IMX35 Series: 35W DC-DC Converters 9-36V, 18-75V, 40-121V & 60-150V Inputs Dual/Triple/Quad Outputs 3.3V, 5V, 12V & 15V Product Specifications Aug 2002 Wide input voltage ranges up to 150 V DC 2...4 outputs up to 60 V DC 1500 V DC I/O electric strength test voltage * Extremely wide input voltage ranges * Electrical isolation I/O, also between outputs * Emissions below EN 55022, level B * Immunity to IEC/EN 61000-4-2,-3,-4,-5 and -6 * Programmable input undervoltage lock-out 47.8 1.88" * Shut down/inhibit input 8.9 0.35" 72.8 2.87" * Output voltages adjustable with flexible load distribution * Frequency synchronisation * Outputs no-load, overload and short-circuit proof * Operating ambient temperature from -40...110C * Thermal protection * 3" x 2.5" case with 10.5 mm profile or 8.9 mm open frame * Basic insulation * Flexible output possibilities between 3.3 V & 60 V 63.5 2.5" Safety according to IEC/EN 60950, UL 1950 LGA 10.5 0.41" 76.2 3" Approvals pending Summary The IMX 35 series of board mountable 35 Watt DC-DC converters has been designed according to 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 V up to 150 V with 4 different types. The units are available with up to quadruple outputs (electrically isolated) from 3.3 V up to 60V 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 basic insulation. Table of Contents Page Summary .......................................................................... 1 Type Survey and Key Data .............................................. 2 Type Key .......................................................................... 2 Functional Description ..................................................... 3 Electrical Input Data ......................................................... 4 Electrical Output Data ...................................................... 6 AUG 13, 2002 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, operation to 110C with airflow. For extremely high vibration environments the case has holes for screw mounting. Inhibit or open frame mounting provide a high level of application specific engineering and design-in flexibility. Page Auxiliary Functions ........................................................... 9 Electromagnetic Compatibility (EMC) ............................ 11 Immunity to Environmental Conditions .......................... 12 Mechanical Data ............................................................ 13 Safety and Installation Instructions ................................ 14 Description of Option ..................................................... 15 Rev 1.0 www.power-one.com Page 1 of 15 IMX35 Series: 35W DC-DC Converters 9-36V, 18-75V, 40-121V & 60-150V Inputs Dual/Triple/Quad Outputs 3.3V, 5V, 12V & 15V Product Specifications Aug 2002 Type Survey and Key Data Table 1: Type survey Output 1 Vo nom Io nom [V DC] [A] Output 2 Vo nom Io nom [V DC] [A] Output 3 Vo nom Io nom [V DC] [A] Output 4 Vo nom Io nom [V DC] [A] Input voltage Vi min...Vi max [V DC] Eff. typ [%] Type designation Trim1 Opt.2 3.3 3.3 3.3 4.15 4.15 4.15 5 12 15 1.35 0.7 0.6 5 12 15 1.35 0.7 0.6 - - 18...75 18...75 18...75 81 83 84 40 IMX 35-03D05-9 40 IMX 35-03D12-9 40 IMX 35-03D15-9 second. -8 i Z 5.1 5.1 5.1 3.25 3.25 3.25 5 12 15 1.4 0.7 0.6 5 12 15 1.4 0.7 0.6 - - 18...75 18...75 18...75 82 83 84 40 IMX 35-05D05-9 40 IMX 35-05D12-9 40 IMX 35-05D15-9 second. -8 i Z 5 5 5 5 1.35 1.4 1.4 1.4 5 5 5 5 1.35 1.4 1.4 1.4 5 5 5 5 1.35 1.4 1.4 1.4 5 5 5 5 1.35 1.4 1.4 1.4 9...36 18...75 40...121 60...150 86 87 86 