Board Mountable DC-DC Converters 7 Watt DC-DC Converters IMX 7 Series IMX 7 Series Wide input voltage ranges up to 150 V DC 1 or 2 outputs up to 48 V DC 1500...2500 V DC I/O electric strength test * Extremely wide input voltage ranges * Electrical isolation, also between outputs * Emissions below EN 55 022 level B. * Immunity to IEC/EN 61000-4-2, -3, -4, -5 and -6 25.4 1.0" * High efficiency (typ. 84%) 10.5 0.42" 50.8 2.0" * Inhibit input, output voltage adjustable * Flex power: flexible load distribution on outputs * Outputs no-load, overload and short-circuit proof * Operating ambient temperature up to -40...85C * High reliability and no derating * 2" x 1" case with 10.5 mm profile * Supplementary insulation Safety according to IEC/EN 60950, UL 1950 LGA 1 1 For 70/110 IMX types Summary The IMX 7 series of board mountable 7 Watt DC-DC converters has been designed according to the latest industry requirements and standards. The converters are particularly suitable for use in mobile or stationary applications in transport, railways, industry or telecommunications where variable input voltages or high transient voltages are prevalent. Covering a total input voltage range from 8.4 V DC up to 150 V DC with four different types the units are available with single and electrically isolated double outputs allowing the configuration of output voltages from 3.3 V DC up to 48 V DC externally adjustable, with flexible load distribution on double output units. An inhibit input allows remote converter on/off. Features include efficient input and output filtering with unsurpassed transient and surge protection, low output ripple and noise, consistently high efficiency over the entire input voltage range, high reliability as well as excellent dynamic response to load and line changes. The converters provide supplementary insulation with SELV outputs as e.g. required in battery supported systems where the bus voltage may exceed the SELV limit of Table of Contents 60 V DC. They are designed and built according to the international safety standards IEC/EN 60950, UL 1950, CAN/ CSA C22.2 No.950-95 and are LGA and UL marked. The 70 IMX 7 and 110 IMX 7 types are CE marked. The circuit comprises of integrated planar magnetics and all components are automatically assembled and solidly soldered onto a single PCB without any wire connections. Magnetic feedback ensures maximum reliability and repeatability in the control loop over all operating conditions. Careful considerations of possible thermal stresses ensure the absence of hot spots providing long life in environments where temperature cycles are a reality. The thermal design allows operation at full load up to an ambient temperature of 85C in free air without using any potting material. For extremely high vibration environments the case has holes for screw mounting. Various options as e.g. extended temperature range -40...85C, industrial C pinout or SMD pinout provide a high level of application specific engineering and design-in flexibility. Page Page Summary .......................................................................... 1 Type Survey and Key Data .............................................. 2 Type Key .......................................................................... 3 Functional Description ..................................................... 4 Electrical Input Data ......................................................... 5 Electrical Output Data ...................................................... 7 Auxiliary Functions ......................................................... 10 Electromagnetic Compatibility (EMC) ............................ 12 Immunity to Environmental Conditions .......................... 13 Mechanical Data ............................................................ 14 Safety and Installation Instructions ................................ 15 Description of Options .................................................... 17 Edition 6/5.2000 1/18 Board Mountable DC-DC Converters IMX 7 Series Type Survey and Key Data Table 1: Type survey Output 1 Uo1 nom Io1 nom [V DC] [A] 1 1 2 3 Output 2 Uo2 nom Io2 nom [V DC] [A] 1 Output Power Po nom [W] Input voltage range [V DC] Efficiency htyp [%] Type designation Options 2 3.3 3.3 3.3 3.3 1.5 1.5 1.5 1.5 - - 5 5 5 5 8.4...36 16.8...75 3 40...121 60...150 79 81 79 79 20 IMX 7-03-9 40 IMX 7-03-9 70 IMX 7-03-9 110 IMX 7-03-9 -8, D, M, C, L, Z -8, D, M, C, L, Z -8, D, M, L, Z -8, D, M, L, Z 5.1 5.1 5.1 5.1 1.2 1.2 1.2 1.2 - - 6.1 6.1 6.1 6.1 8.4...36 16.8...75 3 40...121 60...150 80 81 80 80 20 IMX 7-05-9 40 IMX 7-05-9 70 IMX 7-05-9 110 IMX 7-05-9 -8, D, M, C, L, Z -8, D, M, C, L, Z -8, D, M, L, Z -8, D, M, L, Z 12 12 12 12 0.5 0.6 0.6 0.6 - - 6 7.2 7.2 7.2 8.4...36 16.8...75 3 40...121 60...150 84 84 83 84 20 IMX 7-12-9C2 40 IMX 7-12-9C2 70 IMX 7-12-9C2 110 IMX 7-12-9C2 -8, Z -8, Z -8, Z -8, Z 15 15 15 15 0.4 0.48 0.48 0.48 - - 6 7.2 7.2 7.2 8.4...36 16.8...75 3 40...121 60...150 84 84 83 84 20 IMX 7-15-9C2 40 IMX 7-15-9C2 70 IMX 7-15-9C2 110 IMX 7-15-9C2 -8, Z -8, Z -8, Z -8, Z 24 24 24 24 0.26 0.3 0.3 0.3 - - 6.2 7.2 7.2 7.2 8.4...36 16.8...75 3 40...121 60...150 84 84 83 84 20 IMX 7-24-9C2 40 IMX 7-24-9C2 70 IMX 7-24-9C2 110 IMX 7-24-9C2 -8, Z -8, Z -8, Z -8, Z 5 5 5 5 0.6 0.7 0.7 0.7 5 5 5 5 0.6 0.7 0.7 0.7 6 7 7 7 8.4...36 16.8...75 3 40...121 60...150 82 83 82 82 20 IMX 7-05-05-9 40 IMX 7-05-05-9 70 IMX 7-05-05-9 110 IMX 