board mountable dc-dc converters imr 40 series edition 5/5.2000 1/9 40 watt dc-dc converters imr 40-series input voltage range 2 :1 input filter built-in high efficiency up to 84% short-circuit proof no derating low cost summary the imr 40 series of dc-dc converters have been devel- oped 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 40 converters fea- ture good efficiency and good dynamic response to load changes and at start-up. the imr 40 modules are short-cir- cuit proof. 70 2.76" 100 3.94" 23 0.91" table of contents page summary .......................................................................... 1 type survey and key data .............................................. 2 type key .......................................................................... 2 functional description ...................................................... 3 electrical input data ......................................................... 3 page electrical output data ...................................................... 4 electromagnetic compatibility (emc) .............................. 6 immunity to environmental conditions ............................. 7 mechanical data .............................................................. 7 safety and installation instructions .................................. 8 input voltage range up to 72 v dc 1, 2 or 3 outputs up to 30 v dc 1500 v dc i/o electric strength test voltage
board mountable dc-dc converters imr 40 series edition 5/5.2000 2/9 type key 24 imr 40 - 12 12 -2 nominal input voltage in volt ................................... 12...48 series .......................................................................... imr nominal output power in watt ......................................... 40 nominal output voltage for output 1 in volt .............. 05...24 nominal output voltage for output 2 in volt .............. 12...15 operational ambient temperature range t a ?0...50 c .................................................. -2 type survey and key data table 1: type survey output 1 output 2 output 3 output power input voltage eff. 1 types designation u o nom i o nom u o nom i o nom u o nom i o nom t a = 50 c range h min [v] [a] [v] [a] [v] [a] p o nom [w] u i [v dc] [%] 3.3 10 - - - - 33 9...18 75 12 imr 40-03-2 3.3 10 - - - - 33 18...36 79 24 imr 40-03-2 3.3 10 - - - - 33 36...72 79 48 imr 40-03-2 5 8 - - - - 40 9...18 75 12 imr 40-05-2 5 8 - - - - 40 18...36 79 24 imr 40-05-2 5 8 - - - - 40 36...72 79 48 imr 40-05-2 12 3 - - - - 42 9...18 78 12 imr 40-12-2 12 3 - - - - 42 18...36 81 24 imr 40-12-2 12 3 - - - - 42 36...72 81 48 imr 40-12-2 15 3 - - - - 45 9...18 79 12 imr 40-15-2 15 3 - - - - 45 18...36 81 24 imr 40-15-2 15 3 - - - - 45 36...72 82 48 imr 40-15-2 24 2 - - - - 48 9...18 80 12 imr 40-24-2 24 2 - - - - 48 18...36 83 24 imr 40-24-2 24 2 - - - - 48 36...72 84 48 imr 40-24-2 +5 +7 ? ?.5 - - 37.5 9...18 75 12 imr 40-0505-2 +5 +8 ? ?.5 - - 42.5 18...36 77 24 imr 40-0505-2 +5 +8 ? ?.5 - - 42.5 36...72 79 48 imr 40-0505-2 +12 +3 ?2 ?.5 - - 42 9...18 78 12 imr 40-1212-2 +12 +3 ?2 ?.5 - - 42 18...36 78 24 imr 40-1212-2 +12 +3 ?2 ?.5 - - 42 36...72 81 48 imr 40-1212-2 +15 +2 ?5 ?.5 - - 37.5 9...18 79 12 imr 40-1515-2 +15 +2 ?5 ?.5 - - 37.5 18...36 80 24 imr 40-1515-2 +15 +2 ?5 ?.5 - - 37.5 36...72 82 48 imr 40-1515-2 +5 +6 +12 +0.5 ? ?.5 38.5 18...36 78 24 imr 40-050512-2 +5 +6 +12 +0.5 ? ?.5 38.5 36...72 79 48 imr 40-050512-2 +5 +6 +12 +0.5 ?2 ?.5 42 9...18 76 12 imr 40-051212-2 +5 +6 +12 +0.5 ?2 ?.5 42 18...36 77 24 imr 40-051212-2 +5 +6 +12 +0.5 ?2 ?.5 42 36...72 78 48 imr 40-051212-2 +5 +6 +15 +0.5 ?5 ?.5 45 9...18 77 12 imr 40-051515-2 +5 +6 +15 +0.5 ?5 ?.5 45 18...36 78 24 imr 40-051515-2 +5 +6 +15 +0.5 ?5 ?.5 45 36...72 79 48 imr 40-051515-2 1 efficiency at u i nom and i o nom .
