IBX15 Series
Boost Converters
The boost converters were designed in accordance
with the standards EN 50155 and EN 50121-3-2 to
meet the requirements of various railway and industrial
applications in rugged environment. They are particularly
suitable to expand the input voltage range of power
supplies (e.g. 110IMY15 or 110IMY70 Series DC-DC
converters). An additional circuit allows for providing a
predefined interruption time.
When the input voltage exceeds a predefined output
voltage level, the input voltage is directly fed forward.
The converters exhibit an input EMC-filter.
54.9
2.16"
54.9
2.16"
11.5
0.45"
The boost converters are available in a fully enclosed
case or open-frame (option Z).
Features
•
•
•
•
•
•
•
•
•
•
•
RoHS-compliant for all 6 substances
5 year warranty
Wide input voltage range 16.8 to 160 VDC
Output: 50 to 80 VDC
Class III equipment (no isolation input/output)
Extremely high efficiency
Excellent surge and transient protection
Externally adjustable output voltage
Programmable undervoltage lockout and inhibit
Interruption time with external capacitor
EN 50155, 50121-3-2 observed
Safety-approved to the latest edition of IEC/EN 62368-1
and UL/CSA 60950-1
Table of Contents
Page
Description............................................................................1
Model Selection.....................................................................2
Functional Description...........................................................2
Electrical Input Data..............................................................3
Electrical Output Data...........................................................5
Auxiliary Functions................................................................6
Page
Electromagnetic Compatibility (EMC)....................................7
Immunity to Environmental Conditions..................................9
Mechanical Data..................................................................10
Safety and Installation Instructions......................................10
Options................................................................................ 11
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BCD.00197 Rev AG, 09-Mar-2021
IBX15 Series
Boost Converters
Model Selection
Table 1: Model Selection
Input voltage
1
Operating input range
Output Voltage
Output Current
Efficiency 1
Type designation
Vi nom
Vi
Vo nom
Io nom
η min
η typ
24 V
16.8 - 160 VDC
50 - 160 VDC
1.6 A
89 %
93 %
24IBX15-50-0G
36 V
25.2 - 160 VDC
50 - 160 VDC
2.2 A
91 %
95 %
36IBX15-50-0G
Options
Z
Efficiency at Vi = Vi min, Vo = Vo nom, I o = Io nom
Functional Description
The IBX15 boost converter is designed as step-up converter in order to increase the input voltage Vi to the regulated boost voltage VoBr.
When Vi exceeds VoB tr, the output voltage follows Vi. The resulting voltage (see fig. 1) is within the range of VoB tr to Vi max, which is
suitable for adequate DC-DC converters, e.g. 110IMY15 or 110IMY70 for 24/36IBX15-50. The IBX15 converters have no input-to-output
isolation; isolation is provided by the DC-DC converters connected to the output.
Vo
150
125
100
75
50
VoB tr = 80 V
VoB tr = 50 V
25
0
25
50
75 100
125 150
Vi
Fig. 1
Vo versus Vi depending on VoB tr
The inrush current is not limited, but the output capacitor of the IBX15 and the input capacitors of the connected DC-DC converters
are relatively small.
The switching frequency is approximately 2 × 200 kHz (interleaved). A current limiting circuit protects the main FETs from overload.
However, the output is not short-circuit proof.
The logic is biased by an auxiliary converter with a switching frequency of approx. 350 kHz. The boost voltage VoB can be trimmed
by resistor R BA to a higher level VoB tr. This allows together with an external storage capacitor Chu the realization of an interruption
time as requested by the railway standard EN 50155. No other components are needed.
JM081b
12
1
11
Vo+
2
PTC
Vi+
Boost
control
logic
Dhu
11
Chu
+
Auxiliary
converter
350 kHz
Gi–
3
Chu
15
Signal logic
13
4
Go–
RPUL
Fig. 2
Functional diagram
D
16
17
PUL
RBA
BA
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IBX15 Series
Boost Converters
Electrical Input Data
General conditions:
- TA = 25 °C, unless TC is specified.
