Rugged Environment DC-DC Converters <40 Watt 15 Watt DC-DC Converters IMX/IMY 15 Series IMX 15 Series IMY 15 Series Input to output electric strength test up to 4 kV DC Input voltage: 8.4...36, 16.8...75, 50...150 V DC Single, dual and double outputs Configurable output voltages from 3.3 to 48 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 * High efficiency (typ. 87%) 40.6 1.5" * Input undervoltage lock-out 10.5 0.42" 51 2.0" * Shut down input, output voltages adjustable * Flex power: Flexible load distribution on outputs * Outputs no-load, overload and short-circuit proof * Operating ambient temperature up to -40...85 C * Thermal protection * 2" x 1.6" case with 10.5 mm profile * Supplementary insulation: 20/40 IMX 15 types * Double or reinforced insulation: 110 IMY 15 types Safety according to IEC/EN 60950, UL 1950 LGA 1 Approvals pending 1 For 110 IMY 15 types Summary The IMX 15 and IMY 15 series of board mountable 15 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 8.4 up to 150 V with 3 different types, the units are available with single, dual and electrically isolated double outputs from 3.3 up to 48 V externally adjustable, with flexible load distribution on dual and double output units. 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 20 IMX 15 and 40 IMX 15 types provide supplementary insulation. Connected to a secondary circuit the Table of Contents Page Summary .......................................................................... 1 Type Survey and Key Data .............................................. 2 Type Key and Product Marking ........................................ 2 Functional Description ...................................................... 3 Electrical Input Data ......................................................... 4 Electrical Output Data ...................................................... 6 MELCHER The Power Partners. 40 IMX 15 types provide SELV outputs even if the bus voltage at the converter input exceeds the SELV-limit of 60 V DC. The 110 IMY 15 types provide double insulation and are CE marked. They may be connected to e.g. a rectified 110 V AC source without any further isolation barrier. The circuit comprises of integrated planar magnetics 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 allows operation at full load up to an ambient temperature of 71C 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 or an alternative pinout provide a high level of application specific engineering and designin flexibility. Page Auxilliary Functions ........................................................ 10 Electromagnetic Compatibility (EMC) ............................ 11 Immunity to Environmental Conditions ........................... 12 Mechanical Data ............................................................ 13 Safety and Installation Instructions ................................ 14 Description of Option ...................................................... 16 Edition 6/7.99 1/16 IMX/IMY 15 Series DC-DC Converters <40 Watt Rugged Environment Type Survey and Key Data Table 1: Type survey Output 1 Uo nom Io nom 1 [V DC] [A] 1 2 3 4 Output 2 Uo nom Io nom 1 [V DC] [A] Output power Po nom [W] Input voltage Ui min...Ui max [V DC] Efficiency htyp [%] Type designation Options 2 3.3 3.3 3.3 4.5 4.5 4.5 - - 14.9 14.9 14.9 8.4...36 16.8...75 3 50...150 4 85 85 84 20 IMX 15-03-9RG 40 IMX 15-03-9RG 110 IMY 15-03-9RG -9, -8, i -9, -8, i -9, -8, i 5.1 5.1 5.1 3.5 3.5 3.5 - - 17.8 17.8 17.8 8.4...36 16.8...75 3 50...150 4 87 87 86 20 IMX 15-05-9RG 40 IMX 15-05-9RG 110 IMY 15-05-9RG -9, -8, i -9, -8, i -9, -8, i 5.1 5.1 5.1 2.3 2.5 2.5 - - 11.7 12.8 12.8 8.4...36 16.8...75 3 50...150 4 85 83 83 20 IMX 15-05-7R 40 IMX 15-05-7R 110 IMY 15-05-7R -9, -8, i -9, -8, i -9, -8, i 5.1 5.1 5.1 1.35 1.5 1.5 3.3 3.3 3.3 1.35 1.5 1.5 11.3 12.6 12.6 8.4...36 16.8...75 3 50...150 4 84 84 82 20 IMX 15-0503-7R 40 IMX 15-0503-7R 110 IMY 15-0503-7R -9, -8, i -9, -8, i -9, -8, i 5 5 5 1.3 1.4 1.4 5 5 5 1.3 1.4 1.4 13.0 14.0 14.0 8.4...36 16.8...75 3 50...150 4 86 86 86 20 IMX 15-05-05-7 40 IMX 15-05-05-7 110 IMY 15-05-05-7 -9, -8, R, K, i -9, -8, R, K, i -9, -8, R, i 12 12 12 0.65 0.7 0.7 12 12 12 0.65 0.7 0.7 15.6 16.8 16.8 