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rugged environment dc-dc converters <40 watt imx/imy 15 series edition 6/7.99 1/16 melcher the power partners. 15 watt dc-dc converters 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%) input undervoltage lock-out 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 ?0...85 c thermal protection 2" 1.6" case with 10.5 mm profile supplementary insulation: 20/40 imx 15 types double or reinforced insulation: 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 lat- est industry requirements and standards. the converters are particularly suitable for use in mobile or stationary appli- cations in transport, railways, industry, or telecommunica- tion 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 re- mote 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 in- ternational 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 sup- plementary insulation. connected to a secondary circuit the 40 imx 15 types provide selv outputs even if the bus volt- age 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 recti- fied 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 re- peatability 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 71 c 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 tem- perature range 40...85 c or an alternative pinout provide a high level of application specific engineering and design- in flexibility. safety according to iec/en 60950, ul 1950 approvals pending 51 2.0" 40.6 1.5" 10.5 0.42" lga 1 1 for 110 imy 15 types 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 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
imx/imy 15 series dc-dc converters <40 watt rugged environment edition 6/7.99 2/16 melcher the power partners. type key and product marking 20 imx 15 - 05 - 05 -7 r g k i input voltage range u i 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 t a 25...71 c (standard) ................................. -7 40...71 c (standard) ................................. -9 40...85 c (option) ..................................... -8 2 options and features: r input and magnetic feedback .................. r 2 3 synchronous rectification ............................ g alternative pinout ......................................... k 2 4 inhibit ............................................................ i 2 5 1 not applicable with option k or -0503- types. 2 for delivery lead times contact factory. some types require a minimum order quantity. 3 standard features for single output and -0503- types. optional for double output units. excludes option k. 4 option k excludes option r. 5 option inhibit excludes shut down and option k. type survey and key data table 1: type survey output 1 output 2 output input voltage efficiency type designation options 2 u o nom i o nom 1 u o nom i o nom 1 power u i min ... u i max h typ [v dc] [a] [v dc] [a] p o nom [w] [v dc] [%] 3.3 4.5 - - 14.9 8.4...36 85 20 imx 15-03-9rg -9, -8, i 3.3 4.5 - - 14.9 16.8...75 3 85 40 imx 15-03-9rg -9, -8, i 3.3 4.5 - - 14.9 50...150 4 84 110 imy 15-03-9rg -9, -8, i 5.1 3.5 - - 17.8 8.4...36 87 20 imx 15-05-9rg -9, -8, i 5.1 3.5 - - 17.8 16.8...75 3 87 40 imx 15-05-9rg -9, -8, i 5.1 3.5 - - 17.8 50...150 4 86 110 imy 15-05-9rg -9, -8, i 5.1 2.3 - - 11.7 8.4...36 85 20 imx 15-05-7r -9, -8, i 5.1 2.5 - - 12.8 16.8...75 3 83 40 imx 15-05-7r -9, -8, i 5.1 2.5 - - 12.8 50...150 4 83 110 imy 15-05-7r -9, -8, i 5.1 1.35 3.3 1.35 11.3 8.4...36 84 20 imx 15-0503-7r -9, -8, i 5.1 1.5 3.3 1.5 12.6 16.8...75 3 84 40 imx 15-0503-7r -9, -8, i 5.1 1.5 3.3 1.5 12.6 50...150 4 82 110 imy 15-0503-7r -9, -8, i 5 1.3 5 1.3 13.0 8.4...36 86 20 imx 15-05-05-7 -9, -8, r, k, i 5 1.4 5 1.4 14.0 16.8...75 3 86 40 imx 15-05-05-7 -9, -8, r, k, i 5 1.4 5 1.4 14.0 50...150 4 86 110 imy 15-05-05-7 -9, -8, r, i 12 0.65 12 0.65 15.6 8.4...36 88 20 imx 15-12-12-7 -9, -8, r, k, i 12 0.7 12 0.7 16.8 16.8...75 3 88 40 imx 15-12-12-7 -9, -8, r, k, i 12 0.7 12 0.7 16.8 50...150 4 87 110 imy 15-12-12-7 -9, -8, r, i 15 0.5 15 0.5 15.0 8.4...36 88 20 imx 15-15-15-7 -9, -8, r, k, i 15 0.56 15 0.56 16.8 16.8...75 3 88 40 imx 15-15-15-7 -9, -8, r, k, i 15 0.56 15 0.56 16.8 50...150 4 87 110 imy 15-15-15-7 -9, -8, r, i 24 0.32 24 0.32 15.4 8.4...36 86 20 imx 15-24-24-7 -9, -8, r, k, i 24 0.35 24 0.35 16.8 16.8...75 3 86 40 imx 15-24-24-7 -9, -8, r, k, i 24 0.35 24 0.35 16.8 50...150 4 86 110 imy 15-24-24-7 -9, -8, r, i 1 flexible load distribution on dual and double outputs possible up to 75% of the total output power p o 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 n ot ex- ceed the difference to the total output power p o nom . 2 see: description of options. 3 short-time operation down to u i min 14.4 v possible. p o reduced to approx. 85% of rated output power. 4 short-time operation down to u i min 43.2 v possible. p o reduced to approx. 85% of rated output power.
