Rugged Environment DC-DC Converters <40 Watt 35 Watt DC-DC Converters IMX 35 Series IMX 35 Series Input to output electric strength test up to 4 kV DC Input voltage: 9...36, 18...75 V DC 2, 3 and 4 outputs Configurable output voltages from 3.3 to 60 V DC * Extremely wide input voltage ranges * Electrical isolation, also between outputs * Emissions below EN 55022, level B * Immunity to IEC/EN 61000-4-2,-3,-4,-5 and -6 63.5 2.5" * Programmable input undervoltage lock-out 10.5 0.41" 76.2 3" * Shut down input * Output voltages adjustable with flexible load distribution * Frequency synchronisation * Outputs no-load, overload and short-circuit proof * Operating ambient temperature up to -40...85C * Thermal protection * 3" x 2,5" case with 10.5 mm profile or 8.9 mm open frame * Supplementary insulation 47.8 1.88" Safety according to IEC/EN 60950, UL 1950 8.9 0.35" 72.8 2.87" LGA Approvals pending Summary The IMX 35 series of board mountable 35 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 telecommunication where variable input voltages or high transient voltages are prevalent. Covering a total input voltage range from 9 up to 75 V with 2 different types. The units are available with double, triple and quadruple outputs, electrically isolated, from 3.3 V up to 60 V externally adjustable and with flexible load distribution. A shut down input allows remote converter on-off. Features include consistently high efficiency over the entire input voltage range, high reliability and excellent dynamic response to load and line changes. The converters are designed and built according to the international safety standards IEC/EN 60950, UL 1950, CAN/ CSA C22.2 No.950-95. LGA, UL and cUL approvals are in progress. The IMX 35 types provide supplementary insula- Table of Contents Page Summary .......................................................................... 1 Type Survey and Key Data .............................................. 2 Type Key .......................................................................... 3 Functional Description ...................................................... 4 Electrical Input Data ......................................................... 6 Electrical Output Data ...................................................... 8 tion. Connected to a secondary circuit the 40 IMX 35 types provide SELV outputs even if the voltage at the converter input exceeds the SELV-limit of 60 V DC. The circuit comprises of two planar magnetics devices and all components are automatically assembled and solidly soldered onto a single PCB without any wire connection. 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 without using any potting material allows operation at full load up to an ambient temperature of 71C in free air. For extremely high vibration environments the case has holes for screw mounting. Various options as e.g. extended temperature range -40...85C or an alternative pinout provide a high level of application specific engineering and design-in flexibility. Page Auxiliary Functions ......................................................... 11 Electromagnetic Compatibility (EMC) ............................ 13 Immunity to Environmental Conditions ........................... 14 Mechanical Data ............................................................ 15 Safety and Installation Instructions ................................ 16 Description of Option ...................................................... 18 Edition 1/10.99 1/18 IMX 35 Series DC-DC Converters <40 Watt Rugged Environment Type Survey and Key Data Table 1: Type survey Output 1 Uo nom Io nom [V DC] [A] Output 2 Uo nom Io nom [V DC] [A] Output 3 Uo nom Io nom [V DC] [A] Output 4 Uo nom Io nom [V DC] [A] Input voltage Ui min...Ui max [V DC] Eff. htyp [%] Type designation Trim Opt. -8 Z i 3.3 3.3 4.25 4.5 5 5 2.7 2.8 - - - - 9...36 18...75 83 20 IMX 35-03-05-9 40 IMX 35-03-05-9 second. 5.1 5.1 3.3 3.5 5 5 2.7 2.8 - - - - 9...36 18...75 84 20 IMX 35-05-05-9 40 IMX 35-05-05-9 second. 12 12 1.3 1.4 12 12 1.3 1.4 - - - - 9...36 18...75 87 87 20 IMX 35-1212-9 40 IMX 35-1212-9 primary 15 15 1.1 1.2 15 15 1.1 1.2 - - - - 9...36 18...75 20 IMX 35-1515-9 40 IMX 35-1515-9 primary 3.3 3.3 3.3 3.3 3.3 3.3 4.25 4.5 4.25 4.5 4.25 4.5 5 5 12 12 15 15 1.35 1.4 0.65 0.7 0.55 0.6 5 5 12 12 15 15 1.35 1.4 0.65 0.7 0.55 0.6 - - 9...36 18...75 9...36 18...75 9...36 18...75 20 IMX 35-03D05-9 40 IMX 35-03D05-9 20 IMX 35-03D12-9 40 IMX 35-03D12-9 20 IMX 35-03D15-9 40 IMX 35-03D15-9 second. 