20IMX4-03-8G

IMX4 Series Data Sheet 4 Watt DC-DC Converters Features • RoHS lead-free-solder and lead-solder-exempted products are available. • 5 year warranty for RoHS lead-free-solder products with temperature index - 8. • Input voltage ranges up to 121 VDC 20 0.8" 8.5 0.34" • Voltage withstand test 1500 VAC • 1 or 2 isolated outputs up to 48 V 32 1.25" • Extremely wide input voltage ranges • Immunity according to IEC/EN 61000-4-2, -3, -4, -5, -6 • High efficiency (typ. 83%) • Flexible load distribution on outputs • Outputs no-load, overload, and short-circuit proof • High reliability • Operating ambient temperature – 40 to +85 °C • Thermal protection • Industrial and alternative pinout • DIL 24 case with 8.5 mm profile Safety-approved to the latest edition of IEC/EN 60950-1 and UL/CSA 60950-1 Description The IMX4 Series of board-mountable 4-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, industry, or telecom, where variable input voltages or high transient voltages are prevalent. 1 1 70IMX4 models Covering a total input voltage range from 8.4 VDC up to 121 VDC with three different models, the converters are available with single or dual output from 3.3 up to ±24 VDC with flexible load distribution. Features include efficient input and output filtering with unsurpassed transient and surge protection, low output ripple and noise, consistently high efficiency over the entire input voltage range and high reliability as well as excellent dynamic response to load and line changes. A special feature is their small case size, DIL 24 with only 8.5 mm profile. The circuit is comprised of integrated planar magnetics, and all components are automatically assembled and solidly soldered onto a single PCB without any wire connection. Thanks to the rigid mechanical design, the converters withstand an extremely high level of shock and vibrations. Careful consideration 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 85 °C in free air without using any potting material. The converters exhibit basic insulation and are designed and built according to the international safety standards IEC/EN 60950-1. 70IMX4 models are CE-marked. Several options, such as open-frame or an alternative industrial pinout, provide a high level of application-specific engineering and design-in flexibility. Table of Contents Page Page Description ............................................................................. 1 Model Selection ..................................................................... 2 Functional Description ........................................................... 3 Electrical Input Data ............................................................... 4 Electrical Output Data ............................................................ 6 Electromagnetic Compatibility (EMC) .................................... 8 Mechanical Data .................................................................... 9 Immunity to Environmental Conditions ................................ 10 Safety and Installation Instructions ...................................... 10 Description of Options ......................................................... 11 Copyright © 2018, Bel Power Solutions Inc. All rights reserved. MELCHER BCD20006-G Rev AF, 10-Apr-2018 The Power Partners. Page 1 of 12 IMX4 Series Data Sheet 4 Watt DC-DC Converters Model Selection Table 1: Model Selection Output 1 Io1 nom Vo1 nom [ VDC] [mA] 1 1 Output 2 Vo2 nom Io2 nom [ VDC] [mA] 1 Output power Po nom [W ] Input voltage range [ VDC] Efficiency η min η typ [%] [%] Model Options 3.3 3.3 900 900 - - 3.0 3.0 8.4 to 36 16.8 to 75 76 76 77.5 78 20IMX4-03-8G 40IMX4-03-8G Z, non-G Z, non-G 5 5 5 5 700 700 700 700 - - 3.5 3.5 3.5 3.5 4.7 to 16.8 8.4 