8.4...36 16.8...75 3 50...150 4 88 88 87 20 IMX 15-12-12-7 40 IMX 15-12-12-7 110 IMY 15-12-12-7 -9, -8, R, K, i -9, -8, R, K, i -9, -8, R, i 15 15 15 0.5 0.56 0.56 15 15 15 0.5 0.56 0.56 15.0 16.8 16.8 8.4...36 16.8...75 3 50...150 4 88 88 87 20 IMX 15-15-15-7 40 IMX 15-15-15-7 110 IMY 15-15-15-7 -9, -8, R, K, i -9, -8, R, K, i -9, -8, R, i 24 24 24 0.32 0.35 0.35 24 24 24 0.32 0.35 0.35 15.4 16.8 16.8 8.4...36 16.8...75 3 50...150 4 86 86 86 20 IMX 15-24-24-7 40 IMX 15-24-24-7 110 IMY 15-24-24-7 -9, -8, R, K, i -9, -8, R, K, i -9, -8, R, i Flexible load distribution on dual and double outputs possible up to 75% of the total output power Po nom on one of the 2 outputs. IMX/IMY 15-0503 types have reduced load distribution flexibility; 1.8 A max. on one of the 2 outputs. The other output should not exceed the difference to the total output power Po nom. See: Description of Options. Short-time operation down to Ui min 14.4 V possible. Po reduced to approx. 85% of rated output power. Short-time operation down to Ui min 43.2 V possible. Po reduced to approx. 85% of rated output power. Type Key and Product Marking 20 IMX 15 - 05 - 05 -7 R G K i Input voltage range Ui 8.4...36 V DC ........................................... 20 16.8...75 V DC ........................................... 40 50...150 V DC ......................................... 110 Series ......................................................... IMX 15, IMY 15 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 .................. 03, 05, 12, 15, 24 Operating ambient temperature range TA -25...71C (standard) ................................. -7 -40...71C (standard) ................................. -9 -40...85C (option) ..................................... -8 Options and features: R input and magnetic feedback .................. R Synchronous rectification ............................ G Alternative pinout ......................................... K Inhibit ............................................................ i 1 3 4 2 23 24 25 2 Not applicable with option K or -0503- types. For delivery lead times contact factory. Some types require a minimum order quantity. Standard features for single output and -0503- types. Optional for double output units. Excludes option K. Option K excludes option R. 5 Option inhibit excludes shut down and option K. MELCHER The Power Partners. Edition 6/7.99 2/16 Rugged Environment DC-DC Converters <40 Watt IMX/IMY 15 Series Examples: 20 IMX 15-05-05-7: DC-DC converter, input voltage range 8.4...36 V, 2 electrically isolated outputs each providing 5 V, 1.3 A. 110 IMY 15-0503-7R: DC-DC converter, input voltage range 50...150 V, 2 outputs with common return providing +5.1 V, 1.5 A and +3.3 V, 1.5 A. Unit fitted with magnetic feedback for tight output voltage regulation. Product Marking Basic type designation, output voltages and currents, applicable safety approval and recognition marks, Melcher patent nos. and company logo. Date code and serial no. Functional Description The IMX/IMY 15 series of DC-DC converters are magnetic feed-back controlled flyback converters using current mode PWM (Pulse Width Modulation). The -05- and -0503- output voltage versions as well as all double output versions fitted with option R feature an active magnetic feedback loop via a pulse transformer which results in very tight regulation of the output voltage (see fig.: Block diagram, single output types, -0503- types and double output types with option R). The output voltages of these versions can be adjusted via the R input. The R input is referenced to the secondary side and allows for programming of the output voltages in the range of approximately 80 to 105% of Uo nom using either an external resistor or an external voltage source. The voltage regulation on the dual and double output versions without option R is achieved with a passive transformer feedback from the main transformer (see fig.: Block diagram, for double output types). The output voltages can be adjusted via the Trim input. The Trim input is referenced to the primary side of the converter and allows for programming of the output voltages in the range 100 to 105% of Uo nom by an external resistor or within 75 to 