Rugged Environment
DC-DC Converters <40 Watt
IMX 7 Series
7 Watt DC-DC Converters
Input to output electric strength test up to 2.5 kV DC
Input voltage ranges:
8.4...36, 16.8...75, 40...121 and 60...150 V DC
Single, double outputs of 3.3, 5, 12, 15 and 24 V DC
• Extremely wide input voltage ranges
• Electrical isolation, also between outputs
• Emissions below EN 55 022 level B.
• Immunity to IEC/EN 61000-4-2, -3, -4, -5 and -6
• High efficiency (typ. 84%)
• Inhibit input, output voltage adjustable
• Flex power: flexible load distribution on outputs
• Outputs no-load, overload and short-circuit proof
• Operating ambient temperature up to –40...85°C
• High reliability and no derating
• 2"
×
1" case with 10.5 mm profile
• Supplementary insulation
Safety according to IEC/EN 60950, UL 1950
LGA
C
IMX 7 Series
25.4
1.0"
10.5
0.42"
50.8
2.0"
1
1
For 70/110 IMX types
Summary
The IMX 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 particularly
suitable for use in mobile or stationary applications in trans-
port, railways, industry or telecommunications where vari-
able input voltages or high transient voltages are prevalent.
Covering a total input voltage range from 8.4 V DC up to
150 V DC with four different types the units are available
with single and electrically isolated double outputs allowing
the configuration of output voltages from 3.3 V DC up to
48 V DC externally adjustable, with flexible load distribution
on double output units. An inhibit input allows remote con-
verter 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 sys-
tems 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 and are LGA and UL marked. The
70 IMX 7 and 110 IMX 7 types are CE marked.
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 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 85°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 temperature range
–40...85°C, industrial C pinout or SMD pinout provide a
high level of application specific engineering and design-in
flexibility.
Table of Contents
Page
Page
Auxiliary Functions ........................................................... 8
Electromagnetic Compatibility (EMC) ............................ 10
Immunity to Environmental Conditions ........................... 11
Mechanical Data ............................................................ 12
Safety and Installation Instructions ................................ 13
Description of Options .................................................... 14
Summary .......................................................................... 1
Type Survey and Key Data .............................................. 2
Type Ke ............................................................................ 2
Functional Description ...................................................... 3
Electrical Input Data ......................................................... 4
Electrical Output Data ...................................................... 6
MELCHER
The Power Partners.
Edition 5/9.99
1/15
IMX 7-Series
Type Survey and Key Data
Table 1: Type survey
Output 1
U
o1 nom
I
o1 nom
[V DC]
[A]
1
3.3
3.3
3.3
3.3
5.1
5.1
5.1
5.1
5
5
5
5
12
12
12
12
15
15
15
15
24
24
24
24
1
2
3
DC-DC Converters <40 Watt
Rugged Environment
Output 2
U
o2 nom
I
o2 nom
[V DC]
[A]
1
-
-
-
-
-
-
-
-
5
5
5
5
12
12
12
12
15
15
15
15
24
24
24
24
-
-
-
-
-
-
-
-
0.6
0.7
0.7
0.7
0.25
0.3
0.3
0.3
0.2
0.24
0.24
0.24
0.13
0.15
0.15
0.15
Output Power
P
o nom
[W]
5
5
5
5
6.1
6.1
6.1
6.1
6
7
7
7
6
7.2
7.2
7.2
6
7.2
7.2
7.2
6.2
7.2
7.2
7.2
Input voltage
range
[V DC]
8.4...36
16.8...75
3
40...121
60...150
8.4...36
16.8...75
3
40...121
60...150
8.4...36
16.8...75
3
40...121
60...150
8.4...36
16.8...75
3
40...121
60...150
8.4...36
16.8...75
3
40...121
60...150
8.4...36
16.8...75
3
40...121
60...150
Efficiency
h
typ
[%]
79
81
79
79
80
81
80
80
82
83
82
82
84
84
83
84
84
84
83
84
84
84
83
84
Type
designation
20 IMX 7-03-7
40 IMX 7-03-7
70 IMX 7-03-7
110 IMX 7-03-7
20 IMX 7-05-7
40 IMX 7-05-7
70 IMX 7-05-7
110 IMX 7-05-7
20 IMX 7-05-05-7
40 IMX 7-05-05-7
70 IMX 7-05-05-7
110 IMX 7-05-05-7
20 IMX 7-12-12-7
40 IMX 7-12-12-7
70 IMX 7-12-12-7
110 IMX 7-12-12-7
20 IMX 7-15-15-7
40 IMX 7-15-15-7
70 IMX 7-15-15-7
110 IMX 7-15-15-7
20 IMX 7-24-24-7
40 IMX 7-24-24-7
70 IMX 7-24-24-7
110 IMX 7-24-24-7
Options
2, 4
1.5
1.5
1.5
1.5
1.2
1.2
1.2
1.2
0.6
0.7
0.7
0.7
0.25
0.3
0.3
0.3
0.2
0.24
0.24
0.24
0.13
0.15
0.15
0.15
-8, D, M, C
-8, D, M, C
-8, D, M
-8, D, M
-8, D, M, C
-8, D, M, C
-8, D, M
-8, D, M
-8, M, C
5
-8, M, C
5
-8, M
-8, M
-8, M, C
5
-8, M, C
5
-8, M
-8, M
-8, M, C
5
-8, M, C
5
-8, M
-8, M
-8, M, C
5
-8, M, C
5
-8, M
-8, M
4
Temperature range -9 (–40...71°C) will be standard in the future.
