25 to 30 Watt XC Triple Series DC/DC Converters Features ! Single and Dual Output Sections Isolated from each Other and Independently Regulated ! Overall Output Accuracy up to 10:1 Better than Competitive Products ! Standby Current Less than 0.5 mA for Low Power Pulsed Battery Operation ! Fully Filtered and Specified; Very Low Noise Inputs and Outputs ! PCB Mounting with Optional Heat Sink and Chassis Mounting Kit ! Industrial Operating Temperature Range Standard, -40 to 85°C ! Five Year Warranty Description Selection Chart The 25-30 Watt Triple Series opens up new application areas in high efficiency DC/DC conversion. The unique dual control loop output design allows for independent regulation of both the single and dual outputs. This increases the total output accuracy by up to 10:1 over competitive designs. The design also eliminates cross regulation from the +5 section to the dual outputs. The 25-30 Watt Triple Series runs at 80-85% efficiency. Input Range VDC Model 12T5.12XC 12T5.15XC 24T5.12XC 24T5.15XC 48T5.12XC 48T5.15XC Min Max 10.0 10.0 18.0 18.0 36.0 36.0 20.0 20.0 36.0 36.0 72.0 72.0 Outputs VDC Outputs mA 5, ±12 5, ±15 5, ±12 5, ±15 5, ±12 5, ±15 2500, ±500 2500, ±400 3000, ±625 3000, ±500 3000, ±625 3000, ±500 25-30 Watt Triple Series Block Diagram SHIELDED ISOLATION TRANSFORMERS SINGLE SECTION A THERMAL SHUTDOWN 48T MODELS ONLY + INPUT 1 - INPUT 2 DIFFERENTIAL MODE INPUT FILTER 6 +5 7 + 5 CMN ANTI-PHASE DUAL PWM CONTROLLER 9 + 5 TRIM ISOLATION BARRIER 3 + 12/15 ON/OFF 8 12T AND 24T MODELS 4 ± CMN 5 - 12/15 SHIELDED, LOW THERMAL GRADIENT COPPER CASE DUAL SECTION 2401 Stanwell Drive • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 1 3/2001 25 to 30 Watt XC Triple Series DC/DC Converters Input Parameters* Model 12T5.12XC Voltage Range Reflected Ripple (2), 0-20MHz bw Input Current Full Load No Load Efficiency Switching Frequency Maximum Input Overvoltage, 100ms No Damage Turn-on Time, 1% Output Error MIN MAX TYP MAX TYP TYP TYP 12T5.15XC 24T5.12XC 10.0 20.0 350 500 2550 30 80 48T5.12XC 18.0 36.0 150 300 1465 20 85 TYP MAX 24T5.15XC 48T5.15XC 36.0 72.0 150 350 735 15 85 VDC mA P-P mA % 120 25 kHz 45 TYP Recommended Fuse Units 85 VDC 35 ms (3) Amps Output Parameters* 24T5.12XC 24T5.15XC 48T5.12XC 48T5.15XC +5 +5 0 0 2500 3000 4.950 5.000 5.050 N/A N/A 0.4 0.7 0.5 0.75 N/A N/A 12T5.12XC 12T5.15XC Model Output Voltage Rated Current (4) Voltage Range 100% Load Output Balance (Plus to Minus Output, Full Load) Load Regulation 25-100% Load (5) 0-100% Cross regulation (6) Line Regulation Vin = Min-Max VDC Short Term Stability (7) Long Term Stability Transient Response (8) Dynamic Response (9) Input Ripple Rejection (10) Noise, 0-20MHz bw (2) Temperature Coefficient Overvoltage Clamp (11) Short Circuit Protection to Common for all Outputs MIN MAX MIN TYP MAX TYP MAX TYP MAX TYP MAX TYP MAX TYP MAX TYP TYP TYP TYP TYP TYP MAX TYP MAX TYP 12T5.12XC 24T5.12XC 48T5.12XC 12T5.15XC 24T5.15XC 48T5.15XC ±12 160 500 ±12 160 625 ±15 125 400 ±15 125 500 Units VDC mA 11.925 14.925 12.000 15.000 VDC 12.075 15.075 0.5 0.5 % 0.7 0.7 0.05 0.05 0.1 0.1 % 0.1 0.1 0.2 0.2 0.6 0.5 % 0.8 0.75 0.0 % 0.1 0.02 % 0.1 %/kHrs 100 200 200 µs 270 250 200 mV peak >70 dB 30 mV P-P 65 50 50 50 ppm/°C 100 200 200 6.8 15 18 VDC Provides minimum of 8 hours continuous protection with current limiting and thermal overload techniques A NOTES * (2) (3) (4) (5) The dual section load regulation is defined as the voltage change in either output as the loads on both outputs are changed from minimum load to maximum load at the same time. (6) Cross regulation is defined as the change in one output when the other output is changed from minimum to maximum load. (7) Short term stability is specified after a 30 minute warmup at full load, constant line, load and ambient conditions. (8) Transient response is defined as the time for the output to settle from a 25 to 75 % step load change to a 1% error band (rise time of step = 2µ Sec). (9) Dynamic response is defined as the peak overshoot during a transient as defined in note 8 above. (10) The input ripple rejection is specified for DC to 120 Hz ripple with a modulation amplitude of 1% of Vin. All parameters measured at Tc = 25°C, nominal input voltage and full rated load unless otherwise noted. Refer to the CALEX Application Notes for the definition of terms, measurement circuits and other information. Noise is measured per CALEX Application Notes found in the CALEX Power Conversion Design Guide and Catalog. Measurement bandwidth is 0 - 20 MHz. See the applications section of this note for more information. Determine the correct fuse size by calculating the maximum DC current drain at low line input, maximum load and then adding 20 to 25% to get the desired fuse size. A slow blow type fuse is recommended. Minimum load is required for proper regulation only. No module damage is sustained if run less than minimum load. Regulation of the dual output degrades with substantial load unbalance. 2401 Stanwell Drive • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 2 3/2001 25 to 30 Watt XC Triple Series DC/DC Converters General Specifications* All Models ON/OFF Function (12) ON Logic Level or Leave Pin Open OFF Logic Level Input Resistance Converter Idle Current, Shut Down Pin Low Isolation Isolation Voltage Input to Either Output Single to Dual Output 10µA Leakage Input to Output Capacitance Input to Single Output Input to Dual Output Single to Dual Output Environmental Case Operating Range No Derating Case Funtional Range (13) Storage Range Thermal Impedance Pin Mount Version Thermal Shutdown Case Temperature General Unit Weight Mounting Kit Agency Aprovals Units MIN 2.4 VDC MAX TYP 1.5 2 VDC kohms TYP 12 mA MIN MIN 1544 500 VDC TYP TYP TYP 95 90 45 MIN MAX MIN MAX MIN MAX -40 85 -40 90 -55 105 °C TYP 4.4 °C/Watt TYP 100 °C 6.2 oz. BOTTOM VIEW pF SIDE VIEW Mechanical tolerances unless otherwise noted: X.XX dimensions: ±0.020 inches °C X.XXX dimensions: ±0.005 inches Seal around terminals is not hermetic. Do not immerse units in any liquid. °C MS12 UL 1459 (11) For module protection only, see also note 3. (12) The ON/OFF pin is Open Collector TTL, CMOS, and relay compatible. The input to this pin is referenced to the -input. (13) The functional temperature range is intended to give an additional data point for use in evaluating this power supply. At the low functional temperature the power supply will function with no side effects, however, sustained operation at the high functional temperature will reduce expected operational life. The data sheet specifications are not guaranteed over the functional temperature range. (14) Specifications subject to change without notice. Pin 1 2 3 4 Function +INPUT -INPUT +12/15V CMN 5 -12/15V Pin 6 7 8 9 Function +5V CMN ON/OFF +5V TRIM A Heat Sink Option Chassis Mounting Kit - MS12 The 25-30 Watt Triple can be ordered with a “-I” configuration which provides a case with 3 by M3 inserts located on the top surface of the case for attaching a heat sink. When an “-HS” is ordered CALEX will ship the converter with a heat sink attached. The CALEX HS heat sink was specially developed for this model and can reduce the case temperature rise to below 3.3°C per watt with natural convection and less with moving air. One heat sink is needed for each 25-30 Watt Triple ordered. The MS12 chassis mounting kit allows for direct wire connection to the 25-30 Watt Triple Series. The mounting kit includes two barrier strips for wire attachment, an input fuse and an output trim pot for trimming the +5 volt output. Provisions are also made for additional output bypassing and grounding. If the MS12 is ordered at the same time as a 25-30 Watt Triple the mounting kit will be shipped with the correct fuse size. The MS12 may be conveniently attached to a chassis by using the 4 - 0.156 inch diameter mounting holes provided at each corner. Customer installed heat sinks may also be used. It is recommended that only liquid heat sink compound be used on the heat sink interface. Avoid the so called “Dry” pad heat sink materials. In our experience these materials are actually worse than using no compound at all. Although the MS12 comes with solderless sockets for the 25-30 Watt Triple, it is recommended that the converter be soldered to the mounting kit for improved reliability under severe environmental or vibration conditions. 