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Benign Environment
DC-DC Converters <40 Watt
IMR 3 Series
3 Watt DC-DC Converters
Input to output electric strength test 500 V DC Single or dual output * Input voltage range up to 3:1 * High efficiency up to 73% * Short-circuit proof * No derating * DIL 24 plastic package * Low cost
IMR 3 Series
33 1.3"
12 0.47" 20 0.79"
Summary
The IMR 3 serie of DC-DC converters have been developed for powering commercial type of electronic circuits, e.g. telephone systems components, industrial controllers and small appliances. They are suitable for applications with standard battery voltages. The IMR 3 converters feature good efficiency and good dynamic response to load changes and at start-up. The IMR 3 modules are short-circuit and no-load proof.
Type Survey and Key Data
Table 1: Type survey
Output Uo nom Io nom [V] [mA] 3.3 5 12 15 5 12 15
1 2
Output power Efficiency 1 hmin Po max [W] [%] 2.3 2.5 3 3 2.5 3 3 63 63 65 65 65 67 67
Ui min...Ui max 9...18 V DC 2
12 IMR 3-03-2 12 IMR 3-05-2 12 IMR 3-12-2 12 IMR 3-15-2 12 IMR 3-0505-2 12 IMR 3-1212-2 12 IMR 3-1515-2
Input voltage range Ui min...Ui max Ui min...Ui max 18...36 V DC 20...60 V DC 24 IMR 3-03-2 24 IMR 3-05-2 24 IMR 3-12-2 24 IMR 3-15-2 24 IMR 3-0505-2 24 IMR 3-1212-2 24 IMR 3-1515-2 40 IMR 3-03-2 40 IMR 3-05-2 40 IMR 3-12-2 40 IMR 3-15-2 40 IMR 3-0505-2 40 IMR 3-1212-2 40 IMR 3-1515-2
Option
Ui min...Ui max 36...72 V DC
48 IMR 3-03-2 48 IMR 3-05-2 48 IMR 3-12-2 48 IMR 3-15-2 48 IMR 3-0505-2 48 IMR 3-1212-2 48 IMR 3-1515-2 -7
700 500 250 200 250 125 100
Efficiency at Ui nom and Io nom 12 IMR 3 types: Output current Io nom see: Output Data
Table of Contents
Page
Page Electrical Output Data ...................................................... 3 Electromagnetic Compatibility (EMC) .............................. 4 Immunity to Environmental Conditions ............................. 4 Mechanical Data .............................................................. 5 Safety and Installation Instructions .................................. 5
Summary .......................................................................... 1 Type Survey and Key Data .............................................. 1 Type Key .......................................................................... 2 Functional Description ...................................................... 2 Electrical Input Data ......................................................... 2
MELCHER
The Power Partners.
Edition 4/4.99 1
IMR 3 Series
Type Key
Type Key
DC-DC Converters <40 Watt
Benign Environment
24 IMR 3 - 12 12 -2 Nominal input voltage in volt ................................... 12...48 Series .......................................................................... IMR Nominal output power in watt ........................................... 3 Nominal output voltage for output 1 in volt .............. 05...15 Nominal output voltage for output 2 in volt .............. 05...15 Operational ambient temperature range TA -10...50C .................................................. -2 -25...71C (option) ..................................... -7
Functional Description
03060
03059
22
Vi+
Vo+
14
22
Vi+
Vo+
14
23
23
Ref.
Ci Control Ref.
2 16
Co
9 16
Co
Ci
Control
COM
Co
11
2
Vi-
3
Vo-
Vi-
3
Vo-
Fig. 1 Single output converter block diagram
Attention: Ci = 4.7 F/100 V must be added in any application. Co = 10 F to minimize ripple and noise to <100 mVPP (Capacitors should be of low ESR types).
Fig. 2 Dual output converter block diagram
Electrical Input Data
General condition: TA = 25C unless otherwise specified
Table 2a: Input data
Input Characteristics Conditions min 9 12 0 22 18 1.25 P i nom shunt diode use external fuse 0 12 1.25 P i nom shunt diode use external fuse 12 IMR 3 typ max 18 min 18 24 40 mA W 24 IMR 3 typ max 36 Unit V DC
Ui U i nom Ui Ii 0 Ii L U i rev
Input voltage range Nominal input voltage Input voltage without damage No load input current Input current limitation response Reverse input voltage protection
TA min...TA max Io = 0...Io nom
Ui nom, Io = 0 Ui nom, full load Ui = negative or reverse polarity
MELCHER
The Power Partners.
