IMS30 SERIES JAN, 2001 48Vinput Powering Communciations and Technology Dual outputs 5V & 3.3V ; 3.3V & 1.8V Input to output electric strength test 1500 V DC Input voltage ranges 32...75VDC for -0302 IMS30 Series 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...71 o 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 Safety according to IEC/EN 60950, UL 1950 LGA C Approvals pending Summary The IMS 30 series of board mountable 30 Watt DC-DC converters has been designed according to the latest industry requirements and standards. The converters are particularly suitable for applications in industry and telecommunication where variable input voltages or high transient voltages are prevalent. Features include efficient input and output filtering with unsurpassed 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. Table of Contents Page Summary ......................................................................... 1 Type Survey and Key Data ............................................. 2 Type Key ......................................................................... 2 Functional Description ..................................................... 2 Electrical Input Data ........................................................ 3 Electrical Ouput Data ...................................................... 4 The converters provide supplementary insulation with SELV outputs as e.g. required in battery supported systems where the bus voltage may exceed the SELV limit of 60 V DC. They are designed and built according to the international 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 proprietary magnetic feedback solution ensures maximum reliabilityand 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 71°C in free air without using any potting material. Page Auxiliary Functions .......................................................... 6 Electromagnetic Compatibility (EMC) ............................. 7 Immunity to Environmental Conditions ............................ 8 Mechanical Data ............................................................. 9 Safety and Installation Instructions ............................... 10 Description of Option ..................................................... 11 1/11 10130 DC Type Survey and Key Data Table 1: Type survey Output 1 Uo1 nom Io1 nom [V DC] [A] Output 2 I o1 nom U o2 nom [V DC] [A] Output power P o nom [W] Input Voltage Range and Efficiency Ui min...Ui max typ 32...75 V DC [%] Option 5.1 4.5 3.3 6.0 30 48 IMS 30-0503-9G 87 i 3.3 4.0 1.8 5.0 22 48 IMS 30-0302-9G 83 i Type Key 48 IMS 30 - 0503 -9 G i Input voltage range Ui 32...75 V DC .................................... 48 Series ...................................................................... IMS 30 Output voltage type output .................... ( 5.1 and 3.3Vout) Operating ambient temperature range TA –40...71°C .................................................. -9 Synchronous rectifier ...................................................... G Option: Inhibit ............................................................ i Functional Description The IMS 30 series of DC-DC converters are magnetic feedback controlled forward converters using current mode PWM (Pulse Width Modulation). This product range features synchronous rectifiers delivering in very high efficiency. The output voltage of these versions can be adjusted via the Trim input. The Trim input is referenced to the secondary side and allows for programming of the output voltage in the range of approximately 90 to 110% of Uo nom using an external resistor. 13 Uo1+ Vi+ 1 SD PUL 4 i The voltage regulation is achieved with a magnetic feedback circuit providing excellent line and load regulation. Current limitation is provided by the primary circuit, thus limiting the total output power to approx. 130% of Po nom (see: Type Survey). The shut down input allows remote converter on/off. Overtemperature protection will shut down the unit in excessive overload conditions with automatic restart. 2/11 11 Uo2+ PWM 15 Com 4n7F 1500 V Vi – 2 W 3 Fig. 1 Block diagram (-0503, -0302 Outputs ) 17 Trim Electrical Input Data 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 1 2 3 4 1 Conditions min TC min...TC max Io = 0...Io nom 32 Ui Input voltage range Ui nom Nominal input voltage Ui sur Repetitive input surge voltage max 3 s t start up Converter Switch on start-up time SD high Ui min, Io = Io nom 2 t rise Rise time I i NL No load input current Io = 0, Ui min...Ui max SD high Ci Input capacitance for surge calculation USD Shut down voltage Unit disabled Unit operating typ max Unit 75 V DC 48 100 0.25 0.5 s 0.1 5 ms 30 40 mA –10 0.7 V DC 1.5 5 1.5 ISD Input current of SD input Iinr p Inrush peak current 4 Ui = Ui nom 1.5 fs Switching frequency Ui min, Io nom approx. 