Industrial Environment
DC-DC Converters <40 Watt
IMS 15 Series
15 Watt DC-DC Converters
Input to output electric strength test 1500 V DC
Input voltage ranges: 14...36 and 36...75 V DC
Single, dual and double outputs
Configurable output voltages from 3.3 to 48 V DC
• Electrical isolation, also between outputs
• Emissions below EN 55022, level B
• Immunity to IEC/EN 61000-4-2,-3,-4,-5 and -6
• High efficiency (typ. 86%)
• Input undervoltage lock-out
• Shut down input, output voltages adjustable
• Flex power: Flexible load distribution on outputs
• Outputs no-load, overload and short-circuit proof
• Operating ambient temperature –25...71
o
C
• Thermal protection
• 2"
×
1.6" case with 10.5 mm profile
• Supplementary insulation
Safety according to IEC/EN 60950, UL 1950
LGA
C
IMS 15 Series
40.6
1.5"
10.5
0.42"
51
2.0"
Approvals pending
Summary
The IMS 15 series of board mountable 15 Watt DC-DC con-
verters has been designed according to the latest industry
requirements and standards. The converters are particu-
larly suitable for applications in industry and telecommuni-
cations where variable input voltages or high transient
voltages are prevalent.
Providing two wide input voltage ranges, 14...36 V DC and
36...75 V DC, the units are available with single, dual and
electrically isolated double outputs allowing the configura-
tion of output voltages from 3.3 up to 48 V DC externally ad-
justable, with flexible load distribution on dual and double
output units. A shut down input allows remote converter on/
off. Features include efficient input and output filtering with
unsurpassed transient and surge protection, low output rip-
ple and noise, consistently high efficiency over the entire
input voltage range, high reliability as well as excellent dy-
namic response to load and line changes.
The converters provide supplementary insulation with
SELV 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 inter-
national safety standards IEC/EN 60950, UL 1950, CAN/
CSA C22.2 No.950-95. Approvals pending.
The circuit comprises of integrated planar magnetics and
all components are automatically assembled and solidly
soldered onto a single PCB without any wire connections.
The proprietary magnetic feedback solution ensures maxi-
mum reliability and 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. An extended temperature range –
40...71°C is available as an option. For extremely high vi-
bration environments the case has holes for screw mount-
ing.
Table of Contents
Page
Summary .......................................................................... 1
Type Survey and Key Data .............................................. 2
Type Key and Product Marking ........................................ 2
Functional Description ...................................................... 3
Electrical Input Data ......................................................... 4
Electrical Ouput Data ....................................................... 5
Page
Auxilliary Functions .......................................................... 8
Electromagnetic Compatibility (EMC) .............................. 9
Immunity to Environmental Conditions ........................... 10
Mechanical Data ............................................................ 11
Safety and Installation Instructions ................................ 11
Description of Option ...................................................... 13
MELCHER
The Power Partners.
Edition 5/7.99
1/13
IMS 15 Series
Type Survey and Key Data
Table 1: Type survey
Output 1
U
o1 nom
I
o1 nom 1
[V DC]
[A]
5.1
5.1
5
12
15
24
1
DC-DC Converters <40 Watt
Industrial Environment
Output 2
U
o2 nom
I
o2 nom 1
[V DC]
[A]
-
3.3
5
12
15
24
-
1.6
1.4
0.7
0.56
0.35
Output
power
P
o nom
[W]
13.8
13.5
14
16.8
16.8
16.8
Input Voltage Range and Efficiency
U
i min
...U
i max
h
typ
U
i min
...U
i max
14...36 V DC
[%]
36...75 V DC
24 IMS 15-05-7R
24 IMS 15-0503-7R
24 IMS 15-05-05-7
24 IMS 15-12-12-7
24 IMS 15-15-15-7
24 IMS 15-24-24-7
84
82
85
88
88
87
48 IMS 15-05-7R
48 IMS 15-0503-7R
48 IMS 15-05-05-7
48 IMS 15-12-12-7
48 IMS 15-15-15-7
48 IMS 15-24-24-7
Option
h
typ
[%]
83
82
83
86
86
86
-9, i
-9, i
-9, K
2
, i
-9, K
2
, i
-9, K
2
, i
-9, i
2.7
1.6
1.4
0.7
0.56
0.35
2
Flexible load distribution on dual and double outputs possible up to 75% of
P
o nom
on one of the 2 outputs, 24/48 IMS 15-0503-7 types
allow; 2 A max. on one of the 2 outputs. The other output should not exceed the difference to the total output power
P
o nom
.
Option K: Alternative pinout with common ground (Vo+, Go, Vo–), excludes option i.