Table 2: Input data
Model
24IBX15-50-0G
Characteristics
Conditions
min
Vi
Operating input voltage
Vi 2s
Temporary input voltage
2s
Vi abs
Input voltage limits
2 s, without damage
∆Vi o
Voltage drop Vi – Vo
Ii
Typical input current
Ci
Input capacitance
for surge calculation
tstart
Start-up time of Vo
Vi → Vi min or after shutdown
Pi 0
No-load input power
Vi min – Vi max, Io = 0
P i SD
Input power with shutdown
Vi min – Vi max, VPUL = 0
typ
36IBX15-50-0G
typ
Unit
max
min
max
16.8
160
25.2
160
12
168
21.3
168
V
176
176
Vi > VoB
1
1
Vi min, I o nom
8
6
A
500
ms
4
500
1.0
1.5
1.0
µF
1.5
W
Input Protection and Fuse
No fuse is incorporated inside the converter. Consequently, an external fuse or a circuit breaker at system level should be installed
to protect against severe defects; see table 3.
Reverse polarity protection is provided by an antiparallel diode across the input, causing the external input fuse or circuit breaker
to trip.
Note: The fuses in table 4 apply to batteries with Vi nom = 24 or 36 V. In applications using batteries with higher voltage, fuses with lower current
may suit better.
Table 3: Recommended external fuses in the non-earthed input line
Converter model
Fuse type
24IBX15-50-0G
Littlefuse 218, 10 A / 250 VAC, fast
36IBX15-50-0G
Littlefuse 218, 8 A / 250 VAC, fast, or:
Schurter SPT 8 A, 300 VDC
Programmable Undervoltage Lockout PUL
The programmable input undervoltage lockout (PUL, pin 17) should be adjusted adequately in order to limit the input current.
Table 4 shows the values of the resistor R PUL, connected between PUL and Vi–, versus the resultant minimum input voltage and
the resultant maximum input current.
Note: If PUL is connected to Vi–, the converter is disabled (shutdown).
Table 4: Typical values for R PUL and the resultant turn-on input voltage Vi LO. Valid for version V105 (Rev. AE) or later.
24IBX15-50-0G
36IBX15-50-0G
R PUL [kΩ]
Vi LO [V]
R PUL [k Ω]
Vi LO [ V]
∞
15
∞
23
110
18
100
27
68
20
56
30
43
23
36
34
27
27
27
38
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IBX15 Series
Boost Converters
Efficiency
η [%]
JM121
100
Vi = 36 V
90
Vi = 24 V
80
70
60
0.2
0
0.6
0.4
0.8
Io / Io nom
Fig. 3
Efficiency versus input voltage and output current (24IBX15-50-0G)
Interruption Time
The interruption time of a system comprised of a step-up converter IBX15 (Rev. AB or later) and connected converters can easily
be increased by an external capacitor C hu and adjusting the boost voltage VoB tr to a higher level.
As an example, fig. 4 shows a 36IBX15-50 supplying a DC-DC converter 110IMY70-12.
Formula for the external boost capacitor C hu:
2 • Po • t hu
Chu = ––––––––––––––
(VoB tr 2 – V i min2)
whereas:
C hu
Po
t h u
Vi m in
VoB t r
=
=
=
=
=
external boost capacitance [mF]
output power = input power of the supplied converter [W]
interruption or hold-up time [ms]
min. input voltage of supplied converters [V]
boost voltage trimmed using R BA [V]
[V]
JM122
120
+
+
+
Input
RPUL
36IBX15
+
Chu
80
110IMY70-12 Output
RBA
Vo
100
JM123
60
VChu
40
20
0
Fig. 4
System with increased interruption time
0
10
20
30
ms
t
Fig. 5
Increased interruption time. Vi = 110 V, C hu = 560 µF /100 V,
Po = 90 W, VoB t r = 80 V, RBA = 0 Ω. (24IBX15-50-0G)
The external boost capacitor is loaded by a current source to the preselected boost voltage VoB tr. This current source is activated
after Vo has reached or exceeded VoB tr. If the input voltage is increasing further, the boost capacitor is not charged beyond VoB tr.