7-05-05-9 -8, M, C, L, Z -8, M, C, L, Z -8, M, L, Z -8, M, L, Z 12 12 12 12 0.25 0.3 0.3 0.3 12 12 12 12 0.25 0.3 0.3 0.3 6 7.2 7.2 7.2 8.4...36 16.8...75 3 40...121 60...150 84 84 83 84 20 IMX 7-12-12-9 40 IMX 7-12-12-9 70 IMX 7-12-12-9 110 IMX 7-12-12-9 -8, M, C, L, Z -8, M, C, L, Z -8, M, L, Z -8, M, L, Z 15 15 15 15 0.2 0.24 0.24 0.24 15 15 15 15 0.2 0.24 0.24 0.24 6 7.2 7.2 7.2 8.4...36 16.8...75 3 40...121 60...150 84 84 83 84 20 IMX 7-15-15-9 40 IMX 7-15-15-9 70 IMX 7-15-15-9 110 IMX 7-15-15-9 -8, M, C, L, Z -8, M, C, L, Z -8, M, L, Z -8, M, L, Z 24 24 24 24 0.13 0.15 0.15 0.15 24 24 24 24 0.13 0.15 0.15 0.15 6.2 7.2 7.2 7.2 8.4...36 16.8...75 3 40...121 60...150 84 84 83 84 20 IMX 7-24-24-9 40 IMX 7-24-24-9 70 IMX 7-24-24-9 110 IMX 7-24-24-9 -8, M, C, L, Z -8, M, C, L, Z -8, M, L, Z -8, M, L, Z Flexible load distribution on double outputs possible. See table: Survey of options. Operation at lower input voltage possible: Po approx. 80% of Po nom at Ui min = 14.4 V. Edition 6/5.2000 2/18 Board Mountable DC-DC Converters IMX 7 Series Type Key 20 IMX 7 - 05 - 05 -9 D M C L Z Input voltage range Ui 8.4...36 V DC ............................................ 20 16.8...75 V DC ............................................ 40 40...121 V DC ............................................ 70 60...150 V DC .......................................... 110 Series ........................................................................ IMX 7 Output voltage type output 1 .................. 03, 05, 12, 15, 24 Dash: Designates double output unit with two independent electrically isolated outputs ...... - 1 Output voltage type output 2 ........................ 05, 12, 15, 24 Operating ambient temperature range TA -40...71C .................................................. -9 -40...85C (option) ..................................... -8 Options: 1 2 Signal Out OK ............................................. D Surface mount version with pins ................. M C-pinout ...................................................... C Surface mount version with PCB lid ............ L Open frame .................................................. Z Not applicable for option C. Option -8 excludes option D and vice versa. Examples: 3 4 24 24 34 34 Option M excludes option C and vice versa. For delivery lead times contact factory. Some types require a minimum order quantity. 40 IMX 7-05-05-9M: DC-DC converter, input voltage range 16.8...75 V, 2 electrically isolated outputs each providing 5 V, 700 mA, surface mount version. 20 IMX 7-0505-9C: DC-DC converter, input voltage range 8.4...36 V, C pinout with outputs 5 V, 600 mA. 20 IMX 7-12-9C2: DC-DC converter, input voltage range 8.4...36 V, C pinout with one output 12 V, 500 mA. Edition 6/5.2000 3/18 Board Mountable DC-DC Converters IMX 7 Series Functional Description The IMX 7 DC-DC modules are feedback controlled flyback converters using current mode PWM (Pulse Width Modulation). See block diagram for single and double output types. In the case of the single output units the output is directly monitored and fed back to the primary control circuit via a pulse transformer, resulting in tight regulation of the output voltage. The R input is referenced to the secondary side and allows for programming of the output voltages in the range 75 to 105% of Uo nom using either an external resistor or an external voltage source. In the case of the dual and double output units the output voltage is monitored by a separate transformer winding close to the secondary windings and fed back to the control circuit. The R (Trim) input is referenced to the primary side and allows programming of the output voltage in the range 100 to 105% of Uo nom by an external resistor or within 75 to 105% of Uo nom using an external voltage source. Current limitation is provided by the primary circuit, thus limiting the total output power. The inhibit input allows remote converter on/off. 03042 03041 Vi+ 1 11 Vo+ Vi+ 1 11 Vo1+ PWM (Trim) R 4 i 3 10 Vo- 2 x 2200 pF 12 10 Vo1- PWM 10 nF i 3 13 Vo2+ Vi - 2 12 Vo2- V i- 2 13 R n.c. 4 2 x 2200 pF 14 D Fig. 1 Block diagram, single output types, standard pinout 14 n.c. Fig. 2 Block diagram, double output types, standard pinout 03063 03062 Vi+ 1 3 Vo+ Vi+ 1 3 Vo+ PWM 10 Go PWM 5 Vo- 10 nF 2 x 2200 pF Vi- 2 Vi- 2 5 Vo- 2 x 2200 pF Fig. 3 Block diagram, single output types, C pinout Edition 6/5.2000 Fig. 4 Block diagram, dual output types, C pinout 4/18 Board Mountable DC-DC Converters IMX 7 Series Electrical Input Data General conditions: - TA = 25C, unless TC is specified. - Connector pins i and Vi- interconnected. - Trim or R input not connected. Table 2: Input Data Input 20 IMX 7 Characteristics Conditions Ui Input voltage range Ui nom Nominal input voltage Ui sur Repetitive surge voltage t start up Converter 2 2 3 4 5 6 7 TC min...TC max Io = 0...Io nom 8.4 36 20 16.8 6 75 40 abs. max input (3 s) inh. release 70 IMX 7 110 IMX 7 Worst case condition at Ui min and full load 40 121 60 150 70 110 4 4 Unit V DC 100 50 5 150 V switch on start-up time 1 1 40 IMX 7 min typ max min typ max min typ max min typ max 0.25 0.5 4 0.25 0.5 0.1 0.25 0.5 0.1 0.25 0.5 0.1 s 0.1 t rise Rise time 2 Ui nom Io nom Ii o No load input current Io = 0, Ui min...Ui max Ci Input capacitance for surge calculation 4.7 0.5 0.2 0.2 F Uinh Inhibit voltage unit operating -10...0.8 -10 ...0.8 -10 ...0.8 -10 ...0.8 V DC unit inhibited open or 2.4...Ui max open or 2.4...Ui max open or 2.4...75 open or 2.4...75 unit operating -0.5 -0.5 -0.5 -0.5 unit inhibited 1 resistive load capacitive load 5 5 12 15 12 30 Iinh Inhibit current I i inh Input current if unit shut down Ui I inr p Inrush peak current Ui = Ui nom 7 fs Switching frequency Ui min...Ui max, Io = 0...Io nom approx. 