IMX4 Series Data Sheet 4 Watt DC-DC Converters

Transcription

1 0 0.8" " 3.5" Features RoHS lead-free-solder and lead-solder-exempted products are available. Input voltage ranges up to VDC or isolated outputs up to 48 V Extremely wide input voltage ranges Immunity according to IEC/EN , -3, -4, -5, -6 High efficiency (typ. 83%) Flexible load distribution on outputs Outputs no-load, overload, and short-circuit proof High reliability Operating ambient temperature 40 to +85 C Thermal protection Industrial and alternative pinout DIL 4 case with 8.5 mm profile Safety-approved to IEC nd Ed and CSA/UL nd Ed. except 70IMX4 70IMX4 models Description The IMX4 Series of board-mountable, 4-watt DC-DC 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 telecom, where variable input voltages or high transient voltages are prevalent. Covering a total input voltage range from 8.4 VDC up to VDC with three different models, the converters are available with single and dual outputs from 3.3 up to ±4 VDC with flexible load distribution. 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 and high reliability as well as excellent dynamic response to load and line changes. The converters exhibit basic insulation and are designed and built according to the international safety standards IEC/EN nd Ed. 70IMX4 models are CE-marked. A special feature is their small case size, DIL 4 with only 8.5 mm profile. The circuit is comprised of integrated planar magnetics, and all components are automatically assembled and solidly soldered onto a single PCB without any wire connection. 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 85 C in free air without using any potting material. Several options, such as open-frame or an alternative industrial pinout, provide a high level of application-specific engineering and design-in flexibility. Table of Contents Page Page Description... Model Selection... Functional Description... 3 Electrical Input Data... 4 Electrical Output Data... 6 Electromagnetic Compatibility (EMC)... 8 Mechanical Data... 9 Immunity to Environmental Conditions... 0 Safety and Installation Instructions... 0 Description of Options... BCD0006-G Rev AC, 06-Jul-0 Page of

2 Model Selection Table : Model Selection Output Output Output power Input voltage Efficiency Model Options V o nom I o nom V o nom I o nom P o nom range η min η typ [VDC] [ma] [VDC] [ma] [W] [VDC] [%] [%] to IMX Z, G to IMX Z, G to IMX Z, G to IMX K, Z, G to IMX K, Z, G to IMX G to IMX4--8 Z, G to IMX4--8 K, Z, G to IMX4--8 K, Z, G to IMX4--8 G to IMX4-5-8 Z, G to IMX4-5-8 K, Z, G to IMX4-5-8 K, Z, G to IMX4-5-8 G to IMX K, Z, G to IMX K, Z, G to IMX G to IMX4--8 K, Z, G to IMX4--8 K, Z, G to IMX K, Z, G to IMX K, Z, G to IMX Z, G to IMX Z, G Flexible load distribution on double-outputs possible For availibility and lead times ask Power-One! Preferred for new designs. Part Number Description Input voltage range V i 0 IMX K Z G 4.7 to 6.8 VDC to 36 VDC to 75 VDC to VDC Series... IMX4 Output voltage of output... 03, 05,, 5, 4 Output voltage of output... 05,, 5, 4 Operating ambient temperature range 40 to 85 C Options: Alternative pinout... K Open frame... Z RoHS compliant for all six substances... G G is always placed at the end of the part number. G is preferred for new designs. Note: The sequence of options must follow the order above. Example: 40IMX KG: DC-DC converter, input voltage range 6.8 to 75 V, outputs providing ± 5 V, 350 ma, temperature range 40 to 85 C, alternative pinout, RoHS-compliant for all six substances BCD0006-G Rev AC, 06-Jul-0 Page of

3 Functional Description The IMX4 Series converters are feedback-controlled flyback converters using current mode PWM (Pulse Width Modulation). The 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 single- and the sum I o nom + I o nom for dual-output models). The close magnetic coupling provided by the planar construction ensures very good regulation and allows for flexible load distribution on dual-output models. Vi+ n.c. Vi 4 PWM Fig. 3 Block diagram for single-output models with alternative pinout (option K) Vo+ Vo Vi+ Vi 3 3 PWM Fig. Block diagram for single-output models with standard pinout. 4 Vo+ 6 Vo 0 Vi+ Vi 4 PWM Fig. 4 Block diagram for dual-output models with alternative pinout (option K) Vo+ Go Vo Vi+ 4 Vo+ 3 PWM 6 Go Vi 3 Vo Fig. Block diagram for dual-output models with standard pinout. BCD0006-G Rev AC, 06-Jul-0 Page 3 of

