24IMS6-05-9

IMS6 POWER-ONE | Alldatasheet

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Technical content

6 Watt SMD and through hole IMS 6 Series

Input to output electric strength test up to 2 kV DC Input voltage ranges: Single and dual outputs of 5, 12, 15 V DC

• Wide input voltage ranges
• Electrical isolation, single and dual outputs
• Immunity to IEC/EN 61000-4-2, -3, -4, -5 and -6
• High efficiency (typ. 82%)
• Flex power: flexible load distribution
• No load and short-circuit proof
• High reliability and no derating
• Operating ambient temperature –40...+ 71 C
• Industrial, alternative and SMD pinout
• DIL 24 case with 9.0 mm profile Safety approvals pending to IEC/EN 60950, UL 1950 LGA C Summary The IMS 6 series of board mountable 6 W DC-DC convert- ers has been designed according to the latest industry re- quirements and standards. The converters are particularly suitable for use in mobile or stationary applications in trans- port, industry or telecommunications where variable input voltages or high transient voltages are prevalent. Covering a total input voltage range from 18 V DC up to 75 V DC. The converters are designed and built according to the international safety standards IEC/EN 60950, UL 1950, CAN/CSA C22.2 No.950-95 and are LGA and UL marked. A special feature is their small case size, DIL 24 with only 9.0 mm profile. The circuit comprises integrated planar magnetics and all components are automatically assem- bled and solidly soldered onto a single PCB without any wire connections. Thanks to the rigid mechanical design the units withstand an extremely high level of shock and vibra- tions. Careful considerations of possible thermal stresses ensure the absence of hot spots providing long life in envi- ronments where temperature cycles are a reality. The ther- mal design allows operation at full load up to an ambient temperature of 71 C in free air without using any potting material. Options : SMD pinout or K-pinout, an alternative to the standard industrial pinout, provide a high level of applica- tion specific engineering and design-in flexibility. Table of Contents Page Page Edition 1 06.00 Industrial Environment DC/DC Converters < 40W IMS6 Series o DC/DC converters

Table 1: Type survey Output 1 Output 2 Output Power Input voltage Efficiency Type Options Uo1 nom Io1 nom Uo2 nom Io2 nom Po nom range typ designation [V DC] [A] 1 [V DC] [A] 1 [W] [V DC] [%] 5 1000 - - 5.0 18...36 82 24IMS6-05-9 M, K, Z 1 Flexible load distribution on double outputs possible to 75% , 25% asymetric loading. Type Key

48 IMS 6 - 05 05 -9 K M Z

Operating ambient temperature range TA 1 Option M excludes option K and vice versa 2 For delivery lead times contact factory. Some types require a minimum order quantity. Industrial Environment DC/DC Converters < 40W IMS6 Series 5 1000 - - 5.0 36...75 82 48IMS6-05-9 M, K, Z 12 500 - - 6.0 18...36 83 24IMS6-12-9 M, K, Z 12 500 - - 6.0 36...75 83 48IMS6-12-9 M, K, Z 15 400 - - 6.0 18...36 84 24IMS6-15-9 M, K, Z 15 400 - - 6.0 36...75 84 48IMS6-15-9 M, K, Z 5 500 5 500 6.0 18...36 82 24IMS6-0505-9 M, K, Z 5 500 5 500 6.0 36...75 82 48IMS6-0505-9 M, K, Z 12 250 12 250 6.0 18...36 83 24IMS6-1212-9 M, K, Z 12 250 12 250 6.0 36...75 83 48IMS6-1212-9 M, K, Z 15 200 15 200 6.0 18...36 84 24IMS6-1515-9 M, K, Z 15 200 15 200 6.0 36...75 84 48IMS6-1515-9 M, K, Z Edition 1 06.00 1 2