400 I i rr Reflected ripple current Io = 0...Io nom ui RFI Input RFI level conducted and radiated EN 55022 3 min...Ui max 8 3.8 5 12 15 1 <3.0 8 3.7 ms 12 15 1 <3.0 8 15 1 <3.0 4.2 <3.0 5.6 A approx. 400 approx. 300 30 20 10 B B mA mA approx. 400 50 B 5 kHz mApp B Ui min will not be as stated if Uo is increased above Uo nom by use of the R input. If the output voltage is set to a higher value, Ui min will be proportionally increased. Measured with a resistive and max. admissible capacitive load. Measured with a lead lenght of 0.1 m, leads twisted. Double output units with both outputs in parallel. 70/110 IMX 7 types need an external capacitor at the input. (e.g. 1F film or ceramic) See 19 Pfl 1: Electromagnetic Immunity. The DC-DC converter shuts down automatically at approx. 38 V. Operation at lower input voltage possible: Po approx. 80% of Po nom at Ui min = 14.4 V. Source impedance according to prETS 300132-2, version 4.3, at Ui nom. Uo Uo nom t rise t start up 04008 t Fig. 5 Converter start-up and rise time Edition 6/5.2000 5/18 Board Mountable DC-DC Converters IMX 7 Series Input Transient Voltage Protection In many applications transient voltages on the input of the converter are always possible. These may be caused for example by short circuits between Vi+ and Vi- where the network inductance may cause high energy pulses. In order to protect the converters the IMX 7 types have a built-in transient protection as per table below: Table 3: Built-in transient voltage suppressor Type Breakdown Voltage VBR nom 20 IMX 7 1 1 2 Peak Power at 1 ms PP Peak Pulse Current IPP To achieve IEC/EN 61000-4-5, level 2 compliance an additional inductor and capacitor should be provided externally as shown in the figure below. The components should have similar characteristics as listed in table: Components for external circuitry to comply with IEC/EN 61000-4-5. Please note: The suppressor diode D is only necessary for 20 IMX 7 types. To withstand 150 V transients according to 19 Pfl 1, applicable for 40 IMX 7 types, the same external circuitry with similar components as for IEC/EN 61000-4-5, level 2 compliance can be used. 07064 over voltage lockout at approx. 38 V 40 IMX 7 2 100 V 1500 W 11 A 70 IMX 7 2 144 V 600 W 2.9 A 110 IMX 7 2 167 V 600 W 2.5 A Vi+ L C + i D Vi- The built-in overvoltage lockout circuit shuts down the converter at approx. 38 V protecting the input up to 50 V DC. For higher transient voltages an external suppressor or voltage limiting circuit as e.g. for IEC/EN 61000-4-5, level 2 compliance should be provided. If transients generating currents above the peak pulse current are possible then an external limiting network such as the circuit recommended for IEC/EN 61000-4-5, level 2 compliance is necessary. Fig. 6 Example for external circuitry to comply with IEC/EN 61000-4-5, level 2 (transzorb D not necessary for 40/70/110 IMX 7 types). Table 4: Components for external circuitry to comply with IEC/EN 61000-4-5 20 IMX 7 40 IMX 7 70 IMX 7 110 IMX 7 L 330 H, 0,115 , 1 A TDK SF-T8-110S-01 330 H, 0,42 , 600 mA TDK TSL1110-331KR55 1000 H, 2.9 , 290 mA Toko 822LY-102K 330 H, 0.65 , 430 mA Toko 822LY-331K C 68 F, 63 V, 85C 68 F, 100 V, 85C 47 F, 150 V, 85C 200 F, 200 V, 105C D Motorola 1.5KE39A n.a. n.a. n.a. 04029 10.5 25 5 5 Fig. 7 Dimensions of inductor L. (TDK SF-T8-110S-01) 0.7 The suppressor diode on the input also provides for reverse polarity protection by conducting current in the reverse direction, thus protecting the unit. An external fuse is required to limit this current: - For 20 IMX 7 a fast 2 A (F2A) fuse is recommended. - For 40 IMX 7 a fast 1 A (F1A) fuse is recommended. - For 70 IMX 7 a fast 0.63 A (F.63A) fuse is recommended. - For 110 IMX 7 a fast 0.63 A (F.63A) fuse is recommended. Inrush Current The inrush current has been kept as low as possible by choosing a very small input capacitance. A series resistor may be inserted in the input line to limit this current further. Edition 6/5.2000 7.5 04032 0.7 Fig. 8 Dimensions of inductor L. (TDK TSL1110-331KR55) Reverse Polarity Protection at Input 5 8.5 10 5 17.5 04033 11.5 Circuit Ref. 1 A/Div. 4 Fig. 9 Dimensions of inductor L. (Toko R622LY-102K) 04030 3 2 1 0 10 s/Div. Fig. 10 Typical inrush current at Ui nom, Po nom vs. time (40 IMX 7) measured according to prETS 300132-2 (Version 4.3) 6/18 Board Mountable DC-DC Converters IMX 7 Series Electrical Output Data General conditions: - TA = 25C, unless T C is specified. - Connector pins i and Vi- interconnected. - Trim or R input not connected. Table 5a: Output data for single output units Uo nom 3.3 V 5.1 V Characteristics Output Conditions min typ max min typ max Unit Uo1 Ui nom 3.28 5.07 VDC Output voltage Io nom Output current Io L Current limit 3.32 Ui min...Ui max 2 uo1, 2 Output voltage noise 20/40/70 IMX Ui min...Ui max Io = (0.05...1) Io nom Ui min...Ui max I o = I o nom 5 20 110 IMX aUo 3.0 2.4 1 1 % 70 mVpp 40 40 20 50 115 130 Dynamic Voltage deviat. load Recovery time regulat Ui nom Io nom 1/2 Io nom Temperature coefficient DUo /DTC (TC min...TC max) Ui min...Ui max I o = 0...I o max 40 40 50 115 2500 