4 Electrical Input Data General conditions: T A = 5 C, unless T C is specified. Table : Input Data Input 5IMX4 0IMX4 40IMX4 70IMX4 Unit Characteristics Conditions min typ max min typ max min typ max min typ max V i Input voltage range T C min to T C max VDC I Nominal input voltage o = 0 to I o nom V i nom V i sur Repetitive surge voltage abs. max input (3 s) t start-up Converter start-up time Worst case condition at s V i min and full load t rise Rise time V i nom resistive load 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 Input capacitance µf I inr p Inrush peak current V i = V i nom A f s Switching frequency V i min to V i max, I o = 0 to I o nom khz I i rr Reflected ripple current I o = 0 to I o nom ma pp v i RFI Input RFI level EN 550/ A A A Class conducted Measured with a resistive or max. admissible capacitive load; see fig. 5 Operation at lower input voltage possible: P o approx. 80% of P o nom at V i min = 4.4 V 3 Source impedance according to ETS 3003-, version External capacitors required according to table 3. Start-up Filter to Comply with EN 550/550 V o V o nom Fig. 5 Converter start-up and rise time Inrush Current t startup 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 further limit this current. A 04034a t rise 04008b t Electromagnetic emission requirements according to table Electrical Input Data can be achieved by adding an external capacitor as close as possible to the input terminals (see fig. 7 and table 3). Fig. 7 Input capacitors Table 3: Input electrolytic capacitors + C i Vi+ Vi 04035b 3 Model 0IMX4 40IMX4 70IMX4 C i 00 µf 47 µf 330 µf 50 V 00 V 00 V 0 Fig µs Typ. inrush current at V i nom, P o nom versus time measured according to ETS 3003-, version 4.3 (40IMX4). BCD0006-G Rev AC, 06-Jul-0 Page 4 of

5 Input Transient Voltage Protection In many applications transient voltages on the converter input are always possible. These may be caused for example by short circuits between Vi+ and Vi, where the network inductance may generate high energy pulses. In order to protect the converter, a transient voltage suppressor diode is fitted to the input; see table below. Table 4: Built-in transient voltage suppressor Model Breakdown Peak power Peak pulse voltage at ms current V BR nom P P I PP 5IMX IMX4 40 V 600 W 0.3 A 40IMX4 00 V 600 W 4. A 70IMX4 50 V 600 W.9 A Fuse and Reverse Polarity Protection The suppressor diode on the input also protects against reverse polarity input voltage. An external fast fuse is required to limit this reverse current; see table below. Table 6: External input fuse Model 5IMX4 0IMX4 40IMX4 70IMX4 Fuse type Fast.6 A Fast A Fast 0.5 A Fast 0.35 A If transients generating currents above the peak pulse current I PP are possible, an external limiting network such as the circuit shown in figure 8 is recommended. It provides compliance with transients according to IEC/EN , level. The components are specified in table 5. If 40IMX4 converters should withstand 50 V transients according to 9Pfl, the same external circuitry with similar components as shown in figure 8 can be used. L i + C i D Vi+ Vi 04036b Fig. 8 External circuitry to comply with IEC/EN , level. Table 5: Components for the circuitry fig. 8 Model 0IMX4 40IMX4 70IMX4 L i 330 µh, 0.4 W 330 µh, 0.4 W 330 µh, 0.65 W A 0.6 A 0.3 A C i 68 µf, 50 V 68 µf, 00 V 00 µf, 00 V D ON.5KE 39 A ON.5KE 8 A BCD0006-G Rev AC, 06-Jul-0 Page 5 of

