Datasheet 48IMS30-0503-9G, 48IMS30-0302-9G Datasheet (Power-one)

IMS30 SERIES JAN, 2001

Powering Communciations and Technology

Input to output electric strength test 1500
Input voltage ranges 32...75VDC for -0302

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

• 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

•

o

V DC

C

48Vinput

Dual outputs 5V & 3.3V ; 3.3V & 1.8V

IMS30 Series

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

Summary......................................................................... 1

Type Survey and Key Data ............................................. 2

Type Key ......................................................................... 2

Functional Description..................................................... 2

Electrical Input Data ........................................................ 3

Electrical Ouput Data ...................................................... 4

Page

The converters provide supplementary insulation with
SEL V 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 Output power Input Voltage Range and Efficiency Option

U

o1 nom

[V DC] [A] [W] 32...75 V DC [%]

5.1 4.5 30 48 IMS 30-0503-9G 87 i

3.3 4.0 48 IMS 30-0302-9G 83 i

I

o1 nom

Output 2

U

o2 nom

[V DC]

3.3

1.8 5.0

I

o1 nom

[A]

6.0

P

o nom

22

U

...

i min

U

i max



Type Key

48 IMS 30 - 0503 -9 G i

Input voltage range

U

i

typ

32...75 V DC

.................................... 48

Series ......................................................................IMS 30

Output voltage type output .................... ( 5.1 and 3.3Vout)

Operating ambient temperature range

T

A

–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 deliver-

ing 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

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
(see:
converter on/off.

Overtemperature protection will shut down the unit in ex­cessive overload conditions with automatic restart.

U

using an external resistor.

o nom

Type Survey)

P

o nom

. The shut down input allows remote

Vi+

1

SD

PUL

Vi–

4

i

2

3

W

PWM

4n7F



1500 V

Fig. 1
Block diagram (-0503, -0302 Outputs )

13

Uo1+

11

Uo2+

15

Com

17

Trim

2/11

Electrical Input Data

General conditions:

– T

= 25C, unless

A

– Shut down pin left open circuit (not connected).
– Trim input not connected.

Table 2: Input Data

Input 48 IMS

Characteristics Conditions min typ max Unit

U
U
U

t

start up

t

rise

I

i NL

C
U

I

SD

I

inr p

f

s

I

i rr

u

1

U
U

2

Measured with a resistive and the max. admissible capacitive load.

3

Measured with a lead length of 0.1 m, leads twisted.

4

Source impedance according to prETS 300132-2, version 4.3.

Input voltage range

i

Nominal input voltage

i nom

Repetitive input surge max 3 s 100

i sur

voltage
Converter Switch on

start-up time
Rise time 5 ms

No load input current

Input capacitance for surge calculation 1.5  uF

i

Shut down voltage Unit disabled –10 0.7 V DC

SD

Input current of SD input 1 2 mA
Inrush peak current
Switching frequency
Reflected

ripple current
Input RFI levelconducted EN 55022

i RFI

will not be as stated if

i min

will be proportionally increased.

i min

T

is specified.

C

1

T

C min

I

= 0...

o

U

i min

...

T

C max

I

o nom

,

I

2

=

I

o

o nom

32

48

0.25 0.5 s

SD high 0.1

I

= 0,

U

...

i min

U

i max

o

30 40 mA

SD high

Unit operating 1.5 5

4

U

o

U

=

U

i

i nom

U

,

I

i min

o nom

I

= 0...

I

o

o nom

is increased above

approx. 250 kHz

3

U

by use of the Trim input. If the output voltage is set to a higher value,

o nom

B

1.5 A

75 V DC

60 mA

pp

Inrush Current

The inrush current has been kept as low as possible by
choosing a very small input capacitance.

A series resistor may be installed in the input line to further
limit this current.

I

[A]

1.4

04058

1.2

1

0.8

0.6

0.4

0.2

t

0

–101 23456

–2

[ms]

7

8

Fig. 2
Typical inrush current at U

i nom

, P

o nom

versus time
(48 IMS30-0503-9G). Source impedance according to
prETS 300132-2, version 4.3 at U

i nom

.

Input Undervoltage Lock-out

The IMS30 converters are fitted with a defined input under­voltage lock-out:

48 IMS 30 turn off

turn on  32 V

31.5 V



(approx. values)

04008

t

U

U

o nom

o

t

start up

t

rise

Fig. 3
Converter start-up and rise time (applying U

i nom

).

