48IPS3-1515-S - Power-One - Datasheet.Directory

3 Watt-Family DC-DC Converters <40 W Rugged Environment

6 - 10 Edition 2/96 - © Melcher AG

MELCHER

The Power Partners.

6.1

IBEK DC-DC Converters 3 Watt-Family

Input to output and output to output isolation

Test voltage 500 Vrms or 1 kVrms

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

•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

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).

Table of Contents Page

Description ................................................................6 - 10

Type Surve y .............................................................. 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

Rugged Environment DC-DC Converters <40 W 3 Watt-Family

Edition 2/96 - © Melcher AG 6 - 11

MELCHER

The Power Partners.

6.1

Type Survey

Gener al Condition:

A = 25°C

Table 1a: Type survey IPS 3

Output 1 Output 2 Input Voltage Group 1 700 V DC/500 Vrms Option

o nom

iIsolation test voltage

[V DC] [mA] [V DC] [mA] [V DC] Type 2

5 500 - - 01 .. IPS 3-05-T S

12 250 - - .. IPS 3-12-T

15 200 - - 24 IPS .. .. IPS 3-15-T

+5 250 –5 250 10...33 02 .. IPS 3-0505-T

+12 125 –12 125 (nominal 24) .. IPS 3-1212-T

+15 100 –15 100 .. IPS 3-1515-T

5 250 5 250 48 IPS .. 03 3 .. IPS 3-05-05-T

5 250 12 125 18...72 .. IPS 3-05-12-T

5 250 15 100 (nominal 48) .. IPS 3-05-15-T

12 125 12 125 .. IPS 3-12-12-T

15 100 15 100 .. IPS 3-15-15-T

Table 1b: Type survey CPS 3

Output 1 Output 2 Input Voltage Group 1 700 V DC/500 Vrms Option

o nom

iIsolation test voltage

[V DC] [mA] [V DC] [mA] [V DC] Type 2

5 500 - - 24 CPS .. 04 4 .. CPS 3-05-T S

12 250 - - 10...33 .. CPS 3-12-T

15 200 - - (nominal 24) .. CPS 3-15-T

+5 250 –5 250 48 CPS .. 05 4 .. CPS 3-0505-T

+12 125 –12 125 18...72 .. CPS 3-1212-T

+15 100 –15 100 (nominal 48) .. CPS 3-1515-T

Table 1c: Type survey IPW 3

Output 1 Output 2 Input Voltage Group 1 1500 V DC/1060 Vrms Option

o nom

iIsolation test voltage

[V DC] [mA] [V DC] [mA] [V DC] Type 2

5 500 - - 01 .. IPW 3-05-T S

12 250 - - .. IPW 3-12-T

15 200 - - 24 IPW .. .. IPW 3-15-T

+5 250 –5 250 10...33 02 .. IPW 3-0505-T

+12 125 –12 125 (nominal 24) .. IPW 3-1212-T

+15 100 –15 100 .. IPW 3-1515-T

5 250 5 250 48 IPW .. 03 3 .. IPW 3-05-05-T

5 250 12 125 18...72 .. IPW 3-05-12-T

5 250 15 100 (nominal 48) .. IPW 3-05-15-T

12 125 12 125 .. IPW 3-12-12-T

15 100 15 100 .. IPW 3-15-15-T

1See "Block Diagrams"

2Nominal input voltage should be added to the type designation (e.g. 24 IPS 3-05-T)

3Group 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.

4See Mechanical Data: "Alternative Pin Configuration"

Other types with different input and output specifications available upon request.

3 Watt-Family DC-DC Converters <40 W Rugged Environment

6 - 12 Edition 2/96 - © Melcher AG

MELCHER

The Power Partners.

6.1

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 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. Ho w ev er, 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 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 2

≤72 V Unearthed hazardous Operational Earthed SELV

voltage secondary circuit 3 circuit 1 2

Double or reinforced ≤60 V SELV circuit Operational SELV circuit 2

≤72 V Double or reinforced insu- Operational

lated unearthed hazardous

voltage secondary circuit,

supplying an SELV circuit 4

1The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC 950.