86 20 IMX 35 D05D05-9 40 IMX 35 D05D05-9 70 IMX 35 D05D05-8 110 IMX 35 D05D05-8 12 12 12 12 0.65 0.7 0.7 0.7 12 12 12 12 0.65 0.7 0.7 0.7 12 12 12 12 0.65 0.7 0.7 0.7 12 12 12 12 0.65 0.7 0.7 0.7 9...36 18...75 40...121 60...150 86 88 88 88 20 IMX 35 D12D12-9 40 IMX 35 D12D12-9 70 IMX 35 D12D12-8 110 IMX 35 D12D12-8 15 15 15 15 0.55 0.6 0.6 0.6 15 15 15 15 0.55 0.6 0.6 0.6 15 15 15 15 0.55 0.6 0.6 0.6 15 15 15 15 0.55 0.6 0.6 0.6 9...36 18...75 40...121 60...150 88 89 88 88 20 IMX 35 D15D15-9 40 IMX 35 D15D15-9 70 IMX 35 D15D15-8 110 IMX 35 D15D15-8 5 5 5 5 1.35 1.4 1.4 1.4 12 12 12 12 0.65 0.7 0.7 0.7 12 12 12 12 0.65 0.7 0.7 0.7 5 5 5 5 1.35 1.4 1.4 1.4 9...36 18...75 40...121 60...150 88 89 88 88 20 IMX 35 D05D12-9 40 IMX 35 D05D12-9 70 IMX 35 D05D12-8 110 IMX 35 D05D12-8 5 5 5 5 1.35 1.4 1.4 1.4 15 15 15 15 0.55 0.6 0.6 0.6 15 15 15 15 0.55 0.6 0.6 0.6 5 5 5 5 1.35 1.4 1.4 1.4 9...36 18...75 40...121 60...150 88 89 88 88 20 IMX 35 D05D15-9 40 IMX 35 D05D15-9 70 IMX 35 D05D15-8 110 IMX 35 D05D15-8 primary primary primary primary primary -8 i,Z i Z -8 i,Z i Z -8 i,Z i Z -8 i,Z i Z -8 i,Z i Z 1 The Trim input (pin 5) on the primary side influences all outputs simultaneously on equal voltage types (eg D12D12) for unequal voltages (eg D05D12) it only influences the power train Vo1/Vo4, while Trim1 (pin 18) on the secondary side influences the first output (Vo1) only. 2 For minimum quantity contact Power-One, not all options immediately available. TYPE KEY 20 IMX 35 D05 D05 -9 i Z Input voltage range Ui 9...36 V DC 18...75 V DC 40..121V DC 60..150V DC ........................................... 20 ........................................... 40 ........................................... 70 ......................................... 110 Series ...................................................................... IMX 35 Output 1 of triple types ........................................... -03, -05 Output 1 & 4 of quad types1 ................................. D05, D12, D15 Output 2 & 3 of quad types1 ................................. D05, D12, D15 Operating ambient temperature range TA -40...71C ................................................... -9 -40...85C (110C ) .................................... -8 Options: 1 Dual Inhibit ........................................................... -i Open frame .................................................. Z output models can be achieved by paralleling outputs AUG 13, 2002 Rev 1.0 www.power-one.com Page 2 of 15 IMX35 Series: 35W DC-DC Converters 9-36V, 18-75V, 40-121V & 60-150V Inputs Dual/Triple/Quad Outputs 3.3V, 5V, 12V & 15V Product Specifications Aug 2002 Functional Description 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.) The IMX35 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 two main types. The triple output types consist of 3 outputs Vo1, Vo2, Vo3. Vo1 (3.3 V or 5.1 V) is generated by a power train using synchronous rectifier technology 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 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 90...105% of Vo nom is possible via Trim input on the primary side. Adjustment of the output 1 (Vo1) is provided by the Trim1 pin referenced to the secondary side and allows for programming of the voltage of output 1 in the range of approx. 