5.1 5.1 5.1 5.1 5.1 5.1 3.3 3.5 3.3 3.5 3.3 3.5 5 5 12 12 15 15 1.35 1.4 0.65 0.7 0.55 0.6 5 5 12 12 15 15 1.35 1.4 0.65 0.7 0.55 0.6 - - 9...36 18...75 9...36 18...75 9...36 18...75 second. 87 20 IMX 35-05D05-9 40 IMX 35-05D05-9 20 IMX 35-05D12-9 40 IMX 35-05D12-9 20 IMX 35-05D15-9 40 IMX 35-05D15-9 5 5 1.35 1.4 5 5 1.35 1.4 5 5 1.35 1.4 5 5 1.35 1.4 9...35 18...75 86 87 20 IMX 35 D05D05-9 40 IMX 35 D05D05-9 primary 12 12 0.65 0.7 12 12 0.65 0.7 12 12 0.65 0.7 12 12 0.65 0.7 9...35 18...75 87 89 20 IMX 35 D12D12-9 40 IMX 35 D12D12-9 primary 15 15 0.55 0.6 15 15 0.55 0.6 15 15 0.55 0.6 15 15 0.55 0.6 9...35 18...75 88 89 20 IMX 35 D15D15-9 40 IMX 35 D15D15-9 primary 83 86 83 86 Trim The Trim input on the primary side influences all outputs, while Trim1 on the secondary side influences the first output (Uo1) only. For the units IMX 35-12-12 and IMX 35-15-15 primary Trim (pin 5) is the Trim input influencing both outputs, while pin 18 is not connected. For the units IMX 35-03-05 and IMX 35-05-05, secondary Trim1 (pin 18) is the Trim1 input influencing only Uo1, while pin 5 is not connected. Edition 1/10.99 2/18 Rugged Environment DC-DC Converters <40 Watt IMX 35 Series Type Key Dual output units 20 IMX 35 - 12 - 12 -9 i Z Input voltage range Ui 9...36 V DC ........................................... 20 18...75 V DC ........................................... 40 Series ...................................................................... IMX 35 Output 1 of double types .............................. 03, 05, 12, 15 Output 2 of double types .................................... 05, 12, 15 Operating ambient temperature range TA -40...71C (standard) ................................. -9 -40...85C (option) ..................................... -8 Options: Inhibit ............................................................ i Open frame .................................................. Z Triple output units 20 IMX 35 - 05 D05 -9 i Z Input voltage range Ui 9...36 V DC ........................................... 20 18...75 V DC ........................................... 40 Series ...................................................................... IMX 35 Output 1 of triple types ............................................. 03, 05 Output 2 and 3 of triple types ..................... D05, D12, D15 Operating ambient temperature range TA -40...71C (standard) ................................. -9 -40...85C (option) ..................................... -8 Options: Inhibit ............................................................ i Open frame .................................................. Z Quad output units 20 IMX 35 D05 D05 -9 i Z Input voltage range Ui 9...36 V DC ........................................... 20 18...75 V DC ........................................... 40 Series ...................................................................... IMX 35 Output 1 and 4 of quad types ..................... D05, D12, D15 Output 2 and 3 of quad types ..................... D05, D12, D15 Operating ambient temperature range TA -40...71C (standard) ................................. -9 -40...85C (option) ..................................... -8 Options: Inhibit ............................................................ i Open frame .................................................. Z Edition 1/10.99 3/18 IMX 35 Series DC-DC Converters <40 Watt Rugged Environment Functional Description The IMX 35 family of DC-DC converters consists of two feedback controlled interleaved switching flyback power trains using current mode PWM (pulse width modulation). Functionally the converters are of three main types. The dual output types consist of two electrically isolated outputs Vo1, Vo2. Vo1 and Vo2 derives from two power trains and are electrically isolated. Voltage regulation for each output is achieved with passive transformer feedback from the main transformer of each power train. Adjustment of the outputs voltages in the range of 80...105% of Uo nom is possible via Trim input on the primary side (See: Block diagram, dual output types.) The triple output types consist of 3 outputs Vo1, Vo2, Vo3 and two configurations. In the first configuration Vo1 is a power train with a 5.1 