105% using an external voltage source. The load regulation output characteristic allows for paralleling of one or several double output units with equal output voltages. Current limitation is provided by the primary circuit, thus limiting the total output power of double output types. The shut down input allows remote converter on/off. Overtemperature protection will shut down the unit in excessive overload conditions with automatic restart approximately every 50 to 60 ms. 03089 03039 Vi+ 1 3 Vo+ Vi+ 1 13 Vo1+ PWM SD 4 5 15 Go PWM Vo- n.c. 3 11 Vo2+ Vi- 2 12 Go 2 x 2200 pF 1500 V V i- 2 2 x 2200 pF Fig. 1 Block diagram, single output types 17 R 03088 Vi+ 1 11 Vo+ Fig. 3 Block diagram, -0503- types. SD 4 PWM 13 Go Trim 3 Vi - 2 15 Vo- 2 x 2200 pF 17 n.c. Fig. 2 Block diagram, dual output types, alternative K-pinout. MELCHER The Power Partners. Edition 6/7.99 3/16 IMX/IMY 15 Series DC-DC Converters <40 Watt Rugged Environment 03092 03090 Vi+ 1 SD 4 11 Vo1+ Vi+ 1 12 Vo1- SD 4 13 Vo1+ 12 Vo1- PWM PWM Trim 3 13 Vo2+ n.c. 3 11 Vo2+ Vi- 2 15 Vo2- Vi - 2 15 Vo2- 17 n.c. 2 x 2200 pF 2 x 2200 pF Fig. 4 Block diagram, double output types, standard pinout. 17 R Fig. 5 Block diagram, double output types with option R. Electrical Input Data General conditions: - TA = 25C, unless TC is specified. - Shut down pin left open circuit (not connected). - Trim or R input not connected. Table 2: Input Data Input 20 IMX Characteristics 3 4 5 6 7 8 9 8.4 5 typ 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 2 Ui nom resist load 5 Io nom capac. load 10 40 IMX max min 36 16.8 5 6 20 typ 110 IMY max min 75 50 5 7 40 40 9 typ max Unit 150 V DC 110 100 168 0.25 0.5 0.25 0.5 0.25 0.5 0.1 0.1 0.1 5 20 10 5 20 10 s ms 20 Ii o No load input current Io = 0, Ui min...Ui max 40 20 10 Iirr Reflected ripple current Io = 0...Io nom 30 30 20 Iinr p Inrush peak current 3 Ui = Ui nom 8 9 10 Ci Input capacitance for surge calculation 1.5 0.75 0.35 F U SD Shut down voltage Unit shut down -10...0.7 -10...0.7 -10...0.7 V DC Unit operating open or 2...20 open or 2...20 open or 2...20 R SD Shut down input resistance For current calculations approx. 10 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 2 min Ui t rise 1 1 Conditions Input RFI level conducted min...Ui max EN mA A k 6 3 1 mA approx. 300 approx. 300 approx. 300 kHz B8 B B 55022 4 Ui min will not be as stated if Uo is increased above Uo nom by use of the R or the Trin input. If the output voltage is set to a higher value, Ui min will be proportionately increased. 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. Double output units with both outputs in parallel. Input undervoltage lock-out at typ. 80% of Ui min. Short time operation down to Ui min >14.4 V possible. Po reduced to approx. 85% of Po nom. Short time operation down to Ui min >43.2 V possible. Po reduced to approx. 85% of Po nom. 20 IMX 15 types require 4.7 F/50 V capacitance accross the input (Polyester, Philips 372 series). See: Transient ETR 283 (19Pfl1), Electromagnetic Immunity. MELCHER The Power Partners. Edition 6/7.99 4/16 Rugged Environment DC-DC Converters <40 Watt IMX/IMY 15 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 5: 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 15 40 1500 22 1 40 IMX 15 100 1500 9.7 110 IMY 15 167 600 0.5 t [s] 0 20 10 30 40 50 60 70 80 90 100 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. Fig. 6 Typical inrush current at Ui nom, Po nom versus time (40 IMX 15). Source impedance according to prETS 300132-2, version 4.3 at Ui nom. 04008 Uo Note: The suppressor diode D is only necessary for 20 IMX 15 types. t rise Uo nom Table 6: Components for external circuitry for IEC/EN 61000-4-5, level 2 or ETR 283 (19Pfl1) compliance. t t start up Fig. 7 Converter start-up and rise time Type Inductor (L) Capacitor (C) Diode (D) 20 IMX 68 H, 2.7 A 330 F, 63 V 1.5 k E47A 40 IMX 220 H, 1.3 A 2 x 100 F, 100 V - 110 IMY 330 H, 0.43 A 2 x 100 F, 200 V - Vi+ 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 3: Turn on and turn off voltage Turn Off Units 20 IMX 7.5...8 7...7.5 V 40 IMX 12.5...13.5 12...13 110 IMY 40...42.5 38...40.5 Vi- Fig. 8 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 15 types. 