IMS6 Series Data Sheet, 6-Watt DC-DC Converters

Transcription

1 Input to output electric strength test up to kvdc Input voltage ranges: 8 to 36 and 36 to 75 VDC Single and dual outputs of 5,, & 5 VDC Features RoHS leadsolderexempt compliant Wide input voltage ranges Rated to Basic Isolation Electrical isolation, single and dual outputs Immunity to IEC/EN 6004, 3, 4, and 6 High efficiency (typ. 84%) Flex power: flexible load distribution No load and shortcircuit proof High reliability and no derating Operating ambient temperature 40 to +7 C 0 0.8" " Industrial and alternative pinouts DIL 4 case with 8.5 mm profile 3.5" Safety according to IEC/EN 60950, UL 950 Description The IMS6 Series of boardmountable 6 Watt DCDC converters has been designed according to the latest industry requirements and standards. The converters are particularly suitable for use in mobile or stationary applications in transport, industry or telecommunications where variable input voltages or high transient voltages are prevalent. Covering a total input voltage range from 8 VDC up to 75 VDC, with single and dual outputs from 5 VDC up to ±5 VDC with flexible load distribution on dual outputs. The converters are designed and built according to the international safety standards IEC/EN 60950, UL 950, CAN/CSA C. No and are UL marked. Table of Contents A special feature is their small case size, DIL 4 with only an 8.5 mm profile. The circuit comprises integrated planar magnetics and all components are automatically assembled and solidly soldered onto a single PCB without any wire connections. Thanks to the rigid mechanical design, the converters withstand an extremely high level of shock and vibrations. 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 7 C in free air without using any potting material. Option: Kpinout, an alternative to the standard industrial pinout, provides a high level of application specific engineering and designin flexibility. Page Page Description... Model Selection... Part Number Description... Functional Description... 3 Electrical Input Data... 4 Electrical Output Data... 5 Thermal considerations... 6 Mechanical Data... 7 Electromagnetic Compatibility (EMC)... 7 Immunity to Environmental Conditions... 8 Safety and Installation Instructions... 9 Description of Options... MCD6 Rev..0, 7FEB09 Page of

2 Model Selection Table : Model Selection Output Output Output Power Input voltage Efficiency Type Options U o nom I o nom U o nom I o nom P o nom range η typ designation [VDC] [A] [VDC] [A] [W] [VDC] [%] IMS IMS6059 Z IMS IMS IMS IMS IMS IMS IMS IMS69 Z IMS IMS6559 Flexible load distribution on double outputs possible. Not all K/Z options exist, to check if option exists and/orfor minimum quantity and lead time contact PowerOne. Part Number Description 4 IMS 6 9 K Z Input voltage range V i 8 to 36 VDC to 75 VDC Series... IMS6 Output voltage type for output... 05,, 5 Output voltage type for output... 05,, 5 Operating ambient temperature range T A 40 to 7 C... 9 Options: Alternative pinout (check availability)... K Open frame... Z Examples: 48IMS69Z: DCDC converter, input voltage range 36 to 75V, outputs providing ± V, 50 ma, temperature range 40 to 7 C, no case. JUN 4, 004 revised to JUL 7, 006 Page of

3 Functional Description The IMS6 DCDC converters are feedback controlled flyback converters using current mode PWM (Pulse Width Modulation). 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. Current limitation is provided by the primary circuit, thus limiting the total output current (I o nom for the single and I o nom + I o nom for the dual output types). The close magnetic coupling provided by the planar construction ensures very good regulation and allows for flexible load distribution on dual output types PWM 3 PWM 6 Go Fig. Block diagram for single output types. Standard industrial pinout. Fig. Block diagram for dual output types. Standard industrial pinout n.c. PWM PWM Go Fig. 3 Block diagram for single output types. Special pinout (option K). Fig. 4 Block diagram for dual output types. Special pinout (option K). MCD6 Rev..0, 7FEB09 Page 3 of

