3 Watt-Family DC-DC Converters <40 W IBEK DC-DC Converters Rugged Environment 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 6.1 Table of Contents Page Description ................................................................ 6 - 10 Type Survey .............................................................. 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 Description This series of DC-DC converters has been developed for powering electronic circuits, e.g. telephone system components, 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 6 - 10 constant over the entire input voltage range. Two input to output isolation test voltage categories and two temperature ranges are available. All modules are manufactured according to ISO 9001. Case: DIL 24 package, grey coloured plastics, self cooling (free air convection). MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Rugged Environment DC-DC Converters <40 W 3 Watt-Family Type Survey General Condition: TA = 25 C Table 1a: Type survey IPS 3 Output 1 Uo nom I o nom [V DC] [mA] Output 2 Uo nom Io nom [V DC] [mA] 5 12 15 500 250 200 - - +5 +12 +15 250 125 100 -5 -12 -15 250 125 100 5 5 5 12 15 250 250 250 125 100 5 12 15 12 15 250 125 100 125 100 Input Voltage Ui [V DC] Group 1 700 V DC/500 Vrms Isolation test voltage Type 2 01 .. IPS 3-05-T .. IPS 3-12-T .. IPS 3-15-T 02 .. IPS 3-0505-T .. IPS 3-1212-T .. IPS 3-1515-T 48 IPS .. 18...72 (nominal 48) 03 3 .. IPS 3-05-05-T .. IPS 3-05-12-T .. IPS 3-05-15-T .. IPS 3-12-12-T .. IPS 3-15-15-T Input Voltage Ui [V DC] Group 1 24 IPS .. 10...33 (nominal 24) Option S Table 1b: Type survey CPS 3 Output 2 Uo nom Io nom [V DC] [mA] 700 V DC/500 Vrms Isolation test voltage Type 2 5 12 15 500 250 200 - - 24 CPS .. 10...33 (nominal 24) 04 4 .. CPS 3-05-T .. CPS 3-12-T .. CPS 3-15-T +5 +12 +15 250 125 100 -5 -12 -15 250 125 100 48 CPS .. 18...72 (nominal 48) 05 4 .. CPS 3-0505-T .. CPS 3-1212-T .. CPS 3-1515-T Input Voltage Ui [V DC] Group 1 Option S Table 1c: Type survey IPW 3 Output 1 Uo nom I o nom [V DC] [mA] Output 2 Uo nom Io nom [V DC] [mA] 5 12 15 500 250 200 - - +5 +12 +15 250 125 100 -5 -12 -15 250 125 100 5 5 5 12 15 250 250 250 125 100 5 12 15 12 15 250 125 100 125 100 24 IPW .. 10...33 (nominal 24) 48 IPW .. 18...72 (nominal 48) 1500 V DC/1060 Vrms Isolation test voltage Type 2 01 .. IPW 3-05-T .. IPW 3-12-T .. IPW 3-15-T 02 .. IPW 3-0505-T .. IPW 3-1212-T .. IPW 3-1515-T 03 3 .. IPW 3-05-05-T .. IPW 3-05-12-T .. IPW 3-05-15-T .. IPW 3-12-12-T .. IPW 3-15-15-T Option S 1 See "Block Diagrams" Nominal input voltage should be added to the type designation (e.g. 24 IPS 3-05-T) 3 Group 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. 4 See Mechanical Data: "Alternative Pin Configuration" 2 Other types with different input and output specifications available upon request. Edition 2/96 - (c) Melcher AG MELCHER The Power Partners. 6 - 11 6.1 Output 1 Uo nom I o nom [V DC] [mA] 3 Watt-Family DC-DC Converters <40 W Rugged Environment 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 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. 