Industrial Environment DC-DC Converters <40 W IBEK DC-DC Converters 6 Watt-Family 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...85C (optional) * Case height only 10.5 mm Table of Contents Page 6.2 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 response to the increasing need for decentralised power supply systems. They are especially suitable for powering medium 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 Edition 2/96 - (c) Melcher AG minimise 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: 2"x 2" metal, black anodized, self cooling (free air convection). MELCHER The Power Partners. 6 - 43 6 Watt-Family DC-DC Converters <40 W Industrial Environment Type Survey General Condition: TA = 25 C Table 1: Type survey Output Io nom [mA] 5 12 15 1000 500 400 12 15 250 200 5 12 15 1000 500 400 12 15 250 200 5 12 15 1000 500 400 5 12 15 1000 500 400 12 15 250 200 5 12 15 1000 500 400 12 15 250 200 5 12 15 1000 500 400 12 15 250 200 6.2 Uo nom [V DC] 1 2 Input Ui nom [V DC] Typ. no load Input Current ( Ui nom , I o = 0) [mA] Efficiency (typ.) [%] Group 1 5 32 46 52 68 72 72 01 5 ICR 5-05-T.. 5 ICR 6-12-T.. 5 ICR 6-15-T.. 125 150 68 70 02 5 ICR 6-1212-T.. 5 ICR 6-1515-T.. 20 25 30 70 75 75 01 12 ICR 5-05-T.. 12 ICR 6-12-T.. 12 ICR 6-15-T.. 60 63 72 73 02 12 ICR 6-1212-T.. 12 ICR 6-1515-T.. 15 18 19 20 72 75 75 01 15 ICR 5-05-T.. 15 ICR 6-12-T.. 15 ICR 6-15-T.. 24 18 19 20 72 76 76 37 39 74 75 02 24 ICR 6-1212-T.. 24 ICR 6-1515-T.. 18 19 20 72 76 76 01 28 ICR 5-05-T.. 28 ICR 6-12-T.. 28 ICR 6-15-T.. 34 36 75 75 02 28 ICR 6-1212-T.. 28 ICR 6-1515-T.. 12 13 14 70 72 72 01 48 ICR 5-05-T.. 48 ICR 6-12-T.. 48 ICR 6-15-T.. 28 30 73 73 02 48 ICR 6-1212-T.. 48 ICR 6-1515-T.. 12 28 48 Type 2 PinConfig. Option C, B S 24 ICR 5-05-T.. 24 ICR 6-12-T.. 24 ICR 6-15-T.. See "Block Diagrams" Pin configuration should be added to the type designation (e.g. 5 ICR 5-05-TC) 6 - 44 MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Industrial Environment DC-DC Converters <40 W 6 Watt-Family Safety Instructions If the output circuit of a DC-DC converter is operator-accessible 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 insulation, 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). 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 nominal output voltage of 30 V (2 x 15 V in series). Table 2: Insulation concept for SELV circuits Nominal mains supply voltage (AC) Minimum required grade of isolation, to be provided by the AC-DC front end, including mains supplied battery charger 250 V Basic Double or reinforced Maximum output voltage from the front end 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 Resulting safety status of the DC-DC converter output circuit 60 V Earthed SELV circuit 1 Operational SELV circuit 65 V Unearthed hazardous voltage secondary circuit 2 Operational Earthed SELV circuit 1 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 The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC 950. 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 input 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 1 Conditions Option -S 1 Standard -T TA Ambient temperature TC Case temperature Ui min...Ui max I o = 0... Io nom TS Storage temperature not operational Unit min max min max -25 71 -40 85 -25 95 -40 105 -55 105 -55 105 C ICR 6: Linear derating of the output power from 6 to 5 watts for TA = 71C to 85C. The case temperature TC must 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 TC max! Table 4: MTBF Values at specified Case Temperature Modules Types 40C 40 C 70C 40C 70C MTBF according to MIL-HDBK-217F Single output 2'150'000 570'000 270'000 190'000 90'000 Double output 1'850'000 510'000 250'000 150'000 70'000 Edition 2/96 - (c) Melcher AG Ground Benign Ground Fixed MELCHER The Power Partners. Ground Mobile Unit h 6 - 45 6.2 1 2 6 Watt-Family DC-DC Converters <40 W Industrial Environment Electrical Input and Output Data General Conditions: TA = 25C Table 