250 I i rr Reflected ripple current Io = 0...Io nom ui RFI Input RFI level conducted EN 55022 3 1 uF 2 mA A kHz 60 mApp B 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. Measured with a resistive and the max. admissible capacitive load. Measured with a lead length of 0.1 m, leads twisted. Source impedance according to prETS 300132-2, version 4.3. Inrush Current Input Undervoltage Lock-out The inrush current has been kept as low as possible by choosing a very small input capacitance. The IMS30 converters are fitted with a defined input undervoltage lock-out: A series resistor may be installed in the input line to further limit this current. 48 IMS 30 I [A] turn off turn on (approx. values) 04058 1.4 31.5 V 32 V 1.2 04008 Uo 1 t rise Uo nom 0.8 0.6 0.4 t 0.2 t start up 0 –2 –1 0 1 2 3 4 5 6 7 t [ms] 8 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. 3/11 Fig. 3 Converter start-up and rise time (applying Ui nom). Input Transient Voltage Protection A built-in suppressor diode provides effective 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 Circuit Ref. 48 IMS 30 L Breakdown voltage VBR nom [V] Peak power at 1 ms PP [W] Peak pulse current IPP [A] 100 600 4.1 48 IMS 30 Table 4: Components for external circuitry to comply with IEC/EN 61000-4-5, level 2 or ETR 283 (19Pfl1) (48 IMS types). 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. 04009 C 150 uH 100 uF, 100 V, 85 C Reverse Polarity Protection at the Input The built-in suppressor diode also provides for reverse polarity protection at the input by conducting current in the reverse direction. An external fuse is required to limit this current: 48 IMS 30: 3.15 A (F3.15A) L V+ 1 Vi+ C + V– Module Fig. 4 Example for external circuitry to comply with IEC/EN 61000-4-5 or ETR 283 (19 Pfl1) (48 IMS 30 types). 2 Vi– Electrical Ouput Data Table 5a: Output data. Model 48IMS30-0503-9G 5.1 V 3.3 V Characteristics Conditions min typ max Uo1 Output voltage Ui nom, Io = 0.5 Io nom 5.00 5.20 Io nom Output current Ui min...Ui max IoL Current limit Uo 1 Line regulation Load regulation uo1 Output voltage noise 2 Co ext Admissible capacitive load uo d Dynamic load regulation td Uo Voltage deviation Recovery time Temperature coefficient U o/ T C 3.5 0 Ui min...Ui max Io = (0...1) Io nom 1 V 0 6 A 9 +/-0.5 +/-0.5 See Fig. 6 +/-1 % 75 50 mVpp 2000 2000 uF 250 250 mV 1 1 ms 0.02 0.02 %/K /2 Io nom Ui nom , Io nom TC min...TC max Unit 3.35 6 Ui nom Ui nom Io nom min typ max 3.25 Table 5b: Output data. Model 48IMS30-0302-9G Conditions min typ max min typ max Uo1 Output voltage Ui nom, Io = 0.5 Io nom 3.25 3.35 1.77 1.83 V Io nom Output current Ui min...Ui max 5 A Uo Current limit 1 Line regulation Load regulation uo1 Output voltage noise 2 Co ext Admissible capacitive load uo d Dynamic load regulation td Voltage deviation Recovery time Ui nom Ui nom Io nom 0 4 0 1 /2 Io nom Temperature coefficient U o/ T C 4/11 +/-0.5 See Fig. 6 Unit 7 6 Ui min...Ui max Io = (0...1) Io nom Ui nom , Io nom TC min...TC max The current limit is primary side controlled. BW = 20 MHz Uo 2 1.8 V Characteristics IoL 1 3.3 V +/-0.5 % +/-3 50 50 mVpp 2000 2000 uF 250 150 mV 1 1 ms 0.02 0.02 %/K Fig 6: Cross regulation and load regulation for double output units. Regulation window for unspecified output (Tab 5a,5b) Unspecified Output Current (A) +/-4% +/-3% +/-1% 100 % 30W Output power limit line Specified Output Current (A) 50 % 1.0 2.0 3.0 4.0 5.0 6.0 Specified Output Current (A) 5/11 Auxiliary Functions Fig. 9 Output voltage Trim. 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. 2.0...5.0 V –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. 06133 Vo+ Vi+ SD/PUL Rext Vi– Vo– Fig. 8 Shut down (SD) and undervoltage lockout (PUL) function. Table 6: Typical values for undervoltage lockout (PUL) settings. 