Industrial Environment
DC-DC Converters <40 Watt
IMS 7 Series
7 Watt DC-DC Converters
Input to output electric strength test 1500 V DC
Input voltage ranges: 14...36 V DC and 36...75 V DC
Single and double outputs of 3.3, 5, 12, 15, 24 V DC
•
Wide input voltage ranges
•
Electrical isolation, single and double output units
•
High efficiency (typ. 84%)
•
Emissions below EN 55 022 level B
•
Immunity to IEC/EN 61000-4-2, -3, -4, -5 and -6
•
Inhibit input, output voltage adjustable
• Flex power: Flexible load distribution
•
No load and short-circuit proof
•
Operating ambient temperature range –25...71°C
•
High reliability and no derating
•
2"
×
1" case with 10.5 mm profile
• Supplementary insulation
Safety according to IECEN 60950, UL 1950
LGA
C
IMS 7 Series
25.4
1.0"
10.5
0.42"
50.8
2.0"
Summary
The IMS 7 series of board mountable 7 Watt DC-DC con-
verters has been designed according to the latest industry
requirements and standards. The converters are particu-
larly suitable for use in industry or telecommunications
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 and electri-
cally isolated double outputs allowing the configuration of
output voltages from 3.3 up to 48 V DC externally adjust-
able, with flexible load distribution on double output units.
An inhibit input allows remote converter on/off.
Features include efficient input and output filtering with un-
surpassed 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.
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 in-
ternational safety standards IEC/EN 60950, UL 1950, CAN/
CSA C22.2 No. 950-95 and are LGA and UL marked.
A special feature is their small case size, 2"
×
1" with
10.5 mm profile.
The circuit comprises of integrated planar magnetics and
all components are automatically assembled and solidly
soldered onto a single PCB without any wire connections.
Magnetic feedback ensures maximum reliability and
repeatability in the control loop over all operating condi-
tions. Careful considerations of possible thermal stresses
ensure the absence of hot spots providing long life in envi-
ronments where temperature cycles are a reality. The ther-
mal 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.
Optionally the IMS 7 series is available with the industrial
C pinout or with an SMD pinout.
Table of Contents
Page
Page
Electromagnetic Compatibility (EMC) ............................ 10
Immunity to Environmental Conditions ........................... 11
Mechanical Data ............................................................ 12
Safety and Installation Instructions ................................ 13
Description of Options .................................................... 15
Accessories .................................................................... 15
Summary .......................................................................... 1
Type Survey and Key Data .............................................. 2
Type Key .......................................................................... 2
Functional Description ...................................................... 3
Electrical Input Data ......................................................... 4
Electrical Output Data ...................................................... 6
Auxiliary Functions ........................................................... 8
MELCHER
The Power Partners.
Edition 5/9.99
1/15
IMS 7-Series
Type Survey and Key Data
Table 1: Type survey
Output 1
U
o nom
I
o nom 1
[V DC]
[A]
3.3
5.1
5
12
15
24
1
2
DC-DC Converters <40 Watt
Industrial Environment
Output 2
U
o nom
I
o nom 1
[V DC]
[A]
-
-
5
12
15
24
-
-
0.7
0.3
0.24
0.15
Output
power
P
o nom
[W]
5
6.1
7
7.2
7.2
7.2
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 7-03-7
24 IMS 7-05-7
24 IMS 7-05-05-7
24 IMS 7-12-12-7
24 IMS 7-15-15-7
24 IMS 7-24-24-7
79
81
83
84
84
84
48 IMS 7-03-7
48 IMS 7-05-7
48 IMS 7-05-05-7
48 IMS 7-12-12-7
48 IMS 7-15-15-7
48 IMS 7-24-24-7
Options
h
typ
[%]
79
82
83
84
84
84
2
1.5
1.2
0.7
0.3
0.24
0.15
-9, M, C
-9, M, C
-9, M, C
-9, M, C
-9, M, C
-9, M
Flexible load distribution on double outputs possible.