Consequently, its rated voltage needs not to be much higher than VoB tr.
In the case of input voltage loss, the output voltage VoB drops rapidly to VoB tr until the diode D hu connects the output with the boost
capacitor, sustaining the output voltage; see fig. 5. As long as Vi min of the supplied converter is not undercut (during t hu), the output
voltage of the supplied converter is not affected.
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IBX15 Series
Boost Converters
Electrical Output Data
General conditions:
- TA = 25 °C, unless TC is specified. Vi < VoB min, Io < Io nom
Table 5: Output data
Output
24IBX15-50-0G
Characteristics
Conditions
Unit
min
typ
max
min
typ
max
50
51
49
50
51
80
49
V oB r
Boost voltage regulated
Vi min, I o nom, R BA = ∞
49
V oB tr
Boost voltage trim range
depending on R BA
49
Io nom
Nominal output current
Vi min – Vi max , VoB r
1.6
vow
Static line / load regulation
Vi min – VoB r, 0 – I o nom
±1
vod
Dynamic line / load regulation
td
Dynamic recovery time
IBC
Current to boost capacitor
Vo ≥ VoB r
t hu
Interruption time 1
t loadC
Load time for C hu 1
Chu = 1000 µF,
VoB tr = 50 V, Vi = Vi min
t hu
Interruption time
t loadC
Load time for C hu 1
1
36IBX15-50-0G
2.2
±2
A
±1
±2
±2
Chu = 560 µF,
VoB tr = 80 V, Vi = Vi min
1
4.3
V
±2
2
3.9
V
80
4.8
3.9
4.3
2
ms
4.8
mA
-
-
ms
-
-
s
10
11
12
15
18
10
11
12
15
ms
18
s
For other values use the formula in section Interruption Time !
Parallel or Series Operation
Not possible.
Thermal Considerations
If a converter, mounted on a PCB, is located in free, quasi-stationary air (convection cooling) at the indicated maximum ambient
temperature TA max (see table Temperature specifications) and is operated at its nominal operating conditions, the case temperature
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.
Caution: The case temperature TC measured at the measuring point of case temperature TC (see Mechanical Data) shall 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.
Overtemperature Protection
The converters are protected from possible overheating by an internal temperature monitoring circuit. It shuts down the converter
above the internal temperature limit, and automatically restarts, after the temperature dropped.
Io / Io nom
Io / Io nom
1.0
1.0
JM180
Option Z
0.8
0.6
0.4
0.4
0.2
0.2
20
40
60
80
Fig. 6a
24IBX15: Io versus temperature
Io nom = 1.6 A, Vi = 16.8 V, VoB tr = 50 V
100
Option Z
0.8
0.6
0
JM181
°C
TA
0
20
40
60
80
100
°C
TA
Fig. 6b
36IBX15: I o versus temperature
Io nom = 2.2 A, Vi = 25.2 V, VoB tr = 50 V
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IBX15 Series
Boost Converters
Auxiliary Functions
Boost Voltage Adjust
The regulated boost voltage VoB tr can be adjusted by an external adjust resistor R BA; see fig. 1. The values of RBA are specified in
table 6.
Table 6: Typical values for R BA and the resultant boost voltage VoB tr and the possible output current I o.
