Rugged Environment
DC-DC Converters <40 Watt
IMX/IMY 15 Series
15 Watt DC-DC Converters
Input to output electric strength test up to 4 kV DC
Input voltage: 8.4...36, 16.8...75, 50...150 V DC
Single, dual and double outputs
Configurable output voltages from 3.3 to 48 V DC
• Extremely wide input voltage ranges
• 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. 87%)
• 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 up to –40...85
°
C
• Thermal protection
• 2"
×
1.6" case with 10.5 mm profile
• Supplementary insulation: 20/40 IMX 15 types
• Double or reinforced insulation: 110 IMY 15 types
Safety according to IEC/EN 60950, UL 1950
LGA
1
IMX 15 Series
IMY 15 Series
40.6
1.5"
10.5
0.42"
51
2.0"
Approvals pending
1
For 110 IMY 15 types
Summary
The IMX 15 and IMY 15 series of board mountable 15 Watt
DC-DC converters has been designed according to the lat-
est industry requirements and standards. The converters
are particularly suitable for use in mobile or stationary appli-
cations in transport, railways, industry, or telecommunica-
tion where variable input voltages or high transient voltages
are prevalent.
Covering a total input voltage range from 8.4 up to 150 V
with 3 different types, the units are available with single,
dual and electrically isolated double outputs from 3.3 up to
48 V externally adjustable, with flexible load distribution on
dual and double output units. A shut down input allows re-
mote converter on-off. Features include consistently high
efficiency over the entire input voltage range, high reliability
and excellent dynamic response to load and line changes.
The converters are designed and built according to the in-
ternational safety standards IEC/EN 60950, UL 1950, CAN/
CSA C22.2 No.950-95. LGA, UL and cUL approvals are in
progress. The 20 IMX 15 and 40 IMX 15 types provide sup-
plementary insulation. Connected to a secondary circuit the
40 IMX 15 types provide SELV outputs even if the bus volt-
age at the converter input exceeds the SELV-limit of
60 V DC. The 110 IMY 15 types provide double insulation
and are CE marked. They may be connected to e.g. a recti-
fied 110 V AC source without any further isolation barrier.
The circuit comprises of integrated planar magnetics and
all components are automatically assembled and solidly
soldered onto a single PCB without any wire connection.
Magnetic feedback ensures maximum reliability and re-
peatability 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. For
extremely high vibration environments the case has holes
for screw mounting. Various options as e.g. extended tem-
perature range –40...85°C or an alternative pinout provide
a high level of application specific engineering and design-
in flexibility.
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 Output Data ...................................................... 6
Page
Auxilliary Functions ........................................................ 10
Electromagnetic Compatibility (EMC) ............................ 11
Immunity to Environmental Conditions ........................... 12
Mechanical Data ............................................................ 13
Safety and Installation Instructions ................................ 14
Description of Option ...................................................... 16
MELCHER
The Power Partners.