90...105% of Vo nom. (See: Block diagram, triple output types) 03097a Vi+ 4 17 Vo1+ Vi+ 4 PUL 1 Control n.c. 5 PWM W 6 03098 Ref 7 SD 8 16 n.c. 16 Vo1+ PUL 1 15 Vo1-- 15 Vo1--Trim 5 W 6 PWM 17 Vo4+ 18 Trim1 Ref 7 SD 8 Vi-- 2 18 Vo4-- Vi-- 2 n.c. 3 13 Vo2+ n.c. 3 14 Vo2-- 13 Vo2+ 14 Vo2-- 12 Vo3+ 12 Vo3+ 11 Vo3-- 11 Vo3-- 19 n.c. 19 n.c. Fig. 2 Block diagram, quadruple output types Fig. 1 Block diagram, triple 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 Vo nom , the entire converter will shut down and automatically restart in short intervals. Overtemperature protection is provided, this will shut down the converter in excessive overload conditions with automatic restart approximately in short intervals. AUG 13, 2002 Rev 1.0 www.power-one.com Page 3 of 15 IMX35 Series: 35W DC-DC Converters 9-36V, 18-75V, 40-121V & 60-150V Inputs Dual/Triple/Quad Outputs 3.3V, 5V, 12V & 15V Product Specifications Aug 2002 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 1 Conditions min 92 typ Vi Input voltage range Vi nom Nominal input voltage TA min...TA max Io = 0...Io nom Vi 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 3 Io nom capac. load 6 t rise 5 6 max Unit 75 V DC 40 40 0.25 100 0.5 0.25 0.5 0.1 s 0.1 3 12 ms 6 12 No load input current Io = 0, Ui min...Ui max 70 50 Reflected ripple current Io = 0...Io nom 30 30 Iinr p Inrush peak current 4 Ui = Ui nom 8 9 mA A Ci Input capacitance for surge calculation 2 1.3 F U SD Shut down voltage Unit shut down -10...0.7 -10...0.7 V DC Unit operating open circuit or 2...20 open circuit 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 Input RFI level, conducted min...Ui max EN approx. 220 B6 B6 70 IMX 110 IMX min Input voltage range Vi nom Nominal input voltage TA min...TA max Io = 0...Io nom Vi 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 40 6 approx. 220 55022 5 Conditions 1 k 12 Vi t rise 4 typ Ii o Characteristics 3 36 18 2 20 Input 2 min Iirr ui RFI 1 40 IMX max typ max min 121 602 2 70 typ 150 max Unit 150 V DC 0.5 170 0.25 0.1 3 Io nom capac. load 6 kHz 110 0.25 Ui nom resist load mA 0.5 s 0.1 3 12 6 ms 12 Ii o No load input current Io = 0, Ui min...Ui max 30 20 Iirr Reflected ripple current Io = 0...Io nom 30 30 Iinr p Inrush peak current 4 Ui = Ui nom Ci Input capacitance for surge calculation U SD Shut down voltage R SD Shut down input resistance For current calculations 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 7 mA 7 A 0.5 0.5 F Unit shut down -10...0.7 -10...0.7 V DC Unit operating open circuit or 2...20 open circuit or 2...20 approx. 10 approx. 10 min...Ui max 3.5 k 4 approx. 220 approx. 220 B6 B6 mA kHz Vi min will not be as stated if Vo is increased above Vo nom by use of Trim input. If the output voltage is set to a higher value, Vi min will be proportionately increased. Input undervoltage lock-out at typ. 85% of Ui min. Measured with resistive and max. admissible capacitive load. Source impedance according to ETS 300132-2, version 4.3. Measured with a lead length of 0.1 m, leads twisted. External capacitor required. AUG 13, 2002 Rev 1.0 www.power-one.com Page 4 of 15 IMX35 Series: 35W DC-DC Converters 9-36V, 18-75V, 40-121V & 60-150V Inputs Dual/Triple/Quad Outputs 3.3V, 5V, 12V & 15V Product Specifications Aug 2002 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 39 1500 22 1 40 IMX 35 100 1500 9.7 70 IMX 35 151 600 2.9 110 IMX 35 176 600 2.5 t [s] 0 10 20 30 40 50 60 70 80 90 100 Fig. 3 Typical inrush current at Ui nom, Po nom versus time (40 IMX 35). Source impedance according to prETS 300132-2, version 4.3 at Vi nom. Uo Uo nom t rise 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. 