3/11

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 Breakdown Peak power Peak pulse

48 IMS 30 100

voltage at 1 ms current

V

BR nom

[V]

P

P

[W]

I

PP

600 4.1

[A]

Table 4: Components for external circuitry to comply with
IEC/EN 61000-4-5, level 2 or ETR 283 (19Pfl1)
(48 IMS types).

Circuit Ref.

L 150 uH
C

48 IMS 30

 

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 re-

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

capacitor are required.

L

V+

C

+

) an external inductor and

04009

Vi+

1

Module

verse direction. An external fuse is required to limit this cur­rent:

48 IMS 30: 3.15 A (F3.15A)

Fig. 4
Example for external circuitry to comply with

V–

Vi–

2

IEC/EN 61000-4-5 or ETR 283 (19 Pfl1) (48 IMS 30 types).

Electrical Ouput Data

Table 5a: Output data.

Model 48IMS30-0503-9G 3.3 V5.1 V

Characteristics Conditions min typ maxmin typ max Unit

U

Output voltage

o1

I

Output current

o nom

I

oL

U

o

Current limit
Line regulation

1

Load regulation

u

Output voltage noise

o1

C

Admissible capacitive load 20002000 uF

o ext

u

Dynamic Voltage deviation

o d

load

t

d

regulation



Temperature coefficient

Uo

U

/

T

o

C TC min

2

Recovery time

Table 5b: Output data.

Model 48IMS30-0302-9G 3.3 V 1.8 V

Characteristics Conditions min typ max min typ max Unit

U

Output voltage

o1

I

Output current

o nom

I

Current limit

oL

Line regulation

U

o

Load regulation

u

Output voltage noise

o1

C

Admissible capacitive load 2000 2000 uF

o ext

u

Dynamic Voltage deviation

o d

load

t

d

regulation



Temperature coefficient

Uo

U

/

1

The current limit is primary side controlled.

2

BW = 20 MHz

o

1

Recovery time

T

C

2

U

,

I

= 0.5

i nom

U

...

i min

U

i nom

U

...

i min

I

= (0...1)

o

U

i nom

I

1/2

o nom

U

,

i nom

...

U

,

i nom

U

...

i min

U

i nom 6

U

...

i min

I

= (0...1)

o

I

o

o nom

U

i max

U

i max

I

o nom

  +/-0.5

0

+/-0.5

See Fig. 6

  250250 mV

I

o nom

I

o nom

T

C max

I

= 0.5

I

o

o nom

U

i max

U

i max

I

o nom

11ms

  0.020.02 %/K

3.25 3.35 1.831.77 V
0

4

 +/-0.5 

See Fig. 6

3.25 3.355.00 5.20 V

3.5

9

0

6

0 5

50 50 mV

U

i nom

I

1/2

o nom

U

i nom

T

C min

I

o nom

,

I

o nom

...

T

C max

  250  150 mV

11ms

  0.02  0.02 %/K

6

+/-1

5075 mV

7

+/-0.5

+/-3

A

%

pp

A

%

pp

4/11

Fig 6: Cross regulation and load regulation for double output units.

Unspecified Output Current (A)

100 %

Specified Output Current (A)

50 %

Regulation window for unspecified output (Tab 5a,5b)

+/-4%
+/-3%

+/-1%

30W Output power limit line

1.0 2.0 3.0 4.0 5.0 6.0
Specified Output Current (A)

5/11

Extendable output power characterisation of 48IMS30-0302-9G

Auxiliary Functions

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.

Converter operating: 2.0...5.0 V
Converter shut down: –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

06134

06133

Vo+

R

ext

Vo+

Vo–

connected be-

which can be trimmed up by means of an external resistor
connected between the SD/PUL pin and Vi– pin.

Vi+

SD/PUL

R

ext

Vi–

Fig. 8
Shut down (SD) and undervoltage lockout (PUL) function.

Table 6: Typical values for undervoltage lockout (PUL)
settings.

48 IMS 30

R

[k ]

ext

 31
50 34
29 36
20 38
15 40

U

[V]

i min

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

U

. Adjustment of the output voltage is pos-

o nom

sible by means of an external resistor
tween the Trim pin and the either Vo+ or Vo–.