Co ext Admissible capacitive load td A 70 6 Uo clp Output overvoltage limitation 7 uo d 1.2 Ui nom, TC = 25C DUo U Line and load regulation 5.13 1.5 130 % 2000 F 250 250 mV 1 1 ms 0.02 0.02 %/K Table 5b: Output data for single output units Uo nom Output Characteristics Uo1 Ui nom Output voltage Io nom Output current 1 Io L Conditions Current limit 2, 3 20 IMX 12 V 15 V 24 V min typ max min typ max min typ max 11.90 Ui min...Ui max 40/70/110 IMX 20 IMX 12.10 0.6 7 0.5 1.2 1.1 0.6 1 1 1 3 3 3 uo1, 2 Output voltage noise Ui min...Ui max I o = I o nom 120 150 240 aUo 6 0.95 Ui nom Io = (0.1...1) Io nom td 5 0.3 1.0 Ui min...Ui max, Io nom 5 6 25 50 115 130 30 Dynamic Voltage deviat. load Recovery time regulat. Ui nom Io nom 1/2 Io nom Temperature coefficient DUo /DTC (TC min...TC max) Ui min...Ui max I o = 0...I o max 60 115 130 300 VDC A Load regulation 4 uo d 4 24.19 0.26 DUo l Co ext Admissible capacitive load 3 3 23.81 0.48 Ui nom, TC = 25C Uo clp Output overvoltage limit. 7 Minimum load 1% 2 15.12 0.4 40/70/110 IMX DUo U Line regulation 1 14.88 0.5 Unit % mVpp 50 100 115 200 130 % 100 F 330 350 600 mV 1 1 1 ms 0.02 0.02 0.02 %/K Each output is capable of delivering full output power, Po nom according to table: Type Survey. The current limit is primary side controlled. Measured with both outputs connected in parallel. Conditions for specified output. Other output loaded with constant current Io = 0.5 Io nom. BW = 20 MHz Measured with a probe according to EN 61204. The overvoltage protection is not tracking with the R control. Edition 6/5.2000 7/18 Board Mountable DC-DC Converters IMX 7 Series Table 5c: Output data for double output units Uo nom Output Characteristics Uo1 Uo2 Io nom Output current 1 Io L Conditions Current limit 2, 3 20 IMX 4.96 4.95 5.04 5.05 2 x 0.6 Ui min...Ui max 2 x 0.7 40/70/110 IMX 20 IMX Ui nom, TC = 25C 40/70/110 IMX 7 24.19 24.25 2 x 0.25 2 x 0.2 2 x 0.13 2 x 0.3 2 x 0.24 2 x 0.15 2.4 1.0 0.95 0.5 2.8 1.2 1.1 0.6 1 1 1 3 3 3 3 uo1, 2 Output voltage noise Ui min...Ui max I o = I o nom 5 80 120 150 240 aUo 6 min typ max 23.81 23.75 1 td 5 15.12 15.15 Ui nom Io = (0.1...1) Io nom uo d 4 min typ max 14.88 14.85 Ui min...Ui max, Io nom 6 20 40 115 130 25 Dynamic Voltage deviat. load Recovery time regulat. Ui nom Io nom 1/2 Io nom Temperature coefficient DUo /DTC (TC min...TC max) Ui min...Ui max I o = 0...I o max 50 115 130 2000 Co ext Admissible capacitive load 3 3 12.10 12.12 2 x 24 V Load regulation 4 Uo clp Output overvoltage limit. 7 Minimum load 1% 2 min typ max 11.90 11.88 2 x 15 V DUo l DUo U Line regulation 1 2 x 12 V min typ max Ui nom I o = 0.5 I o nom Output voltage 2x5V 30 60 115 130 300 Unit VDC A % mVpp 50 100 115 200 130 % 100 F 150 330 350 600 mV 1 1 1 1 ms 0.02 0.02 0.02 0.02 %/K Each output is capable of delivering full output power, Po nom according to table: Type Survey. The current limit is primary side controlled. Measured with both outputs connected in parallel. Conditions for specified output. Other output loaded with constant current Io = 0.5 Io nom. BW = 20 MHz Measured with a probe according to EN 61204. The overvoltage protection is not tracking with the R control. Edition 6/5.2000 8/18 Board Mountable DC-DC Converters IMX 7 Series Short Circuit Behaviour Connection in Series or in Parallel The current limit characteristic shuts down the converter whenever a short circuit is applied to its output. It acts selfprotecting and automatically recovers after removal of the overload condition (hiccup mode). Connection in series: The outputs of single or double output units can be connected in series without any precautions, taking into consideration that the highest output voltage should remain below 60 V for SELV operation. Thermal Considerations If a converter, mounted on a pcb, is located in free, quasistationary air (convection cooling) at the indicated maximum ambient temperature TA max (see table: Temperature specifications) and is operated at its nominal input voltage and output power, the case temperature TC measured at the Measuring point of case temperature TC (see: Mechanical Data) will approach the indicated value TC max after the warm-up phase. However, the relationship between TA and TC depends heavily on the conditions of operation and integration into a system. The thermal conditions are influenced by input voltage, output current, airflow, temperature of surrounding components and surfaces and the properties of the printed circuit board. TA max is therefore only an indicative value and under practical operating conditions, the ambient temperature TA may be higher or lower than this value. Caution: The case temperature TC measured at the Measuring point of case temperature TC (see: Mechanical Data) may under no circumstances exceed the specified maximum value. The installer must ensure that under all operating conditions TC remains within the limits stated in the table: Temperature specifications. Connection in parallel: The outputs of one or several double output units with equal nominal voltage can be connected in parallel. Approximate current sharing between 2 or several units is ensured by their load dependent output characteristic. Output overvoltage protection The outputs of single output units and -05-05- types are protected against overvoltages by a second control loop. In the event of an overvoltage on the output the unit will shutdown and attempt to restart approximately every 