rugged environment dc-dc converters <40 watt imx/imy 15 series edition 6/7.99 3/16 melcher the power partners. examples: 20 imx 15-05-05-7: dc-dc converter, input voltage range 8.4...36 v, 2 electrically isolated outputs each pro- viding 5 v, 1.3 a. 110 imy 15-0503-7r: dc-dc converter, input voltage range 50...150 v, 2 outputs with common return provid- ing +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 u o nom using either an external resistor or an external voltage source. the voltage regulation on the dual and double output ver- sions without option r is achieved with a passive trans- former 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 program- ming of the output voltages in the range 100 to 105% of u o nom by an external resistor or within 75 to 105% using an external voltage source. the load regulation output charac- teristic 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 ex- cessive overload conditions with automatic restart approxi- mately every 50 to 60 ms. pwm 2 2200 pf 1 2 4 11 15 13 vi+ sd vi vo+ go vo 03088 17 n.c. 3 trim pwm 2 2200 pf 1 2 3 4 13 15 12 11 vi+ sd vi vo1+ go n.c. vo2+ go 03089 17 r pwm 2 2200 pf 1500 v 1 2 3 5 vi+ vi vo+ vo 03039 fig. 1 block diagram, single output types fig. 2 block diagram, dual output types, alternative k-pinout. fig. 3 block diagram, -0503- types.
imx/imy 15 series dc-dc converters <40 watt rugged environment edition 6/7.99 4/16 melcher the power partners. pwm 2 2200 pf 1 2 3 4 11 12 15 13 vi+ sd vi vo1+ vo1 trim vo2+ vo2 03090 17 n.c. pwm 2 2200 pf 1 2 3 4 13 12 15 11 vi+ sd vi vo1+ vo1 n.c. vo2+ vo2 03092 17 r fig. 4 block diagram, double output types, standard pinout. fig. 5 block diagram, double output types with option r. electrical input data general conditions: t a = 25 c, unless t c is specified. shut down pin left open circuit (not connected). trim or r input not connected. table 2: input data input 20 imx 40 imx 110 imy characteristics conditions min typ max min typ max min typ max unit u i input voltage range 1 t a min ... t a max 8.4 5 36 16.8 5 6 75 50 5 7 150 v dc u i nom nominal input voltage i o = 0... i o nom 20 40 110 u i sur repetitive surge voltage abs. max input (3 s) 40 9 100 168 t start up converter switch on worst case condition at 0.25 0.5 0.25 0.5 0.25 0.5 s start-up time 2 sd high u i min and full load 0.1 0.1 0.1 t rise rise time 2 u i nom resist load 5 5 5 ms i o nom capac. load 10 20 10 20 10 20 i i o no load input current i o = 0, u i min ... u i max 40 20 10 ma i irr reflected ripple current i o = 0... i o nom 30 30 20 i inr p inrush peak current 3 u i = u i nom 8910a c i 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 k ? i sd input current if unit u i min ... u i max 631ma shut down f s switching frequency u i min ... u i max , i o = 0... i o nom approx. 300 approx. 300 approx. 300 khz u i rfi input rfi level conducted en 55022 4 b 8 bb 1 u i min will not be as stated if u o is increased above u o nom by use of the r or the trin input. if the output voltage is set to a higher value, u i min will be proportionately increased. 2 measured with resistive and max. admissible capacitive load. 3 source impedance according to prets 300132-2, version 4.3. 4 measured with a lead length of 0.1 m, leads twisted. double output units with both outputs in parallel. 5 input undervoltage lock-out at typ. 80% of u i min . 6 short time operation down to u i min >14.4 v possible. p o reduced to approx. 85% of p o nom . 7 short time operation down to u i min >43.2 v possible. p o reduced to approx. 85% of p o nom . 8 20 imx 15 types require 4.7 f/50 v capacitance accross the input (polyester, philips 372 series). 9 see: transient etr 283 (19pfl1), electromagnetic immunity .
