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DATASHEET
Rev. C
DC100 SERIES
2:1 Wide Input Voltage Ranges
100 Watts, Single Outputs
Industry Standard Half-Brick Footprint
DC/DC Power Converters
Standard
FEATURES
 Soft-Start
 RoHS Compliant
 2:1 Wide Input Voltage Ranges
 Up to 100 Watts Output Power
 Single Outputs Ranging from 3.3VDC to 48VDC
 Output Current up to 25A
Terminal Block
 Under Voltage Lockout
 Six-Sided Shielding
APPLICATIONS






Wireless Networks
Telecom / Datacom
Industry Control Systems
Semiconductor Equipment
Distributed Power Architectures
Military Applications
OPTIONS






Pin Length
Heatsinks
Thru-Hole Inserts
Negative Logic Remote On/Off
Terminal Block
Terminal Block with EMC Filter
 High Efficiency up to 93%
 No Minimum Load Requirements
 Adjustable Output Voltage
 Industry Standard Half-Brick Footprint
 Remote On/Off Control
 Input to Output Basic Insulation: 2250VDC
 Threaded Inserts and Thru-Hole Inserts Available
 Input Reverse Protection
 Short Circuit, Over Voltage, Over Current, and Over Temperature
Protection
 UL60950-1, EN60950-1, and IEC60950-1 Safety Approvals
 Several Mechanical Options Available
DESCRIPTION
The DC100 series of DC/DC power converters provides up to 100 Watts of output power in an industry standard half-brick
package and footprint. This series consists of single output models ranging from 3.3VDC to 48VDC with 2:1 wide input
voltage ranges of 9~18VDC, 18~36VDC and 36~75VDC. Some features include high efficiency up to 93%, adjustable
output voltage, positive remote on/off control, and six-sided shielding. These converters also have short circuit, over
voltage, over current, over temperature, and input reverse protection. The DC100 series is RoHS compliant and has
UL60950-1, EN60950-1, and IEC60950-1 safety approvals. Several different options are available for this series including
negative remote on/off, terminal block, pin length, heatsinks, and thru-hole inserts. Please call factory for more details.
10/23/2012
Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 1 of 8
Rev. C
DC100 Series
2:1 Input Voltage Ranges
Up to 100 Watts, Single Outputs
Half-Brick DC/DC Power Converters
SPECIFICATIONS: DC100 SERIES
All specifications are based on 25°C, Nominal Input Voltage, and Maximum Output Current unless otherwise noted.
We reserve the right to change specifications based on technological advances.
SPECIFICATION
TEST CONDITIONS
Min
Typ
Max
12VDC nominal input models
24VDC nominal input models
48VDC nominal input models
12VDC nominal input models
24VDC nominal input models
48VDC nominal input models
12VDC nominal input models
24VDC nominal input models
48VDC nominal input models
12VDC nominal input models
24VDC nominal input models
48VDC nominal input models
No Load
9
18
36
12
24
48
18
36
75
9
18
36
Low line to high line at full load
No load to full load
Full load an nominal Vin
-0.1
-0.1
-1
-20
Unit
INPUT SPECIFICATIONS
Input Voltage Range
Start-up Voltage
Shutdown Voltage
Input Surge Voltage (100ms)
Input Current
Input Filter (See Note 11)
Input Reverse Protection (See Note 14)
OUTPUT SPECIFICATIONS
Output Voltage
Line Regulation
Load Regulation
Voltage Accuracy
Voltage Adjustability (See Note 7)
Output Power
Output Current
Minimum Load
Ripple & Noise (peak to peak)
Transient Response Recovery Time
Power Up
Start-Up Time
Remote On/Off
Remote Sense (See Note 8)
Temperature Coefficient
PROTECTION
Over Voltage Protection Threshold
Over Current Protection Threshold
Short Circuit Protection
Over Temperature Protection
GENERAL SPECIFICATIONS
Efficiency
Switching Frequency
I/P to O/P (Basic Insulation)
Isolation Voltage
I/P to Case
O/P to Case
Isolation Resistance
Isolation Capacitance
Maximum Capacitive Load
10/23/2012
7.5
16
34
36
50
100
See Table
Pi Type
Parallel diode
See Table
+0.1
+0.1
+1
+10
See Table
See Table
0
Nominal input and constant resistive load
-0.02
115
110
Minimum input and constant resistive load
Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
VDC
VDC
%
%
%
%
See Table
200
25
25
10
+0.02
µs
ms
ms
% Vo
%/°C
130
% Vo
140
% Io
Hiccup, automatic recovery
+115
°C
Nominal input voltage and full load
For 1 minute
For 1 minute
For 1 minute
VDC
%
20MHz Bandwidth
25% load step change
Hiccup
VDC
255
2250
1600
1600
1
See Table
300
330
2500
See Table
KHz
VDC
VDC
VDC
GΩ
pF
Page 2 of 8
DC100 Series
2:1 Input Voltage Ranges
Up to 100 Watts, Single Outputs
Half-Brick DC/DC Power Converters
Rev. C
SPECIFICATIONS: DC100 SERIES
All specifications are based on 25°C, Nominal Input Voltage, and Maximum Output Current unless otherwise noted.
