40IMX7-05-05-8

IMX7 BEL

Document overview

• PDF pages: 14

Technical content

Page 1

10.5 0.42"

2.0"

Description

The IMX7/IMS7 Series of board-mountable 7 Watt DC-DC converters have 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 telecom, where variable input voltages or high transient voltages are prevalent. Covering a total input voltage range from 8.4 V to 150 V with six different models, the converters are available with single and electrically-isolated double outputs from 3.3 up to 48 V with flexible load distribution on double outputs. A shutdown input allows remote on/off. Features include efficient input and output filtering with good

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. The converters provide supplementary insulation with SELV outputs as for instances required in battery-supported systems, where the bus voltage may exceed the SELV limit of 60 V. The models 70IMX7 and 110IMX7 are CE-marked.

Table of Contents

Page

Description ............................................................................. 1 Model Selection ..................................................................... 2 Functional Description ........................................................... 3 Electrical Input Data ............................................................... 4 Electrical Output Data ............................................................ 7 Auxiliary Functions ................................................................. 9

Features

• RoHS lead-free-solder and lead-solder-exempted products are available.
• Input voltage ranges up to 150 VDC
• 1 or 2 isolated outputs up to 48 V
• 1500 to 2000 VAC voltage withstand test
• Extremely wide input voltage ranges
• Immunity according to IEC/EN 61000-4-2, -3, -4, -5, -6
• High efficiency (typ. 84%)
• Input undervoltage lockout
• Inhibit input, adjustable output voltages
• Flex power: flexible load distribution on outputs
• Outputs no-load, overload, and short-circuit proof
• High reliability and no derating
• Operating ambient temperature –40 to +85 °C
• Thermal protection
• Supplementary insulation
• Planar technology for best mechanical stability
• 2” × 1” case with 10.5 mm profile Safety-approved to IEC 60950-1 and UL/CSA 60950-1 2nd Ed.

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1 70/110IMX7 models

The circuitry is comprised of integral planar magnetics. All components are automatically assembled and securely soldered onto a single PCB without any wire connections. 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 85 °C in free air without using any potting material. For extremely high vibration environments the case has holes for screw mounting.

Several options, such as open-frame, provide a high level of application-specific engineering and design-in flexibility.

Page

Electromagnetic Compatibility (EMC) .................................. 11 Immunity to Environmental Conditions ................................ 12 Mechanical Data .................................................................. 13 Safety and Installation Instructions ...................................... 13 Description of Options ......................................................... 14

Copyright © 2015, Bel Power Solutions Inc. All rights reserved.

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Model Selection

Table 1: Model Selection

1 Flexible load distribution on double-outputs possible. If only one output is used, connect both outputs of double-output models in parallel. 2 Operation at low input voltage possible, if Po is reduced to approx. 80% of Po nom at Vi min = 14.1 V. 3 Up to 154 V for 2 s

Preferred for new designs

NFND: Not for new designs. Note: Use 20IMX7 to replace 24IMS7 and 40IMX7 to replace 48IMS7.

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Part Number Description Input voltage range Vi

40 IMX7 - 05 - 05 -8 Z G

8.4 – 36 V .............................................. 20

14 – 36 V ............................................... 24 16.8 – 75 V ............................................ 40 36 – 75 V ............................................... 48 40 – 121 V ............................................. 70 60 – 150 V ........................................... 110

Series .............................................................. IMX7, IMS7 Output voltage of output 1...................... 03, 05, 12, 15, 24 Output voltage of output 2............................ 05, 12, 15, 24 Operating ambient temperature TA

–40 to 85 °C ............................................... -8 –40 to 71 °C ............................................... -9

Options: Surface mount version1 ............................................M

Open frame1 .....................................................................Z RoHS-compliant for all six substances ........ G

Obsolete option: C-pinout ............................................... C 1 Option M and Z exclude each other. Note: The sequence of options must follow the order above. Example: 40IMX7-05-05-8ZG: DC-DC converter, input voltage range 16.8 – 75 V, 2 outputs providing each 5 V, 700 mA,

temperature range –40 to 85 °C, open frame, RoHS compliant for all six substances.