V or 3.3 V output and a synchronous rectifier, thus enabling high efficiency. Also there is active magnetic feedback on this output via a pulse transformer which results in very tight and reliable regulation of the output voltage. The other two outputs Vo2 and Vo3 are electrically isolated double outputs. Vo2, Vo3 are restricted to being of the same output voltage (i.e. D05, D12, etc.). Voltage regulation is achieved with a passive transformer feedback from the main transformer of that power train. The quadruple output type consists of 4 outputs and two power trains. Vo1, Vo4 derive from the first power train and Vo2, Vo3 from the second one (thus each pair of outputs is independent from the other one). Voltage regulation for each pair of outputs is achieved with passive transformer feedback from the main transformer of each power train. Each pair of outputs are restricted to being of the same output voltage type (i.e. D05, D12, etc.). If both power trains have the same output voltage, all outputs may be adjusted by means of the Trim input. (In case of different output voltages, the Trim1 input influences only Vo1 and Vo4. See: Block diagram, quadruple output types.) Current limitation is provided by the primary circuit for each power train and limits the possible output power for each pair of outputs. In the case of an overload on either of the power trains which causes the output voltage to fall less than typically 60% of Uo nom , the entire converter will shut down and automatically restart in short intervals. Overtemperature protection is provided for each power train which will shut down the converter in excessive overload conditions with automatic restart approximately in short intervals. Adjustment of the output voltages is provided for Vo1 via the Trim1 pin referenced to the secondary side and allows for programming of the voltage of output 1 in the range of approx. 80...105% of Uo nom. (See: Block diagram, triple output types) 03100 Vi+ 4 17 Vo1+ PUL 1 15 Vo1- Trim/n.c. 5 W 6 PWM Ref 7 18 Trim1/n.c. SD 8 Vi- 2 n.c. 3 13 Vo2+ 11 Vo2- 19 n.c. 16 n.c. Fig. 1 Block diagram 1, double output types Edition 1/10.99 4/18 Rugged Environment DC-DC Converters <40 Watt IMX 35 Series 03097 Vi+ 4 17 Vo1+ PUL 1 Control n.c. 5 W 6 15 Vo1- PWM Ref 7 18 Trim1 SD 1 Vi- 2 n.c. 3 13 Vo2+ 14 Vo2- 12 Vo3+ 11 Vo3- 19 n.c. Fig. 2 Block diagram 2, triple output types 03098 Vi+ 4 15 Vo1+ PUL 1 16 Vo1- Trim 5 W 6 17 Vo4+ PWM Ref 7 18 Vo4- SD 8 Vi- 2 n.c. 2 13 Vo2+ 14 Vo2- 12 Vo3+ 11 Vo3- 19 n.c. Fig. 3 Block diagram 3, quadruple output types Edition 1/10.99 5/18 IMX 35 Series DC-DC Converters <40 Watt Rugged Environment Electrical Input Data General conditions: - TA = 25C, unless TC is specified. - Shut down pin left open circuit (not connected). - Trim not connected. Table 2: Input Data Input 20 IMX Characteristics 2 3 4 5 6 min 92 typ Ui Input voltage range Ui nom Nominal input voltage TA min...TA max Io = 0...Io nom Ui sur Repetitive surge voltage Abs. max input (3 s) t start up Converter Switch on start-up time 2 SD high Worst case condition at Ui min and full load Rise time 3 Ui nom resist load 5 Io nom capac. load 10 t rise 1 1 Conditions 40 IMX max min 36 18 2 20 typ Unit 75 V DC 40 40 0.25 max 0.5 100 0.25 0.1 0.5 5 20 s 0.1 10 ms 20 Ii o No load input current Io = 0, Ui min...Ui max 70 50 Iirr Reflected ripple current Io = 0...Io nom 30 30 Iinr p Inrush peak current 4 Ui = Ui nom 8 9 Ci Input capacitance for surge calculation 1.5 0.75 F U SD Shut down voltage Unit shut down -10...0.7 -10...0.7 V DC Unit operating open or 2...20 open or 2...20 R SD Shut down input resistance For current calculations approx. 10 approx. 10 I SD Input current if unit shut down Ui fs Switching frequency Ui min...Ui max, Io = 0...Io nom ui RFI Input RFI level, conducted EN 55022 5 min...Ui max 12 approx. 200 B6 B Ui min will not be as stated if Uo is increased above Uo nom by use of Trim input. If the output voltage is set to a higher value, Ui min will be proportionately increased. Input undervoltage lock-out at typ. 90% of Ui min. Measured with resistive and max. admissible capacitive load. Source impedance according to prETS 300132-2, version 4.3. Measured with a lead length of 0.1 m, leads twisted. External capacitor required. Edition 1/10.99 6/18 A k 6 approx. 