0.4 seconds. Double output units (with exception of the -05-05types) are protected against overvoltages by a Zener diode across the second output. Under worst case conditions the Zener diode will short circuit. Since with double output units both outputs track each other the protection diode is only provided in one of the outputs. The main purpose of this feature is to protect against possible overvoltages which could occur due to a failure in the feedback control circuit. The output overvoltage protection is not designed to withstand externally applied overvoltages. Typical Performance Curves Uo [V] Uo [V] 05087 5.5 05086 13 12 5.0 11 4.5 10 4.0 9 3.5 8 3.0 7 0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 Io [A] Fig. 11 Uo versus Io (typ) of single output units with Uo = 5.1 V. Uo1 [V] 05088 13.5 12.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 Io total [A] Fig. 12 Uo versus Io (typ) of double output units, with both outputs in parallel. Uo1, Uo4 [V] 05039 14 13.0 12.5 0 13 Io2 = 0.03 A Uo4 Uo1 12 Io2 = 0.3 A 11 11.5 11.0 0.03 0.05 10 0.10 0.15 0.20 0.25 Fig. 13 Uo1 versus Io1 (typ) for various Io2 (2 x 12 V). The cross load effect is negligible. Edition 6/5.2000 0.35 Io1 [A] 0 25 50 75 100 125 150 Io1 [%] Io1 nom Fig. 14 Flexible load distribution on double outputs (2 x 12 V) with load variation from 0...150% of Po1 nom on output 1. Output 2 loaded with 25% of Po2 nom. 9/18 Board Mountable DC-DC Converters IMX 7 Series h [%] Uo [%] 05041 05052 90 overload short circuit condition 100 U i nom U i max U i min 80 switch-off 70 70 60 8.5 50 t [ms] 60.5 60.5 40 Fig. 15 Overload switch-off (hiccup mode). Typical values. Frequency of pulses: 16.5 Hz, puls duration: 8.5 ms. 25 50 75 100 Po [%] Po nom Fig. 16 Efficiency versus input voltage and load. Typical values (40 IMX 7-12-12). Auxiliary Functions Inhibit Function Adjustable Output Voltage (R input) The output(s) of the converter may be enabled or disabled by means of a logic signal (TTL, CMOS, etc.) applied to the inhibit pin. No output voltage overshoot will occur when the unit is turned on. If the inhibit function is not required the inhibit pin should be connected to Vi- to enable the output (active low logic, fail safe). As a standard feature, the IMX 7 single and double output units offer adjustable output voltage(s) by using the control input R. If the R pin is left open circuit the output voltage is set to Uo nom. The output voltage is adjustable in the range 75...105 % of Uo nom.The circuit works for single and double output units in a different way. For output voltages Uo > Uo nom, the minimum input voltage Ui min (see: Electrical Input Data) increases proportionally to Uo /Uo nom. Converter operating: Converter inhibited or inhibit pin left open: -10 V...0.8 V 2.4 V...Ui max (<75 V for 70/110 IMX 7) 06070 Vi+ i Vi- Fig. 17 If the inhibit is not used the inhibit pin should be connected to Vi- Edition 6/5.2000 Single output units: The R input is referenced to the secondary side of the converter. Adjustment of the output voltage is possible by means of either an external resistor or a voltage source. a) Adjustment by means of an external resistor Rext1: Depending upon the value of the required output voltage, the resistor shall be connected either: Between the R pin and Vo- to achieve an output voltage adjustment range of approximately Uo = 75...100 % Uo nom. (85...100% for 3.3 V outputs) Uo Rext1 4 k * --------- Uo nom - Uo or: Between the R pin and Vo+ to achieve an output voltage range of approximately Uo = 100...105 % Uo nom. (Uo - 2.5 V) Rext2 4 k * ------------------- 2.5 V * (Uo/Uo nom - 1) 10/18 Board Mountable DC-DC Converters b) Adjustment by means of an external voltage Uext between Vo- and R pins. The control voltage range is 1.87...2.62 V and allows for an adjustment in the range of approximately 75...105%. (85...105% for 3.3 V outputs) Uo * 2.5 V Uext --------- Uo nom Attempting to adjust the output below this range will cause the converter to shutdown (hiccup mode). Note: Applying an external control voltage >2.75 V may damage the converter. 06029 Vo+ Vi+ Uref 2.5 V Rext2 4 k R control circuit + Vo- Vi- Uext Rext1 Double output units: 06030 Vi+ Vo1+ R (Trim) Vo1- - Rext Vi- Control circuit Uref 2.5 V Programming of the output voltage by means of an external resistor Rext1 is possible within a limited range of 100...105% of Uo nom. Rext1 should be connected between the R-pin and Vi-. Connection of Rext1 to Vi+ may damage the converter. The following table indicates suitable resistor values for typical output voltages under nominal conditions (Ui nom, Io = 0.5 Io nom), with either paralleled outputs or equal load conditions on each output. Table 6: Rext1 for Uo > Uo nom; approximate values (U i nom, Io1, 2 = 0.5 Io1/2 nom) Uo [% Uo nom] Rext [k] 105...108 (107 typically) 105 104 103 102 101 100 0 1.5 5.6 12 27 68 b) Adjustment by means of an external voltage source Uext. The R input (Trim) input is referenced to the primary side. The figure below shows the circuit topology. Adjustment of the output voltage is possible by means of either an external resistor in the range of 100...105% of Uo nom, or an external voltage source in the range of 75...105% of Uo nom. Uext a) Adjustment by means of an external resistor. - Fig. 18 Output voltage control for single output units by means of the R-input + IMX 7 Series Vo2+ For external output voltage programming in the