Edition 6/7.99
1/16
IMX/IMY 15 Series
Type Survey and Key Data
Table 1: Type survey
Output 1
U
o nom
I
o nom 1
[V DC]
[A]
3.3
3.3
3.3
5.1
5.1
5.1
5.1
5.1
5.1
5.1
5.1
5.1
5
5
5
12
12
12
15
15
15
24
24
24
1
DC-DC Converters <40 Watt
Rugged Environment
Output 2
U
o nom
I
o nom 1
[V DC]
[A]
-
-
-
-
-
-
-
-
-
3.3
3.3
3.3
5
5
5
12
12
12
15
15
15
24
24
24
-
-
-
-
-
-
-
-
-
1.35
1.5
1.5
1.3
1.4
1.4
0.65
0.7
0.7
0.5
0.56
0.56
0.32
0.35
0.35
Output
power
P
o nom
[W]
14.9
14.9
14.9
17.8
17.8
17.8
11.7
12.8
12.8
11.3
12.6
12.6
13.0
14.0
14.0
15.6
16.8
16.8
15.0
16.8
16.8
15.4
16.8
16.8
Input voltage
U
i min
...U
i max
[V DC]
8.4...36
16.8...75
3
50...150
4
8.4...36
16.8...75
3
50...150
4
8.4...36
16.8...75
3
50...150
4
8.4...36
16.8...75
3
50...150
4
8.4...36
16.8...75
3
50...150
4
8.4...36
16.8...75
3
50...150
4
8.4...36
16.8...75
3
50...150
4
8.4...36
16.8...75
3
50...150
4
Efficiency
h
typ
[%]
85
85
84
87
87
86
85
83
83
84
84
82
86
86
86
88
88
87
88
88
87
86
86
86
Type designation
Options
2
4.5
4.5
4.5
3.5
3.5
3.5
2.3
2.5
2.5
1.35
1.5
1.5
1.3
1.4
1.4
0.65
0.7
0.7
0.5
0.56
0.56
0.32
0.35
0.35
20 IMX 15-03-9RG
40 IMX 15-03-9RG
110 IMY 15-03-9RG
20 IMX 15-05-9RG
40 IMX 15-05-9RG
110 IMY 15-05-9RG
20 IMX 15-05-7R
40 IMX 15-05-7R
110 IMY 15-05-7R
20 IMX 15-0503-7R
40 IMX 15-0503-7R
110 IMY 15-0503-7R
20 IMX 15-05-05-7
40 IMX 15-05-05-7
110 IMY 15-05-05-7
20 IMX 15-12-12-7
40 IMX 15-12-12-7
110 IMY 15-12-12-7
20 IMX 15-15-15-7
40 IMX 15-15-15-7
110 IMY 15-15-15-7
20 IMX 15-24-24-7
40 IMX 15-24-24-7
110 IMY 15-24-24-7
-9, -8, i
-9, -8, i
-9, -8, i
-9, -8, i
-9, -8, i
-9, -8, i
-9, -8, i
-9, -8, i
-9, -8, i
-9, -8, i
-9, -8, i
-9, -8, i
-9, -8, R, K, i
-9, -8, R, K, i
-9, -8, R, i
-9, -8, R, K, i
-9, -8, R, K, i
-9, -8, R, i
-9, -8, R, K, i
-9, -8, R, K, i
-9, -8, R, i
-9, -8, R, K, i
-9, -8, R, K, i
-9, -8, R, i
2
3
4
Flexible load distribution on dual and double outputs possible up to 75% of the total output power
P
o nom
on one of the 2 outputs.
IMX/IMY 15-0503 types have reduced load distribution flexibility; 1.8 A max. on one of the 2 outputs. The other output should not ex-
ceed the difference to the total output power
P
o nom
.
See:
Description of Options.
Short-time operation down to
U
i min
≥14.4
V possible.
P
o
reduced to approx. 85% of rated output power.
Short-time operation down to
U
i min
≥43.2
V possible.
P
o
reduced to approx. 85% of rated output power.
Type Key and Product Marking
20 IMX 15 - 05 - 05 -7 R G K i
Input voltage range
U
i
8.4...36 V DC ........................................... 20
16.8...75 V DC ........................................... 40
50...150 V DC ......................................... 110
Series ......................................................... IMX 15, IMY 15
Output voltage type output 1 .................. 03, 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 (standard) ................................. -7
–40...71°C (standard) ................................. -9
–40...85°C (option) ..................................... -8
Options and features:
R input and magnetic feedback .................. R
Synchronous rectification ............................ G
Alternative pinout ......................................... K
Inhibit ............................................................ i
1
3
4
1
2
23
24
25
Not applicable with option K or -0503- types.
2
For delivery lead times contact factory. Some types require a minimum order quantity.
Standard features for single output and -0503- types. Optional for double output units. Excludes option K.
Option K excludes option R.
5
Option inhibit excludes shut down and option K.
MELCHER
The Power Partners.
Edition 6/7.99
2/16
Rugged Environment
DC-DC Converters <40 Watt
IMX/IMY 15 Series
Examples: 20 IMX 15-05-05-7: DC-DC converter, input voltage range 8.4...36 V, 2 electrically isolated outputs each pro-
viding 5 V, 1.3 A.
