12IBX15-25-0G

12IBX15-25-0G BEL | Alldatasheet

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Technical content

Features

• RoHS-compliant for all 6 substances  Wide input voltage range 12 to 154 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 IEC/EN 60950-1 and UL/CSA 60950-1 2nd Ed.

Description

The boost converters were designed in accordance with the standards EN 50155 and EN 50121-3-2 to meet the re- quirements 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. The boost converters are available in a fully enclosed case or open-frame (option Z). 54.9 2.16" 54.9 2.16" 11.5 0.45" Copyright © 2016, Bel Power Solutions Inc. All rights reserved. Table of Contents Page Page

BCD.00197 Rev AD, 10-Aug-2016 Page 2 of 9 MELCHER The Power Partners. IBX15 Series Data Sheet Boost Converters Model Selection Table 1: Model selection Input voltage Operating input range Output voltage Output current Type designation Efficiency1 Options Vi nom Vi Vo Io nom ηηηηηmin ηηηηηtyp 12 V 8.0 – 50 VDC 25 – 50 VDC 3.0 A 12IBX15-25-0G 2 Z 24 V 16.8 – 154 VDC 50 – 154 VDC 1.6 A 24IBX15-50-0G 89% 93% 36 V 25.2 – 154 VDC 50 – 154 VDC 2.2 A 36IBX15-50-0G 91% 95%

1 Efficiency at Vi = Vi min, Vo = Vo nom, Io = Io nom

2 In preparation

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. 20IMX15 or 24IMX70 for 12IBX15-25 and 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. 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 (inter- leaved). 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 V oB can be Fig. 2 Functional diagram trimmed by resistor R BA to a higher level VoB tr. This allows together with an external storage capacitor C hu the realization of an interruption time as requested by the railway standard EN 50155. No other components are needed. Boost control logic JM081b Auxiliary converter 350 kHz Signal logic PUL D BA RPUL Dhu Gi– Vi+ PTC Go– Vo+ RBA Chu Chu 150 100 25 50 75 100 125 150 Vo JM182 Vi 125 VoB tr = 80 V VoB tr = 50 V Fig. 1 Vo versus Vi depending on VoB tr.

BCD.00197 Rev AD, 10-Aug-2016 Page 3 of 9 MELCHER The Power Partners. IBX15 Series Data Sheet Boost Converters Electrical Input Data General Conditions: – TA = 25 °C, unless TC is specified. Table 2: Input data Model 12I BX15-25-0G 24I BX15-50-0G 36IBX15-50-0G Unit Characteristics Conditions min typ max min typ max min typ max Vi Operating input voltage 8.0 50.4 16.8 154 25.2 154 V Vi 2s Temporary input voltage 2 s 6.0 60 12 168 21.3 168 Vi abs Input voltage limits 2 s, without damage 60 176 176 ∆Vi o Voltage drop Vi – Vo Vi > VoB 0.7 1 1 Ii Typ. input current Vi min, Io nom 10 8 6 A C i Input capacitance for surge calculation 4 µF tstart Start-up time of Vo Vi → Vi min 500 500 500 ms or after shutdown P i 0 No-load input power Vi min – Vi max , Io = 0 1.0 1.5 1.0 1.5 W P i SD Input power with shutdownVi min – Vi max , VPUL = 0 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 4. 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 4: Recommended external fuses in the non-earthed input line Converter model Fuse type 12IBX15-25-0G 24IBX15-50-0G Littlefuse 218, 10 A / 250 VAC, fast 36IBX15-50-0G Littlefuse 218, 8 A / 250 VAC, fast, or: Schurter SPT 8A, 300 VDC Programmable Undervoltage Lockout PUL The programmable input undervoltage lockout (PUL, pin 17) should be adjusted adequately in order to limit the input Table 5: Typical values for RPUL and the resultant turn-on input voltage Vi LO 24IBX15-50-0G 36IBX15-50-0G R PUL [kΩ ΩΩ ΩΩ ] Vi LO [V] R PUL [kΩ ΩΩ ΩΩ ] Vi LO [V] ∞ 15 ∞ 23 110 18 100 27 68 20 56 30 43 23 36 34 27 27 27 38 current. Table 5 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). Efficiency Interruption Time The interruption time of a system comprised of a step-up converter IBX15 (Rev. AB or later) and connected converters Fig. 3 Efficiency versus input voltage and output current (24IBX15-50-0G) 0.4 0.8 Io / Io nom0 JM121 Vi = 24 V 100 η [%] 0.60.2 Vi = 36 V JM123 RPUL RBA Chu + Output +++ 36IBX15 110IMY70-12Input Fig. 4 System with increased interruption time . Valid for version V105 (Rev. AE) or later.