rugged environment dc-dc converters <40 watt imx/imy 15 series edition 6/7.99 5/16 melcher the power partners. inrush current 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 cur- rent. i [a] t [ s] 04022 0 10 20 30 40 50 60 70 80 90 100 4 3 2 1 fig. 6 typical inrush current at u i nom , p o nom versus time (40 imx 15). source impedance according to prets 300132-2, version 4.3 at u i nom . fig. 7 converter start-up and rise time u o nom u o t start up t rise t 04008 input undervoltage lockout 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 type turn on 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 input transient voltage protection 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. table 5: built-in transient voltage suppressor type breakdown peak power peak pulse voltage at 1 ms current v br nom [v] p p [w] i pp [a] 20 imx 15 40 1500 22 40 imx 15 100 1500 9.7 110 imy 15 167 600 0.5 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 simi- lar characteristics as listed in table: components for exter- nal circuitry for iec/en 61000-4-5, level 2 or etr 283 (19pfl1) compliance . note: the suppressor diode d is only necessary for 20 imx 15 types. table 6: components for external circuitry for iec/en 61000-4-5, level 2 or etr 283 (19pfl1) compliance. 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 2 100 f, 100 v - 110 imy 330 h, 0.43 a 2 100 f, 200 v - vi+ vi c l d + 04036 fig. 8 example for external circuitry to comply with iec/en 61000-4-5 or etr 283 (19pfl1); the diode d is only neces- sary for 20 imx 15 types. reverse polarity protection the built-in suppressor diode also provides for reverse po- larity protection at the input by conducting current in the re- verse direction. an external fuse is required to limit this cur- rent. table 4: recommended external fuses converter type fuse type 20 imx 15 f4.0a 40 imx 15 f2.0a 110 imy 15 f1.0a 10 5 5 10 04051 fig. 9 dimensions of inductor l for 110 imy 15 types (e.g. toko 494lyf-0098k). 22 23.8 11.5 04052 fig. 10 dimensions of inductor l for 20 imx 15 and 40 imx 15 types (e.g. coil craft, pch-45 series).
imx/imy 15 series dc-dc converters <40 watt rugged environment edition 6/7.99 6/16 melcher the power partners. electrical output data general conditions: t a = 25 c, unless t c 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 3.3 v (rg) 5.1 v 5.1 v (rg) 5.1/3.3 v characteristics conditions min typ max min typ max min typ max min typ max unit u o1 output voltage u i nom 3.28 3.32 5.07 5.13 5.07 5.13 5.0 5.12 v dc u o2 i o = 0.5 i o nom 3.13 3.46 i o nom output current 1 20 imx u i min ... u i max 4.5 2.3 3.5 2 1.35 a 40 imx/110 imy 4.5 2.5 3.5 2 1.5 i o1l current limit 2, 4 20 imx u i nom , t c = 25 c 6.0 3.2 4.6 2.7 i o2l u o1 <4.75 v 3.8 i o1l 40 imx/110 imy 6.0 3.6 4.6 2.9 i o2l 4.0 d u o u line/load regulation u i min ... u i max , 1 1 1% i o = (0.05...1) i o nom 5.1 v u i nom +3, 5 3.3 v i o = (0.1...1) i o nom 4.5 u o1/2 output voltage noise u i min ... u i max 5 100 70 100 80 mv pp i o = i o nom 6 60 40 60 40 u o l output overvoltage limit. 7 115 130 115 130 115 130 115 130 % c o ext admissible capacitive load 4000 4000 4000 total: 4000 3 f u o d dynamic voltage deviat. u i nom 250 250 250 150 mv t d load recovery time i o nom ? 1 / 2 i o nom 1111ms regulation iec/en 61204 a uo temperature coefficient u i min ... u i max 0.02 0.02 0.02 0.02 %/k d u o / d t c i o = 0... i o max 1 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 p o nom according to table: type survey . 2 the current limit is primary side controlled. in the event of a sustained overload condition the thermal protection may cause t he unit to shutdown (restart on cool-down ). 3 for -0503- types: total capacitance, of both outputs. 4 conditions for specified output. other output loaded with constant current i o = 0.5 i o nom . 5 bw = 20 mhz 6 measured with a probe according to en 61204 7 the overvoltage protection is via a primary side second regulation loop. it is not tracking with r control
