1 watt-family dc-dc converters <40 w rugged environment 6 - 2 edition 2/96 - ? melcher ag melcher
the power partners. 6.1 ibek dc-dc converters 1 watt-family input to output isolation test voltage up to 5 kv rms 1 or 2 outputs: icr 1, ixr 1, iyr 1, izr 1 1, 2 or 4 outputs: iwr 1 ? extremely high isolation test voltages ? efficient pi input filter ? aluminium solid electrolytic capacitors (os-con) ? outputs equipped with linear voltage regulators ? high reliability ? optimal dynamic response ? operating ambient temperature range up to C40...85 c (optional) ? case height only 10.5 mm table of contents page description .................................................................. 6 - 2 type survey ................................................................ 6 - 3 safety instructions ....................................................... 6 - 4 immunity to environmental conditions ........................ 6 - 4 electrical input and output data ................................. 6 - 5 installation instructions ................................................ 6 - 6 block diagrams ........................................................... 6 - 7 mechanical data ......................................................... 6 - 8 type key and product marking ................................... 6 - 9 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 small loads on pcbs and for realising redundant systems. five input to output isolation test voltage categories and three temperature ranges are available. the dc-dc con- verters feature low output ripple, low module height, high quality and reliability. to minimize 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: dil 24 package, grey colored plastic material, self cooling (free air convection).
rugged environment dc-dc converters <40 w 1 watt-family edition 2/96 - ? melcher ag 6 - 3 melcher
the power partners. 6.1 type survey general condition: t a = 25 c table 1a: type survey icr 1 and iwr 1 output 1 output 2 input voltage 1 group 2 700 v dc/500 v rms group 2 1500 v dc/1060 v rms option u o nom i o nom u o nom i o nom u i i solation test voltage i solation test voltage [v dc] [ma] [v dc] [ma] [v dc] type 1 type 1 5 200 - - 5 ( 5%) 06 .. icr 1-05-n 01 .. iwr 1-05-n t, s 12 80 - - or .. icr 1-12-n .. iwr 1-12-n 15 66 - - 12 ( 10%) .. icr 1-15-n .. iwr 1-15-n 5 50 - - or - - 02 .. iwr 1-0505-n 12 40 - - 15 ( 10%) 07 .. icr 1-1212-n 3 4 .. iwr 1-1212-n 3 4 15 33 - - or .. icr 1-1515-n 3 4 .. iwr 1-1515-n 3 4 5 100 5 100 24 ( 10%) - - 03 .. iwr 1-05-05-n 5 100 12 40 or - - .. iwr 1-05-12-n 5 100 15 33 28 ( 10%) - - .. iwr 1-05-15-n 12 40 12 40 or 08 .. icr 1-12-12-n 3 4 .. iwr 1-12-12-n 3 4 15 33 15 33 48 ( 10%) 5 .. icr 1-15-15-n 3 4 .. iwr 1-15-15-n 3 4 5 50 5 50 - - 05 .. iwr 1-2 0505-n t 12 20 12 20 - - .. iwr 1-2 1212-n 3 4 15 17 15 17 - - .. iwr 1-2 1515-n 3 4 table 1b: type survey ixr 1 and iyr 1 output 1 output 2 input voltage 1 group 2 3530 v dc/2500 v rms group 2 5300 v dc/3750 v rms option u o nom i o nom u o nom i o nom u i i solation test voltage i solation test voltage [v dc] [ma] [v dc] [ma] [v dc] type 1 type 1 5 200 - - 5 ( 5%) 11 .. ixr 1-05-n 11 .. iyr 1-05-n t, s 12 80 - - or .. ixr 1-12-n .. iyr 1-12-n 15 66 - - 12 ( 10%) .. ixr 1-15-n .. iyr 1-15-n 5 50 - - or 12 .. ixr 1-0505-n .. iyr 1-0505-n 12 40 - - 15 ( 10%) .. ixr 1-1212-n 3 4 12 .. iyr 1-1212-n 3 4 15 33 - - or .. ixr 1-1515-n 3 4 .. iyr 1-1515-n 3 4 5 100 5 100 24 ( 10%) 13 .. ixr 1-05-05-n 13 .. iyr 1-05-05-n 5 100 12 40 or .. ixr 1-05-12-n .. iyr 1-05-12-n 5 100 15 33 28 ( 10%) .. ixr 1-05-15-n .. iyr 1-05-15-n 12 40 12 40 or .. ixr 1-12-12-n 3 4 .. iyr 1-12-12-n 3 4 15 33 15 33 48 ( 10%) 5 .. ixr 1-15-15-n 3 4 .. iyr 1-15-15-n 3 4 table 1c: type survey izr 1 output 1 output 2 input voltage 1 group 2 7070 v dc/5000 v rms option u o nom i o nom u o nom i o nom u i i solation test voltage [v dc] [ma] [v dc] [ma] [v dc] type 1 5 200 - - 5 ( 5%) 11 .. izr 1-05-n t, s 12 80 - - or .. izr 1-12-n 15 66 - - 12 ( 10%) .. izr 1-15-n 5 50 - - or 12 .. izr 1-0505-n 12 40 - - 15 ( 10%) .. izr 1-1212-n 3 4 15 33 - - or .. izr 1-1515-n 3 4 5 100 5 100 24 ( 10%) 13 .. izr 1-05-05-n 5 100 12 40 or .. izr 1-05-12-n 5 100 15 33 28 ( 10%) .. izr 1-05-15-n 12 40 12 40 or .. izr 1-12-12-n 3 4 15 33 15 33 48 ( 10%) 5 .. izr 1-15-15-n 3 4 1 the required input voltage value (e.g. 24 v) should be added to the type designation: .. icr 1-1212-n changes to 24 icr 1-1212-n 2 see block diagrams 3 the output current of one output may be increased by 25% if the output current of the other output is reduced by 25% simultaneously. example for a 5 iwr 1-1515-n: the +15 v output current of 33 ma may be increased to 41 ma if the C15 v output current is reduced to 25 ma. 4 the output current of both outputs of the 12, 24, 28 and 48 v input types may be increased by 20% of i o nom . note 3 is applicable at the same time. example for a 24 iwr 1-2 1212-n: i o1 = +29 ma/C19 ma, i o2 = +19 ma/C29 ma or i o1 = 19 ma, i o2 = 29 ma 5 only standard temperature range n or option t available
1 watt-family dc-dc converters <40 w rugged environment 6 - 4 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. 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 double or reinforced 60 v selv circuit operational selv circuit 1 the earth connection has to be provided by the installer according to the relevant safety standard, e.g. iec 950. 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 -n option -t option -s unit min max min max min max t a ambient temperature u i min ... u i max 0 71 C25 71 C40 85 c t c case temperature i o = 0... i o nom 0 91 C25 91 C40 105 t s storage temperature not operational C55 105 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 7'400'000 3'200'000 260'000 880'000 60'000 h mil-hdbk-217f double and dual outputs 5'700'000 2'500'000 200'000 670'000 45'000
rugged environment dc-dc converters <40 w 1 watt-family edition 2/96 - ? melcher ag 6 - 5 melcher
the power partners. 6.1 table 7: efficiency efficiency 5 v 12 v 15 v characteristics conditions unit h efficiency min u i nom , i o nom 50 % typ 58 electrical input and output data general condition: 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 4.75 10.8 13.5 21.6 25.2 43.2 v nom 5 1215242848 max 5.25 13.2 16.5 26.4 30.8 52.8 i i o no load input input typ u i nom , i o = 0 8535301517 8ma current max 110 45 40 23 20 12 u i rfi rfi voltage at typ u i nom , i o nom 50 80 85 100 130 200 mv pp the input l source ? 1 m h i i rfi rfi current at typ 10 ma pp the input u i abs input voltage limits min 0 0 0 0 0 0 v without any damage max max 60 s 6.25 15 18.75 30 35 60 f s switching frequency typ u i nom , i o nom 25 khz 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 typ 1 2 2% accuracy max 3 5 5 u o output ripple, u o = f ( u i ) at u i = 5 12 15 24 28 48 v typ (bw = 20 mhz) 25 35 40 45 50 55 mv pp d u o u static line regulation typ u i min u i max 0.3 0.2 0.2 % i o nom d u o i static load regulation typ u i nom 0.8 0.1 0.1 i o = 0 i o nom a uo temperature coefficient u i nom , i o nom 0.02 %/k c o ext maximum admissible 22 10 10 m f capacitive load
1 watt-family dc-dc converters <40 w rugged environment 6 - 6 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, insulation resistance, clearance and creepage distances characteristics conditions icr iwr 1 ixr iyr izr unit u is io isolation test voltage ac: 50 hz, 500 1060 2500 3750 5000 v rms input to output 1 minute 1400 3000 7070 10600 14100 v pp dc: 1 second 2 700 1500 3530 5300 7070 v dc: 1 second 3 800 1700 4000 6000 8000 u is oo isolation test voltage ac: 50 hz, 500 1060 1060 1060 1060 v rms output to output 4 1 minute 1400 3000 3000 3000 3000 v pp dc: 1 second 2 700 1500 1500 1500 1500 v dc: 1 second 3 800 1700 1700 1700 1700 c io coupling capacitance typ 20 10 10 10 10 pf r is insulation resistance at 100 v dc 3 1000 m w after 1 minute d io clearance and creepage 3 0.6 3 1 3 3 5 3 3 5 3 3 5 mm distances input to output 1 according to en 41003 (1993) 2 for production test purposes in accordance with iec 950/en 60950 3 factory test procedure 4 groups 03, 05, 08 and 13 5 in combination with the high isolation strength of the potting compound, isolation test voltages mentioned are guaranteed. 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. 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