Type Key and Product Marking
Type Key
24 IMS 15 - 05 - 05 -7 R K i
Input voltage range
U
i
14...36 V DC .............................................. 24
36...75 V DC .............................................. 48
Series ...................................................................... IMS 15
Output voltage type output 1 ........................ 05, 12, 15, 24
Dash designates double output unit with two
independent electrically isolated outputs ...... -
Output voltage type output 2 .................. 03, 05, 12, 15, 24
Operating ambient temperature range
T
A
–25...71°C .................................................. -7
–40...71°C .................................................. -9
R input and magnetic feedback ...................................... R
Option:
Alternative pinout ......................................... K
Inhibit ............................................................ i
1
2
3
1
2
3
13
Not applicable with option K
Single output and -0503- types
For delivery lead times contact factory. Requires a minimum order quantity.
Examples: 48 IMS 15-05-05-7: DC-DC converter, input voltage range 36...75 V, 2 electrically isolated outputs each pro-
viding 5 V, 1.4 A.
24 IMS 15-0505-7K: DC-DC converter, input voltage range 14...36 V, alternative pinout with outputs
±5
V,
±1.4
A.
Product Marking
Basic type designation, output voltages and currents, applicable safety approval and recognition marks, Melcher patent
nos. and company logo. Side label: Date code and serial no.
MELCHER
The Power Partners.
Edition 5/7.99
2/13
Industrial Environment
Functional Description
DC-DC Converters <40 Watt
IMS 15 Series
The IMS 15 series of DC-DC converters are magnetic feed-
back controlled flyback converters using current mode
PWM (Pulse Width Modulation). The -05- and -0503- output
voltage versions feature an active magnetic feedback loop
via a pulse transformer which results in very tight regulation
of the output voltage (see fig.:
Block diagram, single and
-0503- output types).
The output voltages of these versions
can be adjusted via the R input. The R input is referenced to
the secondary side and allows for programming of the out-
put voltages in the range of approximately 80 to 105% of
U
o nom
using either an external resistor or an external volt-
age source.
The voltage regulation on the dual and double output ver-
sions is achieved with a passive transformer feedback from
the main transformer (see fig.:
Block diagram, for double
output types).
The output voltages can be adjusted via the
Trim input. The Trim input is referenced to the primary side
of the converter and allows for programming of the output
voltages in the range 100 to 105% of
U
o nom
by an external
resistor or within 75 to 105% using an external voltage
source.The load regulation output characteristic allows for
paralleling of one or several double output units of equal
output voltages.
Current limitation is provided by the primary circuit, thus
limiting the total output power of double output types to
approx. 130% of
P
o nom
(see:
Type Survey).
The shut down
input allows remote converter on/off.
Overtemperature protection will shut down the unit in ex-
cessive overload conditions with automatic restart approxi-
mately every 50 to 60 ms.
03022
Vi+
1
03006
13
Vo1+
Vi+
1
13
Vo+
SD
4
PWM
n.c.
3
15
Go
11
Vo2+
PWM
SD
4
15
Vo–
2
×
2200 pF
1500 V
Vi –
2
17
R
Vi –
2
2
×
2200 pF, 1500 V
12
Go
17
R
Fig. 1
Block diagram, single output types.
03007
Fig. 2
Block diagram, -0503- types.
03023
Vi+
1
11
Vo1+
Vi+
1
11
Vo+
SD
4
PWM
Trim
3
12
Vo1–
13
Vo2+
SD
4
PWM
13
Go
Vi–
2
2
×
2200 pF, 1500 V
15
Vo2–
17
n.c.
Vi–
2
2
×
2200 pF, 1500 V
15
Vo–
17
n.c.
Fig. 3
Block diagram, double output types, standard pinout.
Fig. 4
Block diagram, dual output types, alternative K-pinout.
MELCHER
The Power Partners.
Edition 5/7.99
3/13
IMS 15 Series
Electrical Input Data
DC-DC Converters <40 Watt
Industrial Environment
General conditions:
– T
A
= 25°C, unless
T
C
is specified.
– Shut down pin left open circuit (not connected).
– Trim or R input not connected.
Table 2: Input Data
Input
Characteristics
Conditions
min
14
24
50
0.25
0.5
0.1
5
20
4.0
–10...0.7
2.0...20
10
40
5
10
2.0
–10...0.7
2.0...20
10
3
5
approx. 350
30
B
approx. 350
30
B
1.2
3
4.5
kΩ
mA
A
kHz
mA
pp
20
0.25
24 IMS
typ
max
36
min
36
48
100
0.5
0.1
ms
mA
µF
V DC
s
48 IMS
typ
max
75
Unit
V DC
U
i
U
i nom
U
i sur
t
start up
t
rise
I
i o
C
i
U
SD
R
SD
I
SD
I
inr p
f
s
I
i rr
u
i RFI
1
Input voltage range
1
Nominal input voltage
Repetitive surge
voltage
Converter
start-up time
Rise time
No load input current
Input capacitance
Shut down voltage
Switch on
SD high
T
C min
...T
C max
I
o
= 0...I
o nom
Abs. max input (3 s)
Worst case condition at
U
i min
and full load
2
U
i nom
,
I
o
=
I
o nom 2
I
o
= 0,
U
i min
...U
i max
for surge calculation
Unit disabled
Unit operating
Shut down input
resistance
Input current
if unit shut down
Inrush peak current
4
Switching frequency
Reflected
ripple current
Input RFI level conducted
U
i
min
...U
i max
1.2
U
i
=
U
i nom
U
i min
...U
i max
,
I
o
= 0...I
o nom
I
o
= 0...I
o nom
EN 55022
3
2
3
4
U
i min
will not be as stated if
U
o
is increased above
U
o nom
by use of the R or Trim input. If the output voltage is set to a higher value,
U
i min
will be proportionally increased.