See:
Description of Options
Type Key
24 IMS 7 - 05 - 05 -7 M C
Input voltage range
U
i
14...36 V DC .............................................. 24
36...75 V DC .............................................. 48
Series ........................................................................ IMS 7
Output voltage type for output 1 ............. 03, 05, 12, 15, 24
Dash: Designates double output unit with two indepen-
dent galvanically isolated outputs ................. -
Output voltage type for output 2 ................... 05, 12, 15, 24
Operating ambient temperature range
T
A
–25...71°C .................................................. -7
–40...71°C (standard) ................................. -9
Options:
1
2
3
1
SMD version ............................................... M
C-pinout ................................................ C, C2
2
23
Not applicable for option C.
C-pinout excludes option M and vice versa.
Configures the 2 outputs either to
±
connection or to one strong single output.
For delivery lead times contact factory. Some types require a minimum order quantity.
Examples: 48 IMS 7-05-05-7M: DC-DC converter, input voltage range 36...75 V, 2 galvanically isolated outputs each pro-
viding 5 V, 700 mA, surface mount version.
24 IMS 7-0505-7C: DC-DC converter, input voltage range 14...36 V, C-pinout with outputs
±5
V, 700 mA.
24 IMS 7-15-7C2: DC-DC converter, input voltage range 14...36 V, C-pinout with one output 15 V, 480 mA.
MELCHER
The Power Partners.
Edition 5/9.99
2/15
Industrial Environment
Functional Description
DC-DC Converters <40 Watt
IMS 7 Series
The IMS 7 DC-DC modules are feedback controlled flyback
converters using current mode PWM (Pulse Width Modula-
tion).
In the case of the single output units the output is directly
monitored and fed back to the primary control circuit via a
pulse transformer, resulting in tight regulation of the output
voltage. The R input is referenced to the secondary side
and allows for programming of the output voltages in the
range 75 to 105% of
U
o nom
using either an external resistor
or an external voltage source.
In the case of the double output units the output voltage is
monitored by a separate transformer winding close to the
secondary windings and fed back to the control circuit. The
R-input is referenced to the primary side and allows pro-
gramming of the output voltage in the range 100 to 105% of
U
o nom
by an external resistor or within 75 to 105% of
U
o nom
using an external voltage source.
Current limitation is provided by the primary circuit, thus
limiting the total output current (I
o nom
for the single and
I
o1 nom
+
I
o2 nom
for the double output types).
The inhibit input allows remote converter shutdown.
03025
03026
Vi+
1
11
Vo+
Vi+
1
11
Vo1
PWM
i
3
10
(Trim)
4
R
Vo–
10
Vo1
PWM
10 nF
13
Vo2
2
×
2200 pF
1500 V
V i–
2
12
i
3
13
R
Vi–
2
2
×
2200 pF, 1500 V
12
Vo2
14
n.c.
n.c.
4
14
n.c.
Fig. 1
Block diagram, single output types, standard pinout
03039
Fig. 2
Block diagram, double output types, standard pinout
03040
Vi+
1
3
Vo+
Vi+
1
3
Vo+
PWM
10
Go
5
Vo–
PWM
10 nF
2
×
2200 pF
1500 V
Vi–
2
Vi–
2
2
×
2200 pF, 1500 V
5
Vo–
Fig. 3
Block diagram, single output types, C pinout
Fig. 4
Block diagram, dual output types, C pinout
MELCHER
The Power Partners.
Edition 5/9.99
3/15
IMS 7-Series
Electrical Input Data
DC-DC Converters <40 Watt
Industrial Environment
General conditions:
– T
A
= 25°C, unless
T
C
is specified.
– Connector pins i and Vi– interconnected.
– R input not connected.