4 Electrical Input Data General conditions: T A = 5 C, unless T C is specified. Table : Input Data Input 4IMS6 48IMS6 Characteristics Conditions min typ max min typ max Unit V i Input voltage range T C min to T C max V DC I Nominal input voltage o = 0 to I o nom 4 48 V i nom V i sur Repetitive surge voltage abs. max input (3 s) 40 0 t start up Converter startup time Worst case condition at s V i min and full load t rise Rise time V i nom resistive load 5 5 ms I o nom capacitive load I i o No load input current I o = 0, V i min to V i max ma C i I nput capacitance for surge calculation µf I inr p Inrush peak current V i = V 3 i nom A f s Switching frequency V i min...v i max, I o = 0...I o nom approx. 400 approx. 400 khz I i rr Reflected ripple current I o = 0 to I o nom 0 30 ma 3 pp V i RFI Input RFI level EN 550 B B conducted and radiated Measured with a resistive or max. admissible capacitive load. (See fig.: Converter startup and rise time) External filter required. (See: Filter recommendations for compliance with EN standards) 3 Source impedance according to prets 3003, version 4.3. V o V o nom t start up t rise Fig. 5 Converter startup and rise time t Reverse Polarity Protection at Input The suppressor diode on the input also provides for reverse polarity protection by conducting current in the reverse direction, thus protecting the unit. An external fuse is required to limit this current: For 4IMS6 a fast A (FA) fuse is recommended For 48IMS6 a fast 0.63 A (F0.63A) fuse is recommended 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. Filter recommendations for compliance with EN 550 Electromagnetic emission requirements according to table Input data can be achieved by adding an external capacitor as close as possible to the input terminals. A/Div C i 0 Fig. 7 Input filter arrangement Table 3: Input filter components (EN 550) Ref. 4IMS6 48IMS6 C 4.7 µf, 63 V,. µf, 0 V, MCD6 Rev..0, 7FEB09 5 µs/div. Page of 85 C 85 C Fig. 6 Type ceramic or film Typical inrush current at U i nom, P o nom versus time measured according to prets 3003, version 4.3. MCD6 Rev..0, 7FEB09 Page 4 of

5 Electrical Output Data General conditions: T A = 5 C, unless T C is specified. Table 4a: Output data for single output units Output V o nom 5 V V 5 V Characteristics Conditions min typ max min typ max min typ max Unit V o Output voltage V i nom, I o = 0.5 I o nom VDC I o nom Output current V i min to V i max ma I o L Current limit V i nom, T C = 5 C V o U Line regulation V i min... V i max, I o nom ± ± ± % V Load regulation V i nom ±3 ±3 ± 3 I o = (0...) I o nom V o, Output voltage noise V i min to V i max mv pp I o = I o nom V o clp Output overvoltage Min. load % % limitation C o ext A dmissible µf capacitive load 3 V o d Dynamic Voltage deviat. V i nom ±50 ±50 ±50 mv load t Recovery time Io nom / Io nom ms d regulat. α Vo Temperature coefficient V i min to V i max ±0.0 ±0.0 ±0.0 %/K V o / T C I o = 0 to I o nom Table 4b: Output data for dual output units Output V o nom ±5 V ± V ±5 V Characteristics Conditions min typ max min typ max min typ max Unit V o Output voltage V i nom VDC V o I o = I o = 0.5 I o nom I o nom Output current V i min...v i max x 500 x 50 x 00 ma P o L Power limit 3 V i nom, T C = 5 C x 3.5 x 4.0 x 4. W V o U Line regulation V i min...v i max, I o nom ± ± ± % V Load regulation 4 V i nom ±3 ±3.5 ±3 I o = (0...) I o nom V o, Output voltage noise V i min...v i max mv pp I o = I o nom V o clp Output overvoltage Min. load % % limitation C o ext A dmissible µf capacitive load 3 V o d Dynamic Voltage deviat. V i nom ±50 ±600 ±750 mv load I t d Recovery time o nom / I o nom ms regulat. α Vo Temperature coefficient V i min to V i max ±0.0 ±0.0 ±0.0 %/K U o / T C I o = 0 to I o nom Each output capable of delivering full output power. The current limit is primary side controlled. 3 Sum of both outputs. 4 Conditions for specified output. Other output loaded with constant current I o = 0.5 I o nom. 5 BW = 0 MHz. 6 Measured with a probe according to EN 64. MCD6 Rev..0, 7FEB09 Page 5 of