board mountable dc-dc converters imr 40 series edition 5/5.2000 3/9 functional description fig. 2 dual output converter block diagram fig. 1 single output converter block diagram fig. 3 triple output converter block diagram control vi+ vi ref. input filter vo2+ com vo3 vo1+ 03038 control vi+ vi ref. input filter vo com vo+ 03037 79xx control vi+ vi ref. input filter vo+ vo 03036 electrical input data general condition: t a = 25 c unless otherwise specified. table 2: input data input 12 imr 40 24 imr 40 48 imr 40 characteristics conditions min typ max min typ max min typ max unit u i input voltage range t a min ... t a max 9 1818363672v dc u i nom nominal input voltage i o = 0... i o nom 12 24 48 u i abs input voltage 0 21 0 40 0 75 without damage i i 0 no load input current u i nom , i o = 0 35 30 25 ma i i l input current limitation u i nom , full load 1.25 p i nom 1.25 p i nom 1.25 p i nom w u i rev reverse input voltage u i = negative or shunt diode shunt diode shunt diode protection reverse polarity use external fuse use external fuse
board mountable dc-dc converters imr 40 series edition 5/5.2000 4/9 table 3c: output data for dual output types output .. imr 40-0505 .. imr 40-1212 characteristics conditions output 1 output 2 output 1 output 2 min typ max min typ max min typ max min typ max unit u o output voltage u i nom , i o nom 4.9 5 5.1 -4.85 -5 -5.15 11.76 12 12.24 -11.76 -12 -12.24 v u o max maximum output voltage u i min ... u i max 5.1 -6.2 12.24 -15 i o output current 1400 7000 100 500 700 1 600 3000 100 500 700 1 ma u o output voltage noise u i nom 50 100 70 100 150 240 200 240 mv pp (bw = 20 mhz) i o nom d u o u static line regulation u i min ... u i max 1 1 1 1% i o nom d u o i static load regulation u i nom 4.9 5 5.1 -4.75 -5 -5.25 11.76 12 12.24 -11.4 -12 -12.6 v dc (0.2...1) i o nom t r transient recovery time i o nom ? 1 / 2 500 500 500 500 s a uo temperature coefficient u i nom , i o nom 0.02 0.02 0.02 0.02 %/k f s switching frequency 80 80 80 80 khz 1 total power may not exceed maximum power as stated in table: type survey and key data . electrical output data general condition: t a = 25 c unless otherwise specified. table 3a: output data for single output types output .. imr 40-03 .. imr 40-05 .. imr 40-12 characteristics conditions min typ max min typ max min typ max unit u o output voltage u i nom , i o nom 3.24 3.36 4.9 5 5.05 11.88 12 12.12 v i o output current 10 8 3.5 a u o output voltage noise u i nom 150 50 120 mv pp (bw = 20 mhz) i o nom d u o u static line regulation u i min ... u i max 1 1 1% i o nom d u o i static load regulation u i nom 3.23 3.34 4.9 5.1 11.76 12.24 v dc (0.2...1) i o nom t r transient recovery time i o nom ? 1 / 2 500 500 500 s a uo temperature coefficient u i nom , i o nom 0.02 0.02 0.02 %/k f s switching frequency 200 80 80 khz table 3b: output data for single output types output .. imr 40-15 .. imr 40-24 characteristics conditions min typ max min typ max unit u o output voltage u i nom , i o nom 14.85 15 15.15 23.76 24 24.24 v i o output current 3 2 a u o output voltage noise u i nom 150 240 mv pp (bw = 20 mhz) i o nom d u o u static line regulation u i min ... u i max 1 1% i o nom d u o i static load regulation u i nom 14.7 15.3 23.76 24.24 v dc (0.2...1) i o nom t r transient recovery time i o nom ? 1 / 2 500 500 s a uo temperature coefficient u i nom , i o nom 0.02 0.02 %/k f s switching frequency 80 80 khz
board mountable dc-dc converters imr 40 series edition 5/5.2000 5/9 table 3d: output data for dual output types output .. imr 40-1515 output 1 output 2 characteristics conditions min typ max min typ max unit u o output voltage u i nom , i o nom 14.7 15 15.3 -14.7 -15 -15.3 v u o max maximum output voltage u i min ... u i max 15.3 -18 i o output current 400 2000 100 500 700 1 ma u o output voltage noise u i nom 150 300 200 300 mv pp (bw = 20 mhz) i o nom d u o u static line regulation u i min ... u i max 1 1% i o nom d u o i static load regulation u i nom 14.7 15 15.3 -14.25 -15 -15.75 v dc (0.2...1) i o nom t r transient recovery time i o nom ? 