Functional Description

The IMX7/IMS7 Series DC-DC converters are feedbackcontrolled flyback converters using current mode PWM (Pulse Width Modulation). In the case of single-output models, the output is directly sensed and fed back to the primary control circuit via a pulse transformer, resulting in tight regulation of the output voltage. The R input is referenced to the secondary side and allows for programming the output voltages in the range 75 to 105% of Vo nom, using either an external resistor or an external voltage source. For double-output models, the output voltage is sensed by a separate transformer winding close to the secondary and fed

Fig. 1 Block diagram of single-output models

Fig. 2 Block diagram of double-output models

back to the primary control circuit. Close magnetic coupling is provided by the planar construction, ensuring very good regulation, and allowing for flexible load distribution. The Trim input of double-output models is referenced to the primary side, and allows for programming the output voltages in the range of 100 to 105% of Vo nom by means of an external resistor, or within 75 to 100% of Vo nom, using an external voltage source. Current limitation is provided by the primary circuit, thus limiting the total output current (Io nom for the single- and the sum Io1 nom + Io2 nom for double-output models). The inhibit input i allows remote control of the outputs; pin i

must be connected to Vi– to activate the converter.

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Electrical Input Data

General conditions: – TA = 25 °C, unless TC is specified. – Connector pin i connected with Vi–. – Trim or R input not connected. Table 2a: Input data of IMX7

1 Vi min will not be as stated, if Vo is increased above Vo nom by use of the R or Trim input. If the output voltage is set to a higher value, Vi min will be proportionally increased. 2 Measured with a resistive and the max. admissible capacitive load. 3 Measured with a lead length of 0.1 m, leads twisted. Double-output models with both outputs in parallel. 70/110 IMX7 models need an external capacitor at the input, e.g., 1 µF film or ceramic. 4 Source impedance according to ETS 300132-2, version 4.3, at Vi nom. 5 The DC-DC converter shuts down automatically at approx. 38 V. 6 Operation at lower input voltage possible: Po approx. 80% of Po nom at Vi min = 14.4 V.

7 Up to 154 V for 2 s

Vo nom

Fig. 3 Converter start-up and rise time

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Table 2b: Input data of IMS7; general conditions as in table 2a

1 Vi min will not be as stated, if Vo is increased above Vo nom by use of the R or Trim input. If the output voltage is set to a higher value, Vi min will be proportionally increased. 2 Measured with a resistive and the max. admissible capacitive load. 3 Measured with a lead length of 0.1 m, leads twisted. Double-output models with both outputs in parallel. 70/110 IMX7 models need an external capacitor at the input, e.g. 1 µF film or ceramic. 4 Source impedance according to ETS 300132-2, version 4.3, at Vi nom

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Input Transient Voltage Protection In many applications transient voltages on the input of the converter may occur and are possibly caused by short circuits between Vi+ and Vi–, where the network inductance may cause high energy pulses. In order to protect the converters, transient suppressors are fitted to the input; see table below:

Table 3: Built-in transient voltage suppressor

1 The built-in overvoltage trigger shuts down the converter at approx. 38 V protecting the input up to 50 V. For higher transient voltages an external suppressor or voltage limiting circuit as, e.g., for IEC/EN 61000-4-5, level 2 compliance should be provided. 2 If transients generating currents above the peak pulse current are possible, an external limiting network such as the circuit recommended for IEC/EN 61000-4-5, level 2 compliance, is necessary.

To achieve IEC/EN 61000-4-5, level 2 compliance, an additional inductor and capacitor should be provided externally as shown in the figure below. The components should have similar characteristics as listed in table 4.

Fig. 4 Example for external circuitry to comply with IEC/EN 61000-4-5, level 2 (transzorb D only for 20IMX7).

Table 4: Components for external circuitry to comply with IEC/EN 61000-4-5, see table 8

Note: Suppressor diode D is only necessary for 20IMX7 models. To withstand 150 V transients according to 19 Pfl 1, applicable for 40IMX7 models, the same external circuitry with similar components as for IEC/EN 61000-4-5, level 2 compliance can be used.