04008 Note: The suppressor diode D is only necessary for 20 IMX 35 types. t t start up Table 5: Components for external circuitry for IEC/EN 61000-4-5, level 2 or ETR 283 (19Pfl1) compliance. Fig. 4 Converter start-up and rise time Type Reverse Polarity Protection 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. Inductor (L) Capacitor (C) Diode (D) 20 IMX 35 22 H/5A 470 F/40 V 1.5 k E47A 40 IMX 35 68 H/2.7 A 2 x 100 F/100 V - 70 IMX 35 100 H/1 A 2 x 82 F/200 V - 2 x 82 F/200 V - 110 IMX 35 150 H/0.8 A Table 3: Recommended external fuses Converter type Vi+ Fuse type 20 IMX 35 F8.0A 40 IMX 35 F4.0A 70 IMX 35 F2.0A 110 IMX 35 F1.5A AUG 13, 2002 04036 L C + D Vi- Fig. 5 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. Rev 1.0 www.power-one.com Page 5 of 15 IMX35 Series: 35W DC-DC Converters 9-36V, 18-75V, 40-121V & 60-150V Inputs Dual/Triple/Quad Outputs 3.3V, 5V, 12V & 15V Product Specifications Aug 2002 Electrical Output Data General conditions: - TA = 25C, unless TC is specified - Shutdown pin left open circuit (not connected) - Trim not connected Table 6a: Output data for single synchronous rectifier (main) output. [only 40IMX35-03 & 40IMX35-05 triple output units] Output 3.3 V Characteristics Conditions min Uo Output voltage Ui nom, Io = 0.5 Io nom Io nom Output current Io1L Io2L Current limit 1 Ui nom, TC = 25C Uo1 = 93% Uo nom Uo U Line/load regulation Ui min...Ui max, Io = (0.05...1) * Io nom uo1/2 Output voltage noise Ui min...Ui max Io = Io nom 5.1 V typ 3.28 max min 3.32 5.07 typ 4.15 3.3 5.5 4.6 max Unit 5.13 V DC A 1 1 % 2 70 80 mVpp 3 40 40 limit. 4 Uo L Output overvoltage 130 % Co ext Admissible capacitive load 3900 2700 F uo d Dynamic load regulation 250 250 mV 1 1 ms 0.02 0.02 %/K td Uo 115 130 Voltage deviat. Ui nom I x 1/2 Io nom Recovery time o nom IEC/EN 61204 Temperature coefficient Uo/TC Ui min...Ui max Io = 0...Io max 115 Table 6b: Output data for double output power trains. (Vo1/Vo4 or Vo2/Vo3, i.e. each output train has two outputs) Output 2x5V Characteristics Conditions Uo1 Uo2 Output voltage Io nom Output current IoL Current limit min Ui nom Io = 0.5 Io nom 20 IMX min 14.85 14.82 typ max Unit 15.15 15.18 V DC 2 x 0.55 2 x 0.70 2 x 0.60 70 IMX 2 x 1.4 2 x 0.70 2 x 0.60 110 IMX 2 x 1.4 2 x 0.70 2 x 0.60 20 IMX Ui nom, TC = 25C Uo = 93% Uo nom 3.5 1.8 1.5 3.8 2.0 1.7 3.8 2.0 1.7 3.8 2.0 A 1.7 Uo U Line regulation Ui min...Ui max, Io nom 1 1 1 Uo 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 2 80 120 150 3 40 60 70 % mVpp Uo L Output overvoltage limit. 4 Co ext Admissible capacitive load 4000 470 330 F uo d Dynamic load regulation 250 480 520 mV 0.75 0.75 0.75 ms 0.02 0.02 0.02 %/K td Uo 4 max 12.12 12.14 2 x 0.65 110 IMX 3 typ 2 x 1.4 70 IMX 2 min 11.88 11.86 2 x 1.35 1 Ui min...Ui max max 5.05 5.06 2 x 15 V 40 IMX 40 IMX 1 typ 4.95 4.94 2 x 12 V Min. load 1% Voltage deviat. Ui nom I x 1/2 Io nom Recovery time o nom Temperature coefficient Uo/TC Ui min...Ui max Io = 0...Io max 115 130 115 130 115 130 % 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. AUG 13, 2002 Rev 1.0 www.power-one.com Page 6 of 15 IMX35 Series: 35W DC-DC Converters 9-36V, 18-75V, 40-121V & 60-150V Inputs Dual/Triple/Quad Outputs 3.3V, 5V, 12V & 15V Product Specifications Aug 2002 Thermal Considerations Short Circuit Behaviour 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 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). 