Edition 4/4.99 2
Benign Environment
Table 2b: Input data
Input Characteristics
DC-DC Converters <40 Watt
40 IMR 3 Conditions min 20 36 0 75 8 1.25 P i nom shunt diode use external fuse 0 8 1.25 P i nom shunt diode use external fuse typ max 60 min 36 48 75 48 IMR 3 typ
IMR 3 Series
max 72
Unit V DC
Ui U i nom Ui Ii 0 Ii L U i rev
Input voltage range Nominal input voltage Input voltage without damage No load input current Input current limitation response Reverse input voltage protection
TA min...TA max Io = 0...Io nom
Ui nom, Io = 0 Ui nom, full load Ui = negative or reverse polarity
mA W
Electrical Output Data
General condition: TA = 25C unless otherwise specified
Table 3a: Output data for single output types
Output Characteristics Conditions .. IMR 3-03 min typ max 3.24 560 700 300 100 1 2 0.02 50 50 2 0.02 50 3.36 .. IMR 3-05 min typ max 4.90 400 500 300 100 1 2 0.02 50 5.10 .. IMR 3-12 min typ max 11.76 200 250 300 100 1 2 0.02 %/K kHz 12.24 .. IMR 3-15 min typ max 14.70 150 200 300 100 1 15.30 Unit V mA
Uo Io nom
Output voltage Nominal output current: - 12 IMR 3 types - other types Output voltage noise: - without Co - with Co Static line regulation Static load regulation Temperature coefficient Switching frequency
Ui nom, Io nom Ui min...Ui max (0.2...1) Io nom Ui nom Io nom (BW = 20 MHz) U i min...U i max Io nom U i nom (0.2...1) Io nom U i nom Io nom
uo
mVpp %
DUo U DUo I aUo
fs
Table 3b: Output data for dual output types
Output Characteristics Conditions .. IMR 3-0505 min 4.90 200 250 300 100 1 5 0.02 50 50 5 0.02 50 typ max 5.10 .. IMR 3-1212 min 11.76 100 125 300 100 1 5 0.02 %/K kHz typ max 12.24 .. IMR 3-1515 min 14.70 80 100 300 100 1 typ max 15.30 Unit V mA
Uo Io nom
Output voltage Nominal output current: - 12 IMR 3 types - other types Output voltage noise: - without Co - with Co Static line regulation Static load regulation Temperature coefficient Switching frequency
Ui nom, Io nom Ui min...Ui max (0.2...1) Io nom Ui nom Io nom (BW = 20 MHz) U i min...U i max, Io nom U i nom (0.2...1) Io nom U i nom Io nom
uo
mVpp %
DUo U DUo I aUo
fs
MELCHER
The Power Partners.
Edition 4/4.99 3
IMR 3 Series
Thermal Considerations
DC-DC Converters <40 Watt
Connection in Parallel
Benign Environment
If a converter is operated, the relationship between the ambient temperature TA and the case temperature 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. The specified maximum ambient temperature TA max is therefore only an indicative value and under practical operating conditions, 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: Mechanical Data) may 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. Connection in Series The outputs of one or more units can be connected in series. No suppressor diodes are required. Melcher however recommends to protect each individual output with a Zener diode or preferably a suppressor diode, to avoid reverse polarity that may occur if the output voltages do not rise simultaneously.
The outputs of several units can be connected in parallel. However, the use of a single unit with a higher power rating is a better choice because of uneven power distribution among the outputs connected in parallel. It is recommended to select converters to be connected in parallel with very small output voltage differences at full load (i.e. <0.5%). A decoupling diode is not required but recommended. Protection Scheme The IMR series is continuously short circuit protected by means of input power limitation. The unit will not be damaged if started up into a short circuit. After removal of the short circuit, it will resume normal operation. The IMR series is also no-load proof, meaning that the regulation is still effective with no load and the output voltage does not rise. However, due to component tolerances, oscillation could occur and ripple and noise can be outside of specified values. If the converter is used in senitive electronic circuits with no-load conditions, it is recommended to pre-load the outputs with at least 20% of the specified nominal load.
Electromagnetic Compatibility (EMC)
07025
Filter recommendations for compliance with CISPR 22/EN 55022, class B Electromagnetic emission requirements according to EN 55022, class B can be easely achieved by adding an external input filter consisting of three additional capacitors and one commom mode ring core choke. The filter components should be placed as close as possible to the input of the converter.