rugged environment dc-dc converters <40 watt imx/imy 15 series edition 6/7.99 7/16 melcher the power partners. table 7b: output data for dual and double output units. output 2 5 v 2 12 v 2 15 v 2 24 v characteristics conditions min typ max min typ max min typ max min typ max unit u o1 output voltage u i nom 4.95 5.05 11.90 12.10 14.88 15.12 23.80 24.20 v dc u o2 i o = 0.5 i o nom 4.94 5.06 11.88 12.12 14.85 15.15 23.75 24.25 i o nom output current 1 20 imx u i min ... u i max 2 1.3 2 0.65 2 0.50 2 0.32 a 40 imx/110 imy 2 1.4 2 0.70 2 0.56 2 0.35 i ol current limit 2, 4 20 imx u i nom , t c = 25 c 3.0 1.6 1.3 0.85 40 imx/110 imy u o = 93% u o nom 3.2 1.7 1.4 0.90 d u o u line regulation u i min ... u i max , i o nom 1 1 1 1% d u o l load regulation u i nom 3 3 3 3 i o = (0.1...1) i o nom u o1/2 output voltage noise u i min ... u i max 5 80 120 150 240 mv pp i o = i o nom 6 40 60 70 120 u o l output overvoltage limit. 7 min. load 1% 115 130 115 130 115 130 115 130 % c o ext admissible capacitive load 3 4000 620 470 180 f u o d dynamic voltage deviat. u i nom 250 300 300 600 mv t d load recovery time i o nom ? 1 / 2 i o nom 1111ms regulation a uo temperature coefficient u i min ... u i max 0.02 0.02 0.02 0.02 %/k d u o / d t c i o = 0... i o max table 7c: output data for double output units fitted with option r. output 2 5 v 2 12 v 2 15 v 2 24 v characteristics conditions min typ max min typ max min typ max min typ max unit u o1 output voltage u i nom 4.96 5.04 11.94 12.06 14.92 15.08 23.88 24.12 v dc u o2 i o = 0.5 i o nom 4.95 5.05 11.90 12.10 14.88 15.12 23.80 24.20 i o nom output current 1, 8 20 imx u i min ... u i max 2 1.3 2 0.65 2 0.50 2 0.32 a 40 imx/110 imy 2 1.4 2 0.70 2 0.56 2 0.35 i ol current limit 2, 4 20 imx u i nom , t c = 25 c 3.0 1.6 1.3 0.85 40 imx/110 imy u o = 93% u o nom 3.2 1.7 1.4 0.90 d u o u line regulation u i min ... u i max , i o nom 1 1 1 1% d u o l load regulation u i nom 1 1 1 1 i o = (0.1...1) i o nom u o1/2 output voltage noise u i min ... u i max 5 80 120 150 240 mv pp i o = i o nom 6 40 60 70 120 u o l output overvoltage limit. 7 min. load 1% 115 130 115 130 115 130 115 130 % c o ext admissible capacitive load 3 4000 620 470 180 f u o d dynamic voltage deviat. u i nom 250 300 300 600 mv t d load recovery time i o nom ? 1 / 2 i o nom 1111ms regulation a uo temperature coefficient u i min ... u i max 0.02 0.02 0.02 0.02 %/k d u o / d t c i o = 0... i o max 1 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 p o nom according to table: type survey . 2 the current limit is primary side controlled. in the event of a sustained overload condition the thermal protection may cause t he unit to shutdown (restart on cool-down). 3 measured with both outputs connected in parallel. 4 conditions for specified output. other output loaded with constant current i o = 0.5 i o nom . 5 bw = 20 mhz 6 measured with a probe according to en 61204 7 the overvoltage protection is via a primary side second regulation loop, not tracking with trim control. 8 minimum load of 10% on output 1 recommended to prevent the two output voltages to drop in unbalanced load conditions.