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. Option -8 Extended Temperature Range Extension of the temperature range from standard -40...71C to -40...85C (upto 110C). The modules will provide the specified ouptut power with free air convection cooling. In the upper temperature range the output power derating below should be observed. Overtemperature Protection The converter is protected against 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 excessive internal temperature building up which could occur under heavy overload conditions. Connection in Series The outputs of one or several single or double output power trains may be connected in series without any precautions. Connection in Parallel Several outputs of the same converter with equal output voltage (e.g. 5V / 5V) can be put in parallel and will share their output currents almost equally. NOTE: A separate application note is available for uses when all outputs are paralleled together. Parallel operation of several converters with the same output voltage may cause start-up problems at initial start-up. This is only advisable in applications where one converter is able to deliver the full load current as is required in true redundant systems. It is recommended not to parallel more than three units at full load. Output Power Vs AmbientTemp. and Airflow (-8 version) The first outputs (main output of 5.1V or 3.3V) of triple output units should not be paralleled, except in true redundant systems using decoulping diodes. 120 Output Power (%) 100 80 60 1200LFM (0.5 m/s) 40 0 LFM 20 110 100 85 70 55 40 25 10 0 -20 -40 0 Ambient Temperature (deg C) Fig. 6 Maximum allowed output power versus ambient temperature. AUG 13, 2002 Rev 1.0 www.power-one.com Page 7 of 15 IMX35 Series: 35W DC-DC Converters 9-36V, 18-75V, 40-121V & 60-150V Inputs Dual/Triple/Quad Outputs 3.3V, 5V, 12V & 15V Product Specifications Aug 2002 Uo1, Uo2 [V] Typical Performance Curves 05039 General conditions: - TA = 25C, unless TC is specified. - Shut down pin left open circuit. - Trim input not connected. 14 13 Uo2 Uo1 12 11 Uo [V] 10 05019 5.5 5.0 0 25 50 75 100 Io1 [%] Io1 nom 150 125 Fig. 10 Flexible load distribution on power train 1 of 40 IMX 35 D12D12-9 (4 x 12 V) with load variation from 0...150% of Po1 nom on output 1 (Vo1). Output 2 (Vo4) loaded with 50% of Po4 nom. 4.5 4.0 3.5 h [%] 3.0 0 3 2 1 4 5 Io [A] Fig. 7 Uo versus Io (typ) of units with Uo = 5.1 V. (40 IMX 35-05D12-9). 05152 90 Ui min Ui nom 80 70 Uo [V] 05020 13 Po [%] 100 Po total 12 60 25 11 Fig. 11 Efficiency versus input voltage and load. Typical values 40 IMX 35 D12D12-9 10 50 75 9 h [%] 8 7 90 0 0.2 0.4 05153 Ui min 0.6 0.8 1.0 1.2 1.4 1.6 1.8 Io total [A] 80 Fig. 8 Uo1/2 versus Io1/2 of double output power trains (i.e. 2 x 12 V). See: Block diagram 1 Ui nom 70 Uo4 [V] 05164 13.5 60 25 13.0 12.5 Io4 = 0.035 A 12.0 Io4 = 0.35 A Po [%] 100 Po total 75 Fig. 12 Efficiency versus input voltage and load. Typical values 20 IMX 35 D12D12-9 05041 Uo [%] 11.5 11.0 0.06 0.10 50 overload short circuit condition 100 0.20 0.30 0.40 0.50 0.60 0.70 Io1 [A] switch-off 70 Fig. 9 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) 8.5 t [ms] 60.5 60.5 Fig. 13 Overload switch off (hiccup mode), typical values. AUG 13, 2002 Rev 1.0 www.power-one.com Page 8 of 15 IMX35 Series: 35W DC-DC Converters 9-36V, 18-75V, 40-121V & 60-150V Inputs Dual/Triple/Quad Outputs 3.3V, 5V, 12V & 15V Product Specifications Aug 2002 Quad output adjustment Auxiliary Functions Adjustable Output Voltage As a standard feature, the IMX 35 offer adjustable output voltages in the range 90...105% of Vo nom by use of a control pin. The Trim control is offered either on primary or secondary side of the converter depending on type. The quadruple