200 mA mA kHz Rugged Environment DC-DC Converters <40 Watt IMX 35 Series Inrush current Input Transient Voltage Protection The inrush current has been kept as low as possible by choosing a very small input capacitance. A series resistor may be installed in the input line to further reduce this current. A built-in suppressor diode provides effective protection against input transients which may be caused for example by short-circuits accross the input lines where the network inductance may cause high energy pulses. I [A] Table 4: Built-in transient voltage suppressor 04022 Type 4 3 Breakdown voltage VBr nom [V] Peak power at 1 ms Pp [W] Peak pulse current Ipp [A] 2 20 IMX 35 50 1500 22 1 40 IMX 35 100 1500 9.7 t [s] 0 20 10 30 40 50 60 70 80 90 100 Fig. 4 Typical inrush current at Ui nom, Po nom versus time (40 IMX 35). Source impedance according to prETS 300132-2, version 4.3 at Ui nom. Note: The suppressor diode D is only necessary for 20 IMX 35 types. 04008 Uo t rise Uo nom For very high energy transients as for example to achieve IEC/EN 61000-4-5 or ETR 283 (19 Pfl1) compliance (as per table: Electromagnetic Immunity) an external inductor and capacitor are required. The components should have similar characteristics as listed in table: Components for external circuitry for IEC/EN 61000-4-5, level 2 or ETR 283 (19Pfl1) compliance. Table 5: Components for external circuitry for IEC/EN 61000-4-5, level 2 or ETR 283 (19Pfl1) compliance. Type t Inductor (L) Capacitor (C) Diode (D) 20 IMX 35 1.5 k E47A 40 IMX 35 - t start up Fig. 5 Converter start-up and rise time Vi+ Reverse Polarity Protection C The built-in suppressor diode also provides for reverse polarity protection at the input by conducting current in the reverse direction. An external fuse is required to limit this current. Table 3: Recommended external fuses Converter type 04036 L Fuse type 20 IMX 35 F8.0A 40 IMX 35 F4.0A + D Vi- Fig. 6 Example for external circuitry to comply with IEC/EN 61000-4-5 or ETR 283 (19Pfl1); the diode D is only necessary for 20 IMX 35 types. 22 04052 11.5 23.8 Fig. 7 Dimensions of inductor L for 20 IMX 35 and 40 IMX 35 types (e.g. Coil Craft, PCH-45 series). Edition 1/10.99 7/18 IMX 35 Series DC-DC Converters <40 Watt Rugged Environment Electrical Output Data General conditions: - TA = 25C, unless TC is specified - Shutdown pin left open circuit (not connected) - R input not connected Table 6a: Output data for single synchronous rectifier (main) output. Output 3.3 V Characteristics Conditions Uo Output voltage Io nom Output current min Ui nom, Io = 0.5 Io nom 20 IMX 3.28 Ui min...Ui max 40 IMX Io1L Io2L Current limit 1 20 IMX Io1L Io2L Ui nom, TC = 25C Uo1 = 93% Uo nom 40 IMX td aUo 3.3 4.25 3.5 6.0 4.5 6.1 4.6 V DC A 80 mVpp 40 40 115 130 Voltage deviat. Ui nom I 1/2 Io nom Recovery time o nom IEC/EN 61204 Temperature coefficient DUo/DTC 5.13 70 Ui min...Ui max Io = Io nom Dynamic load regulation 5.07 Unit 3 Output voltage noise uo d 3.32 4.25 max 2 uo1/2 Admissible capacitive load typ % Ui min...Ui max, Io = (0.05...1) * Io nom Co ext min 1 Line/load regulation Output overvoltage limit. 4 5.1 V max 1 DUo U Uo L typ Ui min...Ui max Io = 0...Io max 130 % 4000 115 3300 F 200 250 mV 1 1 ms 0.02 0.02 %/K Table 6b: Output data for double output power trains. 2x5V Output Characteristics Conditions min Ui nom Io = 0.5 Io nom 5.05 5.06 11.88 11.86 2 x 15 V max min typ 12.12 12.14 14.85 14.82 max Unit 15.15 15.18 V DC Output current 20 IMX IoL Current limit 1 20 IMX DUo U Line regulation Ui min...Ui max, Io nom 1 1 1 DUo l Load regulation Ui nom Io = (0.1...1) Io nom 3 3 3 uo1/2 Output voltage noise Ui min...Ui max Io = Io nom 80 120 150 Uo L Output overvoltage limit. 4 Co ext Admissible capacitive load uo d Dynamic load regulation aUo 4 typ Io nom td 3 min Output voltage 40 IMX 2 2 x 12 V max Uo1 Uo2 4.95 4.94 Ui min...Ui max 40 IMX 1 typ Ui nom, TC = 25C Uo = 93% Uo nom Min. load 1% 2 x 1.3 2 x 0.65 2 x 0.50 2 x 1.4 2 x 0.70 2 x 0.56 2.5 1.8 1.5 3.7 2 3 40 115 Voltage deviat. Ui nom I 1/2 Io nom Recovery time o nom Temperature coefficient DUo/DTC 2.0 Ui min...Ui max Io = 0...Io max 130 1.6 60 115 A 130 % mVpp 70 115 130 % 4000 470 330 F 250 400 400 mV 1 1 1 ms 0.02 0.02 0.02 %/K The current limit is primary side controlled. In the event of a sustained overload condition the thermal protection may cause the unit to shutdown (restart on cool-down). BW = 20 MHz Measured with a probe according to EN 61204 The overvoltage protection is via a primary side second regulation loop, not tracking with Trim control. Edition 1/10.99 8/18 Rugged Environment DC-DC Converters <40 Watt IMX 35 Series Thermal Considerations Output Overvoltage Protection 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 the surfaces and 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. The outputs of the converter are protected against overvoltages by a second control loop. In the event of an overvoltage on one of the outputs the unit will shut down and attempt to restart in short intervals. 