24IBX15-50-0G
36IBX15-50-0G
R BA [kΩ ]
VoB tr [V]
Io [A]
VoB tr [V]
Io [A]
∞
50
1.60
50
2.20
121
55
1.42
55
1.95
46.5
60
1.27
60
1.75
23
65
1.05
65
1.45
11.2
70
0.92
70
1.26
4.3
75
0.84
75
1.16
0
80
0.79
80
1.08
Of course, the real output voltage Vo follows Vi when Vi is higher than VBr. However, the voltage on pin 11 will never exceed the
adjusted value of VoB tr. The external capacitor Chu must only be rated to VoB tr.
The max. output current will decrease with higher VoB tr, but the output power remains constant, because the supplied 110IMY
converters need lower input current with higher input voltage.
Out-OK Signal
An open-collector signal controls the function of the boost converter. When VoBr is exceeded, the D-output is connected with a FET
to Go– (pin 15); see table 7.
Table 7: Out-OK data
Characteristics
typ
max
Unit
VOK
Out-OK voltage
Conditions
Output okay, I OK< 50 mA
min
0.3
0.5
V
IOK
Out-OK current
Output fail, VOK ≤ 80 V
15
60
µA
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IBX15 Series
Boost Converters
Electromagnetic Compatibility (EMC)
A suppressor diode together with the input choke form an effective protection against high input transient voltages which typically
occur in many installations, but especially in battery-driven mobile applications. The auxiliary converter has a separate input filter.
Electromagnetic Immunity
Table 8: Electromagnetic immunity (type tests)
Phenomenon
Basic
Standard
Electrostatic
discharge (to case)
IEC/EN
61000-4-2 3
Electromagnetic
field
IEC/EN
61000-4-3
Level
Coupling mode 1
Value
applied
Waveform
-
contact discharge
±6000 Vp
1/50 ns
x4
antenna
20 V/m
AM 80% / 1 kHz
20 V/m
antenna
5
10 V/m
5 V/m
Source
imped.
Test procedure
In
oper.
Perf.
crit. 2
330 Ω
150 pF
10 pos. & 10 neg.
discharges
yes
B
N/A
80 – 1000 MHz
yes
A
N/A
800 – 1000 MHz
yes
A
yes
A
yes
B
0.5 μF
5 pos. & 5 neg.
surges per
coupling mode
yes
B
150 Ω
0.15 – 80 MHz
yes
A
1400 – 2000 MHz
AM 80% / 1 kHz
2000 – 2700 MHz
3 V/m
Electrical fast
transients / burst
IEC/EN
61000-4-4
Surges
IEC/EN
61000-4-5
3
IEC/EN
61000-4-6
Conducted
disturbances
1
3
4
5
6
7
2
direct coupling
+i/-i/c
±2000 Vp
+i/c, -i/c
±2000 Vp
2
+i/-i
±1000 Vp
37
+i/-i/c
10 Vrms
3
6
5100 – 6100 MHz
bursts of 5/50 ns;
5 kHz over 15 ms;
burst period: 300 ms
1.2 / 50 µs
AM 80% / 1 kHz
50 Ω
42 Ω
60 s positive
60 s negative
transients per
coupling mode
i = input, o = output, c = case (not for option Z)
A = normal operation, no deviation from specification, B = temporary deviation from specs. possible.
Corresponds to EN 50121-3-2:2016 table 5.3 and exceeds EN 50121-4:2016 table 2.4.
Corresponds to EN 50121-3-2:2016 table 5.1 and exceeds EN 50121-4:2016 table 2.1.
Corresponds to EN 50121-3-2:2016 table 5.2 and EN 50121-4:2016 table 2.2.
Corresponds to EN 50121-3-2:2016 table 3.2 and EN 50121-4:2016 table 4.2.
Corresponds to EN 50121-3-2:2016 table 3.1 and EN 50121-4:2016 table 4.1.
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IBX15 Series
Boost Converters
Electromagnetic Emissions
The EMC requirements must be observed at the end product system level. However, the company tests the converters to EMC
standards. The integrated input filter reduces the reflected input current and improves EMC features. Further improvements are
possible by adding simple external filters; see fig. below.