imx/imy 15 series dc-dc converters <40 watt rugged environment edition 6/7.99 8/16 melcher the power partners. thermal considerations if a converter, mounted on a pcb, is located in free, quasi- stationary air (convection cooling) at the indicated maxi- mum ambient temperature t a max (see table: temperature specifications ) and is operated at its nominal input voltage and output power, the case temperature t c measured at the measuring point of case temperature t c (see: mechani- cal data ) will approach the indicated value t c max after the warm-up phase. however, the relationship between t a and t c depends heavily on the conditions of operation and inte- gration into a system. the thermal conditions are influ- enced by input voltage, output current, airflow, temperature of surrounding components and surfaces and the proper- ties of the printed circuit board. t a max is therefore only an indicative value and under practical operating conditions, the ambient temperature t a may be higher or lower than this value. caution: the case temperature t c measured at the: measuring point of case temperature t c (see: mechani- cal data ) may under no circumstances exceed the specified maximum value. the installer must ensure that under all operating conditions t c remains within the lim- its 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 sec- ond 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 di- ode will short circuit. since with double output units both outputs track each other the protection diode is only pro- vided in one of the outputs. the main purpose of this fea- ture 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 at- tempts to automatically restart every 50 to 60 ms. this fea- ture 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 self- protecting 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 be- tween 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: t a = 25 o c, unless t c is specified. shut down pin left open circuit. trim or r input not connected. fig. 11 u o versus i o (typ) of units with u o = 5.1 v. (110 imy 15-05-7r) fig. 12 u o versus i o (typ) of double output units (2 12 v), with both outputs in parallel. (110 imy 15-12-12-7) 7 8 9 10 11 12 13 u o [v] 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 i o total [a] 0 05020 5.5 5.0 4.5 4.0 3.5 3.0 00.4 0.8 1.2 1.6 2.0 2.4 2.8 3.2 3.6 4.0 i o [a] u o [v] 05019
rugged environment dc-dc converters <40 watt imx/imy 15 series edition 6/7.99 9/16 melcher the power partners. 11.0 11.5 12.0 12.5 13.0 13.5 u o1 [v] 0.06 0.20 0.30 0.40 0.50 0.60 0.70 i o1 [a] 0.10 05021 i o2 = 0.35 a i o2 = 0.035 a fig. 13 cross load regulation u o1 versus i o1 (typ) for various i o2 (2 12 v) . fig. 17 flexible load distribution on double outputs (2 12 v) with load variation from 0...150% of p o1 nom on output 1. output 2 loaded with 50% of p o2 nom . u o1 , u o2 [v] i o1 i o1 nom 05039 14 13 12 11 10 025 50 75 100 150 [%] u o2 u o1 125 7 8 9 10 11 12 13 u o [v] 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 i o total [a] 0 05150 fig. 14 u o versus i o (typ) of double output units with option r (2 12 v), with both outputs in parallel. 110 imy 15-12-12-7r. u o1 , u o2 [v] i o1 i o1 nom 05151 14 13 12 11 10 025 50 75 100 150 [%] u o2 u o1 125 fig. 18 flexible load distribution on double outputs with option r (2 12 v) with load variation from 0...150% of p o1 nom on output 1. output 2 loaded with 50% of p o2 nom . 110 imy 15-12-12-7r. note: minimum load of approx. 10% on output 1 prevents voltage drop in unballanced load condition. 60 70 80 90 h [%] 50 75 100 p o p o total 25 05152 [%] u i min u i nom u i max 60 70 80 90 h [%] 50 75 100 p o p o total 25 05153 [%] u i min u i nom u i max fig. 15 efficiency versus input voltage and load. typical values 40 imx 15-12-12-7 fig. 19 efficiency versus input voltage and load. typical values 110 imy 15-12-12-7 70 100 u o [%] t [ms] 05041 8.5 60.5 60.5 overload short circuit condition switch-off fig. 16 overload switch off (hiccup mode), typical values.
imx/imy 15 series dc-dc converters <40 watt rugged environment edition 6/7.99 10/16 melcher the power partners. 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: 2.0...20 v converter shut down: 10...0.7 v adjustable output voltage r input for single output units using synchronous rectifi- cation (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 of- fer adjustable output voltage(s) by using the control input r or trim. if the control input is left open-circuit the output volt- age is set to u o nom . for output voltages u o > u o nom , the minimum input voltage u i min (see: electrical input data ) in- creases proportionally to u o / u o nom . single output units using synchronous rectification (g): the r input is referenced to the secondary side of the con- verter. 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 u o ad- justment is different from the standard single output units and -0503- types. 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 r ext in the range of 100...105% of u o nom or an external volt- age source in the range of 75...105% of u o nom . trim vo1+ vo2 + u ext vi+ vi r ext vo1 vo2+ 06089 control circuit u ref 2.5 v fig. 22 output voltage control for double output units by means of the trim input. r vo+ vo + u ext 4 k ? u ref 2.5 v control circuit vi+ vi r ext1 r ext 2 06029 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. single output units, -0503- types and double output units fit- ted with option r: the r input is referenced to the secondary side of the con- verter. 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 r ext . 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 u o = 80...100 % u o nom . u o r ext1 4 k ? u o nom u o or: between the r pin and vo+ to achieve an output volt- age range of approximately u o = 100...105 % u o nom . ( u o 2.5v) r ext2 4 k ? 2.5 v ( u o / u o nom 1) b) adjustment by means of an external voltage u ext be- tween 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 u o nom . u o 2.5 v u ext u o 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. r vo+ vo vi+ vi r ext2 r ext1 06131 fig. 20 output voltage control for single output units synchronous rectification. table 8: u o versus u ext approximate values u o nom typ. values of r ext1 typ. values of r ext2 [v] u o [% of u o nom ] r ext1 [k ? ] u o [% of u o nom ] r ext2 [k ? ] 3.3 75 1.1 100 80 2.2 105 11 90 8.2 110 5.1 5.1 75 0.47 100 80 1.3 105 10 90 3.6 110 5.1
rugged environment dc-dc converters <40 watt imx/imy 15 series edition 6/7.99 11/16 melcher the power partners. a) adjustment by means of an external resistor r ext : programming of the output voltage by means of an exter- nal resistor r ext is possible within a limited range of 100...105% of u o nom . r ext should be connected between the trim pin and vi . connection of r ext to vi+ may dam- age the converter. the following table indicates suitable resistor values for typical output voltages under nominal conditions ( u i nom , i o = 0.5 i o nom ), with either paralleled outputs or equal load conditions on each outputs. b) adjustment by means of an external voltage source u ext . for external output voltage programming in the range 75...105% of u o nom a (0...20 v) source u ext is required, connected to the trim pin and vi . the table below indi- cates typical u o versus u ext values under nominal condi- tions ( u i nom , i o = 0.5 i o nom ), with either paralleled outputs or equal load conditions on each output. applying a con- trol voltage >20 v will set the converter into a hiccup mode. direct paralleling of the trim pins of units con- nected in parallel is feasible. table 9b: u o versus u ext for u o = 75...105% u o nom ; typical values (u i nom , i o1/2 = 0.5 i o1/2 nom ) u o [% u o nom ] u ext [v] 105 0 102 1.6 95 4.5 85 9 75 13 table 9a: r ext1 for u o > u o nom ; approximate values (u i nom , i o1, 2 = 0.5 i o1/2 nom ) u o [% u o nom ] r ext [k ? ] 105...108 (107 typically) 0 105 1.5 104 5.6 103 12 102 27 101 68 100 electromagnetic immunity table 10: immunity type tests phenomenon standard 1 class coupling value waveform source test in per- 3 level mode 2 applied imped. procedure oper. form. electrostatic iec/en 2 contact discharge 4000 v p 1/50 ns 330 ? 10 positive and yes b discharge 61000-4-2 (r pin open) 10 negative to case 3 air discharge 8000 v p discharges (r pin open) electromagnetic iec/en 3 antenna 10 v/m am 80% 26 1000 mhz yes a field 61000-4-3 1 khz env 50204 pm, 50% duty 900 mhz cycle, 200 hz resp. frequ. electrical fast iec/en 4 direct +i/ i 4000 v p bursts of 5/50 ns 50 ? 1 min positive yes b transient/burst 61000-4-4 5 khz rep. rate 1 min negative transients with transients per 15 ms burst coupling mode duration and a 300 ms period surge iec/en 3 +i/ i 2000 v p 1.2/50 s2 ? 5 pos. and 5 neg. yes b 61000-4-5 5 impulses per coupling mode conducted iec/en 3 +i/ i 10 v rms am modulated 50 ? 0.15...80 mhz yes a disturbancies 61000-4-6 (140 db v) 80%, 1 khz 150 ? transient etr 283 +i/ i 150 v p 0.1/0.3 ms limited to 3 positive yes b (19 pfl 1) 4 <100 a 1 related and previous standards are referenced in: technical information: standards . 2 i = input, o = output. 3 a = normal operation, no deviation from specification, b = temporary deviation from specs. possibe. 4 for 40 imx 15 types (additional external components required). not applicable for 20 imx 15 types. 5 external components required. which typically occur in many installations, but especially in battery driven mobile applications. electromagnetic compatibility (emc) a suppressor diode together with an input filter form an ef- fective protection against high input transient voltages