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 overvoltage protection is not designed to withstand externally applied overvoltages. 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. Short Circuit Behaviour Typical Performance Curves General conditions: - TA = 25 oC, unless TC is specified. - Shut down pin left open circuit. - Trim input not connected. Uo [V] 05019 5.5 5.0 4.5 4.0 3.5 The current limit characteristic shuts down the converter whenever a short circuit is applied to an output. It acts selfprotecting and automatically recovers after removal of the overload condition (hiccup mode). Overtemperature Protection The converters individual power trains are protected from possible overheating by means of an internal temperature monitoring circuit. It shuts down the unit above the internal temperature limit and attempts to automatically restart. This feature prevents from excessive internal temperature building up which could occur under heavy overload conditions. Connection in Series 3.0 0 1 2 3 4 5 Io [A] Fig. 8 Uo versus Io (typ) of units with Uo = 5.1 V. (40 IMX 35-05D12-9). Uo [V] 05020 13 12 11 10 The outputs of one or several single or double output power trains may be connected in series without any precautions. 9 8 Connection in Parallel The outputs of one or several double output power trains (except 3.3 or 5.1 V types) with equal nominal output voltage can be connected in parallel. Approximate current sharing between 2 or several power trains is ensured by their load dependent output characteristic. 7 0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 Io total [A] Fig. 9 Uo1/2 versus Io1/2 of double output power trains (i.e. 2 x 12 V). See: Block diagram 1 Edition 1/10.99 9/18 IMX 35 Series DC-DC Converters <40 Watt Uo4 [V] Uo1, Uo2 [V] 05164 13.5 05039 14 13.0 12.5 Io4 = 0.035 A 12.0 Io4 = 0.35 A 13 Uo2 Uo1 12 11 11.5 11.0 0.06 0.10 0.20 0.30 0.40 0.50 0.70 Io1 [A] 0.60 Fig. 10 Cross load regulation Uo4 versus Io1 (typ) for various Io4 for Vo1, Vo4 on power train 1. See: Block diagram dual output types. (20 IMX 35 D12D12-9) h [%] 90 Rugged Environment 10 0 25 50 75 100 125 150 Io1 [%] Io1 nom Fig. 11 Flexible load distribution on power train 1 of 40 IMX 35 D12D12-9 (4 12 V) with load variation from 0...150% of Po1 nom on output 1 (Vo1). Output 2 (Vo4) loaded with 50% of Po4 nom. 05152 Ui min h [%] Ui nom 05153 90 Ui min 80 Ui max 80 Ui nom 70 Ui max 70 60 25 50 Po [%] 100 Po total 75 Fig. 12 Efficiency versus input voltage and load. Typical values 40 IMX 35 D12D12-9 Uo [%] 60 25 05041 switch-off 70 8.5 t [ms] 60.5 75 Po [%] 100 Po total Fig. 13 Efficiency versus input voltage and load. Typical values 20 IMX 35 D12D12-9 overload short circuit condition 100 50 60.5 Fig. 14 Overload switch off (hiccup mode), typical values. Edition 1/10.99 10/18 Rugged Environment DC-DC Converters <40 Watt IMX 35 Series Auxiliary Functions 06136 Shut Down Function Vi+ The outputs of the converters may be enabled or disabled by means of a logic signal (TTL, CMOS, etc.) applied to the shut down pin. If the shut down function is not required then it should be left open-circuit. Converter operating: Converter shut down: 17 4 Vo1+ Rext1 Trim1 18 Rext2 2.0...20 V -10...0.7 V Vi- 2 15 Vo1- Programmable Input Undervoltage Lockout PUL A special feature of these units is the accurate undervoltage lockout protection which protects the units (and system) from large currents caused by operation at low voltages. This ensures easier start-up in distributed power systems. Table 9: Uo1 versus Rext for Uo1 = 80...105% Uo nom; typical values (Ui nom, Io1/2 = 0.5 Io1/2 nom) Table 7: Turn on and turn off voltage Type Fig. 15 Output voltage control for the Trim1 input referenced to the secondary side. Trigger level Hysteresis Units Uo nom 20 IMX 35 7...8 0.5 V [V] Uo1 [V] [k] Uo1 [V] [k] 40 IMX 35 14...15.5 1 3.3 2.5 2.46 2.97 1.1 2.1 8 3.3 3.47 3.673 11 5 5 3.33 3.57 4.08 4.59 0.23 0.45 1.3 3.5 5 5.36 5.61 10 5 See: Electrical input data for a description of the turn on turn off voltage levels of the various types. The under voltage lockout levels may be programmed by use of an external resistor to Trim up the preset levels as indicated in the table below. Table 8: Typical values for Rext and the respective lockout voltage for input voltage. 