range 75...105% of Uo nom a (0...20 V) source Uext is required, connected to the R-pin and Vi-. The table below indicates typical Uo versus Uext values under nominal conditions (Ui nom, Io = 0.5 Io nom), with either paralleled outputs or equal load conditions on each output. Applying a control voltage greater than 20 V will set the converter into a hiccup mode. Direct paralleling of the R-pins of units connected in parallel is feasible. Table 7: Uext for Uo = 75...105% Uo nom; typical values (U i nom, Io1, 2 = 0.5 Io1/2 nom) Uo [% Uo nom] Uext [V] 105 102 95 85 75 0 1.6 4.5 9 13 Vo2- Fig. 19 Output voltage control for double output units by means of the R input Edition 6/5.2000 11/18 Board Mountable DC-DC Converters IMX 7 Series Electromagnetic Compatibility (EMC) A suppressor diode together with an input filter form an effective protection against high input transient voltages which typically occur in many installations, but especially in battery driven mobile applications. Electromagnetic Immunity Table 8: Immunity type tests Phenomenon Standard 1 Class Level Coupling mode 2 Value applied Waveform Source Imped. Test procedure Electrostatic discharge to case IEC/EN 61000-4-2 2 contact discharge R pin open i pin connec. to Vi- 4000 Vp 1/50 ns 330 10 positive and 10 negative discharges yes B 3 air discharge R pin open i pin connec. to Vi- 8000 Vp 3 antenna 10 V/m AM 80% 1 kHz 26...1000 MHz yes A PM, 50% duty cycle, 200 Hz resp. frequ. 900 MHz Electromagnetic IEC/EN field 61000-4-3 ENV 50204 1 3 4 In Per- 3 oper. form. Electrical fast transient/burst IEC/EN 61000-4-4 4 direct +i/-i 4000 Vp bursts of 5/50 ns 5 kHz rep. rate transients with 15 ms burst duration and a 300 ms period 50 1 min positive 1 min negative transients per coupling mode yes B Surge IEC/EN 61000-4-5 5 3 +i/-i 2000 Vp 1.2/50 s 2 5 pos. and 5 neg. impulses per coupling mode yes B Conducted disturbancies IEC/EN 61000-4-6 3 +i/-i 50 0.15...80 MHz 150 yes A Transient 19 Pfl 1 4 limited to <100 A 3 positive yes B 10 Vrms AM modulated (140 dBV) 80%, 1 kHz +i/-i 150 Vp 0.1/0.3 ms Related and previous standards are referenced in: Technical Information: Standards. A = normal operation, no deviation from specification, B = temporary deviation from specs. possibe. For 40 IMX 7 types (additional external components required). Not applicable for 20 IMX 7 types. 2 i = input, o = output. 5 External components required. Electromagnetic Emission Conducted RFI noise at input according to EN 55022 Radiated RFI noise according to EN 55022. [dBV] 90 [dBV/m] 40 07023 80 07024 35 EN 55022 A 70 60 EN 55022 B 30 EN 55022 B 25 30 15 20 10 0 20 30 10 5 2 1 0.5 0.1 0.05 Fig. 20 Typical disturbance voltage (quasi-peak) at the input according to CISPR 11/EN 55011 and CISPR 22/EN 55022 measured at Ui nom and Io nom. Output leads 0.1 m, twisted. (40 IMX 7-15-15). External capacitor (1 F ceramic or film) required at the input for 70 IMX 7, 110 IMX 7 types. Edition 6/5.2000 300 200 80 50 60 100 MHz 0.02 0.01 0 40 [MHz] 30 10 800 20 1000 40 400 500 600 50 Fig. 21 Typical radio frequency-interference voltage at Ui nom, Io nom, measured with an antenna (distance 10 m). Output leads 0.1 m, twisted (70 IMX-7-15-15). 12/18 Board Mountable DC-DC Converters IMX 7 Series Immunity to Environmental Conditions Table 9: Environmental testing Test Method Ca Standard Test Conditions Status 40 2 C Damp heat steady state IEC/DIN IEC 60068-2-3 MIL-STD-810D section 507.2 Temperature: Relative humidity: Duration: 93 +2/-3 % 56 days Unit not operating Ea Shock (half-sinusoidal) IEC/EN/DIN EN 60068-2-27 MIL-STD-810D section 516.3 Acceleration amplitude: Bump duration: Number of bumps: 100 gn = 981 m/s2 6 ms 18 (3 each direction) Unit operating Eb Bump (half-sinusoidal) IEC/EN/DIN EN 60068-2-29 MIL-STD-810D section 516.3 Acceleration amplitude: Bump duration: Number of bumps: 40 gn = 392 m/s2 6 ms 6000 (1000 each direction) Unit operating Fc Vibration (sinusoidal) IEC/EN/DIN EN 60068-2-6 Acceleration amplitude: Unit operating Frequency (1 Oct/min): Test duration: 0.35 mm (10...60 Hz) 5 gn = 49 m/s2 (60...2000 Hz) 10...2000 Hz 7.5 h (2.5 h each axis) Fh Vibration, broad-band random (digital control) IEC/EN 60068-2-64 MIL-STD-810D section 514.3 Acceleration spectral density: Frequency band: Acceleration magnitude: Test duration: 0.05 gn2/Hz 20...500 Hz 4.9 gn rms 3 h (1 h each axis) Unit operating Kb Salt mist, cyclic (sodium chloride NaCl solution) IEC/EN/DIN IEC 60068-2-52 Concentration: Duration: Storage: Storage duration: Number of cycles: 5% (30C) 2 h per cycle 40C, 93% rel. humidity 22 h per cycle 3 Unit not operating Table 10: Temperature specifications, valid for air pressure of 800...1200 hPa (800...1200 mbar) Temperature Characteristics 1 2 TA Ambient temperature 1 TC Case temperature TS Storage temperature 1 Standard -9 Option -8 Conditions min max min max Unit Operational 2 -40 71 -40 85 C -40 95 -40 105 -40 100 -55 105 Non operational MIL-STD-810D section 501.2 and 502.2 See: Thermal Considerations Table 11: MTBF and device hours MTBF Ground Benign Ground Fixed Ground Mobile MTBF acc. to MIL-HDBK-217F TC = 40C TC = 40C TC = 70C TC = 50C 40 IMX 7-05-7 1'671'700 h 248'000 h 83'800 h 84'800 h 40 IMX 7-15-15-7 1'640'000 h 214'000 h 83'000 h 77'000 h Edition 6/5.2000 13/18 Board Mountable DC-DC Converters IMX 7 Series Mechanical Data Dimensions in mm. Tolerances 0.3 mm unless otherwise indicated. European Projection 4.6 (0.18") 