We reserve the right to change specifications based on technological advances.
SPECIFICATION
TEST CONDITIONS
REMOTE ON/OFF CONTROL (See Note 6)
DC/DC ON
Positive Logic (standard)
DC/DC OFF
DC/DC ON
Negative Logic (optional)
DC/DC OFF
Input Current of Remote Control Pin
Remote Off State Input Current
ENVIRONMENTAL SPECIFICATIONS
Operating Case Temperature Range
Storage Temperature
MTBF (See Note 1)
Typ
Max
Unit
Open or 3V < Vr < 12V
Short or 0V < Vr < 1.2V
Short or 0V < Vr < 1.2V
Open or 3V < Vr < 12V
-0.5
1
mA
3
mA
Nominal Vin
Nominal Vin
Standard
Terminal Block type
Standard
Terminal Block type
-40
-40
-55
-40
5
Relative Humidity
Thermal Shock
Vibration
Thermal Impedance (See Note 9)
Min
Standard
With 0.24” Heatsink
With 0.45” Heatsink
BELLCORE TR-NWT-000332
MIL-HDBK-217F
+115
+105
+125
+105
95
MIL-STD-810F
MIL-STD-810F
6.7
5.4
4.7
1,010,000 hours
74,160 hours
°C
°C
% RH
°C/Watt
PHYSICAL SPECIFICATIONS
Weight
Dimensions (L x W x H)
Standard
“T” suffix models
“TF” suffix models
“TF1” suffix models
Standard
“T” suffix models
“TF” suffix models
“TF1” suffix models
Case Material
Base Material
Potting Material
Shielding
SAFETY & EMC CHARACTERISTICS
Safety Approvals
Standard
EMI (See Note 11)
TF or TF1 Option
EN55022
EN55022
ESD
EN61000-4-2
Radiated Immunity
Fast Transient (See Note 11)
Surge (See Note 11)
Conducted Immunity
EN61000-4-3
EN61000-4-4
EN61000-4-5
EN61000-4-6
10/23/2012
3.42oz (97g)
7.05oz (200g)
8.47oz (240g)
26.10oz (740g)
2.4x2.28x0.5 inches (61x57.9x12.7 mm)
3.35x2.4x1.1 inches (85x61x28 mm)
3.35x2.4x1.27 inches (85x61x32.3 mm)
4x3.5x3.5 inches (101.6x88.9x88.9 mm)
Metal
FR4 PCB
Silicon (UL94-V0)
Six-sided
IEC60950-1, UL60950-1, EN60950-1
Class A
Class A
EN55024
Air ±8KV
Contact ±6KV
10 V/m
±2KV
±1KV
10 Vrms
Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Perf. Criteria A
Perf. Criteria A
Perf. Criteria A
Perf. Criteria A
Perf. Criteria A
Page 3 of 8
DC100 Series
2:1 Input Voltage Ranges
Up to 100 Watts, Single Outputs
Half-Brick DC/DC Power Converters
Rev. C
MODEL SELECTION TABLE
Output
Voltage
Min. load
Full load
No Load (2)
Input Current
Ripple & Noise (3) (4)
Output
Power
Maximum
Capacitive Load (5)
DC100-12S3.3
3.3VDC
0mA
25A
155mA
75mVp-p
82.5W
75700µF
90%
DC100-12S05
5 VDC
0mA
20A
150mA
75mVp-p
100W
40000µF
91%
12 VDC
0mA
8.4A
180mA
100mVp-p
100W
7000µF
91%
15 VDC
0mA
6.7A
180mA
100mVp-p
100W
4460µF
91%
Model Number
DC100-12S12
DC100-12S15
DC100-12S24
Input Voltage
12 VDC
(9 – 18 VDC)
Output Current
Efficiency (3)
24 VDC
0mA
4.2A
90mA
200mVp-p
100W
1750µF
90%
DC100-12S28
28 VDC
0mA
3.6A
100mA
200mVp-p
100W
1280µF
90%
DC100-12S48
48 VDC
0mA
2.1A
100mA
300mVp-p
100W
430µF
90%
DC100-24S3.3
3.3VDC
0mA
25A
90mA
75mVp-p
82.5W
75700µF
91%
DC100-24S05
5 VDC
0mA
20A
150mA
75mVp-p
100W
40000µF
93%
12 VDC
0mA
8.4A
185mA