Flexible load distribution on double outputs possible.
5
Single output with C-pinout is possible.
See table:
Survey of options.
Operation at lower input voltage possible:
P
o
approx. 80% of
P
o nom
at
U
i min
= 14.4 V.
Type Key
20 IMX 7 - 05 - 05 -7 D M C
Input voltage range
U
i
8.4...36 V DC ............................................ 20
16.8...75 V DC ............................................ 40
40...121 V DC ............................................ 70
60...150 V DC .......................................... 110
Series ........................................................................ IMX 7
Output voltage type output 1 .................. 03, 05, 12, 15, 24
Dash:
Designates double output unit with two
independent electrically isolated outputs ...... -
1
Output voltage type output 2 ........................ 05, 12, 15, 24
Operating ambient temperature range
T
A
–25...71°C .................................................. -7
–40...85°C (option) ..................................... -8
Options:
Signal Out OK ............................................. D
SMD version ............................................... M
C-pinout ................................................ C, C2
4
5
24
24
34
345
1
2
3
Not applicable for option C.
Option -8 excludes option D and vice versa.
Option M excludes option C and vice versa.
For delivery lead times contact factory. Some types require a minimum order quantity.
Configures the 2 outputs either to
±
connection or to one strong single output.
Examples: 40 IMX 7-05-05-7M: DC-DC converter, input voltage range 16.8...75 V, 2 electrically isolated outputs each
providing 5 V, 700 mA, surface mount version.
20 IMX 7-0505-7C: DC-DC converter, input voltage range 8.4...36 V, C pinout with outputs
±5
V, 600 mA.
20 IMX 7-12-7C2: DC-DC converter, input voltage range 8.4...36 V, C pinout with one output 12 V, 500 mA.
MELCHER
The Power Partners.
Edition 5/9.99
2/15
Rugged Environment
Functional Description
DC-DC Converters <40 Watt
IMX 7 Series
The IMX 7 DC-DC modules are feedback controlled flyback
converters using current mode PWM (Pulse Width Modula-
tion). See block diagram for single and double output types.
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.
03041
In the case of the dual and 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 (Trim) input is referenced to the primary side
and allows programming 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 power.
The inhibit input allows remote converter on/off.
03042
Vi+
1
11
Vo+
Vi+
1
11
Vo1+
PWM
i
3
10
(Trim) R
4
Vo–
2
×
2200 pF
12
10
Vo1–
PWM
i
3
10 nF
13
Vo2+
V i–
2
n.c.
4
13
R
14
D
Vi –
2
2
×
2200 pF
12
Vo2–
14
n.c.
Fig. 1
Block diagram, single output types, standard pinout
Fig. 2
Block diagram, double output types, standard pinout
03063
03062
Vi+
1
3
Vo+
Vi+
1
3
Vo+
PWM
5
Vo–
10
Go
PWM
10 nF
2
×
2200 pF
V i–
2
Vi–
2
2
×
2200 pF
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
IMX 7-Series
Electrical Input Data
DC-DC Converters <40 Watt
Rugged Environment
General conditions:
– T
A
= 25°C, unless
T
C
is specified.
– Connector pins i and Vi– interconnected.
– Trim or R input not connected.
Table 2: Input Data
Input
Characteristics
Conditions
20 IMX 7
40 IMX 7
70 IMX 7
110 IMX 7
Unit
V DC
min typ max min typ max min typ max min typ max
8.4
20
36 16.8
6
40
100
50
5
0.25 0.5
0.1
5
12
15
4.7
–10...0.8
open or
2.4...U
i max
–0.5
1
<3.0
3.8
3.7
approx. 400
30
B
B
30
5
12
8
0.5
–10 ...0.8
open or
2.4...U
i max
–0.5
1
<3.0
4.2
approx. 400
20
B
15
4
4
4
U
i
U
i nom
U
i sur
Input voltage range
1
Nominal input voltage
Repetitive surge
voltage
Converter
2
switch on
start-up time
inh. release
Rise time
2
T
C min
...T
C max
I
o
= 0...I
o nom
abs. max input (3 s)
150 V
Worst case condition at
U
i min
and full load
75
40
70
121
60
110
150
t
start up
t
rise
I
i o
C
i
U
inh
0.25 0.5
0.1
0.25 0.5
0.1
5
12
8
0.2
–10 ...0.8
open or
2.4...75
–0.5
1
<3.0
15
0.25 0.5
0.1
5
12
8
0.2
–10 ...0.8
open or
2.4...75
–0.5
1
<3.0
5.6
approx. 300
10
15
s
U
i nom
I
o nom
resistive load
capacitive load
ms
No load input current
Input capacitance
Inhibit voltage
I
o
= 0,
U
i min
...U
i max
for surge calculation
unit operating
unit inhibited
mA
µF
V DC
I
inh
I
i inh
I
inr p
f
s
I
i rr
u
i RFI
1
Inhibit current
unit operating
unit inhibited
mA
Input current
if unit shut down
Inrush peak current
Switching frequency
Reflected
ripple current
Input RFI level
conducted and radiated
U
i
min
...U
i max
U
i
=
U
i nom 7
I
o
= 0...I
o nom
EN 55022
3
A
kHz
mA
pp
U
i min
...U
i max
,
I
o
= 0...I
o nom
approx. 400
50
B
2
3
4
5
6
7
U
i min
will not be as stated if
U
o
is increased above
U
o nom
by use of the R input. If the output voltage is set to a higher value,
U
i min
will be proportionally increased.