Vi+

Fig. 9
Output voltage Trim.

Table 7: Uo versus U
typical values (U

U

[V]

U

o nom

3.3 

[V] [k]

o

2.97 8 3.63

for Uo = 90...110% U

ext

, I

i nom

= 0.5 I

o1/2

R

ext 1

o1/2 nom

U

o nom

)

R

ext 2

[V] [k]

o

;

5

Thermal Considerations

If a converter, mounted on a PCB, is located in free, quasi­stationary air (convection cooling) at the indicated maxi­mum ambient temperature

specifications

) and is operated at its nominal input voltage

and output power, the case temperature

Measuring point of case temperature T
Data

) will approach the indicated value

warm-up phase. However, the relationship between

T

depends heavily on the conditions of operation and inte-

C

T

A max

(see table:

T

measured at the

C

(see:

C

T

C max

Temperature

Mechanical

after the

T

and

A

gration 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

is therefore only an indica-

A max

tive value and under practical operating conditions, the ad­missible ambient temperature

T

may be higher or lower

A

than this value.

Caution: The case temperature

Measuring point of case temperature T
cal Data

) must under no circumstances exceed the

T

measured at the

C

(see:

Mechani-

C

specified maximum value. The installer must ensure that
under all operating conditions
its stated in the table:

Temperature specifications.

T

remains within the lim-

C

Short Circuit Behaviour

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.

32

30

28

26

under forced air condition

Trim

Vi–

Vo–

R

ext 1

R

ext 2

24

Output Power (W)

22

20

0 100 200 300 400 500 600 700 800

Air-Flow (LFM)

6/11

Electromagnetic Compatibility (EMC)

A suppressor diode together with an input filter form an ef­fective protection against high input transient voltages

Electromagnetic Immunity

Table 8: Immunity type tests

which typically occur in many installations, but especially in
battery driven mobile applications.

Phenomenon Standard 1Class Coupling Value Waveform Source Test In Per-

Level mode

Electrostatic IEC/EN 2 contact discharge 4000 V
discharge 61000-4-2
to case discharges

3 air discharge 8000 V

2

applied Imped. procedure oper. form.

1/50 ns 330  10 positive and yes B

p

p

10 negative

Electromagnetic IEC/EN 2 antenna 3 V/m AM 80% 26…1000 MHz yes A
field 61000-4-3 1 kHz

ENV 50204 PM, 50% duty 900 MHz

cycle, 200 Hz

resp. frequ.

Electrical fast IEC/EN 3 direct +i/–i 2000 Vpbursts of 5/50 ns 50  1 min positive yes A
transient/burst 61000-4-4 5 kHz rep. rate 1 min negative

transients with transients per

15 ms burst coupling mode
duration and a
300 ms period

Surge IEC/EN 2 +i/–i 1000 V

61000-4-5

5

1.2/50  s2  5 pos. and 5 neg. yes B

p

impulses per

coupling mode

Conducted IEC/EN 2 +i/–i3 V

rms

AM modulated

50  0.15...80 MHz yes A

disturbancies 61000-4-6 (130 dB V) 80%, 1 kHz 150 
Transient ETR 283 +i/–i 150 V

(19 Pfl 1)

1

Related and previous standards are referenced in:

2

i = input, o = output.

3

A = normal operation, no deviation from specification, B = temporary deviation from specs. possibe.

4

For 48 IMS 30 types (additional external components required).

5

External components required.

4

Technical Information: Standards

0.1/0.3 ms limited to 3 positive yes B

p

<100 A

.

3

Electromagnetic Emission

[dB V]

90
80

70
60
50
40
30
20

10

0

.01

.02

.05

0.1

0.5

EN 55022 A

EN 55022 B

1

2

07020

10

20

MHz

30

5

Fig. 10
Typical disturbance voltage (quasi-peak) at the input ac­cording to CISPR 11/EN 55011 and CISPR 22/EN 55022,
measured at U

i nom

and I

. Output leads 10 cm, twisted.

o nom

(48 IMS30-0503-9G )

7/11

Immunity to Environmental Conditions

T able 9: Mechanical stress

Test method Standard Test conditions Status

Ca Damp heat IEC/DIN IEC 60068-2-3 Temperature: 40

steady state MIL-STD-810D section 507.2 Relative humidity: 93

Duration: 56 days

Ea Shock IEC/EN/DIN EN 60068-2-27 Acceleration amplitude: 50 gn = 490 m/s

(half-sinusoidal) MIL-STD-810D section 516.3 Bump duration: 11 ms operating

Number of bumps: 18 (3 each direction)