Input Fuse and Reverse Polarity Protection The suppressor diode on the input also provides for reverse polarity protection by conducting current in the reverse direction, thus protecting the converter. An external fuse is required to limit this current. We recommend for: – 20IMX7 and 24IMS7 a fast 2 A (F2A) fuse – 40IMX7 and 48IMS7 a fast 1 A (F1A) fuse – 70IMX7 a fast 0.63 A (F.63A) fuse – 110IMX7 a fast 0.63 A (F.63A) fuse.

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 limit this current further.

A

Fig. 5 Typical inrush current at Vi nom, Po nom measured according to ETS 300132-2 (40IMX7).

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Electrical Output Data

General conditions: – TA = 25 °C, unless TC is specified. – Pin i connected with Vi–; Trim or R input left open-circuit. Table 5a: Output data for single-output models

Table 5b: Output data for double-output models

1 Each output is capable of delivering full output power Po nom according to table Model Selection. 2 The current limit is primary side controlled. Io L is defined when Vo dropped to 85 to 94%. 3 Measured with both outputs connected in parallel. 4 Conditions for specified output. Other output loaded with constant current Io = 0.5 Io nom. 5 BW = 20 MHz 6 Measured with a probe according to EN 61204. 7 The overvoltage protection is not tracking with the R control.

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Thermal Considerations If the 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 (see Mechanical Data) will approach 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, such as 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, TA may be higher or lower. Caution: The case temperature TC measured at the measuring point of case temperature (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.

Po/Po max

Fig. 6 Maximum allowed output power versus ambient temperature

Short-Circuit Behavior 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 [%]

Fig. 7 Overload switch-off (hiccup mode).

Output Overvoltage Protection The outputs are protected against overvoltage by Zener diodes. In the event of an overvoltage, the converter will shut down and attempt to restart automatically. The main purpose of this feature is to protect against possible overvoltage, 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.

Connection in Series or Parallel The outputs of single- or double-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. Both outputs of double-output models can be connected in parallel without any precautions. Several converters (single- or double-output models) with equal output voltage can be put 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.

Vo [V]

Io [A]

1.2

0

0.8

1.6

0.4

Fig. 8a Vo versus Io (typ.) of single-output models with Vo = 5.1 V

Vo [V]

0.8 Io total [A]

0

0.6

0.2 0.4

Fig. 8b Vo versus Io (typ.) of double-output models (2 ×12 V) with both outputs in parallel

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Typical Performance Curves

Vo1 [V]

0.05 0.10 0.15 0.20 0.25 0.3 Io1 [A] Fig. 9 Cross load regulation (typ.) of double-output models (2 ×12 V). The cross-load effect is negligible.

Vo1, Vo2 [V]

Fig. 10 Flexible load distribution on double-outputs models (2 ×12 V) with load variation from 0 to 150% of Po1 nom on output 1. Output 2 loaded with 25% of Po2 nom.

Auxiliary Functions

Inhibit Function 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 converter 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 to 0.8 V

Converter inhibited or inhibit pin i left open: 2.4 V to Vi max (20/40IMX7,

24/48IMS7)

2.4 V to 75 V (70/110IMX7)

Fig. 11 Efficiency versus input voltage and load. Typical values (40IMX7-12-12-8).

Adjustable Output Voltage As a standard feature, all IMX7 and IMS7 converters offer adjustable output voltage(s) by using a control pin. If this pin is left open-circuit, the output voltage is set to Vo nom. The output voltage is adjustable in the range of 75 to 105% of Vo nom.The circuit works for single- and double-output models in a different way. For output voltages Vo > Vo nom, the minimum input voltage Vi min (see Electrical Input Data) increases proportionally to Vo/ Vo nom.

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Single-output models with R-input: The R-input (pin 13) 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.