output units are shown in block diagram (fig. 2). All types with equal output voltage have the Trim function connected to pin 5 referenced to the primary side which influences all outputs simultaneously. The schematics are shown in fig. 15, the values of the adjust resistor Rext in Table 8 and the external voltage source in Table 9. Adjustment by means of an external resistor Rext: Triple output adjustment Adjustment of the output voltage by means of an external resistor Rext is possible within the range of 100...105% of Vo nom. Rext should be connected between Trim (pin 5) and Vi- (pin 2). Connection of Rext to Vi+ may damage the converter. The following table indicates suitable resistor values for typical output voltages under nominal conditions (Vi nom, Io = 0.5 Io nom). Block diagram (fig. 1) shows the triple output units. They offer a Trim1 input (pin 18) on the secondary side to adjust Vo1. The other outputs remain unchanged. The IMX 35 triple output feature a main power train with magnetic feedback and synchronous rectifier. The simplified circuit is shown in Fig. 14. The Trim1 (pin 18) is secondary referenced and influences only the main 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 Vo1 nom. Table 8: Rext1 for Vo > Vo nom; approximate values (Vi nom, Io = 0.5 Io nom) Rext [k] Vo [% Vo nom] 105...108 (107 typically) 105 102 100 Table 7 lists typical values required to program the output voltage to approximately the values of Vo1 indicated. Trim [k] Trim 1/4 [k] 0 10 62 0 17 110 06136 Vi+ 17 4 06137 Vo1+ Vi+ Rext1 18 Trim Trim1 2 15 Uext Table 7: Vo1 versus Rext for Vo1 = 90...105% Vo nom; typical values (Vi nom, Io1/2 = 0.5 Io1/2 nom) Rext1 5 15 Rext2 [V] Vo1 [V] [k] Vo1 [V] [k] 3.3 2.97 3.135 1.8 4.7 3.3 3.47 3.673 11 5 5.1 4.59 4.84 5.0 2.2 9.1 33 5.1 5.25 5.35 8.5 3 Control circuit Uref = 2.5 V Rext - Vo1- Fig. 14 Output voltage control for the Trim1 input referenced to the secondary side. Vo nom 17 + Rext2 Vi- 4 Vi- 2 11 Vo1- Vo2+ Vo2- Fig. 15 Output voltage control for Quad (double) output units by means of the Trim input on the primary side. Adjustment by means of an external voltage source Vext For external output voltage adjustment in the range 85...105% of Vo nom a (0...20 V) source Vext is required, connected to the Trim (pin 5) and Vi-. The table below indicates typical Vo versus Vext 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 9: Vo versus Vext for Vo = 85...105% Vo nom; typical values (Vi nom, Io = 0.5 Io nom) Uo [% Uo nom] >105 102 100 95 90 85 AUG 13, 2002 13 Vo1+ Rev 1.0 www.power-one.com Uext [V] Trim [V] Trim 1/4 [V] 0 1.8 2.5 4.3 6.2 8 0 1.5 2.5 4.25 6.2 8 Page 9 of 15 IMX35 Series: 35W DC-DC Converters 9-36V, 18-75V, 40-121V & 60-150V Inputs Dual/Triple/Quad Outputs 3.3V, 5V, 12V & 15V Product Specifications Aug 2002 Synchronisation (W) It is posible to synchronise the switching frequency of one or more converters to an external symmetrical clocksignal. Consult factory if this option is required, for full application details. 