48 IMS 30 Rext [k ] Ui min [V] 50 29 20 15 31 34 36 38 40 Uo nom [V] Uo [V] 3.3 2.97 Rext 2 [k] 8 Uo [V] [k] 3.63 5 Thermal Considerations If a converter, mounted on a PCB, is located in free, quasistationary air (convection cooling) at the indicated maximum 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 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 and under practical operating conditions, the admissible 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: Mechanical Data) must 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. Short Circuit Behaviour Synchronisation The IMS 30 provides a bi-directional synchronisation function to synchronise several IMS 30 units operated in parallel connection. When the W pins (SYNC) are connected together, the converters will lock to the highest switching frequency. The faster controller becomes the master, producing a 4.3 V, 200 ns pulse train. Only one, the highest frequency SYNC signal, will appear on the Sync line. Adjustable Output Voltage As a standard feature, the IMS 30 units offer adjustable output voltage by using the secondary referenced control Trim. If the control input is left open-circuit the output voltage is set to Uo nom. Adjustment of the output voltage is possible by means of an external resistor Rext connected between the Trim pin and the either Vo+ or Vo–. 06134 Vi+ Rext 1 Vo+ Rext 1 Trim The current limit characteristic shuts down the converter whenever a short circuit or an overload is applied to its output. 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 temperature limit and attempts to automatically restart in short periods. This feature prevents excessive internal temperature excursion which could occur in heavy overload conditions. Extendable output power characterisation of 48IMS30-0302-9G under forced air condition 32 30 Output Power (W) Converter operating: Converter shut down: Table 7: Uo versus Uext for Uo = 90...110% Uo nom; typical values (Ui nom, Io1/2 = 0.5 Io1/2 nom) 28 26 24 22 Rext 2 Vi– Vo– 20 0 100 200 300 400 500 Air-Flow (LFM) 6/11 600 700 800 Electromagnetic Compatibility (EMC) A suppressor diode together with an input filter form an effective protection against high input transient voltages which typically occur in many installations, but especially in battery driven mobile applications. Electromagnetic Immunity Table 8: Immunity type tests Phenomenon Standard 1 Electrostatic discharge to case IEC/EN 61000-4-2 Electromagnetic IEC/EN field 61000-4-3 Class Level Coupling mode 2 Value applied Waveform 1/50 ns 2 contact discharge 4000 Vp 3 air discharge 8000 Vp 2 antenna 3 V/m ENV 50204 1 2 3 4 5 Source Imped. 330 Test procedure In Peroper. form. 3 10 positive and 10 negative discharges yes B AM 80% 1 kHz 26…1000 MHz yes A PM, 50% duty cycle, 200 Hz resp. frequ. 900 MHz Electrical fast transient/burst IEC/EN 61000-4-4 3 direct +i/–i 2000 Vp bursts of 5/50 ns 5 kHz rep. rate transients with 15 ms burst duration and a 300 ms period 50 1 min positive 1 min negative transients per coupling mode yes A Surge IEC/EN 61000-4-5 5 2 +i/–i 1000 Vp 1.2/50 s 2 5 pos. and 5 neg. impulses per coupling mode yes B Conducted disturbancies IEC/EN 61000-4-6 2 +i/–i 50 0.15...80 MHz 150 yes A Transient ETR 283 (19 Pfl 1) 4 3 positive yes B 3 V rms AM modulated (130 dB V) 80%, 1 kHz +i/–i 150 Vp 0.1/0.3 ms limited to <100 A Related and previous standards are referenced in: Technical Information: Standards. i = input, o = output. A = normal operation, no deviation from specification, B = temporary deviation from specs. possibe. For 48 IMS 30 types (additional external components required). External components required. Electromagnetic Emission [dB V] 90 07020 80 EN 55022 A 70 EN 55022 B 60 50 40 30 20 10 20 30 10 5 2 1 0.5 0.1 0.05 MHz 0.02 0.01 0 Fig. 10 Typical disturbance voltage (quasi-peak) at the input according 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 ) 7/11 Immunity to Environmental Conditions Table 9: Mechanical stress Test method Standard Test conditions Status 2 Ca Damp heat steady state IEC/DIN IEC 60068-2-3 MIL-STD-810D section 507.2 Temperature: Relative humidity: Duration: 40 C 93 +2/-3 % 56 days Unit not operating Ea Shock (half-sinusoidal) IEC/EN/DIN EN 60068-2-27 MIL-STD-810D section 516.3 Acceleration amplitude: Bump duration: Number of bumps: 50 gn = 490 m/s2 11 ms 18 (3 each direction) Unit operating Eb Bump (half-sinusoidal) IEC/EN/DIN EN 60068-2-29 MIL-STD-810D section 516.3 Acceleration amplitude: Bump duration: Number of bumps: 25 gn = 245 m/s2 11 ms 6000 (1000 each direction) Unit operating Fc Vibration (sinusoidal) IEC/EN/DIN EN 60068-2-6 MIL-STD-810D section 514.3 Acceleration amplitude: Unit operating Frequency (1 Oct/min): Test duration: 0.35 mm (10...60 Hz) 5 gn = 49 m/s2 (60...2000 Hz) 10...2000 Hz 7.5 h (2.5 h each axis) Concentration: Duration: Storage: Storage duration: Number of cycles: 5% (30 C) 2 h per cycle 40 C, 93% rel. humidity 22 h per cycle 3 Unit not operating Kb Salt mist, cyclic (sodium chloride NaCl solution) IEC/EN/DIN IEC 60068-2-52 Table 10: Temperature specifications, valid for air pressure of 800...1200 hPa (800...1200 mbar) Temperature Standard -9G Characteristics 1 TA Ambient temperature 1 TC Case temperature TS Storage temperature 1 Conditions min max Unit Operational –40 71 °C –40 105 –55 105 Non operational MIL-STD-810D section 501.2 and 502.2 Table 11: MTBF Values at specified case temperature MTBF 1 Type 48 IMS 30-0503-9G Ground benign 25 C 927'229 Ground fixed 25 C 55 C 331'251 179'831 Ground mobile 55 C Device hours 272'260 n.a. Statistical values based on an average of 4300 working hours per year and in general field use, over 2 years. 