100mVp-p
100W
7000µF
93%
15 VDC
0mA
6.7A
185mA
100mVp-p
100W
4460µF
93%
DC100-24S12
DC100-24S15
DC100-24S24
24 VDC
(18 – 36 VDC)
24 VDC
0mA
4.2A
85mA
200mVp-p
100W
1750µF
92%
DC100-24S28
28 VDC
0mA
3.6A
85mA
200mVp-p
100W
1280µF
92%
DC100-24S48
48 VDC
0mA
2.1A
85mA
300mVp-p
100W
430µF
92%
DC100-48S3.3
3.3VDC
0mA
25A
80mA
75mVp-p
82.5W
75700µF
91%
DC100-48S05
5 VDC
0mA
20A
90mA
75mVp-p
100W
40000µF
93%
DC100-48S12
12 VDC
0mA
8.4A
90mA
100mVp-p
100W
7000µF
93%
15 VDC
0mA
6.7A
90mA
100mVp-p
100W
4460µF
93%
DC100-48S15
DC100-48S24
48 VDC
(36 – 75 VDC)
24 VDC
0mA
4.2A
40mA
200mVp-p
100W
1750µF
92%
DC100-48S28
28 VDC
0mA
3.6A
40mA
200mVp-p
100W
1280µF
92%
DC100-48S48
48 VDC
0mA
2.1A
40mA
300mVp-p
100W
430µF
92%
NOTES
1. BELLCORE TR-NWT-000332. Case 1: 50% Stress, Temperature at 40°C.
MIL-HDBK-217F Notice2 @Ta=25°C, Full load (Ground, Benign, controlled environment).
2. Typical value at nominal input voltage and no load.
3. Typical value at nominal input voltage and full load.
4. The ripple and noise of 48VDC output voltage models is measured with a 2.2μF/100V X7R 1812 MLCC;
The ripple and noise of all other output voltages is measured with a 4.7μF/50V X7R 1812 MLCC.
5. Test by minimum input and constant resistive load.
6. The CTRL pin voltage is referenced to –INPUT. To order negative logic remote on/off control add the suffix “R” to the model number.
7. Output voltage is adjustable for 10% trim up or -20% trim down of nominal output voltage by connecting a single resistor between TRIM and
+SENSE pins for trim up or between TRIM and -SENSE pins for trim down. To calculate the value of the resistor RU and RD for a particular
output voltage see page 5.
8. Maximum output deviation is +10% inclusive of remote sense and trim. If remote sense is not being used the +SENSE should be connected to its
corresponding +OUTPUT and likewise the -SENSE should be connected to its corresponding -OUTPUT.
9. (1) Thermal test conditions for vertical direction are by natural convection (20LFM).
(2) Heat sink is optional. See the “Product Options” table on page 6 for suffix options.
10. The DC100 series can only meet EN55022 Class A or Class B with external components added. Please contact factory for more information.
11. An external input filter capacitor is required if the module has to meet EN61000-4-4, EN61000-4-5. We recommend connecting one aluminum
electrolytic capacitor (Nippon chemi-con KY series, 220μF /100V, ESR 48mΩ) in parallel.
12. CASE GROUNDING: EMI can be reduced when you connect the four screw bolts to the shield plane.
13. This series comes with several different options: negative remote on/off control, heatsinks, pin length, thru-hole inserts, and terminal blocks. See
the “Product Options” table on page 6 for more ordering information.