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 490...540 kHz (duty cycle 10...90%). The external source frequency is internally divided by 2 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) The signal output provides a stable 5 V (0.1 V) reference signal on pin Ref. It is protected by a 1 k resistor. This signal may be used also in conjunction with the Trim input pin 5 (primary side) as a limited external voltage reference. It is recommended to connect a filter capacitor (0.1 F) between Ref and Vi-, if Vref is used. Shut Down Function 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: 2.0...20 V -10...0.7 V Option i Inhibit (negative shutdown logic) 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). Converter operating: Converter inhibited or inhibit pin left open circuit: -10 V...0.8 V 2.4 V...20 V 06138 Programmable Input Undervoltage Lockout PUL A special feature of these units is the accurate undervoltage lockout protection which protects the unit (and the system) from large currents caused by operation at low voltages. This ensures easier start-up in distributed power systems. Table 10: Turn on and turn off voltage Type Trigger level Hysteresis Units 20 IMX 35 7...8 <0.5 V 40 IMX 35 14...15.5 <1 70 IMX 35 31 ... 34 <3 110 IMX 35 42 ...50 <8 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 11: Typical values for Rext and the respective lockout voltage for input voltage. 20 IMX 35 40 IMX 35 RPUL [k] Ui min [V] Rext [k] Umin [V] 8 15.5 39 10 43 22 19 12 16 26 13 14 10 28 9.1 16 0 32 70 IMX 35 110 IMX 35 RPUL [k] Ui min [V] Rext [k] Umin [V] 31 42 270 40 270 50 110 50 120 60 80 55 51 75 4 Vi+ 8 i 2 Vi- Fig. 16 If the inhibit is not used the inhibit pin should be connected to Vi- AUG 13, 2002 Rev 1.0 www.power-one.com Page 10 of 15 IMX35 Series: 35W DC-DC Converters 9-36V, 18-75V, 40-121V & 60-150V Inputs Dual/Triple/Quad Outputs 3.3V, 5V, 12V & 15V Product Specifications Aug 2002 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 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 4 3 +i/-i 2000 Vp 1.2/50 s 2 5 pos. and 5 neg. impulses per coupling mode yes B 100 triangular yes B 50 0.15...80 MHz 150 yes A EN 50155 Conducted disturbancies 1 2 3 4 In Per- 3 oper. form. IEC/EN 61000-4-6 D 1800V 5/50 s G 8400V .05/01 s 3 +i/-i 10 Vrms AM modulated (140 dBV) 80%, 1 kHz 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. possible. External components required. Electromagnetic Emission [dBV] 90 07020 80 EN 55022 A 70 EN 55022 B 60 50 40 30 20 10 20 30 10 5 2 1 0.5 0.1 0.05 MHz 0.02 0.01 0 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) AUG 13, 2002 Rev 1.0 www.power-one.com Page 11 of 15 IMX35 Series: 35W DC-DC Converters 9-36V, 18-75V, 40-121V & 60-150V Inputs Dual/Triple/Quad Outputs 3.3V, 5V, 12V & 15V Product Specifications Aug 2002 CISPR 22/EN 55022, Level B Radiated Electromagnetic emission requirements according to EN 55022, class B (radiated) 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. 07114 L V+ Module V- Table 13: Input filter components for EN 55022, level B, radiated. Type Vi+ Vi- Current compensated choke 20 IMX 35 40 IMX 35 70 IMX 35 110 IMX 35 Fig. 18 Example for external circuitry to comply with CISPR22/EN 55022, level B, radiated Murata PLH1OA series 7003R6P02 Murata PLH1OA series 1612R1P02 Murata PLH1OA series 2911R2P02 Murata PLH1OA series 3711R0P02 Immunity to Environmental Conditions Table 14: Temperature specifications, valid for air pressure of 800...1200 hPa (800...1200 mbar) -8 3 Temperature Characteristics 1 2 3 TA Ambient temperature 1 TC Case temperature TS Storage temperature 1 Conditions min max Unit Operational 2 -40 852 C -40 110 -55 110 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 (Standard) Ground Benign 40 IMX 35 (MIL-HDBK-217F) Ground Fixed Ground Mobile 336,000 hrs (TC = 40C) 141,000 (TC = 40C) 86,000 (TC = 70C) 110,000 (TC = 50C) 110 IMX 35 (Bellcore) 1,372,000 hrs @ 25C at 100% load Table 16: Environmental testing 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 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 Unit not operating 93 +2/-3 % 56 days 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 AUG 13, 2002 Rev 1.0 www.power-one.com Page 12 of 15 IMX35 Series: 35W DC-DC Converters 9-36V, 18-75V, 40-121V & 60-150V Inputs Dual/Triple/Quad Outputs 3.3V, 5V, 12V & 15V Product Specifications Aug 2002 Mechanical Data European Projection Dimensions in mm. Tolerances 0.3 mm unless otherwise indicated. 