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 6.1 Double or reinforced 1 2 3 4 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 2 72 V Unearthed hazardous voltage secondary circuit 3 Operational Earthed SELV circuit 1 2 60 V SELV circuit Operational SELV circuit 72 V Double or reinforced insu- Operational lated unearthed hazardous voltage secondary circuit, supplying an SELV circuit 4 2 The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC 950. The output has to be protected against overvoltages higher than 60 V by external means, e.g. an overvoltage suppressor diode. 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. 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 Conditions Standard -T Option -S Unit min max min max TA Ambient temperature -25 71 -40 85 TC Case temperature Ui min... Ui max I o = 0...I o nom -25 95 -40 105 TS Storage temperature not operational -55 105 -55 105 C The case temperature TC 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 TC max! Table 4: MTBF Values at specified Case Temperature Modules Types MTBF according to MIL-HDBK-217F Group 01 2'900'000 Group 02/03 2'300'000 6 - 12 Ground Benign Ground Fixed Ground Mobile 40C 40C 70 C 1'400'000 310'000 430'000 150'000 1'000'000 270'000 310'000 110'000 40C MELCHER The Power Partners. 70C Unit h Edition 2/96 - (c) Melcher AG Rugged Environment DC-DC Converters <40 W 3 Watt-Family Electrical Input and Output Data General Conditions: TA = 25C, unless otherwise specified Table 5: Input Data .. IPS/IPW 3-05 .. Characteristics 1 2 min max min max min max Unit TA min...TA max I o = 0...I o nom 10 18 33 72 10 18 33 72 10 18 33 72 V DC 0 0 45 75 0 0 45 75 0 0 45 75 Input voltage range 24 IPS/IPW 48 IPS/IPW Ui abs Input voltage limits without any damage 24 IPS/IPW 1 48 IPS/IPW 2 Ii o No load input current Ui nom = 24 V, Io = 0 Ui nom = 48 V, Io = 0 Ii SD Input current in shutdown condition Ii L Input current limitation response ii rfi typ .. IPS/IPW 3-15 .. Conditions Ui typ .. IPS/IPW 3-12 .. typ 5 3 5 3 5 3 mA Ui min... Ui max TA min...TA max 1.3 1.3 1.3 1.25 I i 1.25 I i 1.25 I i RFI current at the input Ui min... Ui max TA min...TA max I o = 0...I o nom 30 30 30 mApp USD Shutdown voltage for converter operating not operating open or 8...10 -0.3...+2 open or 8...10 -0.3...+2 open or 8...10 -0.3...+2 V DC ISD Shutdown current for converter operating not operating +1...+5 -25...-35 +1...+5 -25...-35 +1...+5 -25...-35 A fs Switching frequency Ui min... max, I o nom TA min...TA max 130 130 130 kHz 35 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 The applied minimum load must be 25% between 72.0...75.0 V DC Table 6: Output Data Output .. IPS/IPW 3-05 .. Characteristics Uo Output voltage Io nom Nominal output current uo Output voltage noise (BW = 20 MHz) Uo U Static line regulation Group 01 Group 02/03 Conditions min Ui nom, Io nom 4.90 .. IPS/IPW 3-12 .. max min 5.10 11.76 typ .. IPS/IPW 3-15 .. max min 12.24 14.70 typ max Unit 15.30 V DC Ui min...Ui max TA min...TA max 500 250 250 125 200 100 mA Ui min... Ui max I o nom 100 100 100 mVpp 10 12 15 mV 0...2 1 % 0.02 %/K Uo I Static load regulation Ui min... Ui max I o nom...0.25 Io nom 0...5 0...2 1 Uo Temperature coefficient Ui nom, Io nom 0.02 0.02 5.6 +5/-0% Output overvoltage clamping Co ext 1 typ Maximum admissible capacitive load 13 33 +5/-0 % 16 +5 /-0% V 15 F 15 0...