1 / 2 500 500 s a uo temperature coefficient u i nom , i o nom 0.02 0.02 %/k f s switching frequency 80 80 khz table 3e: output data for triple output units output .. imr 40-050512 characteristics conditions output 1 output 2 output 3 min typ max min typ max min typ max unit u o output voltage u i nom , i o nom 4.9 5 5.1 11.76 12 12.24 -4.85 -5 -5.15 v u o max maximum output voltage u i min ... u i max 5.1 15 -6.2 i o output current 1200 6000 100 500 700 1 100 500 700 1 ma u o output voltage noise u i nom 50 100 150 240 100 150 mv pp (bw = 20 mhz) i o nom d u o u static line regulation u i min ... u i max 1 1 1% i o nom d u o i static load regulation u i nom 4.9 5 5.1 11.4 12 12.6 -4.75 -5 -5.25 v (0.2...1) i o nom t r transient recovery time i o nom ? 1 / 2 500 500 500 s a uo temperature coefficient u i nom , i o nom 0.02 0.02 0.02 %/k f s switching frequency 80 80 80 khz table 3f: output data for triple output units output .. imr 40-051212 characteristics conditions output 1 output 2 output 3 min typ max min typ max min typ max unit u o output voltage u i nom , i o nom 4.9 5 5.1 11.76 12 12.24 -11.76 -12 -12.24 v u o max maximum output voltage u i min ... u i max 5.1 15 -15 i o output current 1200 6000 100 500 700 1 100 500 700 1 ma u o output voltage noise u i nom 50 100 150 240 150 240 mv pp (bw = 20 mhz) i o nom d u o u static line regulation u i min ... u i max 1 1 1% i o nom d u o i static load regulation u i nom 4.9 5 5.1 11.4 12 12.6 -11.4 -12 -12.6 v (0.2...1) i o nom t r transient recovery time i o nom ? 1 / 2 500 500 500 s a uo temperature coefficient u i nom , i o nom 0.02 0.02 0.02 %/k f s switching frequency 80 80 80 khz 1 total power may not exceed maximum power as stated in table: type survey and key data .
board mountable dc-dc converters imr 40 series edition 5/5.2000 6/9 thermal considerations if a converter is operated, the relationship between the am- bient temperature t a and the case temperature t c depends heavily on the conditions of operation and integration into a system. the thermal conditions are influenced by input volt- age, output current, airflow, temperature of surrounding components and surfaces and the properties of the printed circuit board. the specified maximum ambient temperature t a max is therefore only an indicative value and under practi- cal 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: mechani- cal data ) may under no circumstances exceed the speci- fied maximum value. the installer must ensure that un- der all operating conditions t c remains within the limits stated in the table: temperature specifications. connection in parallel the current limitation characteristics is fold-back. there- fore, parallel connection is not possible. connection in series the outputs of one or more units can be connected in se- ries. 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 si- multaneously. protection scheme the imr series is continuously short circuit protected by means of input power limitation. the unit will not be dam- aged 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 volt- age 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 elec- tronic circuits with no-load conditions, it is recommended to pre-load the outputs with at least 20% of the specified nomi- nal load. electromagnetic compatibility (emc) 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 exter- nal input filter consisting of three additional capacitors and one common mode ring core choke. the filter components should be placed as close as possi- ble to the input of the converter. fig. 4 input filter arrangement for 48 v dc types table 4: input filter components input voltage c 1 c 2 c 3 type l 1 type 12, 24, 48 v dc 4.7 f 2.2 f 2.2 f al-chip 3.9 mh siemens 100 v 100 v 100 v (low ers) 4 a b 82724- z.b. siemens b2402-n1 b 32522, b 32523 1 only valid for input voltages up to 60 v dc. c 2 c 3 l 1 vi+ vi c 1 07069 table 3g: output data for triple output types output .. imr 40-051515 characteristics conditions output 1 output 2 output 3 min typ max min typ max min typ max unit u o output voltage u i nom , i o nom 4.9 5 5.1 14.7 15 15.3 -14.7 -15 -15.3 v u o max maximum output voltage u i min ... u i max 5.1 18 -18 i o output current 1200 6000 100 500 700 1 100 500 700 1 ma u o output voltage noise u i nom 50 100 200 300 200 300 mv pp (bw = 20 mhz) i o nom d u o u static line regulation u i min ... u i max 1 1 1% i o nom d u o i static load regulation u i nom 4.9 5 5.1 14.25 15 15.75 -14.25 -15 -15.75 v (0.2...1) i o nom t r transient recovery time 500 500 500 s a uo temperature coefficient u i nom , i o nom 0.02 0.02 0.02 %/k f s switching frequency 80 80 80 khz 1 total power may not exceed maximum power as stated in table type survey and key data .