The large input capacitor C1 (720 µF /200 V) provides stability during surge tests. The other components are:
C51 = C52 = 10 nF / 300 V, Y2
C2 = 4.7 nF / 300 V, Y2
C3 = 3 µF / 250 V, X7R
C4 = 5 µF / 250 V, X7R
L1 = 4.4 mH
C51
+
Vi
-
C4
C52
L1
C3
+
C1
IBX15
C2
case
Fig. 7
External filter for compliance with EN 50121-3-2
Fig. 8
Conducted emissions of 24IBX15-50-0G. Vi = 24 V, Vo = 50
V, 2 A; case connected to PE; with input filter fig. 7
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IBX15 Series
Boost Converters
Immunity to Environmental Conditions
Table 9: Mechanical and climatic stress
Test method
Standard
Test Conditions
Cab
Damp heat
steady state
IEC/EN 60068-2-78
MIL-STD-810D section 507.2
Temperature:
40 °C
Relative humidity:
93 +2/-3 %
Duration:
56 days
Cooling test
steady state
EN 50155:2007, clause 12.2.3
IEC/EN 60068-2-1
Temperature, duration:
-40 °C, 2 h
Performance test:
+25 °C
Dry heat test
steady state
EN 50155:2007, clause 12.2.4
IEC/EN 60068-2-2
Temperature:
70 °C
Duration:
6h
Salt mist test
sodium chloride
(NaCl) solution
EN 50155:2007, clause 12.2.10
IEC/EN 60068-2-11
class ST2
Temperature:
35 ±2 °C
Duration:
16 h
Vibration
(sinusoidal)
IEC/EN 60068-2-6
MIL-STD-810D section 514.3
Acceleration amplitude:
0.35 mm (10 – 60 Hz)
Ad
Bd
Ka
Fc
Fh
Ea
Random vibration
broad band (digital
control) & guidance
Converter
not operating
Converter
not operating
Converter
operating
Converter
not operating
5 gn = 49 m/s2 (60 - 2000 Hz)
IEC/EN 60068-2-64
Frequency (1 Oct/min):
10 – 2000 Hz
Test duration:
7.5 h (2.5 h in each axis)
Acceleration spectral density:
0.05 gn2/Hz
Frequency band:
8 – 500 Hz
Acceleration magnitude:
4.9 gn rms
Test duration:
1.5 h (0.5 h in each axis)
Converter
operating
Converter
operating
Shock
(half-sinusoidal)
IEC/EN 60068-2-27
MIL-STD-810D section 516.3
Acceleration amplitude:
50 gn = 490 m/s2
Bump duration:
11 ms
Number of bumps:
18 (3 in each direction)
Shock
EN 50155:2007, clause 12.2.11
EN 61373 sect. 10
class B, body mounted 1
Acceleration amplitude:
5.1 gn
Bump duration:
30 ms
Number of bumps:
18 (3 in each direction)
EN 50155:2007, clause 12.2.11
EN 61373 sect. 8 and 9
class B, body mounted 1
Acceleration spectral density:
0.02 g n2/Hz
Frequency band:
5 – 150 Hz
Acceleration magnitude:
0.8 g n r ms
Test duration:
18 (3 in each direction)
Simulated long life
testing at increased
random vibration
levels
1
Status
±2
Converter
operating
Converter
operating
Converter
operating
Body mounted = chassis of a railway coach
Temperatures
Table 10: Temperature specifications, valid for an air pressure of 800 – 1200 hPa (800 – 1200 mbar)
Model
-0G (with case)
Characteristics
TA
Ambient temperature
TC, TCZ
Case temperature
TS
Storage temperature
typ
-0ZG (open frame)
Conditions
min
max
min
Converter operating
- 40
70
- 40
typ
70
max
- 40
100
- 40
120
Not operational
- 55
85
- 55
85
Model
Ground benign
1
Unit
°C
Reliability
Table 11: MTBF and device hours
Ratings
Case temperature
MTBF accord. to Bellcore SR-332, issue 1
36IBX15-50
Ground fixed
Ground mobile
40 °C
40 °C
70 °C
50 °C
850 000
425 000
160 000
104 000
Unit
h
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IBX15 Series
Boost Converters
Mechanical Data
Dimensions are in mm (inches).