6 Electrical Out put Data General conditions: T A = 5 C, unless T C is specified. Table 7a: Output data for single-output models Output V o nom 3.3 V 5 V V 5 V Unit Characteristics Conditions min typ max min typ max min typ max min typ max V o Output setting voltage V i nom, I o = 0.5 I o nom V I o nom Output current (nom.) V i min to V i max 5IMX ma others I o L Current limit V i nom 5IMX others V o V Line regulation V i min to V i max, I o nom ± ± ± ± % V Load regulation V i nom ±3.5 ±3 ±3 ±3 I o = (0. to ) 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 Admissible capacitive load µf v o d Dynamic Voltage deviat. V i nom ±50 ±50 ±50 ±50 mv t d load regulat. Recovery time I o = ( to 0.5) I o nom ms α Vo Temperature coefficient V i min to V i max ±0.0 ±0.0 ±0.0 ±0.0 %/K V o / T C I o = (0. to ) I o nom Table 7b: Output data for dual-output models Output V o nom ±5 V ± V ±5 V ±4 V Unit Characteristics Conditions min typ max min typ max min typ max min typ max V o Output setting voltage V i nom V V o I o = I o = 0.5 I o nom I o nom Output current (nom.) V i min to V i max x 350 x 70 x 40 x 80 ma I o L Current limit 3 V i nom, T C = 5 C V o V Line regulation V i min to V i max, I o nom ± ± ± ± % V Load regulation 4 V i nom ±3 ±3.5 ±3 ±3 I o = (0. to ) 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 Admissible capacitive load µf v o d Dynamic Voltage deviat. V i nom ±50 ±600 ±750 ±750 mv t d load regulat. Recovery time I o = ( to 0.5) I o nom ms α Vo Temperature coefficient V i min to V i max ±0.0 ±0.0 ±0.0 ±0.0 %/K V o / T C I o = (0. to ) I o nom Each output is 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 604 BCD0006-G Rev AC, 06-Jul-0 Page 6 of

7 Thermal Considerations If a converter, mounted on a PCB, is located in free, quasistationary air (convection cooling) at the maximum ambient temperature T A max (see table Temperature specifications) and is operated at 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 warm-up 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 depend on 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. 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. The installer must ensure that under all operating conditions T C remains within the limits stated in the table Temperature Specifications. Short Circuit Behavior The current limitation shuts down the converter, when a short circuit is applied to the output. It acts self-protecting, and automatically recovers after removal of the overload condition. Connection in Parallel Several converters with equal output voltage can be connected in parallel and will share their output current quite equally. However, this may cause start-up problems and is only recommended in applications, where one converter is able to deliver the full load current, e.g., in true redundant systems. Typical Performance Curves V o [V] A Fig. 0 V o versus I o (typ) of single-output models (0IMX4-05) V o + V o [V] b 05057a I o V o [%] 0504a overload short circuit condition switch-off Fig. 9 Overload switch-off (hiccup mode). 0.3 s t [ms] ma Fig. V o versus I o (typ.) of dual-output models (±5 V), with load connected between Vo+ and Vo. I o Output Overvoltage Protection The outputs are protected against overvoltages by Zener diodes. In the event of an overvoltage, the converter will shutdown 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 models can be connected in series without any precautions, taking into consideration that the output voltage should remain below 60 V for SELV operation. V o [V] I o = 4 ma I o = 40 ma 05058a ma Fig. Cross load regulation of dual-output models. V o versus I o (typ) for various I o (40IMX4-55). I o BCD0006-G Rev AC, 06-Jul-0 Page 7 of