10 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. Fig. 9 Dimensions of inductor L for 110 IMY 15 types (e.g. TOKO 494LYF-0098K). 22 Table 4: Recommended external fuses Fuse type 20 IMX 15 F4.0A 40 IMX 15 F2.0A 110 IMY 15 F1.0A MELCHER The Power Partners. 5 5 Reverse Polarity Protection Converter type D 04051 Turn On C + 10 Type 04036 L Input Undervoltage Lockout 04052 11.5 23.8 Fig. 10 Dimensions of inductor L for 20 IMX 15 and 40 IMX 15 types (e.g. Coil Craft, PCH-45 series). Edition 6/7.99 5/16 IMX/IMY 15 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 7a: Output data for single output units and -0503- types. Output Characteristics Conditions Uo1 Uo2 Output voltage Io nom Output current 1 Io1L Io2L Current limit 2, 4 Ui nom Io = 0.5 Io nom 20 IMX 3.3 V (RG) 5.1 V 5.1 V (RG) 5.1/3.3 V min typ max min typ max min typ max min typ max 3.28 5.07 5.07 5.0 3.13 Ui min...Ui max 4.5 40 IMX/110 IMY Io1L Io2L DUo U 20 IMX Ui min...Ui max, Io = (0.05...1) * Io nom 5.1 V 3.3 V uo1/2 Uo L Output overvoltage limit. 7 Co ext Admissible capacitive load uo d Dynamic load regulation td aUo 1 2 3 4 5 6 7 Output voltage noise 5.13 2.5 Ui min...Ui max Io = Io nom Ui min...Ui max Io = 0...Io max V DC A 2 x 1.5 3.5 6.0 3.2 4.6 2.7 3.8 6.0 3.6 4.6 2.9 4.0 1 1 1 % +3, -5 4.5 5 100 70 100 80 6 60 40 60 40 115 Voltage deviat. Ui nom Io nom 1/2 Io nom IEC/EN 61204 5.12 3.46 2 x 1.35 3.5 Ui nom Io = (0.1...1) Io nom Recovery time Temperature coefficient DUo/DTC 5.13 2.3 4.5 Ui nom, TC = 25C Uo1 <4.75 V 40 IMX/110 IMY Line/load regulation 3.32 Unit 130 115 130 115 130 115 mVpp 130 % 4000 4000 4000 total: 4000 3 F 250 250 250 150 mV 1 1 1 1 ms 0.02 0.02 0.02 0.02 %/K Flexible load distribution: 20 IMX 15-0503-7; 1.6 A max. and 40 IMX 15/110 IMY 15-0503-7 types; 1.8 A max. on one of the 2 outputs, the other output should not be loaded such that the total output power exceeds Po nom according to table: Type survey. 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 ). For -0503- types: total capacitance, of both outputs. 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 via a primary side second regulation loop. It is not tracking with R control MELCHER The Power Partners. Edition 6/7.99 6/16 Rugged Environment DC-DC Converters <40 Watt IMX/IMY 15 Series Table 7b: Output data for dual and double output units. Output 2x5V 2 x 12 V 2 x 15 V 2 x 24 V min typ max min typ max min typ max Characteristics Conditions min typ max Uo1 Uo2 Output voltage Ui nom Io = 0.5 Io nom 4.95 4.94 Io nom Output current 1 20 IMX Ui min...Ui max 40 IMX/110 IMY IoL Current limit 2, 4 5.05 11.90 5.06 11.88 12.10 14.88 12.12 14.85 15.12 23.80 15.15 23.75 2 x 1.3 2 x 0.65 2 x 0.50 2 x 0.32 2 x 1.4 2 x 0.70 2 x 0.56 2 x 0.35 A 20 IMX Ui nom, TC = 25C 3.0 1.6 1.3 0.85 40 IMX/110 IMY Uo = 93% Uo nom 3.2 1.7 1.4 0.90 DUo U Line regulation Ui min...Ui max, Io nom 1 1 1 1 DUo l Load regulation Ui nom Io = (0.1...1) Io nom 3 3 3 3 uo1/2 Output voltage noise Ui min...Ui max Io = Io nom 5 80 120 150 240 6 40 60 70 120 limit. 7 Uo L Output overvoltage Co ext Admissible capacitive load 3 uo d Dynamic load regulation td aUo Min. load 1% 115 Voltage deviat. Ui nom Io nom 1/2 Io nom 130 Temperature coefficient DUo/DTC Ui min...Ui max Io = 0...Io max 130 115 130 115 % mVpp 130 % 4000 620 470 180 F 250 300 300 600 mV 1 1 1 1 ms 0.02 0.02 0.02 0.02 %/K Recovery time 115 Unit 24.20 V DC 24.25 Table 7c: Output data for double output units fitted with option R. Output 6 7 8 min typ max min typ max min typ max Ui nom Io = 0.5 Io nom 4.96 4.95 Io nom Output current 1, 8 20 IMX Ui min...Ui max Current limit 2, 4 5.04 11.94 5.05 11.90 12.06 14.92 12.10 14.88 15.08 23.88 15.12 23.80 2 x 1.3 2 x 0.65 2 x 0.50 2 x 0.32 2 x 1.4 2 x 0.70 2 x 0.56 2 x 0.35 A 20 IMX Ui nom, TC = 25C 3.0 1.6 1.3 0.85 40 IMX/110 IMY Uo = 93% Uo nom 3.2 1.7 1.4 0.90 DUo U Line regulation Ui min...Ui max, Io nom 1 1 1 1 Load regulation Ui nom Io = (0.1...1) Io nom 1 1 1 1 uo1/2 Output voltage noise Ui min...Ui max Io = Io nom 80 120 150 240 Output overvoltage limit. 