6 Thermal Considerations If a converter, mounted on a PCB, is located in free, quasistationary air (convection cooling) at the indicated maximum ambient temperature T A max (see table: Temperature specifications) and is operated at its nominal input voltage and output power, the case temperature T C measured at the: Measuring point of case temperature T C (see: Mechanical Data) will approach the indicated value T C max after the warmup phase. However, the relationship between T A and T C 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 and under practical operating conditions, the ambient temperature T A may be higher or lower than this value. Caution: The case temperature T C measured at the Measuring point of case temperature T C (see: Mechanical Data) may 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. Typical Performance Curves V o [V] I o [A] Fig. 8 U o versus I o (typ) of single output units (example for 48IMS6059) V o [V] Output overvoltage protection The outputs of the IMS6 converters are protected against overvoltages by Zener diodes. In the event of an overvoltage 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 converters 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 voltage can be connected in parallel. Approximate current sharing between or several units is ensured by their load dependent output characteristic. Short Circuit Behavior The current limit characteristic shuts down the converter whenever a short circuit is applied to its output. It acts selfprotecting and automatically recovers after removal of the overload condition. V o + V o [V] I o [ma] Fig. 9 U o versus I o (typ) of dual output units (±5 V), with 30 V load connected to and. V o, V o [V] I o = 4 ma I o = 40 ma.4.6 V o V o I o [ma] Fig. Cross load regulation of dual output units. U o versus I o (typ) for various I o (48IMS6559). I. o [%] I o no Fig. Flexible load distribution on dual outputs ( x V) with load variation from 0 to 50% of P o nom on output. Output loaded with 5% of P o nom. MCD6 Rev..0, 7FEB09 Page 6 of

7 η [%] V o [%] 0 70 overload short circuit condition switchoff V i nom V i max V i min t [ms] Fig. Overload switchoff (hiccup mode). Frequency of pulses: 6.5 Hz, puls duration: 8.5 ms. Electromagnetic Emission Conducted RFI noise at input according to EN 550 [dbµv] EN 550 A EN 550 B Fig. 3 Efficiency versus input voltage and load. Typical values (48 IMS 69). Radiated RFI noise according to EN 550. [dbµv/m] P o P o nom [%] EN 550 B Fig. 4 Typical disturbance voltage (quasipeak) at the input according to CISPR /EN 550 and CISPR /EN 550, measured at U i nom and I o nom. Output leads 0. m, twisted. External capacitor at the input required (see: Recommendations for compliance with EN 550) (48IMS6559). Mechanical Data Dimensions in mm. Tolerances ±0.3 mm unless otherwise indicated MHz Fig. 5 Frequency [MHz] Typical radio frequency interference voltage at U i nom, I o nom, measured with an antenna (distance m). Output leads 0. m, twisted (48IMS6559) European Projection 33 (.3") x.54 (0.") 3 (.") x.54 (0.") 5.4 (0.6") (0.79") 5.4 (0.6") (0.79") Measuring point of case temperature T C 3 (0.") S (0.") S (0.33") 0.5 (0.0") 8.5 (0.33") 0.5 (0.0") Fig. 6 Standard or alternative pinout Weight: < g Fig. 7 Open frame (Option Z) Weight: < g MCD6 Rev..0, 7FEB09 Page 7 of

8 Immunity to Environmental Conditions Table 5: Environmental testing Test Method Standard Test Conditions Status Ca Damp heat IEC/DIN IEC Temperature: 40 ± C Unit not steady state MILSTD8D section 507. Relative humidity: 93 +/3 % operating Duration: 56 days Ea Shock IEC/EN/DIN EN Acceleration amplitude: 0 g n = 98 m/s Unit (halfsinusoidal) MILSTD8D section 56.3 Bump duration: 6 ms operating Number of bumps: 8 (3 each direction) Eb Bump IEC/EN/DIN EN Acceleration amplitude: 40 g n = 39 m/s Unit (halfsinusoidal) MILSTD8D section 56.3 Bump duration: 6 ms operating Number of bumps: 6000 (00 each direction) Fc Vibration IEC/EN/DIN EN Acceleration amplitude: 0.35 mm ( to 60 Hz) Unit ( sinusoidal) 5 gn = 49 m/s ( Hz) operating Frequency ( Oct/min): to 000 Hz Test duration: 7.5 h (.5 h each axis) Fh Vibration, IEC/EN Acceleration spectral density: 0.05 g n /Hz Unit broadband DIN part 3 Frequency band: Hz operating (digital control) Test duration: 3 h ( h each axis) random MILSTD8D section 54.3 Acceleration magnitude: 4.9 g n rms Kb Salt mist, cyclic IEC/EN/DIN IEC Concentration: 5% (30 C) Unit not (sodium chloride Duration: h per cycle operating NaCl solution) Storage: 40 C, 93% rel. humidity Storage duration: h per cycle Number of cycles: 3 Table 6: Temperature specifications, valid for air pressure of 800 to 0 hpa (800 to 0 mbar) Temperature Standard 9 Characteristics Conditions T A Ambient temperature Operational 40 7 C T C Case temperature T S Storage temperature Non operational 40 0 MILSTD8D section 50. and 50. See Thermal Considerations Table 7: MTBF and device hours MTBF Ground Benign min Ground Fixed max Ground Mobile MTBF acc. to MILHDBK7F T C = 40 C T C = 40 C T C = 70 C T C = 50 C 48IMS6059 '65'000 h 349'000 h 4'000 h 9'000 h Unit MCD6 Rev..0, 7FEB09 Page 8 of