20 IMX 35 40 IMX 35 Rext [k] Umin [V] Rext [k] Umin [V] 36 10 27 22 18 12 10 26 12 14 0 30 8 15.5 Rext1 Rext2 The units INX 35-12-12 and IMX 35-15-15 exhibit a Trim input connected to pin 5. This input influences both outputs simultaneously. Both power trains have passive transformer feedback and the Trim input (pin 5) is referenced to the primary side. Fig. 16 shows the circuit topology. Adjustment of the output voltage is possible by means of either an external resistor Rext in the range of 100...105% of Uo nom or an external voltage source in the range of 80...105% of Uo nom. 06137 Vi+ Adjustable Output Voltage As a standard feature, the IMX 35 offer adjustable output voltages in the range 80...105% of Uo nom by use of a control input pin. The Trim control is offered either on primary or secondary side of the converter depending on type. Trim The Trim1 (pin 18) is secondary referenced and influences only the first power train. Adjustment of the output voltage is possible by means of an external resistor Rext between the Trim1 pin and either Vo1+ or Vo1-. If the control input is left open circuit, the output voltage is set to Uo1 nom. Table 9 lists typical values required to program the output voltage to approximately the values of Uo1 indicated. 17 5 15 + Uext - For the dual output types refer to the block diagram 1. The units IMX 35-03-05 and IMX 35-05-05 feature a first power train with magnetic feedback and synchronous rectifier. The simplified circuit is shown in Fig. 15. 4 Control circuit Uref = 2.5 V Rext Vi- 2 13 11 Vo1+ Vo1- Vo2+ Vo2- Fig. 16 Output voltage control for double output units by means of the Trim input on the primary side. Edition 1/10.99 11/18 IMX 35 Series DC-DC Converters <40 Watt Rugged Environment Synchronisation (W) a) Adjustment by means of an external resistor Rext: Adjustment of the output voltage by means of an external resistor Rext is possible within the range of 100...105% of Uo nom. Rext should be connected between the Trim pin 5 and Vi-. Connection of Rext 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). Table 10: Rext1 for Uo > Uo nom; approximate values (U i nom, Io = 0.5 Io nom) This logic input can be used to synchronise the oscillator to an external frequency source. This pin is edge triggered with TTL thresholds, and requires a source frequency of 460...520 kHz (duty cycle 10...90%). The external source frequency is internally divided by two to define the switching frequency for the converter. If unused, this pin can be connected to V1- (pin 2) or left open-circuit. Reference (Ref) Uo [% Uo nom] Rext [k] 105...108 (107 typically) 105 104 103 102 101 100 0 3.3 6.2 10 18 39 This option provides a stable 5 V (0.2 V) reference signal on pin Ref. It is buffered through a 1.33 k resistor. This may be used also in conjunction with the Trim input pin 5 (primary side) as a limited external voltage source. We recommend to connect a filter capacitor (0.1 F) between Ref and Vi-, if Vref is used. b) Adjustment by means of an external voltage source Uext. For external output voltage adjustment in the range 80...105% of Uo nom a (0...20 V) source Uext is required, connected to the Trim pin 5 and Vi-. The table below indicates typical Uo versus Uext values. Applying a control voltage 15...20 V will set the converter into a hiccup mode. Direct paralleling of the Trim pins of units of the same type connected in parallel is feasible. Table 11: Uo versus Uext for Uo = 80...105% Uo nom; typical values (Ui nom, Io = 0.5 Io nom) Uo [% Uo nom] Uext [V] 105 102 100 95 85 80 0 1.8 2.5 4.25 8.25 10.2 The block diagram 2 shows the triple output units. They offer a Trim1 input (pin 18) on the secondary side to adjust Uo1. The other outputs remain unchanged. Pin 18 is not connected. Refer to Fig. 15 for the schematic and Table 8 to determine Rext. The quadruple output