1 4 5 x 3.81 (0.15") 14 20.3 (0.8") 3.81(0.15") 3 x 5.08 (0.2") 3.81(0.15") 10 25.4 (1") 0.8 x 1.2 (0.03 x 0.05") Pins 1.6 (0.06) PCB holes 50.8 (2") 3.4 (0.13") PT 2.2 self tapping screws 3.81(0.15") 45.7 (1.8") Measuring point of case temperature TC 10.5 (0.41") S09030 Fig. 22 Case IMX 7 with standard soldering pins Weight: <20 g 1 (0.04") Pins 1.2 (0.05") PCB holes 50.8 (2") 35.5 (1.4") 0.5(0.02") 4 2 5 09032 12.5 (0.49") Measuring point of case temperature TC 3.4 (0.13") 1 20.3 (0.8") 3 5.8 (0.2") 25.4 (1") 15.2 (0.6") 1 14 4 3.5 (0.14") 23 (0.9") 48 (1.9") 5 x 3.81 (0.15") 3 x 5.08 (0.2") 1.27 (0.05") Fig. 23 Case IMX 7 with C pinout (option C) for double output units, pins 6 and 7 are not fitted. With single output units pins 4, 6 and 7 are not fitted. Weight: <24 g 10 43.2 (1.7") 1.2 (0.5") Fig. 24 Open frame (option Z) Weight: <20 g Edition 6/5.2000 8.25 (0.32") S90002 14/18 50.8 (2") 10 4 25.4 (1") 0.8 x 1.2 (0.03 x 0.05") Pins 14 1 IMX 7 Series 5 x 3.81 (0.15") 3 x 5.08 (0.2") DC-DC Converters 3.81(0.15") Board Mountable 42.4 (1.67") S09031 11.0 (0.43") Measuring point of case temperature TC 4.2 (0.17") Fig. 25 Surface mount version with pins (option M) Weight: <20 g 1 Measuring point of case temperature TC 90001 10.5 (0.41") 25.4 (1") 50.8 (2") Fig. 26 Surface mount version with PCB lid (option L) Weight: <20 g Safety and Installation Instructions Installation Instruction Cleaning Agents Installation of the DC-DC converters must strictly follow the national safety regulations in compliance with the enclosure, mounting, creepage, clearance, casualty, markings and segregation requirements of the end-use application. In order to avoid possible damage, any penetration of cleaning fluids has to be prevented, since the power supplies are not hermetically sealed. Connection to the system shall be made via a printed circuit board according to: Mechanical Data. The units should be connected to a secondary circuit. Check for hazardous voltages before altering any connections. Do not open the module. Ensure that a unit failure (e.g. by an internal short-circuit) does not result in a hazardous condition. See also: Safety of operator accessible output circuit. Input Fuse To prevent excessive current flowing through the input supply line in case of a short-circuit across the converter input an external fuse should be installed in a non earthed input supply line. We recommend a fast acting fuse F2A for 20 IMX 7 and F1A for 40 IMX 7 and F0.63A for 70/110 IMX 7 types. Standards and approvals All DC-DC converters are pending to be UL recognized according to UL 1950, UL recognized for Canada to CAN/ CSA C22.2 No. 950-95 and LGA approved to IEC/EN 60950 standards. The units have been evaluated for: * Building in * Supplementary insulation input to output, based on their maximum input voltage * The use in a pollution degree 2 environment * Connecting the input to a secondary circuit which is subject to a maximum transient rating of 1500 V for 20/40 IMX 7, 2000 V for 70 IMX 7 and 2500 V for 110 IMX 7 types. The DC-DC converters are subject to manufacturing surveillance in accordance with the above mentioned UL, CSA, EN and ISO 9001 standards. Protection Degree The protection degree of the DC-DC converters is IP 30. Edition 6/5.2000 15/18 Board Mountable DC-DC Converters Isolation IMX 7 Series Table 15: Pin allocation SMD version (option L) The electric strength test is performed as factory test in accordance with IEC/EN 60950 and UL 1950 and should not be repeated in the field. Power-One will not honour any guarantee claims resulting from electric strength field tests. Table 12: Electric strength test voltages Characteristic I/O 20/40 IMX 70 IMX 110 IMX O/O Unit Pin Single output Dual output 1 Vo Vo1 2 Go Go 3 n.c. Vo2 4 n.c. n.c. 5 n.c. n.c. Electric strength test voltage 1 s 1.2 1.5 2.0 0.1 kVrms 6 n.c. n.c. 1.5 2.0 2.5 0.15 kV DC 7 n.c. n.c. Coupling capacitance 1.2 1.2 1.2 - nF 8 n.c. n.c. 9 n.c. Trim Insulation resist. at 500 V DC >100 10 n.c. n.c. 11 i i 12 no pin no pin 13 no pin no pin 14 n.c. n.c. Partial discharge extinction voltage >100 >100 - Consult factory - M kV Table 13: Pin allocation, standard pinout, option M and Z 15 n.c. n.c. Pin Single output Double output 16 n.c. n.c. 1 Vi+ Vi+ 17 Vi- Vi- 2 Vi- Vi- 18 Vi+ Vi+ 3 i i 4 n.c. R (Trim) 10 Vo- Vo1- 11 Vo+ Vo1+ 12 Vo- Vo2- 13 R Vo2+ 14 n.c. n.c. 10011 1 2 Bottom view 3 4 14 13 12 11 10 Fig. 25 Pin allocation standard pinout Table 14: Pin allocation for C-pinout (option C) Pin Single output Dual output 1 Vi+ Vi+ 2 Vi- Vi- 3 Vo+ Vo+ 4 no pin Go 5 Vo- Vo- 10012 3 1 2 4 5 Fig. 26 Pin allocation C pinout, bottom view Edition 6/5.2000 16/18 Board Mountable DC-DC Converters IMX 7 Series Safety of operator accessible output circuit If the output circuit of a DC-DC converter is operator accessible, it shall be an SELV circuit according to IEC/EN 60950 related safety standards. cuit according to IEC/EN 60950 up to a configured output voltage (sum of nominal voltages if in series or +/- configuration) of 46 V. The insulation concept table below shows some possible installation configurations, compliance with which causes the output circuit of the DC-DC converter to be an SELV cir- However, it is the sole responsibility of the installer to ensure the compliance with the relevant and applicable safety regulations. More information is given in: Technical Information: Safety. Table 16: Insulation