BCD.00197 Rev AD, 10-Aug-2016 Page 4 of 9 MELCHER The Power Partners. IBX15 Series Data Sheet Boost 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: whereas: C hu = external boost capacitance [mF] Po = output power = input power of the supplied converter [W] thu = interruption or hold-up time [ms] Vi min = min. input voltage of supplied converters [V] VoB tr = boost voltage trimmed using R BA [V] 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 V oB 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 Dhu 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 reached (during thu), the output voltages of the supplied converters are not affected. Electrical Output Data General Conditions: – T A = 25 °C, unless TC is specified. Vi < VoB min, Io < Io nom Table 3: Output data Model 12I BX15-25-0G 24I BX15-50-0G 36IBX15-50-0G Unit Characteristics Conditions min typ max min typ max min typ max VoB r Boost voltage regulatedVi min, Io nom, R BA = ∞ 24.5 25 25.5 49 50 51 49 50 51 V VoB tr Boost voltage trim range depending on R BA 24.5 50 49 80 49 80 Io nom Output current, nom. Vi min – Vi max, VoB r 3.0 1.6 2.2 A Vow Static line/load regulationVi min – VoB r, 0 – Io nom ±0.5 ±1 ±1 ±2 ±1 ±2V vod Dynamic line/load regul. ±1.5 ±2 ±2 td Dynamic recovery time 2 2 ms thu Interruption time 1 C hu = 1000 µF, -- -- ms tloadC Load time for C hu 1 VoB tr = 50 V, Vi = Vi min -- -- s thu Interruption time 1 C hu = 560 µF, -- 10 11 10 11 ms tloadC Load time for C hu 1 VoB tr = 80 V, Vi = Vi min -- 12 15 18 12 15 18 s 1 For other values use the formula in section Interruption Time ! Fig. 5 Increased interruption time. Vi = 110 V, Chu = 560 µF/100 V, Po = 90 W, VoB tr = 80 V, RBA = 0 Ω . (24IBX15-50-0G) 0 0 10 20 [V] t JM122 ms 120 100 VChu Vo

BCD.00197 Rev AD, 10-Aug-2016 Page 5 of 9 MELCHER The Power Partners. IBX15 Series Data Sheet Boost Converters Fig. 6a 24IBX15: Io versus temperature Io nom = 1.6 A, Vi = 16.8 V, VoB tr = 50 V 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 T A max (see table Temperature speci- fications) and is operated at its nominal operating conditions, the case temperature measured at the measuring point of case temperature T C (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. T A 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 T C 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. Fig. 6b 36IBX15: I o versus temperature Io nom = 2.2 A, Vi = 25.2 V, VoB tr = 50 V 1.0 0.8 0.6 0.4 0.2 20 40 60 80 100 °C Io / Io nom JM181 TA Option Z 1.0 0.8 0.6 0.4 0.2 20 40 60 80 100 °C Io / Io nom JM180 TA Option Z 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 C hu 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. 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 R BA are specified in table 6. Out-OK Signal An open-collector signal controls the function of the boost converter. When V oBr is exceeded, the D-output is connected with a FET to Go– (pin 15); see table 7. Table 6: Typical values for RBA and the resultant boost voltage VoB tr and the possible output current Io. 24IBX15-50-0G 36IBX15-50-0G R BA [kΩΩΩΩΩ ] VoB tr [V] Io [A] VoB tr [V] Io [A] ∞ 50 1.6 50 2.2 121 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 Table 7: Out-OK data Characteristics Conditions min typ max Unit VOK Out-OK voltage Output okay, IOK < 50 mA 0.3 0.5 V IOK Out-OK current Output fail, VOK ≤ 80 V 15 60 µA