to 36 16.8 to 75 40 to 121 76 78 78 77 81 81 78 5IMX4-05-8G 20IMX4-05-8G 40IMX4-05-8G 70IMX4-05-8G Z, non-G K, Z, non-G K, Z, non-G non-G 12 12 12 12 300 340 340 340 - - 3.6 4.1 4.1 4.1 4.7 to 16.8 8.4 to 36 16.8 to 75 40 to 121 79 78 78 79 82 82 81 5IMX4-12-8G 20IMX4-12-8G 40IMX4-12-8G 70IMX4-12-8G Z, non-G K, Z, non-G K, Z, non-G non-G 15 15 15 15 250 280 280 280 - - 3.75 4.2 4.2 4.2 4.7 to 16.8 8.4 to 36 16.8 to 75 40 to 121 79 78 78.7 79 82 82 80.5 5IMX4-15-8G 20IMX4-15-8G 40IMX4-15-8G 70IMX4-15-8G Z, non-G K, Z, non-G K, Z, non-G non-G +5 +5 +5 350 350 350 –5 –5 –5 350 350 350 3.5 3.5 3.5 8.4 to 36 16.8 to 75 40 to 121 77 76 75.5 81 81 78 20IMX4-0505-8G 40IMX4-0505-8G 70IMX4-0505-8G K, Z, non-G K, Z, non-G non-G +12 +12 170 170 –12 –12 170 170 4.1 4.1 8.4 to 36 16.8 to 75 76 76 82 82 20IMX4-1212-8G 40IMX4-1212-8G K, Z, non-G K, Z, non-G +15 +15 140 140 –15 –15 140 140 4.2 4.2 8.4 to 36 16.8 to 75 78 76 82 82 20IMX4-1515-8G 40IMX4-1515-8G K, Z, non-G K, Z, non-G +24 +24 80 80 –24 –24 80 80 3.8 3.8 8.4 to 36 16.8 to 75 76 76 83 83 20IMX4-2424-8G 40IMX4-2424-8G Z, non-G Z, non-G Flexible load distribution on double-outputs is possible. Not for new designs Part Number Description Input voltage range Vi 20 IMX4 - 05 05 -8 K Z G 4.7 to 16.8 VDC ........................................... 5 8.4 to 36 VDC ............................................ 20 16.8 to 75 VDC .......................................... 40 40 to 121 VDC ........................................... 70 Series ........................................................................ IMX4 Output voltage of output 1 ...................... 03, 05, 12, 15, 24 Output voltage of output 2 ............................ 05, 12, 15, 24 Operating ambient temperature range –40 to 85 °C .... -8 Options: Alternative pinout ......................................... K Open frame ................................................. Z RoHS compliant for all six substances ....... G Note: The sequence of options must follow the order above. Example: 40IMX4-0505-8KG: DC-DC converter, input voltage range 16.8 to 75 V, 2 outputs providing ± 5 V, 350 mA, temperature range – 40 to 85 °C, alternative pinout, RoHS-compliant for all si x substances MELCHER BCD20006-G Rev AF, 10-Apr-2018 The Power Partners. Page 2 of 12 IMX4 Series Data Sheet 4 Watt DC-DC Converters Functional Description 03046 The IMX4 Series converters are feedback-controlled flyback converters using current mode PWM (Pulse Width Modulation). The input is protected against transients by means of a suppressor diode. Vi+ 1 13 Vo+ n.c. 2 PWM The output voltage is monitored by a separate transformer winding close to the secondary windings and fed back to the control circuit. 12 Vo– Vi– 24 Current limitation is provided by the primary circuit, thus limiting the total output current (Io nom for single- and the sum Io1 nom + Io2 nom for dual-output models). The close magnetic coupling provided by the planar construction ensures very good regulation and allows for flexible load distribution on dual-output models. Fig. 3 Block diagram for single-output models with alternative pinout (option K). 03044 Vi+ 22 14 Vo+ 23 03047 15 Vo+ Vi+ 1 PWM PWM 16 Vo– 10 2 11 Vi– 3 Go 10 13 Vo– Vi– 24 Fig. 1 Block diagram for single-output models with standard pinout. Fig. 4 Block diagram for dual-output models with alternative pinout (option K). 