board mountable dc-dc converters imr 40 series edition 5/5.2000 7/9 90 80 70 60 50 40 30 20 10 0 0 .01 0 .05 0.1 0.5 1 2 5 10 20 30 [db v] mhz 0 .02 07070 a b 90 80 70 60 50 40 30 20 10 0 0 .01 0 .05 0.1 0.5 1 2 5 10 20 30 [db v] mhz 0 .02 07071 a b fig. 5 conducted rfi at input according to en 55022 e.g. 12 imr 40-24-2. u i = 12 v dc. fig. 6 conducted rfi at input according to en 55022 e.g. 48 imr 40-24-2. u i = 48 v dc. table 6: mtbf mtbf ground benign ground fixed ground mobile mtbf according to mil-hdbk-217f, n2 40 c40 c70 c 1 50 c 1'996'000 h 389'000 h 198'000 176'000 h 1 available as customer specific model. immunity to environmental conditions table 5: temperature specifications, valid for air pressure of 800...1200 hpa (800...1200 mbar) temperature standard -2 characteristics conditions min max unit t a ambient temperature u i nom 10 50 c t c case temperature i o = 0... i o nom 10 80 t s storage temperature non operational 40 85 humidity non condensing 20 95 % fig. 7 case imr 40 weight: 300 g mechanical data dimensions in mm. tolerances 0.3 mm unless otherwise specified. european projection 100 82.5 10 7.5 23 4.5 70 10 10 10 10 1.5 1 2 7 6 5 4 3 09041 sd
board mountable dc-dc converters imr 40 series edition 5/5.2000 8/9 table 8: isolation characteristic input to output unit electric strength 1.1 kv rms test voltage 1 s 1.5 kv dc coupling capacitance 450 pf insulation resistance >1000 m ? at 500 v dc standards and approvals 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 sub- ject to a maximum transient rating of 1500 v. 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. 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 according to: mechanical data . the units should be connected to a secondary circuit. check for hazardous voltages before altering any connec- tions. 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. 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. table 7: pin allocation pin single output dual output triple output 1 vi+ vi+ vi+ 2vi vi vi 3 vo+ vo+ vo1+ 4 vo+ vo+ com 5vo com vo2+ 6vo com com 7 n.c. vo vo3 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. we recommend a fast acting fuse f12.5a for 12 imr 40 types, f6.3a for 24 imr 40 and f3a for 48 imr 40 types.
board mountable dc-dc converters imr 40 series edition 5/5.2000 9/9 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 (sum of nominal voltages if in series or +/ configuration) of 30 v. however, it is the sole responsibility of the installer to as- sure the compliance with the relevant and applicable safety regulations. more information is given in: technical infor- mation: safety . table 9: 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 diodes 4 , and earthed circuit secondary circuit output circuit 2 double or reinforced 60 v selv circuit operational insulation, pro- selv circuit vided by the dc-dc converter >60 v tnv-2 circuit earthed output circuit 2 earthed selv double or reinforced insu- input fuse 3 and output selv circuit lated unearthed hazardous suppressor diodes 4 voltage secondary circuit 5 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 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 . 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 t he 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 maxim um output voltage from the front end. ac-dc front end dc-dc con- verter mains fuse battery earth connection suppressor diode selv earth connection + ~ ~ 10004 fig. 8 schematic safety concept. use fuse, suppressor diode and earth connection as per table safety concept leading to an selv output circuit .
|