8 V o, V o [V] η [%] b a.4.6 V o V o % Io nom Fig. 3 Flexible load distribution on dual outputs ( V) with load variation from 0 to 50% of P o nom on output. Output loaded with 5% of P o nom. I o Fig. 4 Efficiency versus input voltage and load. Typical values (40IMX4-). V i nom V i max V i min P o P o nom [%] Electromagnetic Compatibility (EMC) Electromagnetic Immunity Table 8: Immunity type tests Phenomenon Standard Class Coupling Value Waveform Source Test In Perlevel mode applied imped. procedure oper. form. Electrostatic IEC/EN contact discharge 4000 V p /50 ns 330 Ω 0 positive and yes B discharge negative 3 air discharge 8000 V p to case discharges Electromagnetic IEC/EN 3 3 antenna 0 V/m AM 80% n.a MHz yes A field khz 3 antenna 0 V/m PM, 50% duty n.a. 900 MHz yes A cycle, 00 Hz repetition frequ. Electrical fast IEC/EN 4 direct +i/ i ±4000 V p bursts of 5/50 ns 50 Ω 60 s positive yes B transients/burst khz repet. rate, 60 s negative 5 ms burst, coupling mode 300 ms period Surges IEC/EN 4 +i/ i 000 V p./50 µs Ω 5 pos. and 5 neg. yes B surges RF conducted IEC/EN 3 +i/ i 3 VAC AM 80% 50 Ω 0.5 to 80 MHz yes A immunity (40 dbµv) khz 50 W i = input, o = output Performance criterion: A = normal operation, no deviation from specifications, B = temporary loss of function or deviation from specs. 3 Corresponds to the railway standard EN 50-3-:000, table 9. 4 External components required. BCD0006-G Rev AC, 06-Jul-0 Page 8 of

9 Electromagnetic Emission Conducted RFI noise at input according to EN 550/550 dbµv 0IMX4-44-8, Peak Vi+, conducted, MHz, Uster, 30-Jun-06 Ci = 00 µf, Vi = 0 V, Ro = 660 ohm, lead length 0 cm. Mechanical Data Dimensions in mm (inchies). Tolerances ±0.3 mm EN 550 A 0IMX4-cond_P 33 (.3") x.54 (0.") European Projection (0.6") (0.79") 0 Fig. 5a MHz Measuring point of case temperature T C Typical disturbance voltage (peak) at the pos. input according to EN 550/550, measured at V i nom and I o nom. Output leads 0. m, twisted. Input capacitors see table (0..") s0904b 8.5 (0.33") (0IMX4-44-8). 0.5 (0.0") Fig. 6 dbµv 40IMX4-05-8Z, Peak Vi+, conducted, MHz, Uster, 30-Jun-06 Ci = 47 µf, Vi = 40 V, Ro = 8. ohm, lead length 0 cm. Standard or alternative pinout (option K) EN 550 A 40IMX4-cond_P Weight: <0 g (.") European Projection x.54 (0.") 0 0 Fig. 5b MHz 5.4 (0.6") (0.79") Typical disturbance voltage (peak) at the pos. input according to EN 550/550, measured at V i nom and I o nom. 3 (0.") S90004a Output leads 0. m, twisted. Input capacitors see table 3. (40IMX4-05-8Z). 0.5 (0.0") 8.5 (0.33") dbµv 70IMX4-5-8, Peak Vi+, conducted, MHz, Uster, -Sep-06 Ci = 330 µf, Vi = 70 V, Ro = 68 ohm, lead length 0 cm. Fig EN 550 A 70IMX4-cond_P Open frame (option Z) Weight: <0 g MHz Fig. 5c Typical disturbance voltage (peak) at the pos. input according to EN 550/550, measured at V i nom and I o nom. Output leads 0. m, twisted. Input capacitors see table 3. (70IMX4-5-8). BCD0006-G Rev AC, 06-Jul-0 Page 9 of