concept leading to an SELV output circuit Conditions Front end Supply voltage Minimum required grade of isolation, to be provided by the AC-DC front end, including mains supplied battery charger Mains Basic 250 V AC Double or reinforced 1 2 3 4 5 DC-DC converter Result Maximum DC output voltage from the front end 1 Minimum required safety status of the front end output circuit Measures to achieve the specified safety status of the output circuit Safety status of the DC-DC converter output circuit 60 V Earthed SELV circuit 2 Operational insulation (proSELV circuit vided by the DC-DC converter) ELV circuit Input fuse 3 output suppressor diode(s) 4, and earthed output circuit(s) 2 >60 V Hazardous voltage secondary circuit 60 V SELV circuit >60 V TNV-2 circuit Earthed SELV circuit Operational insulation (proSELV circuit vided by the DC-DC converter) Supplementary insulation, based on the maximum input Double or reinforced insuvoltage (provided by the lated unearthed hazardous DC-DC converter) voltage secondary circuit 5 The front end output voltage should match the specified input voltage range of the DC-DC converter. The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC/EN 60950. The installer shall provide an approved fuse (type with the lowest rating suitable for the application) in a non-earthed input line directly at the input of the DC-DC converter (see fig.: Schematic safety concept). For UL's purpose, the fuse needs to be UL-listed. See also: Input Fuse. Each suppressor diode should be dimensioned in such a way, that in the case of an insulation fault the diode is able to limit the output voltage to SELV (<60 V) until the input fuse blows (see fig.: Schematic safety concept). Has to be insulated from earth by basic insulation according to the relevant safety standard, based on the maximum output voltage from the front end. 10004 Fuse ~ Mains ~ AC-DC front end Battery + DC-DC converter Earth connection Suppressor diode SELV - Earth connection Fig. 27 Schematic safety concept. Use fuse, suppressor diode and earth connection as per table: Safety concept leading to an SELV output circuit. Description of Options Table 17: Survey of options Option Function Characteristics -8 Operational temperature range TA = -40...85C Extended temperature range. Excludes option D. D Signal Out OK Available for single output units. Excludes option -8. M Surface mount version, SMD Excludes option C. C C-pinout Excludes option M as well as galvanic isolation between output 1 and 2 of double output units. Not available for 70/110 IMX 7 types. Option -8 Extension of the temperature range from standard -25...71 C to -40...85 C. The modules will provide full output power with free air convection cooling. UL recognition up to 80C. This option excludes option D. Edition 6/5.2000 17/18 Board Mountable DC-DC Converters Option C The C-pinout configures the electrically isolated double outputs to the "industrial pinout" Vo1+, Vo2- with common ground Go. With the C-pinout the converter height is increased by the adapter PCB (see also: Mechanical Data). Option D Single output units can be provided with an Out OK function. The D-output is an open collector transistor output referenced to Vo- and indicates that the output voltage is above approximately 90 % of the specified nominal output voltage. It can for example be used for remote signalling or to prevent a connected system from starting up at a low output voltage. The current ID through the NPN transistor should not exceed 20 mA. The NPN output is not protected against external overvoltages. UD should not exceed 25 V. Option D excludes option -8. Table 18: Out OK characteristics Out OK characteristics 3.3 V units 5.1 V units Unit Uo Uo min max min max UD low D output conducting UD high D output disabled Uo Hyst Hysteresis t D on delay Transistor on delay t D off delay Transistor off delay 3.0 4.75 2.85 V 4.5 560 140 100 Option M and L Surface mount version. Note: Precautions should be taken when reflow soldering the SMD version. The reflow soldering instructions below should be strictly adhered to. An inadequate soldering process may permanently damage the converter or degrade its performance and Power-One will not honour any guarantee/warranty claims resulting from damage caused by ignoring the soldering instructions. Infrared soldering is not permitted. The surface mountable version of this product is assembled with high melting point solder (227C) to ensure that the solder joints of of the internal components do not degrade in the end users SMD soldering process. This product is only specified for "Forced Convection Reflow Soldering" (Hot Air). Any conventional soldering profile is acceptable provided that the restriction curve below is not exceeded at any time during the reflow process. Tpeak [C] 11051 240 235 230 30 (typical) 140 IMX 7 Series mV 560 ms 100 s 225 220 215 210 11031 11 0 10 20 ID D Output control circuit 09119 UD Top view 11032 UD high Out OK t r on t D on delay 25.4 4 x 3.81 Fig. 31 Proposed solder lands option M Output voltage t t D off delay Fig. 29 Out OK signal with corresponding transistor status 3.6 (1.4") Foot print 24 (0.94") Uo Hyst 50 2.8 (0.11") Uo [V] 3.81 2 3.81 Vo- 3 x 5.8 4 10 UD low Fig. 28 Option D, Out OK 50 40 30 Fig. 30 Forced convection reflow soldering restriction curve measured on pin 2 Rp 14 t [s] 205 Vo+ 8 x 5 (1.9") Fig. 32 Proposed solder lands option L Edition 6/5.2000 18/18