110 IMY 15-0503-7R: DC-DC converter, input voltage range 50...150 V, 2 outputs with common return provid-
ing +5.1 V, 1.5 A and +3.3 V, 1.5 A. Unit fitted with magnetic feedback for tight output voltage regulation.
Product Marking
Basic type designation, output voltages and currents, applicable safety approval and recognition marks, Melcher patent
nos. and company logo. Date code and serial no.
Functional Description
The IMX/IMY 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 as well as all double output versions fitted
with option R 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 output
types, -0503- types and double output types with option R).
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 output voltages in the
range of approximately 80 to 105% of
U
o nom
using either an
external resistor or an external voltage source.
The voltage regulation on the dual and double output ver-
sions without option R is achieved with a passive trans-
former feedback from the main transformer (see fig.:
Block
03039
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 program-
ming 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 charac-
teristic allows for paralleling of one or several double output
units with equal output voltages.
Current limitation is provided by the primary circuit, thus
limiting the total output power of double output types. 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.
03089
Vi+
1
3
Vo+
Vi+
1
13
Vo1+
PWM
SD
4
5
15
Go
Vo–
PWM
n.c.
3
11
Vo2+
2
×
2200 pF
1500 V
V i–
2
Vi–
2
2
×
2200 pF
12
Go
Fig. 1
Block diagram, single output types
03088
17
R
Vi+
1
11
Vo+
Fig. 3
Block diagram, -0503- types.
SD
4
PWM
Trim
3
13
Go
Vi –
2
2
×
2200 pF
15
Vo–
17
n.c.
Fig. 2
Block diagram, dual output types, alternative K-pinout.
MELCHER
The Power Partners.
Edition 6/7.99
3/16
IMX/IMY 15 Series
Vi+
1
DC-DC Converters <40 Watt
03090
Rugged Environment
03092
11
Vo1+
Vi+
1
13
Vo1+
SD
4
PWM
Trim
3
12
Vo1–
13
Vo2+
SD
4
PWM
n.c.
3
12
Vo1–
11
Vo2+
Vi –
2
2
×
2200 pF
15
Vo2–
17
n.c.
Vi –
2
2
×
2200 pF
15
Vo2–
Fig. 4
Block diagram, double output types, standard pinout.
17
R
Fig. 5
Block diagram, double output types with option R.
Electrical Input Data
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
8.4
5
20
40
0.25 0.5
0.1
5
10
20
40
30
8
1.5
–10...0.7
open or 2...20
approx. 10
6
approx. 300
B
8
0.75
–10...0.7
open or 2...20
approx. 10
3
approx. 300
B
5
10
20
20
30
9
0.35
–10...0.7
open or 2...20
approx. 10
1
approx. 300
B
kΩ
mA
kHz
20 IMX
typ
max
36
min
16.8
5 6
40
9
40 IMX
typ
max
75
min
110 IMY
typ
max
150
110
100
168
0.25 0.5
0.1
5
10
20
10
20
10
A
µF
V DC
mA
ms
s
Unit
V DC
U
i
U
i nom
U
i sur
t
start up
t
rise
I
i o
I
irr
I
inr p
C
i
U
SD
R
SD
I
SD
f
s
u
i RFI
1
Input voltage range
1
Nominal input voltage
Repetitive surge voltage
Converter
Switch on
2
start-up time
SD high
Rise time
2
T
A min
...T
A max
I
o
= 0...I
o nom
Abs. max input (3 s)
Worst case condition at
U
i min
and full load
50
5 7
0.25 0.5
0.1
U
i nom
resist load
I
o nom
capac. load
I
o
= 0,
U
i min
...U
i max
I
o
= 0...I
o nom
U
i
=
U
i nom
for surge calculation
Unit shut down
Unit operating
No load input current
Reflected ripple current
Inrush peak current
3
Input capacitance
Shut down voltage
Shut down input resistance For current calculations
Input current if unit
shut down
Switching frequency
Input RFI level conducted
U
i
min
...U
i max
U
i min
...U
i max
,
I
o
= 0...I
o nom
EN 55022
4
2
3
4
5
6
7
8
9
U
i min
will not be as stated if
U
o
is increased above
U
o nom
by use of the R or the Trin input. If the output voltage is set to a higher value,
U
i min
will be proportionately increased.