European
Projection
Tolerances ±0.3 mm (unless noted)
Recommended PCB hole diameter for the 1mm square pins: 1.4 mm
3
4
15
5.08 (0.2")
41.2 (1.62")
5.08
2
0.8 (0.03")
for holes with
1.6 mm
12
13
5.08 (0.2")
54.9 (2.16")
48.26 (1.91")
12
11
JM115b
11
1
JM104c
0.8 (0.03")
for holes with
1.6 mm
2
3
16
13
1
4
15
bottom view
6 x 5.08 (0.2")
4 × M3
16
17
17
TC
9.6 (0.38")
45.72 (1.8")
45.72 (1.8")
TCZ
4.1 (0.16")
3.3
11.5 +0.2
-0.1
48.06 (1.89")
54.7 (2.15")
50.8 (2")
Fig. 9
Case Zinc,
weight approx. 80 g
Fig. 10
Open frame (option Z),
weight approx. 30 g
Safety and Installation Instruction
Pin Allocation
Table 12: Pin allocation (standard and option Z)
Pin
Name
1
Vi+
Description
Pos. input
2
Vi+
Pos. input
3
Gi-
Neg. input
4
Gi-
Neg. input
11
Chu
External hold-up capacitor
12
Vo+
Pos. output voltage
13
Go-
Neg. output (connected to pins 3 and 4)
14
-
No pin
15
D
Boost function okay
16
BA
Boost voltage adjust
17
PUL
Programmable undervoltage lockout / inhibit
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IBX15 Series
Boost Converters
Installation Instructions
Connection to the system shall be made via a printed circuit board with hole diameters of 1.5 mm for the pins.
The converter must be connected to a secondary circuit.
Do not open the converter!
Ensure that a converter failure (e.g. by an internal short-circuit) does not result in hazardous conditions.
Note: To prevent excessive current flowing through the input supply lines in case of a malfunction an external fuse should be installed in a
non-earthed input supply line; see table 3.
Standards, Approvals, Isolation
The converters have been approved according to the latest edition of IEC/EN 62368-1 and UL/CSA 60950-1. The CE mark is fitted.
All pins are tested against the case with 1500 VAC (2120 VDC) for ≥1 s as routine test in the factory according to EN 62911 and
IEC/EN 60950.
The converters are subject to manufacturing surveillance in accordance with the above mentioned standards and with ISO9001:2015.
CB scheme is available.
Railway Applications
To comply with railway standards, all components are coated with a protective lacquer (except option Z).
Protection Degree and Cleaning Liquids
The protection degree of the converters is IP 40, except open-frame models (option Z).
In order to avoid possible damage, any penetration of cleaning fluids should be prevented, since the converters are not hermetically sealed.
However, open-frame models (option Z) leave the factory unlacquered; they may be lacquered by the customer, for instance
together with the mother board. Cleaning liquids are not permitted – except washing at room temperature with isopropyl alcohol
and de-inonized/destilled water (1 : 1).
The mother board can also be cleaned, before fitting the open-frame converter.
Note: Other cleaning liquids may damage the adhesive joints of the ferrite cores.
Options
Option Z: Open-frame model (no case).
NUCLEAR AND MEDICAL APPLICATIONS - These products are not designed or intended for use as critical components in life support systems,
equipment used in hazardous environments, or nuclear control systems.
TECHNICAL REVISIONS - The appearance of products, including safety agency certifications pictured on labels, may change depending on the
date manufactured. Specifications are subject to change without notice.
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