9 Safety and Installation Instructions Installation Instruction Installation of the DCDC converters must strictly follow the national safety regulations in compliance with the enclosure, mounting, creepage, clearance, casualty, markings and segregation requirements of the enduse 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 connections. Do not open the module. Ensure that a unit failure (e.g. by an internal shortcircuit) does not result in a hazardous condition. See also: Safety of operator accessible output circuit. Fig. 8 Pin numbering Input Fuse Bottom view To prevent excessive current flowing through the input supply line in case of a shortcircuit across the converter input an external fuse should be installed in a nonearthed input supply line. We recommend a fast acting fuse FA for 4IMS6 and F0.5A for 48IMS6 models. Safety of operator accessible output circuits If the output circuit of a DCDC converter is operator accessible, it shall be an SELV circuit according to IEC/EN related safety standards The insulation concept table below shows some possible installation configurations, compliance with which causes the output circuit of the DCDC converter to be an SELV circuit according to IEC/EN up to a configured output voltage (sum of nominal voltages if in series or +/ configuration) of 46 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 8: Pin allocation for standard industrial pinout Pin Single output units Dual output units Table 9: Pin allocation for K pinout (option K) Pin Single output units Dual output units n.c. n.c. Standards and approvals Go Go All DCDC converters are UL recognized according to UL 950, UL recognized for Canada to CAN/CSA C. No and LGA approved to IEC/EN standards. The units have been evaluated for: Building in Basic insulation input to output, based on their maximum input voltage The use in a pollution degree environment Connecting the input to a secondary circuit which is subject to a maximum transient rating of 500 V for IMS 6. The DCDC converters are subject to manufacturing surveillance in accordance with the above mentioned UL, CSA, EN and ISO 900 standards. Go NUCLEAR AND MEDICAL APPLICATIONS PowerOne products are not designed, intended for use in, or authorized for use as critical components in life support systems, equipment used in hazardous environments, or nuclear control systems without the express written consent of the respective divisional president of PowerOne, Inc. 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. MCD6 Rev..0, 7FEB09 Page 9 of

10 Cleaning Agents In order to avoid possible damage, any penetration of cleaning fluids has to be prevented, since the power supplies are not hermetically sealed. Protection Degree The protection degree of the DCDC converters is IP 30. Isolation The electric strength test is performed as factory test in accordance with IEC/EN and UL 950 and should not be repeated in the field. PowerOne will not honor any warranty claims resulting from electric strength field tests. Table : Electric strength test voltages Characteristic Input Output Unit IMS6 Electric strength. kv rms test voltage s.5 kv DC Coupling capacitance Insulation resist. >0 MΩ at 500 V DC. Partial discharge Consult factory kv extinction voltage nf Table : Insulation concept leading to an SELV output circuit Conditions Front end Description of Options Table : Survey of options Option Function of option Characteristic K Z Alternative pinout Open frame DCDC converter Contact factory for availability All models are available without case 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 DCDC by the ACDC front end, voltage output circuit output circuit converter output including mains supplied from the circuit battery charger front end Mains Basic <60 V Earthed SELV circuit Operational insulation, pro SELV circuit <50 V AC vided by the DCDC converter ELV circuit Input fuse 3 output suppressor Earthed SELV diodes >60 V Hazardous voltage 4, and earthed circuit output circuit secondary circuit Double or reinforced <60 V SELV circuit Operational insulation, pro SELV circuit vided by the DCDC converter >60 V TNV circuit Basic insulation, based on the maximum input voltage, prolated unearthed hazardous Double or reinforced insu vided by the DCDC converter voltage secondary circuit 5 The front end output voltage should match the specified input voltage range of the DCDC converter. The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC/EN The installer shall provide an approved fuse (type with the lowest rating suitable for the application) in a nonearthed input line directly at the input of the DCDC converter (see fig.: Schematic safety concept). For UL s purpose, the fuse needs to be ULlisted. 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. ~ Mains ~ ACDC front end Earth connection Fuse Battery DCDC converter Earth connection Suppressor diode SELV Fig. 9 Schematic safety concept. Use fuse, suppressor diode and earth connection as per table: Safety concept leading to an SELV output circuit. MCD6 Rev..0, 7FEB09 Page of