Table 2: Input Data
Input
Characteristics
Conditions
min
14
24
50
0.25
0.5
0.1
5
12
12
0.8
–10...0.8
open, 2.4...U
i max
–0.5
1
3.0
4.0
approx. 330
40
B
B
3.9
approx. 330
30
24
5
12
6
0.5
–10 ...0.8
open, 2.4...U
i max
–0.5
1
3.0
A
kHz
mA
pp
mA
12
mA
µF
V DC
0.25
24 IMS
typ
max
36
min
36
48
100
0.5
0.1
ms
s
48 IMS
typ
max
75
Unit
V DC
U
i
U
i nom
U
i sur
t
start up
t
rise
Input voltage range
1
Input voltage (nominal)
Repetitive surge
voltage
Converter
2
start-up time
Rise time
2
switch on
inh. release
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
U
i nom
,
I
o
=
I
o nom
resistive load
capacitive load
I
io
C
i
U
ih
I
ih
I
i ih
I
inr p
f
s
I
i rr
U
i RFI
1
No load input current
Input capacitance
Inhibit voltage
I
o
= 0,
U
i min
...U
i max
for surge calculation
Converter operating
Converter inhibited
Inhibit current
Converter operating
Converter inhibited
Input current
if unit inhibited
Peak inrush current
4
Switching frequency
Reflected ripple current
Input RFI level
conducted and radiated
U
i
min
...U
i max
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
5
U
i min
will not be as stated if
U
o
is increased above
U
o nom
by use of the R input pin. If the output voltage is set to a higher value,
U
i min
will be proportionally increased.
Measured with a resistive or max. admissible capacitive load. (See fig.:
Converter start-up and rise time).
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.
The level of the switching frequency band varies with the output voltage configuration. (See also fig.:
Switching frequency versus
input voltage and load.)
U
o
U
o nom
04008
t
rise
t
t
start up
Fig. 5
Converter start-up and rise time
MELCHER
The Power Partners.
Edition 5/9.99
4/15
Industrial Environment
Input Transient Voltage Protection
DC-DC Converters <40 Watt
Reverse Polarity Protection at Input
IMS 7 Series
In many applications transient voltages on the input of the
converter are always possible. These may be caused for ex-
ample be short circuits between Vi+ and Vi– where the net-
work inductance may cause high energy pulses.
In order to protect the converter a large transient voltage
supressor has been fitted to the input of the IMS 7 types.
Specifications as per table below.
The suppressor diode on the input also provides for reverse
polarity protection by conducting current in the reverse di-
rection, thus protecting the unit. An external fuse is required
to limit this current:
– For 24 IMS 7 a fast 2 A (F2A) fuse is recommended.
– For 48 IMS 7 a fast 1 A (F1A) fuse is recommended.
Inrush Current
The inrush current has been kept as low as possible by
choosing a very small input capacitance. A series resistor
may be inserted in the input line to limit this current further.
1 A/Div.
4
3
2
1
0
04030
Table 3: Built-in transient voltage suppressor
Type
Breakdown
Voltage
V
BR nom
53 V
100 V
Peak Power
at 1 ms
P
P
600 W
600 W
Peak Pulse
Current
I
PP
7.7 A
4.1 A
24 IMS 7
48 IMS 7
If transients generating currents above the peak pulse cur-
rent
I
pp
are possible then an external limiting network such
as the circuit recommended for IEC 801-5, level 2 compli-
ance is necessary.
To achieve IEC/EN 61000-4-5, level 2 compliance an addi-
tional inductor and capacitor should be provided externally
as shown in the figure below. The components should have
similar characteristics as listed in table 9.
To withstand the 150 V transient according to 19 Pfl 1, appli-
cable for 48 IMS 7 types, the same external circuitry with
similar components as for IEC/EN 61000-4-5, level 2 com-
pliance can be used.
L
V+
C
V–
+
Vi+
i
Vi–
Module
04043
10
µs/Div.
Fig. 8
Typical inrush current at U
i nom
, P
o nom
versus time
(48 IMS 7) measured according to prETS 300132-2 (Ver-
sion 4.3)
Fig. 6
Example for external circuitry to comply with
IEC/EN 61000-4-5, level 2.
Table 4: Components for external circuitry to comply with
IEC 801-5
Circuit Ref.
L
C
24 IMS 7
48 IMS 7
330
µH,
0.42
Ω,
0.6 A
330
µH,
0.42
Ω,
0.6 A
TDK TSL1110-331KR55 TDK TSL1110-331KR55
68
µ,
63 V, 85°C
10.5
68
µF,
100 V, 85°C
04029
5
∅
0.7
Fig. 7
Dimensions for inductor L
MELCHER
The Power Partners.
11.5
5
Edition 5/9.99
5/15
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