8/11 Unit h Mechanical Data Dimensions in mm. Tolerances ±0.3 mm unless otherwise indicated. Tc Measurement point -0503, -0302 Outputs Uo 2 Uo 1 Com 9/11 European Projection Safety and Installation Instructions Installation Instruction Protection Degree Installation of the DC-DC 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. The protection degree of the DC-DC converters is IP 40. 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. 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 supply line in case of a short-circuit across the converter input an external fuse should be installed in a non earthed input supply line. We 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 subject to a maximum transient rating of 1500 V After approvals the DC-DC converters are subject to manufacturing surveillance in accordance with the above mentioned UL, CSA, EN and ISO 9001 standards. Isolation The electric strength test is performed as factory test in accordance with IEC/EN 60950 and UL 1950 and should not be repeated in the field. Melcher will not honour any guarantee claims resulting from electric strength field tests. Table 12: Electric strength test voltages Characteristic Input to output Unit Electric strength test voltage 1 s 1.1 kVrms 1.5 kV DC Coupling capacitance 2.2 nF Insulation resistance at 500 V DC >100 Consult factory In order to avoid possible damage, any penetration of cleaning fluids should be prevented, since the power supplies are not hermetically sealed. Safety of Operator Accessible Output Circuit Check for hazardous voltages before altering any connections. Partial discharge extinction voltage Cleaning Agents M kV 10/11 If the output circuit of a DC-DC converter is operator accessible, it shall be an SELV circuit according to IEC/EN 60950 related safety standards The following table shows some possible installation configurations, 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 ensure the compliance with the relevant and applicable safety regulations. More information is given in: Technical Information: Safety. Table 14: Insulation concept leading to an SELV output circuit Conditions Front end Supply voltage Minimum required grade of isolation, to be provided by the AC-DC front end, including mains supplied battery charger Mains Basic 250 V AC Maximum DC output voltage from the front end 1 60 V >60 V Double or reinforced 1 2 3 4 5 DC-DC converter Result Minimum required safety status of the front end output circuit Measures to achieve the specified safety status of the output circuit Safety status of the DC-DC converter output circuit Earthed SELV circuit 2 Operational insulation (proSELV circuit vided by the DC-DC converter) ELV circuit Input fuse 3 output suppressor diode(s) 4, and earthed output circuit(s) 2 Hazardous voltage secondary circuit 60 V SELV circuit >60 V TNV-2 circuit Earthed SELV circuit Operational insulation (proSELV circuit vided by the DC-DC converter) Supplementary insulation, based on the maximum input Double or reinforced insuvoltage (provided by the lated unearthed hazardous DC-DC converter) 5 voltage secondary circuit The front end output voltage should match the specified input voltage range of the DC-DC converter. The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC/EN 60950. 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. 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). 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. ~ Mains ~ 10004 Fuse AC-DC front end Battery Earth connection + DC-DC converter Suppressor diode SELV – Earth connection Fig. 13 Schematic safety concept. Use fuse, suppressor diode and earth connection as per table: Safety concept leading to an SELV output circuit. Description of Option Option i Inhibit 06070 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: Converter inhibited or inhibit pin left open circuit –10 V...0.8 V Vi+ i Vi– Fig. 14 If the inhibit is not used the inhibit pin should be connected to Vi– 2.4...5 V 11/11