BCD.00197 Rev AD, 10-Aug-2016 Page 6 of 9 MELCHER The Power Partners. IBX15 Series Data Sheet Boost Converters DCA EMC lab: Peak, conducted QP + AV, 2016-06-10 24IBX15-50-0G, Vi=24 V, Vo=50 V Io= 1.6 A, input filter, case connected to PE dBµV 0.2 0.5 1 2 5 10 20 MHz JM135a EN 55022 A (av) EN 55022 A (qp) JM133a IBX15Vi Electromagnetic Immunity Table 8: Immunity type tests Phenomenon Standard Class Coupling V alue Waveform Source Test In Perf- Level mode 1 applied imped. procedure oper. crit. 2 Electrostatic IEC /EN contact discharge ±6000 Vp 1/50 ns 330 Ω 10 positive and yes B discharge 61000-4-2 3 10 negative to case 3 air discharge ±8000 V p discharges Electromagnetic IEC /EN x 4 antenna 20 V/m 80% AM, 1 kHz n.a. 80 – 1000 MHz yes A field 61000-4-3 5 antenna 20 V/m 80% AM, 1 kHz n.a. 800 – 1000 MHz yes A

10 V/m 1400 – 2100 MHz

5 V/m 2100 – 2500 MHz

Electrical fast IEC / EN 3 6 direct coupl. (fig. 9)±2000 Vp6 bursts of 5/50 ns 50 Ω 60 s positive yes A transients/burst 61000-4-4: 4 +i/c, –i/c,+i/–i ±4000 Vp 5 kHz over 15 ms 60 s negative yes B2004 burst period: 300 transients per 3 capacit. (fig. 10), o/c±2000 Vp ms coupling mode yes B Surges IEC / EN 3 7 +i/c, –i/c ±2000 Vp3 1.2/50 µs 42 Ω 5 pos. and 5 neg. yes A 61000-4-5 0.5 µF surges per 2 7 +i/–i ±1000 Vp3 coupling mode yes B Conducted IEC /EN 3 8 i, o, signal wires 10 VAC AM 80% 150 Ω 0.15 – 80 MHz yes A disturbances 61000-4-6 (140 dBµV) 1 kHz 1 i = input, o = output, c = case (not for option Z) 2 A = normal operation, no deviation from specification, B = temporary deviation from specs. possible. 3 Corresponds to EN 50121-3-2:2006, table 9.3 4 Corresponds to EN 50121-3-2:2006 table 9.1 and exceeds EN 50121-4:2006 table 1.1. 5 Corresponds to EN 50121-3-2:2006 table 9.2 and EN 50121-4:2006 table 1.2 (compliance with digital mobile phones). 6 Corresponds to EN 50121-3-2:2006 table 7.2 and EN 50121-4:2006 table 2.2. 7 Measured with an external input capacitor: 600 µF due to the standard network impedance for surge testing 8 Corresponds to EN 50121-3-2:2006 table 7.1 and EN 50121-4:2006 table 2.2. transient voltages which typically occur in many installations, but especially in battery-driven mobile applications. The auxiliary converter has a separate input filter. Electromagnetic Compatibility (EMC) A suppressor diode together with the input choke and an the output capacitor form an effective protection against high input 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. Fig. 7 Input filter for disturbance tests The large input capacitor C1 (100 µF /200 V) provides stability during surge tests. The other components are: C2 = 4.7 nF, Y2; C51 = C52 = 10 nF, Y2 C3 = 3 µF, X7R; C4 = 5 µF, X7R L1 = 4.4 mH Fig. 8 Conducted emissions of 24IBX15-50-0G. V i = 24 V, Vo = 50 V, 2 A; case connected to PE; with input filter fig. 7