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 .. Characteristics Conditions min typ Ui nom = 24 V, I o nom Ui nom = 48 V, Io nom 78 80 80 82 Efficiency Edition 2/96 - (c) Melcher AG max MELCHER The Power Partners. .. IPS/IPW 3-12 .. min typ 78 80 80 82 max .. IPS/IPW 3-15 .. min typ 78 80 80 82 max Unit % 6 - 13 6.1 Input 3 Watt-Family DC-DC Converters <40 W Rugged Environment 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 1 Unit Uis io AC: 50 Hz, 1 minute 500 1060 Vrms 1400 3000 Vpp 700 1500 V Isolation test voltage Input to output DC: 1 second 2 DC: 1 second Uis oo Isolation test voltage output to output 4 AC: 50 Hz, 1 minute Coupling capacitance Ris Insulation resistance 800 1700 500 1060 Vrms 1400 3000 Vpp 2 700 1500 V DC: 1 second 3 800 1700 300 external 5 DC: 1 second Cio 3 typ pF 2000 at 100 V DC after 1 minute M 1 According to EN 41003 (1993) For production test purposes in accordance with IEC 950/EN 60950 3 Factory test procedure 4 Group 03 5 Important: All IPW types need (an) external coupling capacitor(s) C of min. 220 pF, 1 kV io rms 6.1 2 Connection in Series Unit 1 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 (Germany) Submersion of the units in water for rinsing is permitted. Drying should be done in the air. 6 - 14 +Vo +Uo Go -Vo +Vo Unit 2 Go -Vo - Uo Fig. 1 Outputs connected in series Shutdown Description The shutdown terminal is used to switch the converter output voltage Uo 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 terminal 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...12 V will appear. MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG Rugged Environment DC-DC Converters <40 W 3 Watt-Family Functional Description and Block Diagrams 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. These converters are primary controlled flyback converters using Pulse With Modulation (PWM). The output voltage is monitored via a separate transformer winding very close to the secondary winding(s) and fed back to the control circuit. 1 2 PWM Gi 23 SD 20 Vo 12 Go 12 Go 24 Cio Fig. 5 IPW 3, Group 01, external Cio is required 1 2 15 10 11 SD Vo 20 SD PWM Gi 13 23 Gi Fig. 2 IPS 3, Group 01 Vi 2 PWM Cio 24 1 Vi 13 23 13 24 Cio 20 Vi +Vo 1 2 15 PWM 10 Go 11 Gi -Vo +Vo Go 23 -Vo 13 24 20 SD Cio Fig. 3 IPS 3, Group 02 Vi Fig. 6 IPW 3, Group 02, external Cio is required 1 2 PWM Gi SD 12 Vo1 9 Go1 13 Vo2 16 Go2 Vi PWM 23 24 20 1 2 Gi SD 2 x Cio 12 Vo1 9 Go1 13 Vo2 16 Go2 23 24 20 2 x Cio Fig. 4 IPS 3, Group 03 Fig. 7 IPW 3, Group 03, external 2 x Cio is required 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 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. Edition 2/96 - (c) Melcher AG MELCHER The Power Partners. 6 - 15 6.1 Vi 3 Watt-Family DC-DC Converters <40 W Rugged Environment Mechanical Data Dimensions in mm. Tolerances 0.2 mm, unless otherwise specified. European Projection min. 34 33 min. 21 20 15.24 2.54 1 1 6.1 min. 3 10.5 mounting space required o 0.5 Fig. 8 Case: DIL 24. Foot print shown for IBEK pin configurations. Hole diameter required in PCB: 0.8 0.1 mm Weight: 15 g Fig. 9 Foot print shown for alternative pin configurations. Hole diameter required in PCB: 0.8 0.1 mm. 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 TA TA = -25...71 C .................................................... -T TA = -40...85C ................................................... -S Product Marking: Main face: Manufacturer's name (IBEK), specific type designation, input voltage range, input and output pin allocation. Bottom: Date code. 6 - 16 MELCHER The Power Partners. Edition 2/96 - (c) Melcher AG