2The output has to be protected against overvoltages higher than 60 V by external means, e.g. an overvoltage suppressor diode.

3Has 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.

4Has 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 Option -S Unit

min max min max

AAmbient temperature

i min...

i max –25 71 –40 85 °C

CCase temperature

o = 0...

o nom –25 95 –40 105

SStorage temperature not operational –55 105 –55 105

The case temperature

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

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 Group 01 2'900'000 1'400'000 310'000 430'000 150'000 h

MIL-HDBK-217F Group 02/03 2'300'000 1'000'000 270'000 310'000 110'000

Rugged Environment DC-DC Converters <40 W 3 Watt-Family

Edition 2/96 - © Melcher AG 6 - 13

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6.1

Electrical Input and Output Data

General Conditions:

A = 25°C, unless otherwise specified

Table 5: Input Data

Input .. IPS/IPW 3-05 .. .. IPS/IPW 3-12 .. .. IPS/IPW 3-15 ..

Characteristics Conditions min typ max min typ max min typ max Unit

iInput voltage 24 IPS/IPW

A min...

A max 10 33 10 33 10 33 V DC

range 48 IPS/IPW

o = 0...

o nom 18 72 18 72 18 72

i abs Input voltage 24 IPS/IPW 1 045045045

limits without 48 IPS/IPW 2 075075075

any damage

i o No load input current

i nom = 24 V,

o = 0555mA

i nom = 48 V,

o = 0333

i SD Input current in

i min...

i max 1.3 1.3 1.3

shutdown condition

A min...

A max

i L Input current limitation

i min...

i max 1.25

i1.25

response

A min...

A max

i rfi RFI current at the input

o = 0...

o nom 30 30 30 mApp

SD Shutdown voltage operating open or 8...10 open or 8...10 open or 8...10 V DC

for converter not operating –0.3...+2 –0.3...+2 –0.3...+2

SD Shutdown current operating +1...+5 +1...+5 +1...+5 µA

for converter not operating –25...–35 –25...–35 –25...–35

sSwitching frequency

i min...max,

o nom 130 130 130 kHz

A min...

A max

135 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

2The applied minimum load must be 25% between 72.0...75.0 V DC

Table 6: Output Data

Output .. IPS/IPW 3-05 .. .. IPS/IPW 3-12 .. .. IPS/IPW 3-15 ..

Characteristics Conditions min typ max min typ max min typ max Unit

oOutput voltage

i nom,

o nom 4.90 5.10 11.76 12.24 14.70 15.30 V DC

o nom Nominal output Group 01

i min…

i max 500 250 200 mA

current Group 02/03

A min...

A max 250 125 100

oOutput voltage noise

i min...

i max 100 100 100 mVpp

(BW = 20 MHz)

o nom

∆

o U Static line regulation ±10 ±12 ±15 mV

∆

o I Static load regulation

i min...

i max 0...5 0...2 1 0...2 1 %

o nom...0.25

o nom

αUo Temperature coefficient

i nom,

o nom ±0.02 ±0.02 ±0.02 %/K

Output overvoltage clamping 5.6 +5/–0% 13 +5 /–0% 16 +5/–0% V

o ext Maximum admissible 33 15 15 µF

capacitive load

10...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 .. IPS/IPW 3-05 .. .. IPS/IPW 3-12 .. .. IPS/IPW 3-15 ..

Characteristics Conditions min typ max min typ max min typ max Unit

Efficiency

i nom = 24 V,

o nom 78 80 78 80 78 80 %

i nom = 48 V,

o nom 80 82 80 82 80 82

3 Watt-Family DC-DC Converters <40 W Rugged Environment

6 - 14 Edition 2/96 - © Melcher AG

MELCHER

The Power Partners.