rugged environment dc-dc converters <40 w 1 watt-family edition 2/96 - ? melcher ag 6 - 7 melcher
the power partners. 6.1 block diagrams 12 8 3 22 23 2 linear
regulator filter push-pull
converter 25 khz vo1 go1 vi gi 24 1 13 16 linear
regulator vo2 go2 fig. 4 iwr, group 03 13 12 3 22 23 2 linear
regulator filter push-pull
converter 25 khz vo go vi gi 17 24 1 +tp fig. 2 iwr, group 01 fig. 3 iwr, group 02 15 11 13 3 22 23 2 linear
regulator linear
regulator filter push-pull
converter 25 khz +vo ?o vi gi 12 16 24 1 10 go +tp ?p 13 15 17 2 23 24 1 linear
regulator linear
regulator filter push-pull
converter 25 khz +vo1 go1 +vo2 go2 ?o2 vi gi 12 10 8 linear
regulator linear
regulator ?o1 fig. 5 iwr, group 05 14 10 24 12 13 1 linear
regulator filter push-pull
converter 25 khz vo go vi gi 11 15 fig. 6 icr, group 06 fig. 7 icr, group 07 15 2 24 12 13 1 linear
regulator linear
regulator filter push-pull
converter 25 khz +vo ?o vi gi 10 go 1 3 22 11 14 23 14 15 24 12 13 1 linear
regulator filter push-pull
converter 25 khz vo1 go1 vi gi 3 2 linear
regulator vo2 go2 11 23 10 22 fig. 8 icr, group 08 fig. 9 ixr, iyr, izr, group 11 13 12 2 23 24 1 linear
regulator filter push-pull
converter 25 khz vo go vi gi
1 watt-family dc-dc converters <40 w rugged environment 6 - 8 edition 2/96 - ? melcher ag melcher
the power partners. 6.1 fig. 10 ixr, iyr, izr, group 12 15 11 13 2 23 24 1 linear
regulator linear
regulator filter push-pull
converter 25 khz +vo Cvo vi gi 10 go 12 8 2 23 24 1 linear
regulator filter push-pull
converter 25 khz vo1 go1 vi gi 13 16 linear
regulator vo2 go2 fig. 11 ixr, iyr, izr, group 13 pin configuration table 9: pin configuration type group 12381011121314151617222324 iwr 01 vi vi vi - - - go vo - - - +tp gi gi gi iwr 02 vi vi vi - go go Ctp Cvo - +vo +tp - gi gi gi iwr 03 vi vi vi go1 - - vo1 vo2 - - go2 - gi gi gi iwr 05 vi vi - Cvo1 go1 - +vo1 +vo2 - go2 - Cvo2 - gi gi icr 06vi---govogigivogo----vi icr 07 vi Cvo go - go +vo gi gi +vo go - - go Cvo vi icr 08 vi go2 vo2 - go1 vo1 gi gi vo1 go1 - - vo2 go2 vi ixr, iyr, izr 11 vi vi ----govo-----gigi ixr, iyr, izr 12 vi vi - - go go - Cvo - +vo - - - gi gi ixr, iyr, izr 13 vi vi - go1 - - vo1 vo2 - - go2 - - gi gi mechanical data dimensions in mm. tolerances 0.2 mm, unless otherwise specified. european
projection 15.24 min. 21 2.54 min. 34 33 1 ? 0.5 min. 3 20 10.5 mounting space
required fig. 12 case: dil 24. foot print shown for all pin configurations. hole diameter required in pcb: 0.8 0.1 mm weight: 13 g
rugged environment dc-dc converters <40 w 1 watt-family edition 2/96 - ? melcher ag 6 - 9 melcher
the power partners. 6.1 24 iwr 1 - 2x 0505 - t nominal input voltage in volt .............................................. family ................................................................................. nominal output power in watt ............................................. two independent, galvanically isolated double ( ) outputs nominal output voltages in volt for dual ( ) output 1 and dual ( ) output 2 .............. operating ambient temperature range t a ........................... product marking: main face: manufacturer's name (ibek), specific type designation, input voltage range, input and output pin allocation. bottom: date code. type key and product marking type key: 5 i xr 1 - 12 - 12 - n nominal input voltage in volt .............................................. family ................................................................................ nominal output power in watt ............................................. nominal output voltage for output 1 in volt ......................... dash: designates double output unit with two independent, galvanically isolated outputs ................................... nominal output voltage for output 2 in volt ......................... operating ambient temperature range t a ...........................
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