7 Co ext Admissible capacitive uo d Dynamic load regulation Min. load 1% load 3 Voltage deviat. Ui nom Io nom 1/2 Io nom Recovery time Temperature coefficient DUo/DTC Ui min...Ui max Io = 0...Io max 5 6 40 115 130 60 115 130 70 115 130 Unit 24.12 V DC 24.20 DUo l aUo 5 min typ max Conditions td 4 2 x 24 V Output voltage Uo L 3 2 x 15 V Uo1 Uo2 IoL 2 2 x 12 V Characteristics 40 IMX/110 IMY 1 2x5V % mVpp 120 115 130 % 4000 620 470 180 F 250 300 300 600 mV 1 1 1 1 ms 0.02 0.02 0.02 0.02 %/K Flexible load distribution: With double or dual output units each output is capable of delivering 75% of the total output power. The other output should not be loaded such that the total output power exceeds Po nom according to table: Type survey. 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). 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 via a primary side second regulation loop, not tracking with Trim control. Minimum load of 10% on output 1 recommended to prevent the two output voltages to drop in unbalanced load conditions. MELCHER The Power Partners. Edition 6/7.99 7/16 IMX/IMY 15 Series DC-DC Converters <40 Watt 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. Output Overvoltage Protection The output of single output units as well as -0503- and -05-05- types 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 approximately every 50 to 60 ms. Double and dual output units (with exception of the -0503- and -05-05- types) 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 Rugged Environment 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. Overtemperature Protection The converters 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 every 50 to 60 ms. This feature prevents from excessive internal temperature building up which could occur in heavy overload conditions. Short Circuit Behaviour 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 one or several single or double output units can be connected in series without any precautions, taking into consideration that the highest output voltage should remain below 42 V to ensure that the output remains SELV. Connection in Parallel The outputs of one or several double output units (except -0503- types) with equal nominal output voltage can be connected in parallel. Approximate current sharing between 2 or several units is ensured by their load dependent output characteristic. The two outputs of a double output unit fitted with option R can be connected in parallel to configure a single output with tight regulation at full load. Typical Performance Curves General conditions: - TA = 25 oC, unless TC is specified. - Shut down pin left open circuit. - Trim or R input not connected. Uo [V] Uo [V] 05019 5.5 05020 13 12 5.0 11 4.5 10 4.0 9 3.5 8 7 3.0 0 0.4 0.8 1.2 1.6 2.0 2.4 2.8 3.2 3.6 4.0 Io [A] Fig. 11 Uo versus Io (typ) of units with Uo = 5.1 V. (110 IMY 15-05-7R) MELCHER The Power Partners. 0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 Io total [A] Fig. 12 Uo versus Io (typ) of double output units (2 x 12 V), with both outputs in parallel. (110 IMY 15-12-12-7) Edition 6/7.99 8/16 Rugged Environment DC-DC Converters <40 Watt Uo1 [V] Uo1, Uo2 [V] 05021 13.5 IMX/IMY 15 Series 05039 14 13.0 12.5 Io2 = 0.035 A 12.0 Io2 = 0.35 A 13 Uo2 Uo1 12 11 11.5 11.0 0.06 0.10 0.30 0.20 0.40 0.50 0.70 Io1 [A] 0.60 Fig. 13 Cross load regulation Uo1 versus Io1 (typ) for various Io2 (2 x 12 V). 10 0 25 50 75 100 125 150 Io1 [%] Io1 nom Fig. 17 Flexible load distribution on double outputs (2 12 V) with load variation from 0...150% of Po1 nom on output 1. Output 2 loaded with 50% of Po2 nom. Uo [V] Uo1, Uo2 [V] 05150 13 05151 12 14 11 13 10 11 8 7 Uo2 Uo1 12 9 0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 Io total [A] Fig. 14 Uo versus Io (typ) of double output units with option R (2 x 12 V), with both outputs in parallel. 110 IMY 15-12-12-7R. 0 25 50 75 100 125 150 Io1 [%] Io1 nom Fig. 18 Flexible load distribution on double outputs with option R (2 x 12 V) with load variation from 0...150% of Po1 nom on output 1. Output 2 loaded with 50% of Po2 nom. 110 IMY 15-12-12-7R. Note: Minimum load of approx. 10% on output 1 prevents voltage drop in unballanced load condition. h [%] 90 10 05152 Ui min Ui nom h [%] 90 80 Ui max 80 70 05153 Ui min Ui nom Ui max Po 60 25 50 100 Po total 75 [%] Fig. 15 Efficiency versus input voltage and load. Typical values 40 IMX 15-12-12-7 Uo [%] 05041 overload short circuit condition 100 70 60 25 switch-off 8.5 t [ms] 60.5 Fig. 16 Overload switch off (hiccup mode), typical values. MELCHER The Power Partners. 