14. CAUTION: This power converter is not internally fused. An input line fuse must always be used.
10/23/2012
Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 4 of 8
DC100 Series
2:1 Input Voltage Ranges
Up to 100 Watts, Single Outputs
Half-Brick DC/DC Power Converters
Rev. C
DERATING CURVES
DC100-48S05 Derating Curve
With 0.24” Height Heatsink (See Note 9)
20
60
Natural Convection (20LFM)
100LFM
200LFM
300LFM
400LFM
500LFM
40
20
40
80
60
100
20
0
-40
120
Natural Convection (20LFM)
100LFM
200LFM
300LFM
400LFM
500LFM
40
~
~
20
60
~
~
0
-40
80
Output Power (%)
Output Power (%)
80
~
~
0
100
~
~
Natural Convection (20LFM)
100LFM
200LFM
300LFM
400LFM
500LFM
40
~
~
60
120
~
~
100
80
DC100-48S05 Derating Curve
With 0.45” Height Heatsink (See Note 9)
~
~
100
120
~
~
120
~
~
Output Power (%)
DC100-48S05 Derating Curve
20
40
Ambient Temperature (°C)
60
80
100
120
-40
20
Ambient Temperature (°C)
40
60
80
100
120
Ambient Temperature (°C)
EFFICIENCY GRAPHS
DC100-48S05 Efficiency vs Input Voltage
DC100-48S05 Efficiency vs Output Load
94.00
95.0
92.75
92.5
91.50
90.0
87.5
85.0
90.25
Efficiency (%)
Efficiency (%)
89.00
87.75
86.50
85.25
84.00
82.5
80.0
77.5
75.0
72.5
70.0
82.75
80.25
Vin
Vin
Vin
Vin
67.5
65.0
62.5
Iout = 100% F.L.
Iout = 50% F.L.
Iout = 25% F.L.
81.50
79.00
= 18V
= 24V
= 48V
= 75V
60.0
36
40
44
48
52
56
60
64
68
72
75
Input Voltage (VDC)
10
20
30
40
50
60
70
80
90
100
% of Full Load
OUTPUT VOLTAGE ADJUSTMENT
Output is adjustable for 10% trim up or -20% trim down of nominal output voltage by connecting an external resistor between
the TRIM pin and either the +SENSE or -SENSE pins. With an external resistor between the TRIM and -SENSE pin, the
output voltage set decreases. With an external between the TRIM and -SENSE pin, the output voltage set point increases.
Maximum output deviation is +10% inclusive of remote sense. The value of the external resistor can be obtained by the
equations below. The external TRIM resistor needs to be at least 1/8W resistor.
 V 100  % 100  2% 
RU   OUT

K
%
 1.225%

TRIM UP
10/23/2012
 100 
RD  
 2K
 % 
TRIM DOWN
Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 5 of 8
DC100 Series
2:1 Input Voltage Ranges
Up to 100 Watts, Single Outputs
Half-Brick DC/DC Power Converters
Rev. C
MECHANICAL DRAWING
Unit: inches (mm)
SIDE VIEW
2.000 (50.80)
1.400 (35.56)
1.000 (25.40)
0.700 (17.78)
9
0.400
(10.16)
8
7
BOTTOM
VIEW
6
1
2
3
4
0.400
(10.16)
EXTERNAL OUTPUT TRIMMING
Output can be externally trimmed by
using the method shown below.
TRIM UP
0.20 (5.1)
2.28 (57.9)
TRIM DOWN
6
RD
RU
8
1.900 (48.26)
PIN CONNECTIONS
DEFINE
DIAMETER
- INPUT
0.04 in.
CASE
0.04 in.
CTRL
0.04 in.
+ INPUT
0.04 in.
- OUTPUT
0.08 in.
- SENSE
0.04 in.
TRIM
0.04 in.
+ SENSE
0.04 in.
+ OUTPUT
0.08 in.
7
0.50
(12.7)
1.000 (25.40)
0.700 (17.78)
2.40 (61.0)
1.400 (35.56)
0.02 (0.6)
5
Threaded (Standard) 4-M3X0.5
Thru-Hole (“TH” suffix) 4-Ø0.126 (Ø3.2)
The screw locked torque: MAX 0.49N.M
(5.0kgf.cm)
See Note 12
PIN
1
2
3
4
5
6
7
8
9
Product Options
0.200” pin length
0.145” pin length
0.200” pin length
Positive Remote ON/OFF Logic
0.145” pin length
Thru-Hole Inserts (No Thread) (1) Ø0.126 thru-hole (no thread) inserts
Negative Remote ON/OFF Logic
0.200 (5.08)
Suffix
R
RL
None
S
TH
Heatsink
(1)
Terminal Block
(2)(3)
0.50
(12.7)
7
NOTES
1. Tolerance: x.xx±0.02 (x.x±0.5)
x.xxx±0.01 (x.xx±0.25)
2. Pin Pitch Tolerance: ±0.01 (±0.25)
3. Pin Dimension Tolerance: ±0.004 (±0.1)
Product Options
H = 0.45” Vertical
H = 0.24” Horizontal
H = 0.24” Vertical
H = 0.45” Horizontal
Wall Mounted
Wall Mounted with EMC Filter (2)
(2)(3)
Wall Mounted with Fin Type Heatsink and EMC Filter
Suffix
H
H1
H2
H3
T
TF
TF1
NOTES
1. Models with thru-hole inserts cannot be equipped with a heatsink.
2. Models with EMC filter (suffix “TF” and “TF1”) meet EN55011, EN55022 Class A.
3. “TF1” models have an ambient operating temperature of -40°C to +85°C (without derating).