06029e

Vext

Fig. 12 Output voltage adjust for single-output models

a) Adjustment by means of an external resistor: Depending upon the value of the required output voltage, a resistor Rext1 or Rext2 shall be connected as shown in the figure below: Either: Rext1 between the R pin and Vo– to achieve an output voltage adjustment range of Vo = 75 to 100% of Vo nom (85 to 100% for 3.3 V outputs):

Vo

Rext1 ≈ 4 kΩ • ––––––––– Vo nom – Vo or: Rext2 between the R pin and Vo+ to achieve an output voltage range of approximately Vo = 100 to 105% of Vo nom:

(Vo – 2.5 V)

Rext2 ≈ 4 kΩ • –––––––––––––––––– 2.5 V • (Vo/Vo nom – 1) b) Adjustment by means of an external voltage Vext between Vo– and R pin. The control voltage is 1.96 to 2.62 V and allows for adjustment in the range of 75 to 105% of Vo nom. Vo • 2.5 V Vext ≈ –––––––– Vo nom Caution: Applying an external voltage >2.75 V may damage the converter. Note: Attempting to adjust the output below this range will cause the converter to shut down (hiccup mode).

Double-output models with Trim input: The Trim input (pin 4) of double-output models is referenced to the primary side. Figure 13 shows the circuitry. Adjustment of the output voltage is possible in the range of 100 to 105% of Vo nom using an external resistor, or in the range of 75 to 105% of Vo nom using an external voltage source. a) Adjustment by means of an external resistor Rext. Programming of the output voltage by means of an external resistor Rext1 is possible within a limited range of

100 to 105% Vo nom. Rext should be connected between pin 4 and Vi–. The following table indicates suitable resistor values for typical output voltages under nominal conditions (Vi nom, Io = 0.5 Io nom), with paralleled outputs or equal load conditions on each output. Caution: Connection of Rext to Vi+ may damage the converter.

06089a

+

Vext –

Fig. 13 Output voltage adjust for double-output models

Table 6: Rext for Vo > Vo nom approximate values (Vi nom, Io1 = Io2 = 0.5 Io1/2 nom)

Note: Applying a control voltage greater than 20 V will set the converter into a hiccup mode.

b) Adjustment by means of an external voltage source Vext. For external output voltages in the range of 75 to 105% of Vo nom a voltage source Vext (0 to 20 V) is required, connected to the Trim-input (pin 4) and Vi–. The table below indicates typical Vo versus Vext values under nominal conditions (Vi nom, Io = 0.5 Io nom), with paralleled outputs or equal load conditions on each output. Direct paralleling of the Trim-inputs of converters connected in parallel is feasible.

Table 7: Vext for Vo = 75 to 105% Vo nom; typical values (Vi nom, Io1 = Io2 = 0.5 Io1/2 nom)

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Electromagnetic Compatibility (EMC)

typically occur in many installations, but especially in batterydriven mobile applications.

A suppressor diode together with an input filter form an effective protection against high input transient voltages, which

Electromagnetic Immunity

Table 8: Immunity type tests

1 i = input, o = output 2 Performance criterion: A = normal operation, no deviation from specifications, B = temporary deviation from specs possible 3 Valid for 24IMS7 and 48IMS7 4 External components required 5 R or Trim pin open, i pin connected with Vi– 6 Corresponds to the railway standard EN 50121-3-2:2000, table 9.1

Electromagnetic Emissions

Date: 5.9.07 Time: 08:18

PMM 8000 PLUS

dbµV

Name: 20_7_15

20IMX7-15-15-8 Peak

0.2 0.5 1 2 5 10 20 MHz

Fig. 14a 20IMX7-15-15-8: Typical conducted emissions (peak) at the input at Vi nom and Io nom according to EN 55011/22. Output leads 0.1 m, twisted. External input capacitor (1 µF ceramic + 100 µF electrolytic cap)

Date: 5.9.07 Time: 08:00

PMM 8000 PLUS

dbµV

Name: 40_7_24

40IMX7-24-24-8 Peak

Fig. 14b 40IMX7-24-24-8: Typical conducted emissions (peak) at the input at Vi nom and Io nom according to EN 55011/22. Output leads 0.1 m, twisted. External input capacitor (1 µF ceramic + 47 µF electrolytic cap)

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Date: 5.9.07 Time: 08:00

PMM 8000 PLUS

dbµV

Name: 110_7_05

110IMX7-05-8 Peak

Fig. 14c 110IMX7-05-8: Typical conducted emissions (peak) at the input at Vi nom and Io nom according to EN 55011/22. Output leads 0.1 m, twisted. External input capacitor (0.15 µF ceramic + 4.7 µF electrolytic cap).