2401 Stanwell Drive • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 3 3/2001 25 to 30 Watt XC Triple Series DC/DC Converters Application Information The dual control loops are locked together in time by a proprietary “Anti-Phase Dual PWM Controller” subassembly. The synchronization reduces beat frequency problems that occur when two switching supplies run at slightly different frequencies. The “Anti-Phase” operation also evens out the current pulses on the input bulk capacitor allowing for conservative derating and hence longer life. FUSE + INPUT +5 6 1 + INPUT + 5 TRIM 9 2 - INPUT - INPUT The dual loop design allows both the single and dual outputs to be fully isolated from each other. This helps the system design by allowing the common analog and digital ground point to be elsewhere in the system. The dual outputs can also be used as single ended 24 or 30 volt outputs. ON/OFF + 5 LOAD + 5 CMN 7 + 12/15 3 8 ON/OFF ± CMN 4 + 5 TRIM + LOAD - LOAD - 12/15 5 Figure 1. The 25-30 Watt Triple Series is also mindful of battery operation for industrial/medical control and remote data collection. The remote ON/OFF control pin places the converter in a very low power mode that draws only 0.5 mA maximum from the input source. This is at least a 10:1 improvement over industry standard specifications of 5 to 30 mA standby current drain. Standard connections for the 25-30 Watt Triple. The ON/OFF and Trim pins can be left floating if they are not used. The input fuse should not be omitted. The ON/OFF and +5 trim pins may be left floating if they are not used. No external capacitance on either the input or outputs is required for normal use which can, in fact, degrade the converter’s operation. See our application note “Understanding Power Supply Output Impedance for Optimum Decoupling” for more information. The usual 0.1 to 0.01µF bypasses may be used around your PCB as required for local bypassing without harm. Extremely low ESR capacitors ( <0.2 ohms) should not be used at the input. This will cause peaking of the input filters’ transfer function and actually degrade the filters’ performance. These converters achieve an output noise of 30 mV peak to peak typical and are fully specified and tested to a maximum specification of 65 mV peak to peak over a wide bandwidth of 0-20 MHz. Input filtering reduces reflected ripple noise and is similarly low and also fully specified for typical and maximum values (exact value depends on input voltage range). All inputs and outputs are protected from transient overvoltage conditions by 500 watt transient overvoltage suppressors. Full overload protection is provided by independent pulse-by-pulse current limiting and overtemperature shutdown. These protection features assure you that our 25-30 Watt Triple will provide zero failure rate operation. Single Output The single output is independently regulated and isolated from the dual outputs and can be operated independently or with a common ground with the dual output. Six-sided shielding is standard along with specified operation over the full industrial temperature range of -40° to +85°C. The +5 TRIM pin may be used to adjust the +5 volt output by up to ±5 % from the nominal factory setting of +5.000 volts. The trim may be used to adjust for system wiring voltage drops or to adjust the +5 output up to 5.2 volts for ECL applications. Since the 5 volt output is completely