units are shown in block diagram 3 All types with equal output voltage have the Trim function connected to pin 5 which influences all outputs simultaneously. The schematics shown Fig. 16, the values of the adjust resistor Rext in Table 10 and the external voltage source in Table 11. Edition 1/10.99 12/18 Rugged Environment DC-DC Converters <40 Watt IMX 35 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 12: 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) 4000 Vp 1/50 ns 330 yes B 3 air discharge (R pin open) 8000 Vp 10 positive and 10 negative discharges 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 2 3 4 5 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 ETR 283 (19 Pfl 1) 4 limited to <100 A 3 positive yes B AM modulated 10 Vrms (140 dBV) 80%, 1 kHz +i/-i 150 Vp 0.1/0.3 ms Related and previous standards are referenced in: Technical Information: Standards. i = input, o = output. A = normal operation, no deviation from specification, B = temporary deviation from specs. possibe. For 40 IMX 35 types (additional external components required). Not applicable for 20 IMX 35 types. External components required. Electromagnetic Emission [dBV] 90 07020 [dBV/m] 50 80 07108 A EN 55022 A 70 40 B EN 55022 B 60 30 50 40 20 30 20 10 10 Fig. 17 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 35-D12D12-9) [MHz] 1000 500 200 100 50 0 30 20 30 10 5 2 1 0.5 0.1 0.05 MHz 0.02 0.01 0 Fig. 18 Typical radio frequency-interference voltage at Ui nom, Io nom, measured with an antenna (distance 10 m). Output leads 1 m, twisted. Edition 1/10.99 13/18 IMX 35 Series DC-DC Converters <40 Watt Rugged Environment CISPR 22/EN 55022, Level B Radiated Electromagnetic emission requirements according to EN 55022, class B (radiated emmission) can be achieved by adding an external common mode choke and (for 20 IMX 35 types) an additional capacitor, see: Input Data. The filter components should be placed as close as possible to the input of the converter. Table 13: Input filter components for EN 55022, level B, radiated. Type Current compensated choke 20 IMX 35 40 IMX 35 07114 15 V+ 8.5 07110 L Vi+ V- 15 Module Vi- Fig. 20 Choke dimensions Fig. 19 Example for external circuitry to comply with CISPR22/EN 55022, level B, radiated Immunity to Environmental Conditions Table 14: Temperature specifications, valid for air pressure of 800...1200 hPa (800...1200 mbar) Temperature -7 Characteristics 1 2 3 TA Ambient temperature 1 TC Case temperature TS Storage temperature 1 Option -8 3 -9 Conditions min max min max min max Unit Operational 2 -25 71 -40 71 -40 85 C -25 95 -40 95 -40 105 -40 100 -55 100 -55 105 Non operational MIL-STD-810D section 501.2 and 502.2 See: Thermal Considerations Start up at -55C Table 15: MTBF and device hours MTBF Ground Benign MTBF acc. to MIL-HDBK-217F 40 IMX 35 Ground Fixed Ground Mobile TC = 40C TC = 40C TC = 70C TC = 50C h h h h Table 16: Mechanical stress Test Method Standard Test Conditions Status Damp heat steady state IEC/DIN IEC 60068-2-3 MIL-STD-810D section 507.2 Temperature: Relative humidity: Duration: 40 2 C 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 MIL-STD-810D section 514.3 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) Ca 93 +2/-3 % 56 days Unit not operating Fda Random vibration wide band reproducibility high IEC 60068-2-35 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 Edition 1/10.99 14/18 Rugged Environment DC-DC Converters <40 Watt IMX 35 Series Mechanical Data Dimensions in mm. Tolerances 0.3 mm unless otherwise indicated. European Projection 09121 09123 thread M3 47.8 5.08 56.9 0.8 x 0.8 63.5 5.08 0.8 x 0.8 63.5 63.5 72.8 69.6 5 10.5 6.4 8.9 76.2 Fig. 21 Case IMX 35 (Standard) Weight: 67 g Fig. 22 Case IMX 35 open frame (option Z) Weight: 43 g Edition 1/10.99 15/18 IMX 35 Series DC-DC Converters <40 Watt Rugged Environment Safety and Installation Instructions Table 18: Pin allocation Installation Instructions 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. Pin No. Double output Triple output Quadruple output 1 PUL PUL PUL 2 Vi- Vi- Vi- 3 n.c. n.c. n.c. Connection to the system shall be made via a printed circuit board with hole diameters of 1.5 mm for the pins. The units should be connected to a secondary circuit. 4 Vi+ Vi+ Vi+ Check for hazardous voltages before altering any connections. 5 Trim or n.c. n.c. Trim 6 W W W Do not open the module. 