BCD.00197 Rev AD, 10-Aug-2016 Page 7 of 9 MELCHER The Power Partners. IBX15 Series Data Sheet Boost Converters Immunity to Environmental Conditions Table 9: Mechanical and climatic stress Test method Standard Test conditions Status Cab Damp heat IEC/EN 60068-2-78 T emperature: 40 ±2 °C Converter steady state MIL-STD-810D section 507.2 Relative humidity: 93 +2/-3 % not Duration: 56 days operating steady state IEC/EN 60068-2-1 Performance test +25 °C operating Bd Dry heat test EN 50155:2007, clause 12.2.4 Temperature: 70 °C Converter steady state IEC/EN 60068-2-2 Duration: 6 h operating ±2 °C Converter class ST2 operating (sinusoidal) MIL-STD-810D section 514.3 5 g n = 49 m/s2 (60 - 2000 Hz) operating Frequency (1 Oct/min): 10 – 2000 Hz Test duration: 7.5 h (2.5 h in each axis) Fh Random vibration IEC/EN 60068-2-64 Acceleration spectral density: 0.05 g n2/Hz Converter broad band Frequency band: 8 – 500 Hz operating (digital control) and Acceleration magnitude: 4.9 g n rms guidance Test duration: 1.5 h (0.5 h in each axis) Eb Bump IEC/EN 60068-2-29 Acceleration amplitude: 25 g n = 245 m/s2 Converter (half-sinusoidal) MIL-STD-810D section 516.3 Bump duration: 6 ms operating Number of bumps: 6000 (1000 in each direction) Ea Shock IEC/EN 60068-2-27 Acceleration amplitude: 50 g n = 490 m/s2 Converter (half-sinusoidal) MIL-STD-810D section 516.3 Bump duration: 11 ms operating Number of bumps: 18 (3 in each direction) n Converter EN 61373 sect. 10, Bump duration: 30 ms operating class B, body mounted1 Number of bumps: 18 (3 in each direction) n2/Hz Converter testing at EN 61373 sect. 8 and 9, Frequency band: 5 – 150 Hz operating increased random class B, body mounted1 Acceleration magnitude: 0.8 g n rms vibration levels Test duration: 15 h (5 h in each axis)

1 Body mounted = chassis of a railway coach

Table 11: MTBF and device hours Ratings Model Ground Ground fixed Ground Device Unit benign mobile hours Case Temperature 40 °C 40 °C 70 °C 50 °C 40 °C MTBF accord. to Bellcore 36IBX15-50 850 000 425 000 160 000 104 000 h SR-332, issue 1 Temperatures Table 10: Temperature specifications, valid for an air pressure of 800 - 1200 hPa (800 - 1200 mbar) Temperature -0G (with case) -0ZG (open frame) Unit Characteristics Conditions min typ max min typ max TA Ambient temperature Converter operating –40 70 –40 70 °C TC,TCZ Case temperature –40 100 –40 120 TS Storage temperature Non operational –55 85 –55 85 Ad Cooling test EN 50155:2007, clause 12.2.3 Temperature, duration –40 °C, 2 h Conv. not Fc Vibration IEC/EN 60068-2-6 Acceleration amplitude: 0.35 mm (10 – 60 Hz) Converter (NaCl) solution Ka Salt mist test EN 50155:2007, clause 12.2.10 Temperature: 35 sodium chloride IEC/EN 60068-2-11 Duration: 16 h not -- Simulated long life EN 50155:2007 clause 12.2.11, Acceleration spectral density: 0.02 g -- Shock EN 50155:2007 clause 12.2.11, Acceleration amplitude: 5.1 g

BCD.00197 Rev AD, 10-Aug-2016 Page 8 of 9 MELCHER The Power Partners. IBX15 Series Data Sheet Boost Converters Mechanical Data Dimensions are in mm (inches). Tolerances ±0.3 mm (unless noted) Recommended PCB hole diameter for the 1mm square pins: 1.4 mm Fig. 9 Case Zinc, weight approx. 80 g Fig. 10 Open frame (option Z), weight approx. 30 g European Projection 50.8 (2") 41.2 (1.62") JM104b bottom view 4.1 (0.16") 9.6 (0.38") 45.72 (1.8") 5.08 (0.2") 6 x 5.08 (0.2") 0.8 (0.03") for holes with ∅ 1.4 mm TCZ 54.7 (2.15") 48.06 (1.89") 54.9 (2.16") 48.26 (1.91") 4 × M3 JM115a 45.72 (1.8") 5.08 (0.2") TC 11.5 +0.2 3.3 -0.1 5.0816 0.8 (0.03") for holes with ∅ 1.4 mm

BCD.00197 Rev AD, 10-Aug-2016 Page 9 of 9 MELCHER The Power Partners. IBX15 Series Data Sheet Boost Converters Safety and Installation Instructions Pin allocation Standards, Approvals, Isolation The converters have been approved according to UL/CSA 60950-1 and IEC/EN 60950-1 2nd Ed. 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 50514 and IEC/EN 60950. The converters are subject to manufacturing surveillance in accordance with the above mentioned standards and with ISO9001:2008. 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. Installation Instructions 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 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 4. Options Option Z: Open-frame model without case. Table 12: Pin allocation (standard and option Z) Pin Name Description 1 Vi+ 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 PU L Programmable undervoltage lockout / inhibit

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 © 2016, Bel Power Solutions Inc. All rights reserved. www.belpowersolutions.com