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 Vrms
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
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 Mar king .................................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 conver ters 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
T ype 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 η (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..
1See "Block Diagrams"
2Pin 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
AAmbient temperature
U
i min...
U
i max –25 71 –40 85 °C
T
CCase temperature
I
o = 0...
I
o nom –25 95 –40 105
T
SStorage temperature not operational –55 105 –55 105
1ICR 6: Linear derating of the output po wer 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. Ho we ver , 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
1The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC 950.
2Has 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.
3Has 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
iInput 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 µH3%
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
sSwitching 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
oOutput voltage
U
i nom,
I
o nom 51215V
∆
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
oOutput voltage noise max
U
i nom,
I
o nom 1mV
rms
(BW = 20 MHz) 35 mVpp
∆
U
o U Static line regulation typ
U
i min…
U
i max ±0.05 %
I
o nom
∆
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 µs
recovery time
αUo 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
η
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 Vrms
Input to output 1 minute 1400 Vpp
DC: 1 second 1700 V
DC: 1 second 2800
C
io Coupling capacitance typ 70 pF
R
is Insulation resistance at 100 V DC ≥1000 MΩ
after 1 minute
1For production test purposes in accordance with IEC 950/
EN 60950
2Factory 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
–Vo
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.:
– 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)
Unit 1
Unit 2
+
U
o
–
U
o
+Vo
Go
–Vo
+Vo
Go
–Vo
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
ø 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
ø 1
50.8
23 ±0.5
–Vo +Vo
Bottom view
10.1
3 ±0.5
9 ±0.5
+0.0
-0.2
Output
50.8 5.1
Input
20.3
10.210.2
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
ø 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
ø1
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 24 ICR 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 = –25...71°C ....................................................T
TA = –40...85°C ....................................................S
Pin configuration ......................................................... C, B
Type Key and Product Marking
European
Projection