isolated from the dual section the output can be grounded to generate -5.2 volts or +5.2 volts. Figure 2 shows the proper connections for the trim pin. The 25-30 Watt Triple Series, like all CALEX converters, carries the full 5 year CALEX no hassle warranty. We can offer a five year warranty where others can’t because with CALEX it’s rarely needed. A General Operation Figure 1 shows the recommended connections for the 25-30 Watt Triple DC/DC converter. A fuse is recommended to protect the input circuit and should not be omitted. The fuse serves two purposes: +5 6 1) It prevents unlimited current from flowing in the case of a catastrophic system failure. + 5 TRIM 9 2) UL regulations for telecom equipment require the use of a fuse. + 5 CMN 7 TRIM DOWN + 5 LOAD TRIM UP 10K TRIMPOT Figure 2. The 5 volt output can be trimmed by using either a trimpot or fixed resistors. If fixed resistors are used their values may range from zero to infinite ohms the trimpot should be 10K ohms nominal. 2401 Stanwell Drive • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 4 3/2001 25 to 30 Watt XC Triple Series DC/DC Converters Do not use the lowest ESR, biggest value capacitor that you can find! This can only lead to reduced system performance or oscillation. +5 6 R1 R3 C1 R4 + 5 TRIM 9 IC1 R2 See our application note “Understanding Power Supply Output Impedance for Optimum Decoupling” in the CALEX Power Conversion Design Guide and Catalog for more information. REMOTE + 5 VOLT LOAD Q1 R5 + 5 CMN 7 C1 R1 R2 R3 + INPUT 1 100K Parts List R4 0.1µF, 50V, Ceramic R5 470 ohm, 5% Q1 1.0K, 5% 2.4K, 5% IC1 4.99K, 1% 4.99K, 1% 2N3906 TL431 ON/OFF 8 100 W 15V - INPUT 2 Figure 3. This simple circuit allows for remote sensing with the 5 volt output. The circuit can correct for up to 0.25 volts of total drop in the power leads. At 3 amps of output this is approximately 0.08 ohms of line resistance. A trimpot may be added to R5 to allow for exact adjustment of the 5 volt output. Figure 5. The simplified schematic of the ON/OFF pin shows a 100K resistor connected between the +Input and the ON/OFF pin. The maximum open circuit voltage is clamped by the 15 volt zener diode. The 100 ohm resistor prevents large ground currents from flowing out the ON/OFF pin instead of the -Input pin during power up transients. Figure 3 shows how to implement remote sense with the trim pin and a TL431 adjustable voltage reference. This circuit allows automatic correction of the output voltage up to 0.25 volts total. Case Grounding The case serves not only as a heat sink but also as an EMI shield. The case/header shield is tied to the +Input pin for the 48T models. The 12T and 24T models have the case tied to the -Input pin. These connections are shown on the 25-30 Watt Triple block diagram. Dual Output The dual output is independently regulated and isolated from the single output and can be operated separately or with a common ground with the single output. The dual outputs can also be connected for single-ended load applications of either 24 or 30 volts as shown in Figure 4. This configuration allows for full output current operation up to the full 25 or 30 watt rating. For all models the case is floating from the output sections. Remote ON/OFF Pin Operation The remote ON/OFF pin may be left floating if this function is not used. The equivalent input circuit for the ON/OFF pin is shown in Figure 5. The best way to drive this pin is with an open collector/drain or relay contact. See our application note titled “Understanding the Remote ON/OFF Function” for more information about using the remote ON/OFF pin. + 12/15 3 + LOAD ± CMN 4 - LOAD 24 or 30V LOAD A When the ON/OFF pin is pulled low with respect to the Input, the converter is placed in a low power drain state. This low power state typically draws less than 200 mA from the input source. When the ON/OFF pin is released the converter powers up in typically 35 