Measured with a resistive and the max. admissable capacitive load.
Measured with a lead lenght of 0.1 m, leads twisted. Double output units with both outputs in parallel.
Source impedance according to prETS 300132-2, version 4.3.
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]
4
3
2
1
t
[µs]
0
10
20
30
40
50
60
70
80
90 100
04022
Input Undervoltage Lock-out
The IMS 15 converters are fitted with a defined input under-
voltage lock-out (approx. values):
24 IMS 15
48 IMS 15
U
o
U
o nom
turn off
turn on
turn off
turn on
12.5 V
13 V
31.5 V
32 V
04008
t
rise
t
t
start up
Fig. 5
Typical inrush current at U
i nom
, P
o nom
versus time
(48 IMS 15). Source impedance according to
prETS 300132-2, version 4.3 at U
i nom
.
Fig. 6
Converter start-up and rise time.
MELCHER
The Power Partners.
Edition 5/7.99
4/13
Industrial Environment
Input Transient Voltage Protection
DC-DC Converters <40 Watt
IMS 15 Series
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 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
24 IMS 15
48 IMS 15
150
µH,
0.294
Ω,
640 mA
TOKO: 494 LYF-0094K
1
150
µF,
63 V, 85°C
100
µF,
150 V, 85°C
Table 3: Built-in transient voltage suppressor
Type
Breakdown
voltage
V
BR nom
[V]
53
100
Peak power
at 1 ms
P
P
[W]
600
600
Peak pulse
current
I
PP
[A]
7.7
4.1
C
1 Available from TOKO Components Division
24 IMS 15
48 IMS 15
Reverse Polarity Protection at the Input
The built-in suppressor diode also provides for reverse po-
larity protection at the input by conducting current in the re-
verse direction. An external fuse is required to limit this cur-
rent.
– For 24 IMS 15 types a fast 3.15 A (F3.15A) fuse is
recommended.
– For 48 IMS 15 types a fast 2 A (F2A) fuse is recom-
mended.
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)
an external inductor and
capacitor are required.
04009
L
V+
C
V–
+
1
Vi+
Module
2
Vi–
Fig. 7
Example for external circuitry to comply with
IEC/EN 61000-4-5 or ETR 283 (19 Pfl1) (48 IMS15 types).
Electrical Ouput Data
General conditions:
T
A
= 25°C, unless
T
C
is specified. Shut down pin left open (not connected). Trim- or R-input not connected.
Table 5a: Output data for single output units and -0503- types.
Output
Characteristics
Conditions
5.1 V
min typ max
5.05
2.7
3.5
±1
+3, –5
±4.5
70
40
115
130
4000
±250
1
±0.02
115
80
40
130
total 4000
±150
1
%
µF
mV
ms
mV
pp
5.15
5.1/3.3 V
min typ max
5.0
3.25
5.12
3.35
Unit
V
A
U
o1
U
o2
I
o nom
I
o1L
I
o2L
D
U
o
Output voltage
Output current
1
Current limit
2, 4
U
i nom
I
o
= 0.5
I
o nom
U
i min
...U
i max
U
i nom
,
T
C
= 25°C
U
o
= 90%
U
o nom
U
i min
...U
i max
,
I
o
= (0.01...1)
I
o nom
U
i min
...U
i max
I
o
= (0.1...1)
I
o nom
5.1 V
3.3 V
5
6
2
×
1.6
3.0
3.8
Line/load regulation
%
u
o1/2
U
o L
C
o ext
u
o d
t
d
a
Uo
1
Output voltage noise
U
i min
...U
i max
I
o
=
I
o nom
Output overvoltage
limitation
Admissible capacitive load
3
Dynamic
load
regulation
Voltage deviat.
U
i nom
I
↔
1
/
2
I
o nom
Recovery time
o nom
IEC/EN 61204
Temperature coefficient
D
U
o
/DT
C
U
i min
...U
i max
I
o
= 0...I
o max
±0.02
%/K
2
3
4
5
6
7
Flexible load distribution: 24/48 IMS 15-0503-7 types; 2 A max. on one of the 2 outputs, the other output should not be loaded such
that the total output power exceeds
P
o nom
according to table:
Type survey.
The current limit is primary side controlled.
Measured with both outputs connected in parallel. For -0503- types: total capacitance, both outputs.
Conditions for specified output. Other output loaded with constant current
I
o
= 0.5
I
o nom
.
BW = 20 MHz
Measured with a probe according to EN 61204
The overvoltage protection is not tracking with R/Trim control.
MELCHER
The Power Partners.
Edition 5/7.99
5/13
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