03045 Vi+ 22 14 Vo+ 23 PWM 16 Go 2 Vi– 3 11 Vo– Fig. 2 Block diagram for dual-output models with standard pinout. MELCHER BCD20006-G Rev AF, 10-Apr-2018 The Power Partners. Page 3 of 12 IMX4 Series Data Sheet 4 Watt DC-DC Converters Electrical Input Data General conditions: TA = 25 °C, unless TC is specified. Table 2: Input Data Input 5I MX4 20IMX4 40IMX4 70IMX4 Characteristics Conditions min typ max min typ max min typ max min typ max Vi Input voltage range 4.7 5.0 16.8 8.4 Vi nom Nominal input voltage TC min to TC max Io = 0 to I o nom Vi sur Repetitive surge voltage abs. max input (3 s) t start-up Converter t rise start-up time1 Rise time 1 Ii o No-load input current Input capacitance 0.25 0.5 0.25 0.5 0.25 0.5 0.3 5 5 12 12 Io = 0, Vi min to Vi max 3 I i rr Reflected ripple current I o = 0 to I o nom -- 15 -- 0.54 5 10 0.3 5 0.6 s ms 10 mA 0.15 µF 3.8 3.7 4.2 5.6 A 400 400 400 40 0 kHz -- EN 55011 4 20 VDC 150 5 Vi min to Vi max, Io = 0 to Io nom 4 100 12 Vi = Vi nom 3 40 -- Switching frequency 2 121 70 -- Inrush peak current 1 40 resistive load Iinr p Input RFI level conducted 75 40 capacitive load fs vi RFI 20 -- Worst case condition at Vi min and full load Vi nom Io nom Ci 5.0 36 16.8 2 Unit 100 -- 60 A 30 A A mApp Class Measured with a resistive or max. admissible capacitive load; see fig. 5 Operation at lower input voltage possible: Po approx. 80% of Po nom at Vi min = 14.4 V Source impedance according to ETS 300132-2, version 4.3. External capacitors required according to table 3. Start-up Filter to Comply with EN 55011 Vo trise Vo nom Electromagnetic emission requirements according to table Electrical Input Data can be achieved by adding an external capacitor as close as possible to the input terminals (see fig. 7 and table 3). 04008b t tstartup Fig. 5 04035b Vi+ Converter start-up and rise time + Ci Inrush Current The inrush current has been kept as low as possible by choosing a very small input capacitance. A series resistor may be inserted in the input line to further limit this current. A 04034a 3 Vi– Fig. 7 Input capacitors Table 3: Input electrolytic capacitors Model 20IMX4 40IMX4 70IMX4 Ci 100 µF 50 V 47 µF 100 V 330 µF 160 V 2 1 0 Fig. 6 0 10 20 30 40 µs Typ. inrush current at Vi nom, Po nom versus time measured according to ETS 300132-2, version 4.3 (40IMX4). MELCHER BCD20006-G Rev AF, 10-Apr-2018 The Power Partners. Page 4 of 12 IMX4 Series Data Sheet 4 Watt DC-DC Converters Input Transient Voltage Protection Fuse and Reverse Polarity Protection In many applications transient voltages on the converter input are always possible. These may be caused for example by short circuits between Vi+ and Vi–, where the network inductance may generate high energy pulses. The suppressor diode on the input also protects against reverse polarity input voltage. An external fast fuse is required to limit this reverse current; see table below. In order to protect the converter, a transient voltage suppressor diode is fitted at the input; see table below. Table 6: External input fuse Table 4: Built-in transient voltage suppressor Model Breakdown voltage VBR nom Peak power at 1 ms PP Peak pulse current I PP 5IMX4 -- -- -- 20IMX4 40 V 600 W 10.3 A 40IMX4 100 V 600 W 4.1 A 70IMX4 150 V 600 W 2.9 A Model Fuse type 5IMX4 Fast 1.6 A 20IMX4 Fast 1 A 40IMX4 Fast 0.5 A 70IMX4 Fast 0.315 A If transients generating currents above the peak pulse current I PP are possible, an external limiting network such as the circuit shown in figure 8 is recommended. It provides compliance with transients according to IEC/EN 61000-4-5, level 2. The comp onents are specified in table 5. Li 04036b Vi+ Ci + D Vi– Fig. 8 External circuitry to comply with IEC/EN 61000-4-5, level 2. Table 5: Components for the circuitry fig. 8 Model Li 20IMX4 40IMX4 70IMX4 330 µH, 0.42 W 1A 330 µH, 0.42 W 0.6 A 330 µH, 0.65 W 0.3 A Ci 68 µF, 50 V 68 µF, 100 V 100 µF, 200 V D ON 1.5KE 39 A ON 1.5KE 82 A – MELCHER BCD20006-G Rev AF, 10-Apr-2018 The Power Partners. Page 5 of 12 IMX4 Series Data Sheet 4 Watt DC-DC Converters Electrical Out put Data General conditions: TA = 25 °C, unless TC is