imx/imy 15 series dc-dc converters <40 watt rugged environment edition 6/7.99 12/16 melcher the power partners. 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 possi- ble to the input of the converter. fig. 26 choke dimensions vi+ vi l v+ v module 07114 fig. 25 example for external circuitry to comply with cispr22/en 55022, level b, radiated 15 8.5 15 07110 table 11: input filter components for en 55022, level b, radiated. type current compensated choke 20 imx 15 1 mh, 2a 40 imx 15 e.g. tokin, type sc-02-10gs 110 imy 15 table 12: temperature specifications, valid for air pressure of 800...1200 hpa (800...1200 mbar) temperature -7 -9 option -8 3 characteristics conditions min max min max min max unit t a ambient temperature 1 operational 2 25 71 40 71 40 85 c t c case temperature 25 95 40 95 40 105 t s storage temperature 1 non operational 40 100 55 100 55 105 1 mil-std-810d section 501.2 and 502.2 2 see: thermal considerations 3 start up at 55 c table 13: mtbf and device hours mtbf ground benign ground fixed ground mobile mtbf acc. to mil-hdbk-217f t c = 40 c t c = 40 c t c = 70 c t c = 50 c 40 imx 15 h h h h fig. 23 typical disturbance voltage (quasi-peak) at the input ac- cording to cispr 11/en 55011 and cispr 22/en 55022, measured at u i nom and i o nom . output leads 0.1 m, twisted. (40 imx 15-05-7r) electromagnetic emission 07020 en 55022 a en 55022 b 90 80 70 60 50 40 30 20 10 0 0 .01 0 .05 0.1 0.5 1 2 5 10 20 30 [db v] mhz 0 .02 50 40 30 20 10 0 30 50 100 200 500 1000 [db v/m] [mhz] a b 07108 fig. 24 typical radio frequency-interference voltage at u i nom , i o nom , measured with an antenna (distance 10 m). output leads 1 m, twisted. immunity to environmental conditions
rugged environment dc-dc converters <40 watt imx/imy 15 series edition 6/7.99 13/16 melcher the power partners. table 14: mechanical stress test method standard test conditions status ca damp heat iec/din iec 60068-2-3 temperature: 40 2 c unit not steady state mil-std-810d section 507.2 relative humidity: 93 +2/-3 % operating duration: 56 days ea shock iec/en/din en 60068-2-27 acceleration amplitude: 100 g n = 981 m/s 2 unit (half-sinusoidal) mil-std-810d section 516.3 bump duration: 6 ms operating number of bumps: 18 (3 each direction) eb bump iec/en/din en 60068-2-29 acceleration amplitude: 40 g n = 392 m/s 2 unit (half-sinusoidal) mil-std-810d section 516.3 bump duration: 6 ms operating number of bumps: 6000 (1000 each direction) fc vibration iec/en/din en 60068-2-6 acceleration amplitude: 0.35 mm (10...60 hz) unit (sinusoidal) mil-std-810d section 514.3 5 g n = 49 m/s 2 (60...2000 hz) operating frequency (1 oct/min): 10...2000 hz test duration: 7.5 h (2.5 h each axis) fda random vibration iec 60068-2-35 acceleration spectral density: 0.05 g n 2 /hz unit wide band frequency band: 20...500 hz operating reproducibility acceleration magnitude: 4.9 g n rms high test duration: 3 h (1 h each axis) kb salt mist, cyclic iec/en/din iec 60068-2-52 concentration: 5% (30 c) unit not (sodium chloride duration: 2 h per cycle operating nacl solution) storage: 40 c, 93% rel. humidity storage duration: 22 h per cycle number of cycles: 3 mechanical data dimensions in mm. tolerances 0.3 mm unless otherwise indicated. fig. 27 case imx 15, imy 15 weight: <35 g european projection 50.8 40.65 10.5 >5 0.8 x 0.8 45.72 09011 1 4 11 17 bottom view 47 36.83 2.54 fixing hole for m2 or ka 22 self tapping screws 5.0 8 measuring point of case temperature t c
imx/imy 15 series dc-dc converters <40 watt rugged environment edition 6/7.99 14/16 melcher the power partners. safety and installation instructions installation instructions installation of the dc-dc converters must strictly follow the national safety regulations in compliance with the enclo- sure, mounting, creepage, clearance, casualty, markings and segregation requirements of the end-use application. 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. check for hazardous voltages before altering any connec- tions. do not open the module. ensure that a unit failure (e.g. by an internal short-circuit) does not result in a hazardous condition. see also: safety of operator accessible output circuit. input fuse to prevent excessive current flowing through the input sup- ply 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. standards and approvals all dc-dc converters are pending to be ul recognized ac- cording to ul 1950, ul recognized for canada to can/ csa c22.2 no. 950-95 and lga approved to iec/en 60950 standards. the units have been evaluated for: building in supplementary insulation input to output, based on their maximum input voltage (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 sub- ject 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 manu- facturing surveillance in accordance with the above men- tioned ul, csa, en and with iso 9001 standards. table 15: pin allocation pin no. single -0503- double dual output output output output option k 1 vi+ vi+ vi+ vi+ 2vi vi vi vi 3 - n.c. trim - 4sd sd sd sd 11 - vo2+ vo1+ vo+ 12 - go vo1 - 13 vo+ vo1+ vo2+ go 15 vo go vo2 vo 17 r r n.c./r n.c. 10005 1 2 3 4 11 12 13 15 17 bottom view 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 sup- plies are not hermetically sealed. isolation the electric strength test is performed as factory test in ac- cordance with iec/en 60950 and ul 1950 and should not be repeated in the field. melcher will not honour any guar- antee claims resulting from electric strength field tests. table 16: electric strength test voltages characteristic input to output output to unit imx 15 imy 15 output electric strength 1.2 3.0 0.1 kv rms test voltage 1 s 1.5 4.0 0.15 kv dc insulation resistance >100 >100 - m ? at 500 v dc partial discharge consult factory - kv extinction voltage