5: Input Data Input Characteristics Ui 5V 12 V 15 V 24 V 28 V 48 V 4.40 6.50 10.56 15.60 13.20 19.50 21.12 31.20 24.64 36.40 42.24 62.40 Conditions min max Input voltage range at 80% load min max 4.50 6.00 10.80 14.40 13.50 18.00 21.60 28.80 25.20 33.60 43.20 57.60 Input voltage range at 100% load min max 4.65 5.50 11.16 13.20 13.95 16.50 22.32 26.40 26.04 30.80 44.64 52.80 ii rfi RFI current at the input typ max Ui nom, I o nom Lsource = 1 H Ui abs Input voltage limits without any damage max max 60 s 37.80 64.80 min max Ui nom, I o nom fs Switching frequency DC Unit Input voltage range at 60% load V 1% pp of Ii 3% pp of Ii V 6.75 6.20 20.25 32.40 20 40 kHz Table 6: Output Data 6.2 Output Characteristics Conditions Uo Output voltage Ui nom, I o nom U o a Output voltage accuracy max I oL Output current limitation response typ I oS Short-circuit current of the output typ max Ui nom, Uo = 0 uo Output voltage noise max Ui nom, I o nom (BW = 20 MHz) 5V 12 V 15 V 5 12 15 Unit 0.5 Ui nom % 1.25 Io nom 1.4 I o nom 2.0 I o nom 1 mVrms 35 mVpp % U o U Static line regulation typ Ui min...Ui max I o nom 0.05 U o I Static Load regulation typ Dynamic load regulation max Ui nom I o = 0...I o nom 0.1 uod t rr Load transient recovery time Uo Temperature coefficient typ typ max V Ui nom, I o nom 50 mV 20 s 0.01 0.03 %/K Table 7: Efficiency Efficiency 5V Characteristics 6 - 46 Efficiency 12 V Conditions min typ 15 V Unit Ui nom, I o nom 68 75 MELCHER The Power Partners. % Edition 2/96 - (c) Melcher AG Industrial Environment DC-DC Converters <40 W 6 Watt-Family Installation Instructions 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 ICR Unit Uis io Isolation test voltage Input to output AC: 50 Hz, 1 minute 500 Vrms 1400 Vpp DC: 1 second 1 700 V DC: 1 second 2 800 Cio Coupling capacitance typ Ris Insulation resistance at 100 V DC after 1 minute 70 pF 1000 M 1 For production test purposes in accordance with IEC 950/ EN 60950 2 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 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. +Vo Unit 1 +Uo 6.2 Go -Vo +Vo Unit 2 Go -Vo - Uo Fig. 1 Outputs connected in series 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) Submersion of the units in water for rinsing is permitted. Drying should be done in the air. Fig. 2 ICR 5/6, group 01 (single output) Edition 2/96 - (c) Melcher AG Vo Go Vi Gi Push-pull converter 20 kHz Linear regulator Filter Push-pull converter 20 kHz Vi Gi Filter Block Diagrams Linear regulator +Vo Go Linear regulator -Vo Fig. 3 ICR 5/6, group 02 (dual output) MELCHER The Power Partners. 6 - 47 6 Watt-Family DC-DC Converters <40 W Industrial Environment Mechanical Data Dimensions in mm. Tolerances 0.2 mm, unless otherwise specified. 50.8 3 0.5 Vo Output 10.1 15.3 0.5 15.3 0.5 C Output 10.1 20.3 15.3 0.5 15.3 0.5 10.210.2 Bottom view Fig. 4 Single output, pin configuration C Fig. 5 Double output, pin configuration C 50.8 +0.0 10.5 -0.2 4.5 0.5 50.8 +0.0 10.5 -0.2 4.5 0.5 min. 5 42 Vi B Output Go 10.1 3.9 0.5 3.9 0.5 Vo 43.2 43.2 Gi 50.8 43.2 50.8 Input 9 0.5 3 0.5 o1 o1 42 Gi 9 0.5 3 0.5 6.2 Gi Vi -Vo Go +Vo Bottom view min. 5 5.1 Input 9 0.5 20.3 50.8 9 0.5 3 0.5 Gi Vi Go 23 0.5 10.5 -0.2 20.3 o1 Input C 50.8 +0.0 min. 5 5.1 50.8 23 0.5 o1 +0.0 10.5 -0.2 min. 5 European Projection B -Vo 10.1 Vi Input 3.9 0.5 3.9 0.5 Output Go 21.6 Bottom view +Vo 21.6 Bottom view Fig. 6 Single output, pin configuration B Fig. 7 Double output, pin configuration B Type Key and Product Marking Type Key 24 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 = -25...71C .................................................... T TA = -40...85C .................................................... S Pin configuration ......................................................... C, B Product Marking: Main face: Manufacturer's name (IBEK), specific type designation, input and output pin allocation. Bottom: 6 - 48 Date code. MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG