IMS30

IMS30 POWER-ONE | Alldatasheet

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Input to output electric strength test 1500 V DC Input voltage ranges 32...75VDC for -0302 Dual output

• Industry standard pin-out
• Fixed frequency operation
• High efficiency up to 89 %
• 2" x 2" platform with 9.4 mm profile
• Low output noise
• Soft start
• Shut down input, output voltages adjustable
• Programmable input undervoltage lockout
• Synchronisation
• Outputs no-load, overload and short-circuit proof
• Operating ambient temperature –40...71o C
• Thermal protection with auto-reset (non latching) Emissions below EN 55022, level B Immunity to IEC/EN 61000-4-2,-3,-4,-5 and -6 Table of Contents Page Page Summary The IMS 30 series of board mountable 30 Watt DC-DC con- verters has been designed according to the latest industry requirements and standards. The converters are particu- larly suitable for applications in industry and telecommuni- cation where variable input voltages or high transient volt- ages are prevalent. Features include efficient input and output filtering with un- surpassed transient and surge protection, low output ripple and noise, consistently high efficiency over the entire input voltage range, high reliability as well as excellent dynamic response to load and line changes. The converters provide supplementary insulation with SELV outputs as e.g. required in battery supported systems where the bus voltage may exceed the SEL V limit of 60 V DC. They are designed and built according to the in- ternational safety standards IEC/EN 60950, UL 1950, CAN/ CSA C22.2 No.950-95. Approvals pending. The circuit comprises integrated planar magnetics and all components are automatically assembled and soldered onto a single PCB without any wire connections. The pro- prietary magnetic feedback solution ensures maximum reli- abilityand 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 ambi- ent temperature of 71°C in free air without using any potting material. Safety according to IEC/EN 60950, UL 1950 Approvals pending LGA C 1/11 10130 DC Powering Communciations and Technology IMS30 SERIES JAN, 2001

48 Vinput

Dual outputs 5V & 3.3V ; 3.3V & 1.8V

The IMS 30 series of DC-DC converters are magnetic feed- back controlled forward converters using current mode PWM (Pulse Width Modulation). This product range features synchronous rectifiers deliver- ing in very high efficiency. The output voltage of these ver- sions can be adjusted via the Trim input. The Trim input is referenced to the secondary side and allows for program- ming of the output voltage in the range of approximately 90 to 110% of Uo nom using an external resistor. The voltage regulation is achieved with a magnetic feed- back circuit providing excellent line and load regulation. Current limitation is provided by the primary circuit, thus limiting the total output power to approx. 13 0% of Po nom (see: Type Survey) . The shut down input allows remote converter on/off. Overtemperature protection will shut down the unit in ex- cessive overload conditions with automatic restart. Fig. 1 Block diagram (-0503, -0302 Outputs ) PWM 4n7F 1500 V Vi+ SD PUL i Vi– Uo2+ Com Trim3W Type Key

48 IMS 30 - 0503 -9 G i

Operating ambient temperature range TA Type Survey and Key Data Table 1: Type survey Output 1 Output power Input Voltage Range and Efficiency Option Uo1 nom Io1 nom Po nom Ui min...Ui max typ [V DC] [A] [W] 32...75 V DC [%] 5.1 4.5 30 48 IMS 30-0503-9G 87 i Output 2 o2 nomU 3.3 [V DC] o1 nomI [A] 6.0 Uo1+ 3.3 4.0 48 IMS 30-0302-9G 83 i1.8 5.0 22 32...75 V DC

General conditions: – TA = 25 C, unless TC is specified. – Shut down pin left open circuit (not connected). – Trim input not connected. Table 2: Input Data Input 48 IMS Characteristics Conditions min typ max Unit Ui Input voltage range 1 TC min...TC max 75 V DC Ui nom Nominal input voltage Io = 0...Io nom Ui sur Repetitive input surge max 3 s 100 voltage tstart up Converter Switch on Ui min, Io = Io nom 2 0.25 0.5 s start-up time SD high 0.1 trise Rise time 5 ms Ii NL No load input current Io = 0, Ui min...Ui max 30 40 mA SD high Ci Input capacitance for surge calculation 1.5 uF USD Shut down voltage Unit disabled –10 0.7 V DC Unit operating 1.5 5 ISD Input current of SD input 1 2 mA Iinr p Inrush peak current 4 Ui = Ui nom 1.5 A fs Switching frequency Ui min, Io nom approx. 250 kHz Ii rr Reflected Io = 0...Io nom 60 mApp ripple current ui RFI Input RFI levelconducted EN 55022 3 B 1 Ui min will not be as stated if Uo is increased above Uo nom by use of the Trim input. If the output voltage is set to a higher value, Ui 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. 4 Source impedance according to prETS 300132-2, version 4.3. Uo nom Uo tstart up trise t 04008 Fig. 3 Converter start-up and rise time (applying Ui nom). Inrush Current The inrush current has been kept as low as possible by choosing a very small input capacitance. A series resistor may be installed in the input line to further limit this current. Fig. 2 Typical inrush current at Ui nom, Po nom versus time (48 IMS30-0503-9G). Source impedance according to prETS 300132-2, version 4.3 at Ui nom. Input Undervoltage Lock-out The IMS30 converters are fitted with a defined input under- voltage lock-out: 48 IMS 30 turn off 31.5 V turn on 32 V (approx. values) –10 1 23 4 5 6 7 8 t [ms] 0.2 0.4 0.6 0.8 1.2 1.4 I [A] 04058

Input Transient Voltage Protection A built-in suppressor diode provides ef fective protection against input transients which may be caused for example by short-circuits accross the input lines where the network inductance may cause high energy pulses. Table 3: Built-in transient voltage suppressor Type Breakdown Peak power Peak pulse voltage at 1 ms current VBR nom [V] PP [W] IPP [A] 48 IMS 30 100 600 4.1 For very high energy transients as for example to achieve IEC/EN 61000-4-5 or ETR 283 (19 Pfl1) compliance (as per table: Electromagnetic Immunity) an external inductor and capacitor are required. Vi+ Vi– C L Module 04009 Fig. 4 Example for external circuitry to comply with IEC/EN 61000-4-5 or ETR 283 (19 Pfl1) (48 IMS 30 types). Table 4: Components for external circuitry to comply with IEC/EN 61000-4-5, level 2 or ETR 283 (19Pfl1) (48 IMS types). Circuit Ref. 48 IMS 30 L 150 uH C 100 uF, 100 V, 85 C Reverse Polarity Protection at the Input The built-in suppressor diode also provides for reverse po- larity protection at the input by conducting current in the re- verse direction. An external fuse is required to limit this cur- rent: 48 IMS 30: 3.15 A (F3.15A) Electrical Ouput Data Table 5a: Output data. Model 48IMS30-0503-9G 3.3 V5.1 V Characteristics Conditions min typ maxmin typ max Unit Io nom Output current Ui min...Ui max A IoL Current limit 1 Ui nom 9 Uo Line regulation Ui min...Ui max +/-0.5 uo1 Output voltage noise 2 Io = (0...1) Io nom 5075 mVpp Co ext Admissible capacitive load 20002000 uF uo d Dynamic Voltage deviation Ui nom 250250 mV td load Recovery time Io nom 1/2 Io nom 11 msregulation Uo Temperature coefficient Ui nom, Io nom 0.020.02 %/K Uo/ TC TC min...TC max 1 The current limit is primary side controlled.

2 BW = 20 MHz

0 60 3.5 See Fig. 6Load regulation +/-0.5 % +/-1 Model 48IMS30-0302-9G 3.3 V 1.8 V Characteristics Conditions min typ max min typ max Unit Io nom Output current Ui min...Ui max A IoL Current limit 1 Ui nom 6 Uo Line regulation Ui min...Ui max +/-0.5 uo1 Output voltage noise 2 Io = (0...1) Io nom 50 50 mVpp Co ext Admissible capacitive load 2000 2000 uF uo d Dynamic Voltage deviation Ui nom 250 150 mV td load Recovery time Io nom 1/2 Io nom 11 msregulation Uo Temperature coefficient Ui nom, Io nom 0.02 0.02 %/K Uo/ TC TC min...TC max 0 4 0 5 See Fig. 6Load regulation +/-0.5 % +/-3 Table 5b: Output data.

Fig 6: Cross regulation and load regulation for double output units. Unspecified Output Current (A) Specified Output Current (A) +/-4% +/-3% 30W Output power limit line +/-1% Regulation window for unspecified output (Tab 5a,5b) 100 % 50 % Specified Output Current (A)

Extendable output power characterisation of 48IMS30-0302-9G under forced air condition 0 100 200 300 400 500 600 700 800 Air-Flow (LFM) Output Power (W) Table 6: Typical values for undervoltage lockout (PUL) settings.

48 IMS 30

Rext [k ] Ui min [V] 50 34 29 36 20 38 15 40 Auxiliary Functions Shut Down Function The outputs of the converters may be enabled or disabled by means of a logic signal (TTL, CMOS, etc.) applied to the shut down pin. If the shut down function is not required then pin should be left open-circuit. Converter shut down: –1...0.7 V The shut down pin can also be used as a programmable undervoltage lockout. The undervoltage lockout values for the 48 IMS30 series is 31 V with a 0.5V hysteresis window which can be trimmed up by means of an external resistor connected between the SD/PUL pin and Vi– pin. Adjustable Output Voltage As a standard feature, the IMS 30 units of fer adjustable output voltage by using the secondary referenced control Trim. If the control input is left open-circuit the output volt- age is set to Uo nom. Adjustment of the output voltage is pos- sible by means of an external resistor Rext connected be- tween the Trim pin and the either Vo+ or Vo–. Vo+Vi+ Vi– Vo– 06133 Rext SD/PUL Fig. 8 Shut down (SD) and undervoltage lockout (PUL) function. Vo+Vi+ Vi– Vo– 06134 Trim Rext 1 Rext 2 Fig. 9 Output voltage Trim. Table 7: Uo versus Uext for Uo = 90...110% Uo nom; typical values (Ui nom, Io1/2 = 0.5 Io1/2 nom) Rext 1 Rext 2 Uo nom [V] Uo [V] [k] Uo [V] [k] 3.3 2.97 8 3.63 5 Synchronisation The IMS 30 provides a bi-directional synchronisation func- tion to synchronise several IMS 30 units operated in parallel connection. When the W pins (SYNC) are connected to- gether, the converters will lock to the highest switching fre- quency. The faster controller becomes the master, produc- ing a 4.3 V , 200 ns pulse train. Only one, the highest fre- quency SYNC signal, will appear on the Sync line. 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 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 inte- gration into a system. The thermal conditions are influenced by input voltage, output current, airflow, temperature of sur- rounding components and surfaces and the properties of the printed circuit board. TA max is therefore only an indica- tive value and under practical operating conditions, the ad- missible 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 ) must under no circumstances exceed the specified maximum value. The installer must ensure that under all operating conditions TC remains within the lim- its stated in the table: Temperature specifications. Short Circuit Behaviour The current limit characteristic shuts down the converter whenever a short circuit or an overload is applied to its out- put. It acts self-protecting and automatically recovers after removal of the overload condition (hiccup mode). Overtemperature Protection The converters are protected from possible overheating by means of an internal non latching temperature monitoring circuit. It shuts down the unit above the internal tempera- ture limit and attempts to automatically restart in short peri- ods. This feature prevents excessive internal temperature excursion which could occur in heavy overload condi tions. Typical Performance Curves General conditions : TA = 25oC, unless TC is specified. Shut down pin left open- circuit. Trim input not connected. Fig. 5 Overload switch off (hiccup mode), typical values. 100 Uo [%] t [ms] 05162 100

Table 8: Immunity type tests Phenomenon Standard 1 Class Coupling Value Waveform Source Test In Per- Level mode 2 applied Imped. procedure oper. form. 3 Electrostatic IEC/EN 2 contact discharge 4000 Vp 1/50 ns 330 10 positive and yes B discharge 61000-4-2 3 air discharge 8000 Vp 10 negative to case discharges Electromagnetic IEC/EN 2 antenna 3 V/m AM 80% 26… 1000 MHz yes A field 61000-4-3 1 kHz ENV 50204 PM, 50% duty 900 MHz cycle, 200 Hz resp. frequ. Electrical fast IEC/EN 3 direct +i/–i 2000 Vp bursts of 5/50 ns 50 1 min positive yes A transient/burst 61000-4-4 5 kHz rep. rate 1 min negative transients with transients per 15 ms burst coupling mode duration and a 300 ms period Surge IEC/EN 2 +i/–i 1000 Vp 1.2/50 s2 5 pos. and 5 neg. yes B 61000-4-5 5 impulses per coupling mode Conducted IEC/EN 2 +i/–i3 V rms AM modulated 50 0.15...80 MHz yes A disturbancies 61000-4-6 (130 dB V) 80%, 1 kHz 150 Transient ETR 283 +i/–i 150 Vp 0.1/0.3 ms limited to 3 positive yes B (19 Pfl 1) 4 <100 A 1 Related and previous standards are referenced in: Technical Information: Standards. 2 i = input, o = output. 3 A = normal operation, no deviation from specification, B = temporary deviation from specs. possibe. 4 For 48 IMS 30 types (additional external components required). 5 External components required. which typically occur in many installations, but especially in battery driven mobile applications. Electromagnetic Compatibility (EMC) A suppressor diode together with an input filter form an ef- fective protection against high input transient voltages Fig. 10 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 10 cm, twisted. (48 IMS30-0503-9G ) Electromagnetic Emission 07020 EN 55022 A EN 55022 B 0.01 0.05 0.1 0.5 [dB V] MHz 0.02

Immunity to Environmental Conditions Table 9: 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: 50 gn = 490 m/s2 Unit (half-sinusoidal) MIL-STD-810D section 516.3 Bump duration: 11 ms operating Number of bumps: 18 (3 each direction) Eb Bump IEC/EN/DIN EN 60068-2-29 Acceleration amplitude: 25 gn = 245 m/s2 Unit (half-sinusoidal) MIL-STD-810D section 516.3 Bump duration: 11 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) 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 -9G Characteristics Conditions min max Unit TA Ambient temperature 1 Operational –40 71 ° C TC Case temperature –40 105 TS Storage temperature 1 Non operational –55 105 1 MIL-STD-810D section 501.2 and 502.2 Table 11: MTBF Values at specified Type Ground benign Ground fixed Ground mobile Device hours Unit case temperature 25 C2 5 C5 5 C5 5 C MTBF 48 IMS 30-0503-9G 927'229 331'251 179'831 272'260 n.a. h 1 Statistical values based on an average of 4300 working hours per year and in general field use, over 2 years.

Dimensions in mm. Tolerances ±0.3 mm unless otherwise indicated. European Projection -0503, -0302 Outputs Uo 1 Uo 2 Com Tc Measurement point

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 with hole diameters of 1.4 mm 0.1 mm for the pins. 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 conditions. See also: Safety of operator accessible output circuit. 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 F3.15A for 48 IMS 30 types. Standards and approvals All DC-DC converters are pending to be 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 After approvals the DC-DC converters are subject to manu- facturing surveillance in accordance with the above men- tioned UL, CSA, EN and ISO 9001 standards. 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. Table 12: Electric strength test voltages Characteristic Input to output Unit Electric strength 1.1 kVrms test voltage 1 s 1.5 kV DC Coupling capacitance 2.2 nF Insulation resistance >100 M at 500 V DC Partial discharge Consult kV extinction voltage factory Protection Degree The protection degree of the DC-DC converters is IP 40. Cleaning Agents In order to avoid possible damage, any penetration of cleaning fluids should be prevented, since the power sup- plies are not hermetically sealed. Safety of Operator Accessible Output Circuit 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 following table shows some possible installation con- figurations, compliance with which causes the output circuit of the DC-DC converter to be an SELV circuit according to IEC/EN 60950 up to a configured output voltage of 42 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.

Fig. 13 Schematic safety concept. Use fuse, suppressor diode and earth connection as per table: Safety concept leading to an SELV output circuit. Table 14: 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 diode(s) 4, and earthed circuit secondary circuit output circuit(s) 2 Double or reinforced 60 V SELV circuit Operational insulation (pro- SELV circuit vided by the DC-DC converter) >60 V TNV-2 circuit Supplementary insulation, Double or reinforced insu- based on the maximum input lated unearthed hazardous voltage (provided by the voltage secondary circuit 5 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 basic insulation according to the relevant safety standard, based on the maximum output voltage from the front end. Description of Option Option i Inhibit Excluces shut down 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 unit 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...0.8 V Converter inhibited or inhibit pin left open circuit 2.4...5 V Fig. 14 If the inhibit is not used the inhibit pin should be con- nected to Vi– Vi+ Vi– i 06070