mSec. The ON/OFF pin turns the converter off while keeping the input bulk capacitor fully charged. This prevents the large inrush current spike that occurs when the +Input pin is opened and closed. - 12/15 5 Figure 4. The dual output may be used either as a dual polarity or singleended source. If the output is used as a single-ended source, pin 4 should be left unconnected. Grounding Temperature Derating / Mounting Options The +5 and ± dual sections are floating independently from each other. They may be operated this way or with a common ground. The XC Triple Series can operate up to 85°C case temperature without derating. Case temperature may be roughly calculated from ambient by knowing that the XC Triples’ case temperature rise is 4.4°C per package watt dissipated. For example, if the converter was functioning at an output of 30 Watts, at what ambient could it expect to run with no moving air and no additional heatsinks? If the single and dual sections are connected either directly at the converter or at some remote location it is suggested that 1 µF, 35 volt Tantalum capacitor bypasses be used directly at the converter output pins. These capacitors prevent any common mode switching currents from showing up on the converter’s outputs as normal mode output noise. 2401 Stanwell Drive • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 5 3/2001 25 to 30 Watt XC Triple Series DC/DC Converters Efficiency is approximately 85%, this leads to an input power of 35 watts. The case temperature rise would be 5 watts x 4.4 = 22°C. This number is subtracted from the maximum case temperature of 85°C to get 63°C. temperature. Because of the difficulty of defining ambient temperature and the possibility that the loads’ dissipation may actually increase the local ambient temperature significantly, these calculations should be verified by actual measurement before committing to a production design. This is a rough approximation of the maximum ambient Typical Performance (Tc=25°C, Vin=Nom VDC, Rated Load). 12 VOLT EFFICIENCY Vs. LOAD 12 VOLT INPUT CURRENT Vs. LINE INPUT VOLTAGE 85 LINE = 10VDC 50% FULL LOAD 3.0 2.5 100% LOAD 2.0 1.5 50% LOAD 1.0 EFFICIENCY(%) 80 EFFICIENCY (%) INPUT CURRENT (AMPS) 12 VOLT EFFICIENCY Vs. LINE INPUT VOLTAGE 85 3.5 75 LINE = 12VDC 70 100% FULL LOAD 80 75 LINE = 20VDC 65 0.5 60 0.0 0 2 4 6 8 10 12 14 16 18 70 0 20 10 20 30 40 60 70 80 90 100 10 12 14 LOAD (%) LINE INPUT (VOLTS) 24 VOLT INPUT CURRENT Vs. LINE INPUT VOLTAGE 90 2.0 85 16 18 20 LINE INPUT(VOLTS) 24 VOLT EFFICIENCY Vs. LOAD 2.5 24 VOLT EFFICIENCY Vs. LINE INPUT VOLTAGE 90 50% FULL LOAD LINE = 18VDC 1.5 100% LOAD 1.0 50% LOAD EFFICIENCY(%) 85 EFFICIENCY (%) INPUT CURRENT (AMPS) 50 80 75 LINE = 24VDC 100% FULL LOAD 80 75 0.5 70 LINE = 36VDC 0.0 65 0 4 8 12 16 20 24 28 32 36 70 0 10 20 30 40 LINE INPUT (VOLTS) 60 70 80 90 100 18 20 22 24 LOAD (%) 48 VOLT INPUT CURRENT Vs. LINE INPUT VOLTAGE 26 28 30 32 34 36 LINE INPUT(VOLTS) 48 VOLT EFFICIENCY Vs. LOAD 1.25 48 VOLT EFFICIENCY Vs. LINE INPUT VOLTAGE 90 90 85 100% FULL LOAD LINE = 36VDC 1.00 0.75 100% LOAD 0.50 50% LOAD 85 80 EFFICIENCY(%) EFFICIENCY (%) INPUT CURRENT (AMPS) 50 75 70 LINE = 48VDC 65 50% FULL LOAD 80 A 75 0.25 60 LINE = 72VDC 0.00 55 0 10 20 30 40 50 60 70 80 70 0 10 20 LINE INPUT (VOLTS) 40 50 60 70 80 90 100 35 OUTPUT VOLTAGE Vs. OUTPUT LOAD 50 OUTPUT IMPEDANCE Vs. FREQUENCY 90 +/- DUAL OUTPUT 70 60 50 40 30 20 55 60 65 70 75 DERATING 110 INFINITE HEAT SINK 100 90 OUTPUT POWER (%) OUTPUT IMPEDANCE (OHMS) 100 5V OUTPUT 45 LINE INPUT(VOLTS) 10 80 40 LOAD (%) 110 NORMALIZED OUTPUT (%) 30 DUAL OUTPUT 1 5V OUTPUT .1 80 NO HEAT SINK 70 60 50 SAFE OPERATING AREA 40 30 20 10 10 0 .01 0 50 100 150 200 250 300 350 OUTPUT LOAD (%) 400 450 500 0 10 100 1000 10000 FREQUENCY (Hz) 100000 1000000 -40 -25 -10 5 20 35 50 65 80 95 110 AMBIENT TEMPERATURE (Deg C) 2401 Stanwell Drive • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 6 3/2001