10 Immunity to Environmental Conditions Table 9: Mechanical and climatic stress Test Method Standard Test conditions Status Ca Damp heat IEC/EN Temperature: 40 ± C Converter steady state MIL-STD-80D section 507. Relative humidity: 93 +/-3 % not Duration: 56 days operating Ea Shock IEC/EN Acceleration amplitude: 00 g n = 98 m/s Converter (half-sinusoidal) MIL-STD-80D section 56.3 Bump duration: 6 ms operating Number of bumps: 8 (3 each direction) Eb Bump IEC/EN Acceleration amplitude: 40 g n = 39 m/s Converter (half-sinusoidal) MIL-STD-80D section 56.3 Bump duration: 6 ms operating Number of bumps: 6000 (000 each direction) Fc Vibration IEC/EN Acceleration amplitude: 0.35 mm (0 to 60 Hz) Converter (sinusoidal) 5 g n = 49 m/s (60 to 000 Hz) operating Frequency ( Oct/min): 0 to 000 Hz Test duration: 7.5 h (.5 h each axis) Fh Vibration, IEC/EN Acceleration spectral density: 0.05 g n /Hz Converter broad-band Frequency band: 0 to 500 Hz operating random Acceleration magnitude: 4.9 g n rms (digital control) Test duration: 3 h ( h each axis) Kb Salt mist, cyclic IEC/EN Concentration: 5% (30 C) Converter (sodium chloride Duration: h per cycle not NaCl solution) Storage: 40 C, 93% rel. humidity operating Cycles and storage duration: 3 days, h per cycle Covers also EN 5055/EN 6373 category, class B, body mounted (= chassis of coach) Temperatures Table 0: Temperature specifications, valid for air pressure of 800 to 00 hpa (800 to 00 mbar) Temperature Standard (-8) Unit Characteristics Conditions min max T A Ambient temperature Operational C T C Case temperature T S Storage temperature Non operational See Thermal Considerations Failure Rates Table : MTBF MTBF Ground benign Ground fixed Ground mobile Unit T C = 40 C T C = 40 C T C = 70 C T C = 50 C 40IMX (MIL-HDBK-7F) h 40IMX4--8 (Bellcore) BCD0006-G Rev AC, 06-Jul-0 Page 0 of

11 Safety and Installation Instructions Installation Instruction 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. Connection to the system shall be made via a printed circuit board; see Mechanical Data. The converters should be connected to a secondary circuit. Do not open the converter. Ensure that a converter failure does not result in a hazardous condition. To prevent excessive current flowing through the input lines in case of a short-circuit, an external fuse specified in table 6 should be installed in the non-earthed input supply line. Pin Allocation Fig. 8 Foot print 003a 3 4 Bottom view Table : Pin allocation for standard and option Z Pin Single-output models Dual-output models Vi Vi 3 Vi Vi 0 n.c Vo 4 Vo+ Vo+ 6 Vo Go Vi+ Vi+ 3 Vi+ Vi+ Table 3: Pin allocation for option K Pin Single-output models Dual-output models Vi+ Vi+ n.c Go -- Go Vo -- 3 Vo+ Vo 5 -- Vo+ 4 Vi Vi Standards and Approvals The converters are approved according to UL/CSA 60950,IEC :00 and IEC/EN nd Edition. The converters have been evaluated for: Building-in Basic insulation input to output, based on their maximum input voltage Pollution degree environment Connecting the input to a secondary circuit, which is subject to a maximum transient rating of 500 V for 0IMX4 and 40IMX4, and 000 V for 70IMX4 models. The converters are subject to manufacturing surveillance in accordance with the above mentioned standards and with ISO 900:000. Railway Applications To comply with railway standards, all components are coated with a protective lacquer (except option Z). Protection Degree The protection degree of the converters is IP 30, except openframe models (option Z). Cleaning Liquids In order to avoid possible damage, any penetration of cleaning fluids should be prevented, since the power supplies are not hermetical 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 agents are not permitted except washing at room temperature with isopropyl alcohol. If necessary, the mother board must be cleaned, before fitting the open-frame converter. Note: Cleaning liquids may damage the adhesive joints of the ferrite cores. Isolation The electric strength test is performed in the factory as routine test in accordance with EN 506 and IEC/EN 60950, and should not be repeated in the field. Power-One will not honor any warranty claims resulting from electric-strength field tests. Table 4: Electric strength test voltages Characteristic Input to output Unit 5IMX4 0/40IMX4 70IMX4 Factory test > s kvac Equivalent DC test voltage kvdc Coupling capacitance. typ.. typ.. nf Insulation resist. (500 VDC) -- >00 >00 MΩ BCD0006-G Rev AC, 06-Jul-0 Page of

12 Description of Options Option K: Alternative Pinout This pinout is compatible with other converters on the market. Option Z: Open Frame For applications, where the protection of the case is not necessary or in the case that the motherboard should be cleaned and lacquered with the converter fitted. Option G: RoHS-6 Converters with a type designation ending with G are RoHScompatible for all six substances. NUCLEAR AND MEDICAL APPLICATIONS - Power-One 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 Power-One, 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. BCD0006-G Rev AC, 06-Jul-0 Page of