75 Po [%] 100 Po total Fig. 19 Efficiency versus input voltage and load. Typical values 110 IMY 15-12-12-7 70 60.5 50 Edition 6/7.99 9/16 IMX/IMY 15 Series DC-DC Converters <40 Watt Rugged Environment Auxilliary Functions 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 Adjustable Output Voltage - R input for single output units using synchronous rectification (G) - R input for single output units and -0503- types; optional for double output units - Trim input for double output units As a standard feature, the single and double output units offer adjustable output voltage(s) by using the control input R or Trim. If the control input is left open-circuit the output voltage is set to Uo nom. For output voltages Uo > Uo nom, the minimum input voltage Ui min (see: Electrical Input Data) increases proportionally to Uo/Uo nom. Single output units using synchronous rectification (G): The R input is referenced to the secondary side of the converter. Adjustment of the output voltage is possible by means of an external resistor connected between the R pin and either Vo+ or Vo-. Note: For the units with synchronous rectification Uo adjustment is different from the standard single output units and -0503- types. Single output units, -0503- types and double output units fitted with option R: 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 Rext. 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 = 80...100 % Uo nom. 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 - 2.5V) Rext2 4 k * ------------------ 2.5 V * (Uo/Uo nom - 1) b) Adjustment by means of an external voltage Uext between Vo- and R pins. The control voltage range is 1.96...2.62 V and allows for an adjustment in the range of approximately 80...105% of Uo nom. Uo * 2.5 V Uext --------- Uo nom Attempting to adjust the output below this range will cause the converter to shut down (hiccup mode). Note: Applying an external control voltage >2.75 V may damage the converter. 06131 Vo+ Vi+ 06029 Vo+ Vi+ Rext1 Uref 2.5 V Rext2 4 k R R Rext2 Vi- + control circuit Vo- Vi- Uext Rext1 - Vo- Fig. 20 Output voltage control for single output units synchronous rectification. Table 8: Uo versus Uext approximate values Uo nom Typ. values of Rext1 Typ. values of Rext2 [V] Uo [% of Uo nom] Rext1 [k] Uo [% of Uo nom] Rext2 [k] 3.3 75 80 90 1.1 2.2 8.2 100 105 110 11 5.1 5.1 75 80 90 0.47 1.3 3.6 100 105 110 10 5.1 Fig. 21 Output voltage control for single output units, -0503- types and double output units fitted with option R by means of the R input. Double output units with Trim input: The 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 Rext in the range of 100...105% of Uo nom or an external voltage source in the range of 75...105% of Uo nom. 06089 Vi+ Vo1+ Trim Vo1- + Uext - Rext Vi- Control circuit Uref 2.5 V Vo2+ Vo2- Fig. 22 Output voltage control for double output units by means of the Trim input. MELCHER The Power Partners. Edition 6/7.99 10/16 Rugged Environment DC-DC Converters <40 Watt b) Adjustment by means of an external voltage source Uext. a) Adjustment by means of an external resistor Rext: For external output voltage programming in the range 75...105% of Uo nom a (0...20 V) source Uext is required, connected to the Trim 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 >20 V will set the converter into a hiccup mode. Direct paralleling of the Trim pins of units connected in parallel is feasible. Programming of the output voltage by means of an external resistor Rext is possible within a limited range of 100...105% of Uo nom. Rext should be connected between the Trim pin 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), with either paralleled outputs or equal load conditions on each outputs. Table 9a: 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 IMX/IMY 15 Series Table 9b: Uo versus Uext for Uo = 75...105% Uo nom; typical values (Ui 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 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 10: 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 +i/-i 10 Vrms AM modulated (140 dBV) 80%, 1 kHz 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 15 types (additional external components required). Not applicable for 20 IMX 15 types. External components required. MELCHER The Power Partners. Edition 6/7.99 11/16 IMX/IMY 15 Series DC-DC Converters <40 Watt Rugged Environment 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. 