Immunity to Environmental Conditions

Table 9: Mechanical and climatic stress

Date: 5.9.07 Time: 09:10

PMM 8000 PLUS

dbµV

Name: 48_7_15

48IMS7-15-15-8 Peak

Fig. 15 48IMS7-15-15-8: Typical conducted emissions (peak) at the input at Vi nom and Io nom according to EN 55011/22. Output leads 0.1 m, twisted. External input capacitor (1 µF ceramic + 47 µF electrolytic cap).

1 Covers also EN 50155/EN 61373 category 1, class B, body mounted (= chassis of coach)

Temperatures

Table 10: Temperature specifications, valid for air pressure of 800 to 1200 hPa (800 to 1200 mbar)

1 See Thermal Considerations

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Failure Rates

Table 11: MTBF and device hours

0.8 × 1.2 (0.03 × 0.05") pins

Mechanical Data

∅ 1.6 (0.06) PCB holes

Dimensions in mm (inches). Tolerances ±0.3 mm, unless otherwise noted. Material: PPS Fortron 1140L6 Weight: <20 g

Fig. 16 Case IMX7/IMS7 with standard pinout

0.8 × 1.2 Pins

Fig. 17 SMD pins (option M)

Safety and Installation Instructions

Pin Allocation

Fig. 19 Footprint

European Projection

Fig. 18

model (option Z)

Table 12: Pin allocation

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Installation Instruction Installation of the 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. Connection to the system shall be made via a printed circuit board; see Mechanical Data. The converters should be connected to a secondary circuit. Do not open the converter. Ensure that a converter failure does not result in a hazardous conditions. To prevent excessive current flowing through the input lines in case of a short-circuit, an external fuse specified in section Input Fuse and Reverse Polarity Protection should be installed

in the non-earthed input supply line.

Standards and Approvals The converters are approved according to IEC 60950-1 and UL/ CSA 60950-1 2nd Edition. The converters have been evaluated for:

• Building-in
• Basic insulation input to output, based on their maximum input voltage
• Pollution degree 2 environment
• Connecting the input to a secondary circuit, which is subject to a maximum transient rating of - 1500 V for 20IMX7, 24IMS7, 40IMX7, 48IMS7 - 2000 V for 70IMX7 - 2500 V for 110IMX7.

The converters are subject to manufacturing surveillance in accordance with the above mentioned standards.

Railway Applications To comply with railway standards, all components are coated with a protective lacquer (except option Z).

Description of Options

Option M: SMD pins This option allows surface mounting of the converters.

Option Z: Open Frame For applications, where the protection by a housing is not

Protection Degree and Cleaning Liquids The protection degree of the converters is IP 30, except openframe models (option Z). In order to avoid possible damage, any penetration of cleaning fluids should be prevented, since the power supplies are not hermetical 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 agents are not permitted – except washing at room temperature with isopropyl alcohol. If necessary, the mother board must be cleaned, before fitting the open-frame converter. Note: Cleaning liquids may damage the adhesive joints of the

ferrite cores. Isolation The electric strength test is performed in the factory as a routine test in accordance with EN 50514 and IEC/EN 60950, and should not be repeated in the field. The Company will not honor any warranty claims resulting from electric strength field tests.

Table 12: Electric strength test voltages

1 1.5 kVAC according to IEC 60950, sect. 6.2, Telecom equipment; type test with 1.5 kVAC / 60 s (IEE 802.3).= 2 20/40IMX7 produced 2014 or later. 3 The test voltage between outputs is not applied as routine test.

necessary or in the case that the motherboard should be lacquered after fitting the converter; see Cleaning Liquids.

Option G: RoHS-6 Converters with a type designation ending by G are RoHScompliant for all six substances.

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. Copyright © 2015, Bel Power Solutions Inc. All rights reserved.

www.belpowersolutions.com/power

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