Eb Bump IEC/EN/DIN EN 60068-2-29 Acceleration amplitude: 25 gn = 245 m/s

(half-sinusoidal) MIL-STD-810D section 516.3 Bump duration: 11 ms operating

Number of bumps: 6000 (1000 each direction)

Fc Vibration IEC/EN/DIN EN 60068-2-6 Acceleration amplitude: 0.35 mm (10...60 Hz) Unit

(sinusoidal) MIL-STD-810D section 514.3 5 gn = 49 m/s2 (60...2000 Hz) operating

Frequency (1 Oct/min): 10...2000 Hz
Test duration: 7.5 h (2.5 h each axis)

Kb Salt mist, cyclic IEC/EN/DIN IEC 60068-2-52 Concentration: 5% (30C) Unit not

(sodium chloride Duration: 2 h per cycle operating
NaCl solution) Storage: 40 C, 93% rel. humidity

Storage duration: 22 h per cycle
Number of cycles: 3

Table 10: Temperature specifications, valid for air pressure of 800...1200 hPa (800...1200 mbar)

Temperature Standard -9G

Characteristics Conditions min max Unit

T

Ambient temperature

A

T

Case temperature –40 105

C

T

Storage temperature

S

1

MIL-STD-810D section 501.2 and 502.2

1

Operational –40 71 °C

1

Non operational –55 105

 2

C Unit not

+2/-3

% operating

2

2

Unit

Unit

Table 11: MTBF

Values at specified Type Ground benign Ground fixed Ground mobile Device hours Unit
case temperature 25C25C55C55C

MTBF 48 IMS 30-0503-9G 927'229 331'251 179'831 272'260 n.a. h

1

Statistical values based on an average of 4300 working hours per year and in general field use, over 2 years.

8/11

Mechanical Data

Dimensions in mm. Tolerances ±0.3 mm unless otherwise indicated.

European
Projection

-0503, -0302 Outputs

Uo 2

Uo 1

Tc Measurement point

Com

9/11

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 with hole diameters of 1.4 mm  0.1 mm for the pins.

The units should be connected to a secondary circuit.
Check for hazardous voltages before altering any connec-

tions.
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.

Protection Degree

The protection degree of the DC-DC converters is IP 40.

Cleaning Agents

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

If the output circuit of a DC-DC converter is operator acces­sible, it shall be an SEL V 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:

mation: Safety

.

Technical Infor-

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 1.1 kV
test voltage 1 s

Coupling capacitance  2.2 nF
Insulation resistance >100 M

at 500 V DC
Partial discharge Consult kV

extinction voltage factory

1.5 kV DC

rms

10/11

Table 14: 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

Mains Basic  60 V Earthed SELV circuit
 250 V AC vided by the DC-DC converter)

>60 V Hazardous voltage

Double or reinforced  60 V SELV circuit Operational insulation (pro- SELV circuit

>60 V TNV-2 circuit Supplementary insulation,

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 line directly
at the input of the DC-DC converter (see fig.:

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.:

5

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

~

.

AC-DC

front

end

Battery

Earth

connection

Fuse

DC-DC

con-

verter

1

ELV circuit Input fuse 3 output suppressor Earthed SELV

secondary circuit

Double or reinforced insu­lated unearthed hazardous
voltage secondary circuit

Schematic safety concept

Schematic safety concept

10004

Suppressor
diode

Earth

connection

SELV

2

Operational insulation (pro- SELV circuit

diode(s) 4, and earthed circuit
output circuit(s)

vided by the DC-DC converter)

based on the maximum input
voltage (provided by the
DC-DC converter)

5

). For UL’s purpose, the fuse needs to be UL-listed. See also:

).

2

+

Fig. 13

–

Schematic safety concept. Use fuse, suppressor diode
and earth connection as per table:

to an SELV output circuit

.

Safety concept leading

Description of Option

Option i Inhibit

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: –10 V...0.8 V
Converter inhibited or
inhibit pin left open circuit 2.4...5 V

06070

Vi+

i

Vi–

Fig. 14
If the inhibit is not used the inhibit pin should be con­nected to Vi–

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