6.1

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 IPS IPW 1Unit

is io Isolation test voltage AC: 50 Hz, 500 1060 Vrms

Input to output 1 minute 1400 3000 Vpp

DC: 1 second 2700 1500 V

DC: 1 second 3800 1700

is oo Isolation test voltage AC: 50 Hz, 500 1060 Vrms

output to output 4 1 minute 1400 3000 Vpp

DC: 1 second 2700 1500 V

DC: 1 second 3800 1700

io Coupling capacitance typ 300 external 5 pF

is Insulation resistance at 100 V DC ≥2000 MΩ

after 1 minute

1According to EN 41003 (1993)

2 For production test purposes in accordance with IEC 950/EN 60950

3 Factory test procedure

4Group 03

5 Important: All IPW types need (an) external coupling capacitor(s)

io of min. 220 pF, 1 kVrms

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 (Ger many)

Submersion of the units in water for rinsing is permitted.

Drying should be done in the air.

Unit 1

Unit 2

–

+Vo

–Vo

+Vo

–Vo

Fig. 1

Outputs connected in series

Shutdown Description

The shutdown terminal is used to switch the converter out-

put voltage

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...12V will

appear.

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6.1

Functional Description and Block Diagrams

These converters are primary controlled flyback converters

using Pulse With Modulation (PWM). The output v oltage is

monitored via a separate transformer winding very close to

the secondary winding(s) and fed back to the control circuit.

This is the reason why double and dual output units should

always have the same (%) load conditions at both outputs

to comply with the specified data. The current limitation is

located on the primary side, limiting the total output current.

Table 10: Alternative pin configuration

Group 1 2 3 9 11 12 14 16 20 22 23 24

04 - Gi Gi - - - Vo Go - Vi Vi -

05 - Gi Gi Go –Vo - +Vo Go - Vi Vi -

The converters of groups 04 and 05 are designated as CPS 3 types. The type variety and all specifications are the same as for the

IPS 3 group 01 and 02 with the exception of the shutdown function which is not available.

Pin Configuration

Table 9: IBEK pin configuration

Group 1 2 9 10 11 12 13 15 16 20 23 24

01 Vi Vi - - - Go Vo - - SD Gi Gi

02 Vi Vi - Go Go - –Vo +Vo - SD Gi Gi

03 Vi Vi Go1 - - Vo1 Vo2 - Go2 SD Gi Gi

Fig. 2

IPS 3, Group 01

PWM

Fig. 5

IPW 3, Group 01, external C

is required

PWM

+Vo

–Vo



Fig. 6

IPW 3, Group 02, external C

is required

Fig. 3

IPS 3, Group 02

PWM

+Vo

–Vo

PWM

2 ×

Fig. 7

IPW 3, Group 03, external 2

is required

Fig. 4

IPS 3, Group 03

PWM

SD 2 ×

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6.1

Mechanical Data

Dimensions in mm. Tolerances ±0.2 mm, unless otherwise specified. European

Projection

Fig. 8

Case: DIL 24. Foot print shown for IBEK pin configura-

tions. Hole diameter required in PCB: 0.8

0.1

Weight: 15 g

Type Key and Product Marking

Type Key: 24 IPS 3 - 12 - 12 - T

Nominal input voltage in volt .................................... 24, 48

Family ........................................................ IPS, IPW, CPS

Nominal output power in watt........................................... 3

Nominal output voltage for output 1 in volt ......... 05, 12, 15

Dash: Designates double output unit with two independent,

galvanically isolated outputs .................................. -

Nominal output voltage for output 2 in volt ......... 05, 12, 15

Operating ambient temperature range

A = –25...71°C....................................................-T

A = –40...85°C ................................................... -S

Product Marking:

Main face: Manufacturer's name (IBEK), specific type designation, input voltage range, input and output pin allocation.

Bottom: Date code.

15.24

min. 21

2.54

min. 34

ø 0.5

min. 3

10.5

mounting space

required

Fig. 9

Foot print shown for alternative pin configurations.

Hole diameter required in PCB: 0.8

0.1

mm.