23 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 15-05-7R) 1000 500 200 100 30 20 30 10 5 2 1 0.5 0.1 0.05 0.02 0.01 [MHz] 0 MHz 50 0 Fig. 24 Typical radio frequency-interference voltage at Ui nom, Io nom, measured with an antenna (distance 10 m). Output leads 1 m, twisted. 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 15 types) an additional capacitor, see: Input Data. The filter components should be placed as close as possible to the input of the converter. Table 11: Input filter components for EN 55022, level B, radiated. 07114 Type Current compensated choke 20 IMX 15 40 IMX 15 110 IMY 15 1 mH, 2A e.g. Tokin, type SC-02-10GS L Vi+ 15 8.5 07110 V+ Module Vi- 15 V- Fig. 25 Example for external circuitry to comply with CISPR22/EN 55022, level B, radiated Fig. 26 Choke dimensions Immunity to Environmental Conditions Table 12: Temperature specifications, valid for air pressure of 800...1200 hPa (800...1200 mbar) Temperature Characteristics 1 2 3 TA Ambient temperature 1 TC Case temperature TS Storage temperature 1 -7 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 13: MTBF and device hours MTBF MTBF acc. to MIL-HDBK-217F 40 IMX 15 MELCHER The Power Partners. Ground Benign Ground Fixed Ground Mobile TC = 40C TC = 40C TC = 70C TC = 50C h h h h Edition 6/7.99 12/16 Rugged Environment DC-DC Converters <40 Watt IMX/IMY 15 Series Table 14: 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 Mechanical Data Dimensions in mm. Tolerances 0.3 mm unless otherwise indicated. European Projection 45.72 09011 Bottom view 17 4 >5 10.5 47 50.8 Measuring point of case temperature TC Fig. 27 Case IMX 15, IMY 15 Weight: <35 g MELCHER The Power Partners. 36.83 0.8 x 0.8 5.08 40.65 1 2.54 11 Edition 6/7.99 13/16 Fixing hole for M2 or KA 22 self tapping screws IMX/IMY 15 Series DC-DC Converters <40 Watt Rugged Environment Safety and Installation Instructions Table 15: 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. Single output -0503output Double output Dual output option K 1 Vi+ Vi+ Vi+ Vi+ 2 Vi- Vi- Vi- Vi- 3 - n.c. Trim - Check for hazardous voltages before altering any connections. 4 SD SD SD SD 11 - Vo2+ Vo1+ Vo+ Do not open the module. 12 - Go Vo1- - 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. 13 Vo+ Vo1+ Vo2+ Go 15 Vo- Go Vo2- Vo- 17 R R n.c./R n.c. Connection to the system shall be made via a printed circuit board with hole diameters of 1.4 mm 0.1 mm for the pins. The units should be connected to a secondary circuit. Input Fuse 10005 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 F4.0A for 20 IMX 15 types, F2.0 A for 40 IMX 15 types and a fuse F1.0A for 110 IMY 15 types. 11 12 1 2 Standards and approvals 3 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. 4 The units have been evaluated for: * Building in * Supplementary insulation input to output, based on their maximum input voltage (IMX 15 types) * Reinforced insulation input to output, based on their maximum input voltage (IMY 15 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 (IMX 15 types) * Connecting the input to a primary circuit which is subject to a maximum transient rating of 2500 V (IMY 15 types) 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. 13 Bottom view 15 17 Fig. 28 Pin allocation Protection Degree The protection degree of the DC-DC converters is IP 40. Cleaning Agents In order to avoid possible damage, any penetration of cleaning fluids should be prevented, since the power supplies are not hermetically sealed. 