7 Ref Ref Ref 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. 8 SD or i SD or i SD or i 11 Vo2- Vo3- Vo3- 12 n.c. Vo3+ Vo3+ 13 Vo2+ Vo2+ Vo2+ 14 n.c. Vo2- Vo2- 15 Vo1- Vo1- Vo1- 16 n.c. Trim1 Vo1+ 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 F8.0A for 20 IMX 35 types, F4.8 A for 40 IMX 35 types. 17 Vo1+ Vo1+ Vo4+ Standards and approvals 18 Trim1 or n.c. - Vo4- 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. 19 n.c. n.c. n.c. 09122 The units have been evaluated for: * Building in * Supplementary insulation input to output, based on their maximum input voltage (IMX 35 types) * 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 After approvals the DC-DC converters are subject to manufacturing surveillance in accordance with the above mentioned UL, CSA, EN and with ISO 9001 standards. Isolation 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. Melcher will not honour any guarantee claims resulting from electric strength field tests. Table 17: Electric strength test voltages Characteristic Input to output IMX 35 Output to output Electric strength test voltage 1 s 1.2 0.1 kVrms 1.5 0.5 kV DC >100 - M Consult factory - kV Insulation resistance at 500 V DC Partial discharge extinction voltage Unit 1 2 3 4 5 6 7 8 Bottom view 11 12 13 14 15 16 17 18 19 Fig. 23 Pin allocation Protection Degree The protection degree of the DC-DC converters is IP 30 (not for option Z). Cleaning Agents In order to avoid possible damage, any penetration of cleaning fluids should be prevented, since the power supplies are not hermetically sealed. Edition 1/10.99 16/18 Rugged Environment DC-DC Converters <40 Watt IMX 35 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 the IEC/EN 60950 related safety standards The following table shows some possible installation configurations, compliance with which causes the output circuit of the DC-DC converter to be an SELV circuit according to IEC/EN 60950 up to a configured output voltage (sum of nominal voltages if in series or +/- configuration) of 42 V. 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 19: 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 Type Measures to achieve the specified safety status of the output circuit Safety status of the DC-DC converter output circuit Earthed SELV circuit 2 IMX 35 Operational insulation (provided by the DC-DC converter) SELV circuit 75 V Hazardous voltage secondary circuit IMX 35 Input fuse 3 output suppressor diodes 4, and earthed output circuit 2 Earthed SELV circuit 60 V SELV circuit IMX 35 Operational insulation (provided by the DC-DC converter) 75 V Double or reinforced insulated unearthed hazardous voltage secondary circuit 5 IMX 35 Supplementary insulation based on the maximum rated output voltage from the front end (provided by the DC-DC converter) Maximum DC output voltage from the front end 1 Minimum required safety status of the front end output circuit 60 V 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 conductor 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 at least basic insulation according to the relevant safety standard, based on the maximum output voltage from the front end. ~ Mains ~ 10004 Fuse AC-DC front end Battery + DC-DC converter Earth connection Fig. 24 Schematic safety concept. Use fuse, suppressor diode and earth connection as per table: Safety concept leading to an SELV output circuit. Edition 1/10.99 17/18 Suppressor diode SELV Earth connection - IMX 35 Series DC-DC Converters <40 Watt Rugged Environment Description of Option Option -8 Extended Temperature Range Option i Inhibit Extension of the temperature range from standard -40...71C to -40...85C. In the upper temperature range the output power derating below should be observed. The modules will provide the specified ouptut power with free air convection cooling. The output 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 8) should be connected to Vi- to enable the output (active low logic, fail safe). Po /Po max Converter operating: Converter inhibited or inhibit pin left open circuit: 11047 1.2 1.0 -10 V...0.8 V 2.4 V...Ui max 06138 0.8 4 Vi+ 0.6 8 i 0.4 0.2 0 -40 2 Vi- -20 0 20 40 60 80 TA [C] Fig. 25 Maximum allowed output power versus ambient temperature. Fig. 26 If the inhibit is not used the inhibit pin should be connected to Vi- Option Z Open Frame Version Edition 1/10.99 18/18