09121 09123 thread M3 5.08 Tc 47.8 56.9 0.8 x 0.8 63.5 5.08 0.8 x 0.8 Tc Tc 63.5 63.5 72.8 69.6 76.2 5 10.5 Cores Fig. 19 Case IMX 35 (Standard) Weight: 67 g AUG 13, 2002 6.4 8.9 Tc Fig. 20 Case IMX 35 open frame (option Z) Weight: 43 g Rev 1.0 www.power-one.com Page 13 of 15 IMX35 Series: 35W DC-DC Converters 9-36V, 18-75V, 40-121V & 60-150V Inputs Dual/Triple/Quad Outputs 3.3V, 5V, 12V & 15V Product Specifications Aug 2002 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. Triple output Quadruple output 1 PUL PUL 2 Vi- Vi- Connection to the system shall be made via a printed circuit board with hole diameters of 1.5 mm for the pins. 3 n.c. n.c. 4 Vi+ Vi+ The units should be connected to a secondary circuit. 5 n.c. Trim or Trim1 Check for hazardous voltages before altering any connections. 6 W W 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. 7 Ref Ref 8 SD or i SD or i 11 Vo3- Vo3- 12 Vo3+ Vo3+ Input Fuse 13 Vo2+ Vo2+ 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, F4.0 A for 40 IMX 35 types, F2.0 A for 70 IMX 35 types and F2.0 A for 110 IMX 35 types. 14 Vo2- Vo2- 15 Vo1- Vo1- 16 n.c. Vo1+ 17 Vo1+ Vo4+ 18 Trim1 Vo4- 19 n.c. n.c. 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 * Basic 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 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. Power-One will not honour any guarantee claims resulting from electric strength field tests. Table 17: Electric strength test voltages Characteristic Electric strength test voltage 1 s Insulation resistance at 500 V DC Partial discharge extinction voltage AUG 13, 2002 Input to output IMX 35 Output to output Unit 1.5 0.2 kV DC >100 - M Consult factory - kV 1.2 kVrms 09122 1 2 3 4 5 6 7 8 Bottom view 11 12 13 14 15 16 17 18 19 Fig. 21 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. However, open cased units (option Z) which leave the factory unlacquered may be cleaned and lacquered by the customer. Rev 1.0 www.power-one.com Page 14 of 15 IMX35 Series: 35W DC-DC Converters 9-36V, 18-75V, 40-121V & 60-150V Inputs Dual/Triple/Quad Outputs 3.3V, 5V, 12V & 15V Product Specifications Aug 2002 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 1 2 3 4 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 Maximum DC output voltage from the front end 1 Minimum required safety status of the front end output circuit <60 V Earthed SELV circuit 2 IMX 35 Operational insulation (provided by the DC-DC converter) SELV circuit <75 V Hazardous voltage secondary circuit Input fuse 3 output suppressor diodes 4, and earthed output circuit 2 Earthed SELV circuit IMX 35 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.22: Schematic safety concept). ~ Mains ~ 10004 Fuse AC-DC front end + DC-DC converter Battery Earth connection Suppressor diode SELV - Earth connection Fig. 22 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 20: List of options Option Function of option Characteristic Extended temperature range TA = -40...110C, with airflow and derating i Inhibit - Z Open frame - -8 AUG 13, 2002 Rev 1.0 www.power-one.com Page 15 of 15