rugged environment dc-dc converters <40 watt imx/imy 15 series edition 6/7.99 15/16 melcher the power partners. table 17: insulation concept leading to an selv output circuit conditions front end dc-dc converter result supply minimum required grade maximum minimum required type measures to achieve the safety status of voltage of isolation, to be provided dc output safety status of the specified safety status of the dc-dc by the ac-dc front end, voltage front end output the output circuit converter output including mains supplied from the circuit circuit battery charger front end 1 mains operational (i.e. there is 150 v primary imy 15 double or reinforced selv circuit 150 v ac no need for electrical iso- insulation, based on lation between the mains 150 v ac and dc (pro- supply voltage and the vided by the dc-dc dc-dc converter input converter) voltage) mains basic 60 v earthed selv circuit 2 imx 15 operational insulation 250 v ac imy 15 (provided by the dc-dc converter) 75 v hazardous voltage imx 15 input fuse 3 output sup- earthed selv secondary circuit pressor diodes 4 , and circuit earthed output circuit 2 150 v imy 15 supplementary insulation selv circuit 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) double or reinforced 60 v selv circuit imx 15 operational insulation imy 15 (provided by the dc-dc converter) 75 v double or reinforced imx 15 supplementary insulation insulated unearthed based on the maximum hazardous voltage rated output voltage from secondary circuit 5 the front end (provided by the dc-dc converter) 120 v tnv-2 circuit imy 15 double or reinforced 150 v double or reinforced insulation, based on the insulated earthed or maximum rated output unearthed hazardous voltage from the front end voltage secondary (provided by the dc-dc circuit converter) safety of operator accessible output circuit if the output circuit of a dc-dc converter is operator acces- sible, it shall be an selv circuit according to the iec/en 60950 related safety standards the following table shows some possible installation con- figurations, 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 en- sure the compliance with the relevant and applicable safety regulations. more information is given in: technical infor- mation: safety . 1 the front end output voltage should match the specified input voltage range of the dc-dc converter. 2 the earth connection has to be provided by the installer accord- ing to the relevant safety standard, e.g. iec/en 60950. 3 the installer shall provide an approved fuse (type with the low- est 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 . 4 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 ). 5 has to be insulated from earth by at least basic insulation ac- cording to the relevant safety standard, based on the maximum output voltage from the front end. ac-dc front end dc-dc con- verter mains fuse battery earth connection suppressor diode selv earth connection + ~ ~ 10004 fig. 29 schematic safety concept. use fuse, suppressor diode and earth connection as per table safety concept leading to an selv output circuit .
imx/imy 15 series dc-dc converters <40 watt rugged environment edition 6/7.99 16/16 melcher the power partners. description of option option -8 extended temperature range extension of the temperature range from standard 25...71 c to 40...85 c. 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 alternative pinout option k configures the electrically isolated double outputs to the alternative pinout with outputs connected in series (vo+/go/vo ) and common ground. however instead of using units with option k, it is recom- mended to use the standard double output units by provid- ing 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. option i inhibit excluces shut down and option k. 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). converter operating: 10 v...0.8 v converter inhibited or inhibit pin left open: 2.4 v... u i max fig. 31 if the inhibit is not used the inhibit pin should be con- nected to vi vi+ vi i 06070 option -9 extended ambient temperature range 40...71 c. option r r input and magnetic feedback 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 u o 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. 1.2 1.0 0.8 0.6 0.4 0 20 20 60 0.2 40 80 p o / p o max t a [ c] 40 0 11047 fig. 30 maximum allowed output power versus ambient tempera- ture.

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