Measured with a resistive and max. admissible capacitive load.
Measured with a lead lenght of 0.1 m, leads twisted. Double output units with both outputs in parallel. 70/110 IMX 7 types need an
external capacitor at the input. (e.g. 1µF film or ceramic)
See 19 Pfl 1:
Electromagnetic Immunity.
The DC-DC converter shuts down automatically at approx. 38 V.
Operation at lower input voltage possible:
P
o
approx. 80% of
P
o nom
at
U
i min
= 14.4 V.
Source impedance according to prETS 300132-2, version 4.3, at
U
i nom
.
04008
U
o
t
rise
U
o nom
t
t
start up
Fig. 5
Converter start-up and rise time
MELCHER
The Power Partners.
Edition 5/9.99
4/15
Rugged Environment
Input Transient Voltage Protection
DC-DC Converters <40 Watt
IMX 7 Series
In many applications transient voltages on the input of the
converter are always possible. These may be caused for ex-
ample by short circuits between Vi+ and Vi– where the net-
work inductance may cause high energy pulses.
In order to protect the converters the IMX 7 types have a
built-in transient protection as per table below:
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:
Components for
external circuitry to comply with IEC/EN 61000-4-5.
Please note: The suppressor diode D is only necessary for
20 IMX 7 types. To withstand 150 V transients according to
19 Pfl 1, applicable for 40 IMX 7 types, the same external
circuitry with similar components as for IEC/EN 61000-4-5,
level 2 compliance can be used.
07064
Table 3: Built-in transient voltage suppressor
Type
Breakdown
Voltage
V
BR nom
7
1
Peak Power
at 1 ms
P
P
Peak Pulse
Current
I
PP
20 IMX
over voltage lockout at approx. 38 V
100 V
144 V
167 V
1500 W
600 W
600 W
11 A
2.9 A
2.5 A
L
C
+
D
Vi+
i
Vi–
40 IMX 7
2
70 IMX
7
2
110 IMX 7
2
1
2
The built-in overvoltage lockout circuit shuts down the converter
at approx. 38 V protecting the input up to 50 V DC. For higher
transient voltages an external suppressor or voltage limiting
circuit as e.g. for IEC/EN 61000-4-5, level 2 compliance should
be provided.
If transients generating currents above the peak pulse current
are possible then an external limiting network such as the circuit
recommended for IEC/EN 61000-4-5, level 2 compliance is
necessary.
Fig. 6
Example for external circuitry to comply with
IEC/EN 61000-4-5, level 2 (transzorb D not necessary for
40/70/110 IMX 7 types).
Table 4: Components for external circuitry to comply with IEC/EN 61000-4-5
Circuit Ref.
L
C
D
20 IMX 7
330
µH,
0,115
Ω,
1 A
TDK SF-T8-110S-01
68
µF,
63 V, 85°C
Motorola 1.5KE39A
40 IMX 7
330
µH,
0,42
Ω,
600 mA
TDK TSL1110-331KR55
68
µF,
100 V, 85°C
n.a.
70 IMX 7
1000
µH,
2.9
Ω,
290 mA
Toko 822LY-102K
47
µF,
150 V, 85°C
n.a.
110 IMX 7
330
µH,
0.65
Ω,
430 mA
Toko 822LY-331K
200
µF,
200 V, 105°C
n.a.
17.5
10
04033
5
5
10.5
04029
5
7.5
04032
11.5
Fig. 7
Dimensions of inductor L.
(TDK SF-T8-110S-01)
Reverse Polarity Protection at Input
25
∅
0.7
∅
0.7
Fig. 8
Dimensions of inductor L.
(TDK TSL1110-331KR55)
Fig. 9
Dimensions of inductor L.
(Toko R622LY-102K)
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 20 IMX 7 a fast 2 A (F2A) fuse is recommended.
– For 40 IMX 7 a fast 1 A (F1A) fuse is recommended.
– For 70 IMX 7 a fast 0.63 A (F.63A) fuse is recommended.
– For 110 IMX 7 a fast 0.63 A (F.63A) 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
Fig. 10
Typical inrush current at U
i nom
, P
o nom
vs. time (40 IMX 7)
measured according to prETS 300132-2 (Version 4.3)
10
µs/Div.
MELCHER
The Power Partners.
Edition 5/9.99
5/15
8.5
5
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