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 16: Electric strength test voltages Characteristic Electric strength test voltage 1 s MELCHER The Power Partners. Input to output IMX 15 IMY 15 1.2 Output to output Unit 3.0 0.1 kVrms 1.5 4.0 0.15 kV DC Insulation resistance at 500 V DC >100 >100 - M Partial discharge extinction voltage Consult factory - kV Edition 6/7.99 14/16 Rugged Environment DC-DC Converters <40 Watt IMX/IMY 15 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 17: Insulation concept leading to an SELV output circuit Conditions Front end DC-DC converter Result Maximum DC output voltage from the front end 1 Minimum required safety status of the front end output circuit Type Measures to achieve the specified safety status of the output circuit Safety status of the DC-DC converter output circuit Mains Operational (i.e. there is 150 V AC no need for electrical isolation between the mains supply voltage and the DC-DC converter input voltage) 150 V Primary IMY 15 Double or reinforced insulation, based on 150 V AC and DC (provided by the DC-DC converter) SELV circuit Mains Basic 250 V AC 60 V Earthed SELV circuit 2 IMX 15 IMY 15 Operational insulation (provided by the DC-DC converter) 75 V Hazardous voltage secondary circuit IMX 15 Input fuse 3 output suppressor diodes 4, and earthed output circuit 2 Earthed SELV circuit IMY 15 Supplementary insulation based on 250 V AC and double or reinforced insulation, based on the maximum rated output voltage from the front end (provided by the DC-DC converter) SELV circuit Supply voltage Minimum required grade of isolation, to be provided by the AC-DC front end, including mains supplied battery charger 150 V Double or reinforced 1 2 3 4 5 60 V SELV circuit IMX 15 IMY 15 Operational insulation (provided by the DC-DC converter) 75 V Double or reinforced insulated unearthed hazardous voltage secondary circuit 5 IMX 15 Supplementary insulation based on the maximum rated output voltage from the front end (provided by the DC-DC converter) 120 V TNV-2 circuit IMY 15 150 V Double or reinforced insulated earthed or unearthed hazardous voltage secondary circuit Double or reinforced insulation, based on the maximum rated output voltage from the front end (provided by the DC-DC converter) 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. MELCHER The Power Partners. ~ Mains ~ 10004 Fuse AC-DC front end Battery Earth connection + DC-DC converter Suppressor diode SELV Earth connection Fig. 29 Schematic safety concept. Use fuse, suppressor diode and earth connection as per table Safety concept leading to an SELV output circuit. Edition 6/7.99 15/16 - IMX/IMY 15 Series DC-DC Converters <40 Watt Rugged Environment Description of Option Option -8 Extended Temperature Range Option K Alternative Pinout Extension of the temperature range from standard -25...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. Option K configures the electrically isolated double outputs to the alternative pinout with outputs connected in series (Vo+/Go/Vo-) and common ground. Po /Po max 11047 1.2 1.0 However instead of using units with option K, it is recommended to use the standard double output units by providing the printed circuit board with an additional pin hole (for pin 12 of double output units) connected to pin hole 13. This will provide more design-in flexibility since by that both pinouts may be used on the same PCB. 0.8 Option i Inhibit 0.6 Excluces shut down and option K. 0.4 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). 0.2 0 -40 -20 0 20 40 60 80 TA [C] Fig. 30 Maximum allowed output power versus ambient temperature. Converter operating: Converter inhibited or inhibit pin left open: -10 V...0.8 V 2.4 V...Ui max Option -9 06070 Extended ambient temperature range -40...71C. Vi+ Option R R Input and Magnetic Feedback i R specifies magnetic feedback from the output for closer regulation of the output voltages of double output units. It is especially suited for applications where the two outputs are either connected in parallel or in series to form one strong and tight regulated output. It enables the adjustment of the output voltages via the R-input on the secondary side by an external resistor or an external voltage source in the range of approximative 80...105% of Uo nom. Option R excludes the Trim input (see also table: Pin allocation), option K as well as the possibility to operate several converters with the outputs connected in parallel. MELCHER The Power Partners. Vi- Fig. 31 If the inhibit is not used the inhibit pin should be connected to Vi- Edition 6/7.99 16/16