HEATSINK OPTIONS
Vertical Fin Orientation (Suffixes “H”, “H2”)
Horizontal Fin Orientation (Suffixes “H1”, “H3”)
2.28 (57.9)
H
Unit: inches (mm)
Heatsink Options
Heatsink Options
H = 0.24 inches (“H2” suffix)
H = 0.45 inches (“H” suffix)
H = 0.24 inches (“H1” suffix)
H = 0.45 inches (“H3” suffix)
2.40 (61.0)
Unit: inches (mm)
H
2.40 (61.0)
2.28 (57.9)
10/23/2012
Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 6 of 8
DC100 Series
2:1 Input Voltage Ranges
Up to 100 Watts, Single Outputs
Half-Brick DC/DC Power Converters
Rev. C
TERMINAL BLOCK OPTIONS
Wall Mounted without EMC Filter (Suffix “T”)
Wall Mounted with EMC Filter (Suffix “TF”)
TF
(2)
TF1 (2) (3)
Terminal Block Type
T
Weight
7.05oz (200g)
8.47oz (240g)
26.10oz (740g)
Dimensions
3.35 x 2.4 x 1.1 inches (85 x 61 x 28 mm)
3.35 x 2.4 x 1.27 inches (85 x 61 x 32.3 mm)
4.0 x 3.5 x 3.5 inches (101.6 x 88.9 x 88.9 mm)
Thru-Hole Inserts (WxL)
2.126 x 3.071 inches (54.00 x 78.00 mm)
2.126 x 3.071 inches (54.00 x 78.00 mm)
2.126 x 3.071 inches (54.00 x 78.00 mm)
MODEL NUMBER SETUP
DC
100
-
Series Name
Output Power
100: 100 Watts
24
S
12
Input Voltage
Single Output
Output Voltage
S: single
3.3: 3.3 VDC
12: 9~18 VDC
24: 18~36 VDC
05: 5 VDC
48: 36~75 VDC
12: 12 VDC
15: 15 VDC
24: 24 VDC
28: 28 VDC
48: 48 VDC
R
Remote On/Off & Pin Length
None: positive Logic, 0.200” pin length
S: positive Logic, 0.145” pin length
R: negative Logic, 0.200” pin length
RL: negative Logic, 0.145” pin length
TH
Thru-Hole Inserts
H
(1)
Heatsink
None: threaded inserts
TH: Ø0.126 thru-hole inserts
TF
(1)
None: no heatsink
(1)
H: 0.45” vertical
H1: 0.24” horizontal
H2: 0.24” vertical
H3: 0.45” horizontal
Terminal Block (2) (3)
None: no terminal block
T: wall mounted
TF: wall mounted with EMC filter
(2)
TF1: wall mounted with fin type heatsink and
(2) (3)
EMC filter
NOTES
1. Models with thru-hole inserts cannot be equipped with a heatsink.
2. Models with EMC filter (suffix “TF” and “TF1”) meet EN55011, EN55022 Class A.
3. “TF1” models have an ambient operating temperature of -40°C to +85°C (without derating).
10/23/2012
Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 7 of 8
Rev. C
DC100 Series
2:1 Input Voltage Ranges
Up to 100 Watts, Single Outputs
Half-Brick DC/DC Power Converters
COMPANY INFORMATION
Wall Industries, Inc. has created custom and modified units for over 50 years. Our in-house research and development
engineers will provide a solution that exceeds your performance requirements on-time and on budget. Our ISO9001-2008
certification is just one example of our commitment to producing a high quality, well-documented product for our customers.
Our past projects demonstrate our commitment to you, our customer. Wall Industries, Inc. has a reputation for working
closely with its customers to ensure each solution meets or exceeds form, fit and function requirements. We will continue to
provide ongoing support for your project above and beyond the design and production phases. Give us a call today to discuss
your future projects.
Contact Wall Industries for further information:
Phone:
Toll Free:
Fax:
E-mail:
Web:
Address:
10/23/2012
(603)778-2300
(888)587-9255
(603)778-9797
sales@wallindustries.com
www.wallindustries.com
5 Watson Brook Rd.
Exeter, NH 03833
Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 8 of 8