industrial environment dc-dc converters <40 w 6 watt-family edition 2/96 - ? melcher ag 6 - 43 melcher
the power partners. 6.2 ibek dc-dc converters 6 watt-family 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 C40...85 c (optional) ? case height only 10.5 mm 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).
6 watt-family dc-dc converters <40 w industrial environment 6 - 44 edition 2/96 - ? melcher ag melcher
the power partners. 6.2 type survey general condition: t a = 25 c table 1: type survey output input typ. no load efficiency group 1 type 2 pin- option u o nom i o nom u i nom input current h (typ.) config . [v dc] [ma] [v dc] ( u i nom , i o = 0) [ma] [%] 5 1000 5 32 68 01 5 icr 5-05-t.. c, b s 12 500 46 72 5 icr 6-12-t.. 15 400 52 72 5 icr 6-15-t.. 12 250 125 68 02 5 icr 6-1212-t.. 15 200 150 70 5 icr 6-1515-t.. 5 1000 12 20 70 01 12 icr 5-05-t.. 12 500 25 75 12 icr 6-12-t.. 15 400 30 75 12 icr 6-15-t.. 12 250 60 72 02 12 icr 6-1212-t.. 15 200 63 73 12 icr 6-1515-t.. 5 1000 15 18 72 01 15 icr 5-05-t.. 12 500 19 75 15 icr 6-12-t.. 15 400 20 75 15 icr 6-15-t.. 5 1000 24 18 72 24 icr 5-05-t.. 12 500 19 76 24 icr 6-12-t.. 15 400 20 76 24 icr 6-15-t.. 12 250 37 74 02 24 icr 6-1212-t.. 15 200 39 75 24 icr 6-1515-t.. 5 1000 28 18 72 01 28 icr 5-05-t.. 12 500 19 76 28 icr 6-12-t.. 15 400 20 76 28 icr 6-15-t.. 12 250 34 75 02 28 icr 6-1212-t.. 15 200 36 75 28 icr 6-1515-t.. 5 1000 48 12 70 01 48 icr 5-05-t.. 12 500 13 72 48 icr 6-12-t.. 15 400 14 72 48 icr 6-15-t.. 12 250 28 73 02 48 icr 6-1212-t.. 15 200 30 73 48 icr 6-1515-t.. 1 see "block diagrams" 2 pin configuration should be added to the type designation (e.g. 5 icr 5-05-tc)
industrial environment dc-dc converters <40 w 6 watt-family edition 2/96 - ? melcher ag 6 - 45 melcher
the power partners. 6.2 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 60 v dc). 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 option -s 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 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 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 output 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 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 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 65 v unearthed hazardous operational earthed selv voltage secondary circuit 2 circuit 1 double or reinforced 60 v selv circuit operational selv circuit 65 v double or reinforced insu- operational lated unearthed hazardous voltage secondary circuit, supplying an selv circuit 3 1 the earth connection has to be provided by the installer according to the relevant safety standard, e.g. iec 950. 2 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.
6 watt-family dc-dc converters <40 w industrial environment 6 - 46 edition 2/96 - ? melcher ag melcher
the power partners. 6.2 electrical input and output data general conditions: t a = 25 c table 5: input data input 5 v 12 v 15 v 24 v 28 v 48 v characteristics conditions unit u i input voltage range min dc 4.40 10.56 13.20 21.12 24.64 42.24 v at 60% load max 6.50 15.60 19.50 31.20 36.40 62.40 input voltage range min 4.50 10.80 13.50 21.60 25.20 43.20 at 80% load max 6.00 14.40 18.00 28.80 33.60 57.60 input voltage range min 4.65 11.16 13.95 22.32 26.04 44.64 at 100% load max 5.50 13.20 16.50 26.40 30.80 52.80 i i rfi rfi current at typ u i nom , i o nom 1% pp of i i the input max l source = 1 m h3% pp of i i u i abs input voltage limits v without any damage max max 60 s 6.75 6.20 20.25 32.40 37.80 64.80 f s switching frequency min u i nom , i o nom 20 khz max 40 table 6: output data output 5 v 12 v 15 v characteristics conditions unit u o output voltage u i nom , i o nom 51215v d u o a output voltage accuracy max 0.5 % i ol output current typ u i nom 1.25 i o nom limitation response i os short-circuit current typ u i nom , u o = 0 1.4 i o nom of the output max 2.0 i o nom u o output voltage noise max u i nom , i o nom 1mv rms (bw = 20 mhz) 35 mv pp d u o u static line regulation typ u i min u i max 0.05 % i o nom d u o i static load regulation typ u i nom 0.1 u od dynamic load regulation max i o = 0 i o nom 50 mv t rr load transient typ 20 m s recovery time a uo temperature coefficient typ u i nom , i o nom 0.01 %/k max 0.03 table 7: efficiency efficiency 5 v 12 v 15 v characteristics conditions unit h efficiency min u i nom , i o nom 68 % typ 75
industrial environment dc-dc converters <40 w 6 watt-family edition 2/96 - ? melcher ag 6 - 47 melcher
the power partners. 6.2 installation instructions 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 icr unit u is io isolation test voltage ac: 50 hz, 500 v rms input to output 1 minute 1400 v pp dc: 1 second 1 700 v dc: 1 second 2 800 c io coupling capacitance typ 70 pf r is insulation resistance at 100 v dc 3 1000 m w after 1 minute 1 for production test purposes in accordance with iec 950/ en 60950 2 factory test procedure linear
regulator filter push-pull
converter 20 khz vo go vi gi fig. 2 icr 5/6, group 01 (single output) fig. 3 icr 5/6, group 02 (dual output) block diagrams linear
regulator linear
regulator filter push-pull
converter 20 khz +vo ?o vi gi go 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.: C 1n5908 to protect 5 v outputs C bzw04-11 to protect 12 v outputs C 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: C prozone from bp C zestron from dr. o. k. wack chemie gmbh (germany) unit 1 unit 2 + u o u o +vo go ?o +vo go ?o submersion of the units in water for rinsing is permitted. drying should be done in the air. fig. 1 outputs connected in series
6 watt-family dc-dc converters <40 w industrial environment 6 - 48 edition 2/96 - ? melcher ag melcher
the power partners. 6.2 mechanical data dimensions in mm. tolerances 0.2 mm, unless otherwise specified. 10.5 min. 5 ?1 50.8 23 0.5 20.3 15.3 0.5 go vo bottom view 10.1 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 ?o +vo bottom view 10.1 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 15.3 0.5 fig. 4 single output, pin configuration c fig. 5 double output, pin configuration c bottom view 10.5 min. 5 ?1 10.1 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 ? 10.1 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. 6 single output, pin configuration b fig. 7 double output, pin configuration b product marking: main face: manufacturer's name (ibek), specific type designation, input and output pin allocation. bottom: date code. type key 2 4 i cr 6 - 12 12 - t c nominal input voltage in volt .............. 5, 12, 15, 24, 28, 48 family ........................................................................... icr nominal output power in watt ....................................... 5, 6 nominal output voltage for output 1 in volt ......... 05, 12, 15 nominal output voltage for output 2 in volt ............... 12, 15 ambient temperature range ta = C25...71 c .................................................... t ta = C40...85 c .................................................... s pin configuration ......................................................... c, b type key and product marking european
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