. IXR 1-05-15-N
.. IXR 1-12-12-N
3 4
.. IXR 1-15-15-N
3 4
Table 1c: Type survey IZR 1
Output 1
Output 2
Input Voltage
1
Group
2
U
o nom
I
o nom
U
o nom
I
o nom
U
i
[V DC] [mA] [V DC] [mA]
[V DC]
5
12
15
±5
±12
±15
5
5
5
12
15
1
2
7070 V DC/5000 V
rms
I
solation test voltage
Type
1
.. IZR 1-05-N
.. IZR 1-12-N
.. IZR 1-15-N
.. IZR 1-0505-N
.. IZR 1-1212-N
3 4
.. IZR 1-1515-N
3 4
.. IZR 1-05-05-N
.. IZR 1-05-12-N
.. IZR 1-05-15-N
.. IZR 1-12-12-N
3 4
.. IZR 1-15-15-N
3 4
Option
200
80
66
±50
±40
±33
100
100
100
40
33
-
-
-
-
-
-
5
12
15
12
15
-
-
-
-
-
-
100
40
33
40
33
5 (±5%)
or
12 (±10%)
or
15 (±10%)
or
24 (±10%)
or
28 (±10%)
or
48 (±10%)
5
11
T, S
12
13
The required input voltage value (e.g. 24 V) should be added to the type designation: .. ICR 1-1212-N changes to 24 ICR 1-1212-N
See Block Diagrams
3
The output current of one output may be increased by 25% if the output current of the other output is reduced by 25% simultaneously.
Example for a 5 IWR 1-1515-N: The +15 V output current of 33 mA may be increased to 41 mA if the –15 V output current is reduced
to 25 mA.
4
The output current of both outputs of the 12, 24, 28 and 48 V input types may be increased by 20% of
I
3
o nom
. Note is applicable at
the same time. Example for a 24 IWR 1-2×1212-N:
I
o1
= +29 mA/–19 mA,
I
o2
= +19 mA/–29 mA or
I
o1
=
±19
mA,
I
o2
=
±29
mA
5
Only standard temperature range N or option T available
Edition 2/96 - © Melcher AG
MELCHER
The Power Partners.
6-3
6.1
Option
1 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 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
Double or reinforced
1
Maximum
output
voltage
from the
front end
≤60
V
≤60
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
Resulting safety
status of the
DC-DC converter
output circuit
SELV circuit
SELV circuit
Earthed SELV circuit
1
SELV circuit
The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC 950.
Immunity to Environmental Conditions
6.1
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 -N
min
max
71
91
Option -T
min
–25
–25
–55
max
71
91
105
Option -S
min
–40
–40
max
85
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
0
0
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 and dual outputs
7'400'000
5'700'000
Ground Fixed
40°C
3'200'000
2'500'000
70
°C
260'000
200'000
Ground Mobile
40°C
880'000
670'000
70°C
60'000
45'000
h
Unit
6-4
MELCHER
The Power Partners.
Edition 2/96 - © Melcher AG
Rugged Environment
DC-DC Converters <40 W
1 Watt-Family
Electrical Input and Output Data
General Condition:
T
A
= 25°C
Table 5: Input Data
Input
Characteristics
Conditions
min
nom
max
typ
max
typ
typ
min
max
typ
0
6.25
0
15
0
18.75
DC
4.75
5
5.25
85
110
50
10.8
12
13.2
35
45
80
13.5
15
16.5
30
40
85
21.6
24
26.4
15
23
100
10
0
30
25
0
35
0
60
25.2
28
30.8
17
20
130
43.2
48
52.8
8
12
200
5V
12 V
15 V
24 V
28 V
48 V
Unit
V
U
i
Input voltage range
I
i o
u
i rfi
i
i rfi
U
i abs
f
s
No load input input
current
RFI voltage at
the input
RFI current at
the input
Input voltage limits
without any damage
Switching frequency
U
i nom
,
I
o
= 0
U
i nom
,
I
o nom
L
source
≈
1
µH
mA
mV
pp
mA
pp
V
kHz
max 60 s
U
i nom
,
I
o nom
Table 6: Output Data
Output
Characteristics
Conditions
5V
12 V
15 V
Unit
5
±1
±3
at
U
i
=
typ
∆
U
o U
∆
U
o I
α
Uo
Static line regulation
Static load regulation
Temperature coefficient
Maximum admissible
capacitive load
typ
typ
(BW = 20 MHz)
5
25
±0.3
±0.8
12
35
15
40
±0.2
±0.1
±0.02
22
10
10
12
±2
±5
24
45
28
50
±0.2
±0.1
%/K
µF
15
±2
±5
48
55
V
%
V
mV
pp
%
U
o
∆
U
o a
Output voltage
Output voltage
accuracy
Output ripple,
u
o
= f (U
i
)
typ
max
U
i nom
,
I
o nom
u
o
U
i min
…U
i max
I
o nom
U
i nom
I
o
= 0…I
o nom
U
i nom
,
I
o nom
C
o ext
Table 7: Efficiency
Efficiency
Characteristics
Conditions
min
typ
5V
12 V
15 V
Unit
50
58
%
η
Efficiency
U
i nom
,
I
o nom
Edition 2/96 - © Melcher AG
MELCHER
The Power Partners.
6-5
6.1
1 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, insulation resistance, clearance and creepage distances
Characteristics
Conditions
AC: 50 Hz,
1 minute
DC: 1 second
2
DC: 1 second
3
ICR
500
1400
700
800
500
1400
700
800
20
at 100 V DC
after 1 minute
≥0.6
≥1
IWR
1
1060
3000
1500
1700
1060
3000
1500
1700
10
IXR
2500
7070
3530
4000
1060
3000
1500
1700
10
≥1000
≥3
5
≥3
5
≥3
5
IYR
3750
10600
5300
6000
1060
3000
1500
1700
10
IZR
5000
14100
7070
8000
1060
3000
1500
1700
10
pF
MΩ
mm
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
d
io
Coupling capacitance
Insulation resistance
Clearance and creepage
distances input to output
typ
6.1
1
2
3
4
5
According to EN 41003 (1993)
For production test purposes in accordance with IEC 950/EN 60950
Factory test procedure
Groups 03, 05, 08 and 13
In combination with the high isolation strength of the potting compound, isolation test voltages mentioned are guaranteed.
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.
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
6-6
MELCHER
The Power Partners.
Edition 2/96 - © Melcher AG
Electronics Design Contest
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