Measured with resistive and max. admissible capacitive load.
Source impedance according to prETS 300132-2, version 4.3.
Measured with a lead length of 0.1 m, leads twisted. Double output units with both outputs in parallel.
Input undervoltage lock-out at typ. 80% of
U
i min
.
Short time operation down to
U
i min
>14.4 V possible.
P
o
reduced to approx. 85% of
P
o nom
.
Short time operation down to
U
i min
>43.2 V possible.
P
o
reduced to approx. 85% of
P
o nom
.
20 IMX 15 types require 4.7
µF/50
V capacitance accross the input (Polyester, Philips 372 series).
See:
Transient ETR 283 (19Pfl1), Electromagnetic Immunity.
MELCHER
The Power Partners.
Edition 6/7.99
4/16
Rugged Environment
Inrush current
DC-DC Converters <40 Watt
IMX/IMY 15 Series
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.
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 reduce this cur-
rent.
I
[A]
4
3
2
1
t
[µs]
0
10
20
30
40
50
60
70
80
90 100
04022
Table 5: Built-in transient voltage suppressor
Type
Breakdown
voltage
V
Br nom
[V]
40
100
167
Peak power
at 1 ms
P
p
[W]
1500
1500
600
Peak pulse
current
I
pp
[A]
22
9.7
0.5
20 IMX 15
40 IMX 15
110 IMY 15
Fig. 6
Typical inrush current at U
i nom
, P
o nom
versus time
(40 IMX 15). Source impedance according to
prETS 300132-2, version 4.3 at U
i nom
.
U
o
U
o nom
04008
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. The components should have simi-
lar characteristics as listed in table:
Components for exter-
nal circuitry for IEC/EN 61000-4-5, level 2 or ETR 283
(19Pfl1) compliance.
Note: The suppressor diode D is only necessary for
20 IMX 15 types.
t
rise
Table 6: Components for external circuitry for IEC/EN
61000-4-5, level 2 or ETR 283 (19Pfl1) compliance.
Type
Inductor (L)
68
µH,
2.7 A
220
µH,
1.3 A
330
µH,
0.43 A
L
Vi+
C
+
D
Vi–
Capacitor (C)
330
µF,
63 V
2
×
100
µF,
100 V
2
×
100
µF,
200 V
04036
Diode (D)
1.5 k E47A
-
-
t
t
start up
20 IMX
40 IMX
110 IMY
Fig. 7
Converter start-up and rise time
Input Undervoltage Lockout
A special feature of these units is the accurate undervoltage
lockout protection which protects the units (and system)
from large currents caused by operation at low voltages.
This ensures easier start-up in distributed power systems.
Table 3: Turn on and turn off voltage
Type
20 IMX
40 IMX
110 IMY
Turn On
7.5...8
12.5...13.5
40...42.5
Turn Off
7...7.5
12...13
Units
V
Fig. 8
Example for external circuitry to comply with IEC/EN
61000-4-5 or ETR 283 (19Pfl1); the diode D is only neces-
sary for 20 IMX 15 types.
04051
38...40.5
10
10
5
Reverse Polarity Protection
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.
Fig. 9
Dimensions of inductor L for 110 IMY 15 types
(e.g. TOKO 494LYF-0098K).
22
04052
Table 4: Recommended external fuses
Converter type
20 IMX 15
40 IMX 15
110 IMY 15
Fuse type
F4.0A
F2.0A
F1.0A
11.5
23.8
Fig. 10
Dimensions of inductor L for 20 IMX 15 and 40 IMX 15
types (e.g. Coil Craft, PCH-45 series).
MELCHER
The Power Partners.
Edition 6/7.99
5/16
5
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