C1 C2 L1
Vi+ Ci Vi-
Fig. 3 Input filter arrangement
Table 4: Input filter components
Input voltage 12, 24, 40, 48 V DC
C1
2.2 100 V F 1
C2
2.2 100 V F 1
Type Siemens B 32522 C1225-K
L1
2.2 mH
Type Siemens B 82722 A2202-N1
Ci
4.7 F 100 V
Type Al-Chip (low ESR)
1
Only valid for input voltages up to 60 V DC.
Immunity to Environmental Conditions
Table 5: Temperature specifications, valid for air pressure of 800...1200 hPa (800...1200 mbar)
Temperature Characteristics Conditions Standard -2 min -10 -10 -25 max 50 80 85 min -25 -25 -40 Option -7 max 71 85 100 Unit C
TA TC TS
Ambient temperature Case temperature Storage temperature
Ui nom Io = Io nom
Non operational
Table 6: MTBF
Values at specified case temperature MTBF according to MIL-HDBK-217F, N2 Ground Benign 40C 3'984'000 h Ground Fixed 40C 896'100 h Ground Mobile 50C 343'800 h
MELCHER
The Power Partners.
Edition 4/4.99 4
Benign Environment
Mechanical Data
DC-DC Converters <40 Watt
IMR 3 Series
Dimensions in mm. Tolerances 0.3 mm unless otherwise specified.
min. 33.8 31.8 2.54
09038
European Projection
1 mounting space required
12
Measuring point of case temperature TC
Fig. 4 Case: DIL 24 Weight: 16 g
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 according to: Mechanical Data. The units should be connected to a secondary circuit. Check for hazardous voltages before altering any connections. 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. 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 F2A for 12 IMR 3 types, F1A for 24 IMR 3 types, F0.5A for 40 IMR 3 and 48 IMR 3 types. Cleaning Agents In order to avoid possible damage, any penetration of cleaning fluids is to be prevented, since the power supplies are not hermetically sealed. Protection Degree The protection degree of the DC-DC converters is IP 40.
min. 3
o 0.5
Table 7: Pin allocation
Pin 2 3 9 10 11 14 15 16 22 23 Single output unit Vi- Vi- n.c. n.c. n.c. Vo+ n.c. Vo- Vi+ Vi+ Dual output unit Vi- Vi- COM n.c. Vo- Vo+ n.c. COM Vi+ Vi+
Table 8: Electric strength test voltages, clearance and creepage distances
Characteristic Electric strength test voltage 1 s Coupling capacitance Isulation resistance at 500 V DC Input to output 350 500 45 >1000 Unit Vrms V DC pF M
MELCHER
The Power Partners.
Edition 4/4.99 5
min. 22.3
15.24
20.3
IMR 3 Series
DC-DC Converters <40 Watt
Standards and approvals
Benign Environment
Safety of operator accessible output circuit 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 (sum of nominal voltages if in series or +/- configuration) of 30 V. However, it is the sole responsibility of the installer to assure the compliance with the relevant and applicable safety regulations. More information is given in: Technical Information: Safety.
The units have been evaluated for: * Building in * Operational insulation input to output * The use in a pollution degree 2 environment * Connecting the input to a secondary circuit which is subject to a maximum transient rating of 500 V. 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 9: 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 Maximum DC output voltage from the front end 1 60 V Minimum required safety status of the front end output circuit DC-DC converter Measures to achieve the specified safety status of the output circuit Result Safety status of the DC-DC converter output circuit SELV circuit Earthed SELV circuit
Mains Basic 250 V AC
Earthed SELV circuit 2 ELV circuit
Operational insulation, provided by the DC-DC converter Input fuse 3 output suppressor diodes 4, and earthed output circuit 2 Operational insulation, provided by the DC-DC converter Earthed output circuit 2
>60 V Double or reinforced 60 V >60 V
Hazardous voltage secondary circuit SELV circuit TNV-2 circuit
SELV circuit Earthed SELV SELV circuit
Double or reinforced insu- Input fuse 3 and output lated unearthed hazardous suppressor diodes 4 voltage secondary circuit 5
1 2 3
4
5
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 conductor 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 double or reinforced insulation according to the relevant safety standard, based on the maximum output voltage from the front end.
~
Mains
Fuse AC-DC front end Battery DC-DC converter
10004
Suppressor diode SELV
+
~
-
Earth connection
Earth connection
Fig. 5 Schematic safety concept. Use fuse, suppressor diode and earth connection as per table: Safety concept leading to an SELV output circuit.
MELCHER
The Power Partners.
Edition 4/4.99 6

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