The IMS 6 DC-DC modules are feedback controlled flyback converters using current mode PWM (Pulse Width Modula- tion). The converter input is protected against transients by means of a suppressor diode. The output voltage is monitored by a separate transformer winding close to the secondary windings and fed back to the control circuit. Fig. 2 Block diagram for dual output types. Standard industrial pinout. Fig. 1 Block diagram for single output types. Standard industrial pinout. PWM Vi+ Vi– Vo+ Vo– 03044 PWM Vi+ Vi– Vo+ Vo– Go 03045 PWM Vi+ Vi– Vo+ Vo– 03046 n.c. PWM Vi+ Vi– Vo+ Vo– Go 03047 Fig. 4 Block diagram for dual output types. Special pinout (Option K). Fig. 3 Block diagram for single output types. Special pinout (Option K). PWM Vi+ Vi– Vo– 03048 n.c.10 Vo+14 PWM Vi+ Vi– Vo+ Vo– Go 03049 Fig. 6 Block diagram for dual output types. SMD pinout (Option M). Fig. 5 Block diagram for single output types. SMD pinout (Option M). Current limitation is provided by the primary circuit, thus limiting the total output current ( Io nom for the single and Io1 nom + Io2 nom for the dual output types). The close magnetic coupling provided by the planar con- struction ensures very good regulation and allows for flex- ible load distribution on dual output types. Industrial Environment DC/DC Converters < 40W IMS6 Series Edition 1 06.00 9 n.c. n.c.

General conditions: TA = 25 C, unless TC is specified. Table 2: Input Data Input 24 IMS 6 48 IMS 6 Characteristics Conditions min typ max min typ max Unit Ui Input voltage range TC min...TC max 18 36 36 75 V DC Ui nom Nominal input voltage Io = 0...Io nom Ui sur Repetitive surge voltage abs. max input (3 s) 40 100 tstart up Converter start-up time 1 Worst case condition at 0.25 0.5 0.25 0.5 s Ui min and full load trise Rise time 1 Ui nom resistive load 5 5 ms Io nom capacitive load 12 12 Ii o No load input current Io = 0, Ui min...Ui max 15 20 mA Ci Input capacitance for surge calculation 0.54 0.3 uF Iinr p Inrush peak current Ui = Ui nom 3 3.7 4.2 A Ii rr Reflected ripple current Io = 0...Io nom 30 30 mApp ui RFI Input RFI level EN 55022 2 B 1 conducted and radiated 1 Measured with a resistive or max. admissible capacitive load. (See fig.: Converter start-up and rise time) 2 External filter required. (See: Filter recommendations for compliance with EN 55022) 3 Source impedance according to prETS 300132-2, version 4.3. Industrial Environment DC/DC Converters < 40W IMS6 Series 4824 5 10 B Edition 1 06.00

Industrial Environment DC/DC Converters < 40W IMS6 Series Edition 1 06.00 Uo nom Uo tstart up trise t 04008 Fig. 7 Converter start-up and rise time 1 A/Div. 5 s/Div. 04034 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. Fig. 8 Typical inrush current at Ui nom, Po nom versus time (48 IMS6 ) measured according to prETS 300132-2, version 4.3. Reverse Polarity Protection at Input The suppressor diode on the input also provides for reverse polarity protection by conducting current in the reverse di- rection, thus protecting the unit. An external fuse is required to limit this current: – For 24 IMS 6 a fast 0.63 A (F0.63A) fuse is recommended – For 48 IMS 6 a fast 0.35 A (F035A) fuse is recommended Filter recommendations for compliance with EN 55022 Electromagnetic emission requirements according to table Input data can be achieved by adding an external capacitor as close as possible to the input terminals. Fig. 9 Input filter arrangement Vi+ Vi– Ci 04035 Table 3: Input filter components (EN 55022) Ref. 24 IMS 6 48 IMS 6 C1 , 2.2 F, 100 V, 2.2 F, 150 V, Type ceramic or film

General conditions: TA = 25 C, unless TC is specified. Table 6a: Output data for single output units Output Uo nom 5.0 V 12.0 V 15.0 V Characteristics Conditions min typ max min typ max min typ max Unit Io nom Output current Ui min...Ui max 1000 500 400 mA Io L Current limit 2 Ui nom, TC = 25 C 1400 700 600 Uo U Line regulation Ui min...Ui max, Io nom 1 1 1% U Load regulation Ui nom 3 3 3 Io = (0.1...1) Io nom uo1, 2 Output voltage noise Ui min...Ui max 5 80 120 150 mVpp Io = Io nom 6 20 40 40 60 50 75 Uo clp Output overvoltage Min. load 1% 130 130 130 % limitation Co ext Admissible 680 150 100 uF capacitive load 3 uo d Dynamic Voltage deviat. Ui nom 250 250 250 mV td load Recovery time Io nom 1/2Io nom 1 1 msregulat. Uo/ TC Io = 0...Io nom Table 6b: Output data for dual output units Output Uo nom 5 V 12 V 15 V Characteristics Conditions min typ max min typ max min typ max Unit Io nom Output current 1 Ui min...Ui max 2 500 2 350 2 200 mA Uo U Line regulation Ui min...Ui max, Io nom 1 1 1 U Load regulation 4 Ui nom 3 3.5 3 Io = (0.1...1) Io nom uo1, 2 Output voltage noise Ui min...Ui max 5 100 140 150 mVpp Io = Io nom 6 40 60 45 70 50 75 Uo clp Output overvoltage Min. load 1% 130 130 130 % limitation Co ext Admissible 680 150 100 uF capacitive load 3 uo d Dynamic Voltage deviat. Ui nom 250 600 750 mV td load Recovery time Io nom 1/2Io nom 11 1 msregulat. Uo/ TC Io = 0...Io nom 1 Each output capable of delivering full output power. 2 The current limit is primary side controlled. 3 Sum of both outputs. 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. Industrial Environment DC/DC Converters < 40W IMS6 Series Edition 1 06.00 N/A N/A x x x

Output overvoltage protection The outputs of the IMS 6 converters are protected against overvoltages by Zener diodes. In the event of an overvolt- age on the output, the unit will shut-down 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 units are not designed to withstand external overvoltages applied to the outputs. Connection in series The outputs of single or dual output units can be connected in series without any precautions, taking into consideration that the highest output voltage should remain below 60 V for SELV operation. Connection in parallel The outputs of several units with equal nominal output volt- age can be connected in parallel. Approximate current sharing between 2 or several units is ensured by their load dependent output characteristic. Fig. 12 Uo versus Io (typ) of single output units (example for 48IMS6-05-9 Fig. 13 Uo versus Io (typ) of dual output units ( 15 V), with 30 V load connected to Vo+ and Vo–. 5.25 5.0 4.75 4.5 4.25 4.0

0 Io [A]

Uo [V] 05056 28.5 29.5 30.5 31.5 Uo1 + Uo2 [V] 33 66 100 133 166 200 233 Io [mA]0 05057 14.5 15.5 16.5 Uo1 [V] 33 66 100 33 66 200 233 Io1 [mA]0 Io2 = 140 mA Io2 = 14 mA 05058 Uo1, Uo2 [V] Io1 Io1 no 05059 12.8 12.4 11.6 11.2 0 150 300 [%] Uo2 Uo1 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 TA max (see table: Temperature specifications) and is operated at its nominal input voltage and output power , the case temperature TC measured at the: Measuring point of case temperature T C (see: Me- chanical Data) will approach the indicated value TC max af- ter 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 , tem- perature 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 con- ditions, the ambient temperature TA may be higher or lower than this value. Caution: The case temperature TC measured at the Measuring point of case temperature TC (see: Mechani- cal Data) may under no circumstances exceed the speci- fied maximum value. The installer must ensure that un- der all operating conditions TC remains within the limits stated in the table Temperature specifications. 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. Typical Performance Curves Fig. 14 Cross load regulation of dual output units. Uo1 versus Io1 (typ) for various Io2 (48IMS6-1515-9). Fig. 15 Flexible load distribution on dual outputs (2 x 12 V) with load variation from 0...150% of Po1 nom on output 1. Output 2 loaded with 25% of Po2 nom. Industrial Environment DC/DC Converters < 40W IMS6 Series Edition 1 06.00 1.00.5

Uo [%] t [ms] 05041 8.5 60.560.5 overload short circuit condition switch-off [%] 05060 25 50 75 100 Po nom[%] Ui nom Ui max Ui min Fig. 16 Overload switch-off (hiccup mode). Frequency of pulses: 16.5 Hz, puls duration: 8.5 ms. Fig. 17 Efficiency versus input voltage and load. Typical values (48IMS6 -1212-9) Industrial Environment DC/DC Converters < 40W IMS6 Series Edition 1 06.00

Fig. 18 Typical disturbance voltage (quasi-peak) at the input ac- cording to CISPR 11/EN 55011 and CISPR 22/EN 55022, measured at Ui nom and Io nom. Output leads 0.1 m, twisted. External capacitor at the input required (see: Recommen- dations for compliance with EN 55022). (48 IMS6-1515-9) Fig. 19 Typical radio frequency interference voltage at Ui nom, Io nom, measured with an antenna (distance 10 m). Output leads 0.1 m, twisted (48 IMS6-1515-9). 07033 EN 55022 A EN 55022 B 0.01 0.05 0.1 0.5 [dB V] MHz 0.02 EN 55022 B 100 200 500 1000Frequency [MHz] [dB V/m] 07034 Electromagnetic Emission Conducted RFI noise at input according to EN 55022 Radiated RFI noise according to EN 55022. Mechanical Data Dimensions in mm. Tolerances 0.3 mm unless otherwise indicated. European Projection Fig. 20 Case DIL 24, for IMS6 Weight: <10 g 15.24 min. 3 13 24 11 x 2.54 = 27.94 09042 Measuring point of case temperature TC 0.5 8.5 Edition 1 06.00 Industrial Environment DC/DC Converters < 40W IMS6 Series

Immunity to Environmental Conditions Table 8: 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 gn = 981 m/s2 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 gn = 392 m/s2 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 gn = 49 m/s2 (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 gn2/Hz Unit wide band Frequency band: 10...500 Hz operating reproducibility Acceleration magnitude: 4.9 gn 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 Temperature Standard -9 Characteristics Conditions min max Unit TA Ambient temperature 1 Operational 2 –40 71 C TC Case temperature –40 100 TS Storage temperature 1 Non operational –40 100 1 MIL-STD-810D section 501.2 and 502.2

2 See Thermal Considerations

Table 10: MTBF and device hours MTBF Ground Benign Ground Fixed Ground Mobile Device Hours 1 MTBF acc. to MIL-HDBK-217F TC = 40 C TC = 40 C TC = 70 C TC = 50 C 48IMS6-05-9 2'651'000 h 349'000 h 124'000 h 119'000 h

1 Statistical values, based on an average of 4300 working hours per year and in general field use

Industrial Environment DC/DC Converters < 40W IMS6 Series Edition 1 06.00

Safety and Installation Instructions Installation Instruction 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 according to: Mechanical Data. 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. Table 11: Pin allocation for standard industrial pinout Pin Single output units Dual output units 2V i– Vi– 3V i– Vi– 10 n.c. - 11 - Vo–

14 Vo+ Vo+

16 Vo– Go

22 Vi+ Vi+

23 Vi+ Vi+

Table 12: Pin allocation for K pinout (option K) Pin Single output units Dual output units

1 Vi+ Vi+

2 n.c. - 10 - Go 11 - Go

12 Vo– -

13 Vo+ Vo–

24 Vi– Vi–

Table 13: Pin allocation for SMD pinout (option M) Pin Single output units Dual output units 2V i– Vi– 3V i– Vi– 10 n.c. Go

11 Vo– Vo–

12 Vo– Vo–

15 Vo+ Vo+

Fig. 22 Pin numbering 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. W e recommend a fast acting fuse F0.5A for 24 IMS 6 and F0.315A for 48 IMS 6 types. Standards and approvals All DC-DC converters are UL recognized according 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
• 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. The DC-DC converters are subject to manufacturing sur- veillance in accordance with the above mentioned UL, CSA, EN and ISO 9001 standards. Safety of operator accessible output circuits If the output circuit of a DC-DC converter is operator acces- sible, it shall be an SELV circuit according to IEC/EN 60950 related safety standards The insulation concept table below shows some possible installation configurations, compliance with which causes the output circuit of the DC-DC converter to be an SELV cir- cuit according to IEC/EN 60950 up to a configured output voltage (sum of nominal voltages if in series or +/– configu- ration) of 46 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. Industrial Environment DC/DC Converters < 40W IMS6 Series Edition 1 06.00

24 Vi- Vi+

9 n.c. n.c.

Table 14: Electric strength test voltages Characteristic Input - Output Unit 24/48 IMS 6 Electric strength 1.2 kVrms test voltage 1 s 1.5 kV DC Coupling 1.2 nF capacitance Insulation resist. >100 M at 500 V DC Partial discharge Consult factory kV extinction voltage AC-DC front end DC-DC con- verter Mains Fuse Battery Earth connection Suppressor diode SELV Earth connection 10004 Fig. 23 Schematic safety concept. Use fuse, suppressor diode and earth connection as per table: Safety concept leading to an SELV output circuit. Table 15: Insulation concept leading to an SELV output circuit Conditions Front end DC-DC converter Result Supply Minimum required grade Maximum Minimum required safety Measures to achieve the Safety status of voltage of isolation, to be provided DC output status of the front end specified safety status of the the DC-DC by the AC-DC front end, voltage output circuit output circuit converter output including mains supplied from the circuit battery charger front end 1 Mains Basic 60 V Earthed SELV circuit 2 Operational insulation, pro- SELV circuit

250 V AC vided by the DC-DC converter

ELV circuit Input fuse 3 output suppressor Earthed SELV >60 V Hazardous voltage diodes 4, and earthed circuit secondary circuit output circuit 2 Double or reinforced 60 V SELV circuit Operational insulation, pro- SELV circuit vided by the DC-DC converter 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 according to the relevant safety standard, e.g. IEC/EN 60950. 3 The installer shall provide an approved fuse (type with the lowest rating suitable for the application) in a non-earthed input line 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 double or reinforced insulation according to the relevant safety standard, based on the maximum output voltage from the front end. Cleaning Agents In order to avoid possible damage, any penetration of cleaning fluids has to be prevented, since the power sup- plies are not hermetically sealed. Protection Degree The protection degree of the DC-DC converters is IP 30. 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. Edition 1 06.00 Industrial Environment DC/DC Converters < 40W IMS6 Series

Surface mount version. Note: Precautions should be taken when reflow soldering the SMD version, option M. The reflow soldering instruc- tions below should be strictly adhered to. An inadequate soldering process may permanently damage the converter or degrade its performance and Melcher will not honour any guarantee/warranty claims resulting from damage caused by ignoring the soldering instructions. Infrared soldering is not permitted. The surface mountable version of this product is assem- bled with high melting point solder (227 C) to ensure that the solder joints of of the internal components do not de- grade in the end users SMD soldering process. This product is only specified for "Forced Convection Reflow Soldering" (Hot Air). Any conventional soldering profile is acceptable provided that the restriction curve be- low is not exceeded at any time during the reflow process. Description of Options Table 16: Survey of options Option Function of option Characteristic Z Available in 'open frame' version without case M Surface mount version, SMD Not available for 5 IMX 4 and 70 IMX 4 types K Alternative pinout Not available for 5 IMX 4 and 70 IMX 4 types as well as all types with 3.3 V or 24 V outputs 210 220 230 240 0 10 20 30 Tpeak [ C] 11051 t [s] 205 215 225 235 Option K Alternative pinout. This option defines an alternative pinout. Option K excludes option M and vice versa. Fig. 24 Forced convection reflow soldering restriction curve measured on pin 2 26.6 2.5 27.94 ( 11 x 2.54) 11052 26.6 2.5 27.94 ( 11 x 2.54) 11052 Fig. 25 Proposed solder lands. Edition 1 06.00 Industrial Environment DC/DC Converters < 40W IMS6 Series Bare board construction without case. Consult factory.