specified. Table 7a: Output data for single-output models Output Vo nom 3.3 V Characteristics Conditions min Vo Output setting voltage Vi nom, Io = 0.5 Io nom 3.27 Io nom Output current (nom.) Vi min to Vi max 5IMX4 Io L Current limit 2 Vi nom ∆Vo V Line regulation Vi min to Vi max, Io nom ±1 ±1 ±1 ±1 ∆V Load regulation Vi nom Io = (0.1 to 1) Io nom ±3.5 ±3 ±3 ±3 vo Output voltage noise Vi min to Vi max I o = Io nom 80 80 120 150 typ 5V max min max 900 others 1260 1800 955 20 11.90 40 max 15.12 250 340 20 max 12.10 14.88 V mA 280 375 1400 Unit min typ 300 700 1000 5 5.04 15 V min typ 700 5IMX4 950 6 typ 3.33 4.96 -- others 12 V 325 476 680 40 40 392 560 60 50 % mVpp 75 Vo clp Output overvoltage limitation Co ext Admissible capacitive load vo d Dynamic Voltage deviat. load Recovery time regulat. Vi nom Io = (1 to 0.5) Io nom ±250 ±250 ±250 ±250 mV 1 1 1 1 ms Temperature coefficient ∆Vo /∆TC Vi min to Vi max Io = (0.1 to 1) Io nom ±0.02 ±0.02 ±0.02 ±0.02 %/K ±5 V ±12 V ±15 V ±24 V Unit td αVo Min. load 1% 130 0 680 130 0 680 130 0 150 130 0 100 % µF Table 7b: Output data for dual-output models Output Vo nom Characteristics Conditions min Vo1 Vo2 Output setting voltage Vi nom Io1 = Io2 = 0.5 Io nom 4.96 4.95 Io nom Output current (nom.) 1 Vi min to Vi max Io L Current limit 2 Vi nom, TC = 25 °C 3 typ max min typ max 5.04 11.90 5.05 11.88 2 x 350 min 12.10 14.88 12.12 14.85 2 x 170 1000 typ max min 15.12 23.81 15.15 23.75 2 x 140 474 typ max 24.19 24.25 2 x 80 392 mA 232 ∆Vo V Line regulation Vi min to Vi max, Io nom ±1 ±1 ±1 ±1 ∆V Load regulation 4 Vi nom Io = (0.1 to 1) Io nom ±3 ±3.5 ±3 ±3 vo1, 2 Output voltage noise Vi min to Vi max I o = Io nom Vo clp Output overvoltage limitation Co ext Admissible capacitive load 3 vo d Dynamic load regulat. to d αVo 1 2 3 4 5 6 5 40 Min. load 1% Vi min to Vi max Io = (0.1 to 1) Io nom 140 60 45 130 0 Voltage deviat. Vi nom I = (1 to 0.5) Io nom Recovery time o Temperature coefficient ∆Vo /∆TC 100 6 680 150 70 50 130 0 150 V 240 75 40 130 0 100 mVpp 120 130 0 % 47 % µF ±250 ±600 ±750 ±750 mV 1 1 1 1 ms ±0.02 ±0.02 ±0.02 ±0.02 %/K Each output is capable of delivering full output power. The current limit is primary side controlled. Sum 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 MELCHER BCD20006-G Rev AF, 10-Apr-2018 The Power Partners. Page 6 of 12 IMX4 Series Data Sheet 4 Watt DC-DC Converters Thermal Considerations If a converter, mounted on a PCB, is located in free, quasistationary air (convection cooling) at the maximum ambient temperature TA max (see table Temperature specifications) and is operated at 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 depend on 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. Several converters with equal output voltage can be connected in parallel and will share their output current quite equally. However, this may cause start-up problems and is only recommended in applications, where one converter is able to deliver the full load current, e.g., in true redundant systems. Typical Performance Curves Vo [V] 05056b 5.25 5.0 4.75 4.5 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. The installer must ensure that under all operating conditions TC remains within the limits stated in the table Temperature Specifications. 4.25 4.0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 Io 0.9 1.0 A Fig. 10 Short Circuit Behavior Vo versus Io (typ) of single-output models (20IMX4-05) The current limitation shuts down the converter, when a short circuit is applied to the output. It acts self-protecting, and automatically recovers after removal of the overload condition. Vo [%] 05057a 31.5 31 05041a 30.5 overload short-circuit condition 100 Vo1 + Vo2 [V] switch-off 30 70 29.5 29 28.5 0 0.3 s t 0 20 40 60 80 100 120 140 mA Io Fig. 11 Fig. 9 Vo versus Io (typ.) of dual-output models (±15 V), with load connected between Vo+ and Vo –. Overload switch-off (hiccup mode). Vo1 [V] Output Overvoltage Protection The outputs are protected against overvoltages by Zener diodes. In the event of an overvoltage, the converter will shutdown and attempt to restart automatically. 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 converters are not designed to withstand external overvoltages applied to the outputs. 05058a 16.5 16 15.5 Io2 = 140 mA 15 Io2 = 14 mA 14.5 Io1 Series and Parallel Connection The outputs of single or dual-output models can be connected in series without any precautions, taking into consideration that the output voltage should remain below 60 V for SELV operation. 14 0 20 40 60 80 100 120 140 mA Fig. 12 Cross load regulation of dual-output models. Vo1 versus Io1 (typ) for various Io2 (40IMX4-1515). MELCHER BCD20006-G Rev AF, 10-Apr-2018 The Power Partners. Page 7 of 12 IMX4 Series Data Sheet 4 Watt DC-DC Converters Vo1 , Vo2 [V] η [%] 05059b 12.8 05060a 90 Vi nom Vi max Vi min 80 12.4 70 Vo2 Vo1 12 60 11.6 11.2 50 Io1 0 30 60 120 90 150 % Io1 nom 40 25 Fig. 13 50 75 100 Po1 [%] Po nom Fig. 14 Flexible load distribution on dual outputs (2 ×12 V) with load variation from 0 to 150% of Po1 nom on output 1. Output 2 loaded with 25% of Po2 nom. Efficiency versus input voltage and load. Typical values (40IMX4-1212). Electromagnetic Compatibility (EMC) Electromagnetic Immunity Table 8: Immunity type tests Phenomenon Standard Class level Coupling mode Value applied Waveform Source imped. Test procedure Electrostatic discharge to case IEC/EN 61000-4-2 2 contact discharge 4000 Vp 1/50 ns B air discharge 8000 Vp 10 positive and 10 negative discharges yes 3 330 Ω 150 pF Electromagnetic IEC/EN field 61000-4-3 33 antenna 10 V/m AM 80% 1 kHz n.a. 80 – 1000 MHz yes A 3 antenna 10 V/m PM, 50% duty cycle, 200 Hz repetition frequ. n.a. 900 MHz yes A Electrical fast IEC/EN transients/burst 61000-4-4 4 direct +i/–i ±4000 Vp bursts of 5/50 ns 5 kHz repet. rate, 15 ms burst, 300 ms period 50 Ω 60 s positive 60 s negative coupling mode yes B Surges IEC/EN 61000-4-5 24 +i/–i 1000 Vp 1.2/50 µs 2Ω 18 µF 5 pos. and 5 neg. surges yes B RF conducted immunity IEC/EN 61000-4-6 3 +i/–i 3 VAC (140 dBµV) AM 80% 1 kHz 50 Ω 0.15 to 80 MHz 150 W yes A 1 2 3 4 In Peroper. form. 2 i = input, o = output Performance criterion: A = normal operation, no deviation from specifications, B = temporary loss of function or deviation from specs. Corresponds to the railway standard EN 50121-3-2:2000, table 9.1 External components required. MELCHER BCD20006-G Rev AF, 10-Apr-2018 The Power Partners. Page 8 of 12 IMX4 Series Data Sheet 4 Watt DC-DC Converters Electromagnetic Emission Mechanical Data Conducted RFI noise at input according to EN 55011: Dimensions in mm (inchies). Tolerances ±0.3 mm, unless noted 20IMX4-2424-8, Peak Vi+, conducted, 0.15 - 30 MHz, Uster, 30-Jun-06 Ci = 100 µF, Vi = 20 V, Ro = 660 ohm, lead length 10 cm. dbµV EN 55011 A 70 20IMX4-cond_P 80 European Projection 33 (1.3") 60 11 x 2.54 (0.1") 50 15.24 (0.6") 30 20 10 0.5 1 2 5 10 24 12 1 20 MHz Fig. 15a Measuring point of case temperature TC 3.1 (0.12.2") Typical disturbance voltage (peak) at the pos. input according to EN 55011, measured at Vi nom and Io nom. Output leads 0.1 m, twisted. Input capacitors see table 3. (20IMX4-2424-8). s09042c 0.5 (0.02") 40IMX4-05-8Z, Peak Vi+, conducted, 0.15 - 30 MHz, Uster, 30-Jun-06 Ci = 47 µF, Vi = 40 V, Ro = 8.2 ohm, lead length 10 cm. dbµV 8.5 +0 /-0.1 (0.33") 0.2 13 20 (0.79") 40 EN 55011 A 70 40IMX4-cond_P 80 60 Fig. 16 Case with standard or alternative pinout (option K) Material: Fortron black; weight: