Standard Models LV200 SERIES 200 Watt Half-Brick DC/DC Power Converters Advanced Publication Wall Industries, Inc. FEATURES • Soft-Start • 4:1 Ultra Wide Input Voltage Range: 9~36VDC • 200 Watts Output Power • Industry Standard Half-Brick Footprint • Under Voltage Lockout • Remote Sense Compensation to 10% Vout • No Minimum Load Requirements • Single Outputs Ranging from 3.3VDC to 48VDC • Remote ON/OFF Control • 1500VDC I/O Isolation • High Efficiency • Threaded Inserts & Thru-Hole Inserts Available • Fixed Switching Frequency • Short Circuit, Over Voltage, Over Current, and Over • Cost Efficient Solution Size: 2.40x 2.28 x 0.50 inches Temperature Protection • Fast Transient Response Chassis Mount Models (Prefix “CM”) • UL60950-1, EN60950-1, IEC60950-1, & EN50155 • Made in the USA Safety Approvals • 100% Burn-in • Heat Sink and Chassis Mount Options Available APPLICATIONS Size: 5.70 x 3.40 x 1.10 inches • Telecommunications Equipment • For Use in 12V and 24V Battery Applications • Network (LANs/WANs) Equipment • For Use in Intermediate and Distributed Bus • Next Generation Low Voltage, High Architectures (IBA) Current Microprocessors and ICs • Military Applications DESCRIPTION The LV200 is a high density, low input voltage, isolated converter with a 4:1 ultra wide input voltage range. Low input voltage converters are uncommon in the industry and the LV200 series offers the flexibility of operation with both 12V and 24V busses. This state-of-the-art converter's features include fast transient response, short circuit protection, over current protection, soft start, and many other features that are required for today's demanding applications. Options: • Heatsink • Thru-Hole Inserts • Chassis Mount • Active Low Remote ON/OFF Control MODEL SELECTION TABLE Model Number Input Voltage Output Voltage Output Current Min Load Max Load No Load Input Current Ripple & Noise Output Power LV12S3.3-200 3.3 VDC 0mA 60.6A 200W LV12S05-200 5 VDC 0mA 40A 200W 12 VDC 0mA 16.67A 200W 15 VDC 0mA 13.33A LV12S24-200 24 VDC 0mA 8.33A 200W LV12S28-200 28 VDC 0mA 7.14A 200W LV12S48-200 48 VDC 0mA 4.17A 200W LV12S12-200 LV12S15-200 12/24 VDC (9 - 36 VDC) TBD TBD 200W Efficiency TBD NOTES 1. The LV200 series converters may be paralleled both for redundancy and for higher output current. See page 11 for more details. 2. 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. 3. Output voltage is adjustable for 10% trim up or -10% trim down of nominal output voltage by connecting a single resistor between Trim and +Rs pins for trim up or between Trim and -Rs pins for trim down. To calculate the value of the resistor RU and RD for a particular output voltage see page 9. 4. This series comes with several different options: active low remote on/off control, heatsinks, chassis mount, and thru-hole inserts. See the “Model Number Setup” table on page 12 for more ordering information. 07/11/2013 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 1 of 12 Wall Industries, Inc. Advanced Publication LV200 SERIES 200 Watt Half-Brick DC/DC Power Converters SPECIFICATIONS: LV200 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 INPUT SPECIFICATIONS Input Voltage Range UVLO Turn-On At UVLO Turn-off At Input Surge Voltage (100ms) Input Current Input Filter Reflected Ripple Current OUTPUT SPECIFICATIONS Output Voltage Voltage Set Point Line Regulation Load Regulation Voltage Adjustability Remote Sense Compensation Output Power Output Current Minimum Load Ripple Spikes Temperature Drift DYNAMIC RESPONSE Load Step / ΔV Recovery Time Turn-on Delay Turn-on Overshoot Hold-up Time REMOTE ON/OFF CONTROL Active High (standard) Active Low (optional) ±RS shorted to ±Vo ±RS shorted to ±Vo ±RS shorted to ±Vo Max output limited to 200W Max output limited to 200W 12/24 -10 Unit 36 TBD TBD 50 See Table Pi type TBD VDC VDC VDC VDC mA See Table +1.0 0.1 0.2 0.1 0.2 +10 10 See Table See Table % % % % % 0 % mVp-p mVp-p %/°C TBD TBD 0.2 50% to 100% Io, di/dt=1A/uS Recovery to within 1% Nominal Vo From Vin(min) to Vout (nom) Full Load Resistive From Vin (min) to VULVO_Turn_Off Min High (ON/OFF pin) Max Low (ON/OFF pin) Max Low (ON/OFF pin) Min High (ON/OFF pin) Turn-On Delay (Active High) Turn-Off Delay (Active High) PROTECTION Short Circuit Protection Current Limit Over Voltage Protection ON/OFF (max Low) to Vout (min) ON/OFF (0V) to Vout (min) 200 TBD TBD 0 Remote ON Remote OFF Remote ON Remote OFF Active High Active Low 2.2 Isolation Resistance Isolation Capacitance ENVIRONMENTAL SPECIFICATIONS Operating Case Temperature Storage Temperature Relative Humidity MTBF 500VDC VDC 1.2 N/A N/A 2.5 N/A VDC 5.0 VDC 9 160 115 Nominal input voltage and full load 1 minute (basic insulation) mV ms ms % mS 0 Power limited-dependent upon SENSE compensation and TRIM adj. Output clamped Case temperature greater than Case temperature less than Isolation Voltage 07/11/2013 9 -1.0 Max 1µF ceramic and 10µF tantalum 1µF ceramic and 10µF tantalum Over operating voltage range GENERAL SPECIFICATIONS Efficiency Switching Frequency Typ No Load Remote ON/OFF Pin Floating Over Temperature Protection Min ms µs hiccup, automatic recovery TBD 130 +95 +85 See Table 400 1500 500 Input to Output Input/Output to Case 10 TBD Max ambient limited by OTP Calculated using BELLCORE TR-332 Method 1 case 3 -40 -50 5 TBD Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] +100 +125 95 % % °C kHz VDC MΩ pF °C °C % RH hours Page 2 of 12 Advanced Publication Wall Industries, Inc. LV200 SERIES 200 Watt Half-Brick DC/DC Power Converters SPECIFICATIONS: LV200 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 Unit PHYSICAL SPECIFICATIONS Standard models Chassis Mount Models Standard models Chassis Mount Models Weight Dimensions (L x W x H) Case Material Base Material Potting Material Shielding SAFETY & EMC CHARACTERISTICS Safety Approvals EMI ESD Radiated Immunity Fast Transient Surge Conducted Immunity 4.0oz (113g) 7.52oz (213g) 2.40 x 2.28 x 0.50 inches (61.0 x 57.9 x 12.7 mm) 5.70 x 3.40 x 1.10 inches (144.8 x 86.4 x 28.0 mm) Thick, aluminum alloy TBD TBD Six-sided EN55011, EN55022 EN61000-4-2 EN61000-4-3 EN61000-4-4 EN61000-4-5 EN61000-4-6 Air ±8kV and Contact ±6kV 20 V/m ±2kV EN55024 ±2kV and EN50155 ±2kV 10 Vrms IEC60950-1, UL60950-1, EN60950-1, EN50155 Class A Perf. Criteria A Perf. Criteria A Perf. Criteria A Perf. Criteria A Perf. Criteria A MECHANICAL DRAWING STANDARD MODELS LABEL DATE CODE R WALL INDUSTRIES XXXX SEE NOTE-4 EXETER, NH 03833 XXXX +0.5 2.28+.02 -.03 57.9 -0.8 .50 [12.7] TO STANDOFFS ONLY KEY PIN/ NO CONNECTION 2.000 [50.80] +0.5 2.40+.02 -.03 61.0 -0.8 PIN DESIGNATION 1 -OUTPUT 2 -SENSE 3 TRIM 4 +SENSE 5 +OUT 6 -Vin 7 CASE GRD 8 KEY PIN/NC 9 ON/OFF 10 +Vin SERIAL NO: DC/DC CONVERTER MODEL NAME 6 1 1.400 [35.56] 7 2 1.000 [25.40] 8 3 .700 [17.78] 9 4 .400 [10.16] 10 5 .000 [0.00] PIN Ø Ø.081 Ø.040 Ø.040 Ø.040 Ø.081 Ø.081 Ø.040 Ø.081 Ø.040 Ø.081 UNLESS OTHERWISE SPECIFIED ALL DIMENSONS ARE IN INCHES [ XX ] ARE IN MILLIMETERS APPLIED TOLERANCES: ANGLES= ±1° .XX=±.02[0.5] .XXX=±.010[0.25] DO NOT SCALE DRAWING .30 [7.6] INTERPRET DIMENSION AND TOLERANCE PER ASME Y14.5M - 1994 .50 [12.7] NOTES: 1. PIN-TO-PIN TOLERANCE ±.01 [±0.3] PIN DIAMETER TOLERANCE: ±.005 [±0.13] .000 [0.00] LEXAN INSULATOR 2X .19+.02 -.03 1.900 [48.26] 4.8+0.5 -0.6 .20 MIN [5.1 MIN] SEE NOTE-3 PIN LENGTH FROM STANDOFFS ONLY THIRD ANGLE PROJECTION 2. CASE MATERIAL: 0.040 [1.02] THICK, ALUMINUM ALLOY 3003-0, PER: QQA 250/2 3. UNLESS OTHERWISE SPECIFIED 4. UNIT COMES WITH EITHER 3M x 0.5 THREADED THRU INSERTS OR FOR Ø.125 THRU-HOLE ADD “TH” SUFFIX TO THE MODEL NUMBER. 5. CONSULT FACTORY FOR OPTIONAL HEATSINK 07/11/2013 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 3 of 12 Wall Industries, Inc. Advanced Publication LV200 SERIES 200 Watt Half-Brick DC/DC Power Converters MECHANICAL DRAWING CHASSIS MOUNT MODELS (PREFIX “CM”) M3 X 0.5 FULL THD THRU 4X CAUTION: MOUNTING HARDWARE PROTRUDSION INTO UNIT MUST NOT EXCEED A MAXIMUM DEPTH OF .25 [6.4] FROM SURFACE-A MAX RECEIVING TORQUE 4-LBS/IN [0.45-N.m] UNLESS OTHERWISE SPECIFIED ALL DIMENSONS ARE IN INCHES [ XX ] ARE IN MILLIMETERS APPLIED TOLERANCES: ANGLES= ±1° .XX=±.02[0.5] .XXX=±.010[0.25] DO NOT SCALE DRAWING INTERPRET DIMENSION AND TOLERANCE PER ASME Y14.5M - 1994 THIRD ANGLE PROJECTION NOTES 1. PIN TO PIN TOLERANCE ± 0.01 [±0.3], PIN DIAMETER TOLERANCE: ±0.005 [±0.13]. 2. CASE MATERIAL OF THE CONVERTER: Ø.040 [1.02] THICK, ALUMINUM ALLOY 3003-0, PER: QQA 250/2. 3. UNLESS OTHERWISE SPECIFIED. 4. UNIT COMES WITH EITHER .112 (NO.4)-4OUNC-2B THREADED THRU INSERTS OR FOR Ø.125 THRU-HOLE FOR THE CHASSIS MOUNT BOARD ADD: “TH” SUFFIX TO MODEL PART NUMBER. EXAMPLE: CMLV12S15-200TH 07/11/2013 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 4 of 12 Wall Industries, Inc. Advanced Publication LV200 SERIES 200 Watt Half-Brick DC/DC Power Converters CHARACTERISTICS (Based on LV12S15-200) Max Ambient vs Io (Vin=24VDC) Efficiency vs Output Current TBD TBD Input Current vs Input Voltage Power Dissipation vs Input Voltage TBD TBD Min Load Input Current & Power Dissipation vs Input Voltage “Remote Off” Input Current & Power Dissipation vs Input Voltage TBD TBD 07/11/2013 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 5 of 12 Wall Industries, Inc. Advanced Publication LV200 SERIES 200 Watt Half-Brick DC/DC Power Converters CHARACTERISTICS (Based on LV12S15-200) 07/11/2013 Photo 1: Remote Turn On Photo 2: Remote Turn Off TBD TBD Vin=24V, Iout=1.33A Vin=24V, Iout=13.33A Photo 3: Normal Turn On Photo 4: Normal Turn On TBD TBD Vin=24V, Iout=1.33A Vin=24V, Iout=13.33A Photo 5: Remote Turn Off Photo 6: Remote Turn Off TBD TBD Vin=24V, Iout=1.33A Vin=24V, Iout=13.33A Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 6 of 12 Wall Industries, Inc. Advanced Publication LV200 SERIES 200 Watt Half-Brick DC/DC Power Converters CHARACTERISTICS (Based on LV12S15-200) Photo 7: Transient Response 50% to 100% Photo 8: Transient Response Min Load to Max Load TBD TBD Vin = 24V, Iout = 6.66 to 13.33A, Cout = 1µF Ceramic + 10µF tantalum Vin = 24V, Iout = 1.33 to 13.33A, Cout = 1µF Ceramic + 10µF tantalum Photo 9: Output Voltage Ripple (20MHz BW) Photo 10: Output Voltage Ripple (20MHz BW) TBD TBD Vin = 24V, Iout = 1.33A, Cout = 1µF Ceramic + 10µF tantalum Vin = 24V, Iout = 13.33A, Cout = 1µF Ceramic + 10µF tantalum Photo 11: Output Voltage Ripple (Spike) Photo 12: Input Reflected Ripple Voltage and Ripple Current TBD TBD Vin = 24V, Iout = 13.33A, Cout = 1µF Ceramic + 10µF tantalum Vin = 24V, Iout = 13.33A with 680µFaluminum electrolytic and 12µH series inductor 07/11/2013 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 7 of 12 Advanced Publication Wall Industries, Inc. LV200 SERIES 200 Watt Half-Brick DC/DC Power Converters DESIGN CONSIDERATIONS Under Voltage Lock Out (UVLO) The converter output is disabled until the input voltage exceeds the UVLO turn-on limit. The converter will remain ON until the input voltage falls below the UVLO turn-off limit. Over Current Protection The converter is protected from short circuit and over current conditions. During these fault conditions, the converter output will ‘hiccup’. The converter output will recover once the short or over current fault is removed. Over Temperature Protection (OTP) The converter has internal thermal protection that will shut the converter OFF once the case temperature exceeds the OTP turn-off limit. The converter will resume operation when the case temperature has dropped below the OTP turn-on limit. Input Filter It is recommended to bypass the +Vin and –Vin pins of the converter with a minimum of 680µF (100V minimum) capacitor. No other bypassing is needed. However, to reduce the input ripple beyond what is seen in Photo 1, larger values of capacitance may be used. Additionally, an inductor may be placed between the source and the previously mentioned capacitor. No inductor should be placed between the capacitor and the input to the converter. Input Filter Setup +Vin Low Impedance Source 680µF 1µF electrolytic capacitor ceramic capacitor LV200 SERIES -V in Output Filter No additional output capacitor is needed for the power supply to operate. However, to reduce the ripple and noise on the output, additional capacitance may be added. A 100µF Ceramic capacitor may be added across the +Vo and –Vo pins to reduce the ripple and spike noise. Additional capacitance in the form of a tantalum or aluminum electrolytic may also be placed across these pins in order reduce ripple and improve the transient peak-to-peak voltage deviation. Remote Sense To improve the regulation at the load, route the connections from the -RS and the +RS pins to the –Vo and +Vo connections at the load. This will force the converter to regulate the voltage at the load and not at the pins of the converter. If it is not desired to use the Remotes Sense feature, the –RS and +RS pins may be left open or they may be shorted to the -Vo and +Vo pins respectively. Shorting the RS pins to the Vo pins will reduce the voltage drops through the converter pins. 07/11/2013 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 8 of 12 Wall Industries, Inc. Advanced Publication LV200 SERIES 200 Watt Half-Brick DC/DC Power Converters Remote ON/OFF The converter has the ability to be remotely turned ON or OFF. The LV200 series is Active-High. Active-High means that a logic high at the ON/OFF pin will enable the supply. With Active-High, if the ON/OFF pin is left floating, the supply will be enabled. Active High +VIN Low Disables Converter High Enables Converter ON/OFF 200K VCC Low Enables Converter High Disables Converter 0.1µF -VIN -VIN 2.5V LV200 Series Converter Output Voltage Trim The output is adjustable ±10% of rated output voltage. To trim the output voltage down, place the trim resistor between the Trim and -Rs pins. To trim the output voltage up, place the trim resistor between the Trim and +Rs pins. The value of the trim resistor with respect to the desired output voltage (Vo) can be derived from the following formulas. Trim Up Trim Down Vonom U1 - R1 • Vo - R (in KΩ) RTH = lim Vo - Vonom Vo - Vonom R 1 • Vo • RTL = R1 • Vo - R lim (in KΩ) Vonom - Vo +Vout +Vout +Rs +Rs RTH Trim Pins Facing Down Pins Facing Down -Rs -Vout 07/11/2013 Trim R load R load RTL -Rs -Vout Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 9 of 12 LV200 SERIES 200 Watt Half-Brick DC/DC Power Converters Advanced Publication Wall Industries, Inc. TEST SETUP Regulation and Efficiency Setup To ensure that accurate measurements are taken, the voltage measurements are taken directly at the terminal of the module. This minimizes errors due to contact and trace lengths between the load and the output of the supply. The following is a diagram of the test setup. Regulation and Efficiency Probe Setup R trace R contact +Vout R contact +Vin Vin R trace R trace R load Vout R contact R contact -Vin R trace -Vout Output Ripple Voltage Setup The module is tested with a 1µF ceramic capacitor in parallel with a 10µF tantalum capacitor across the output terminals. Ripple Voltage Probe Setup SCOPE PROBE +Vout LV200 SERIES 10µF 1µF Tantalum Ceramic R load -Vout Input Reflected Ripple Current & Input Ripple Current Setup The module is tested for input reflected ripple current (Irrc) and input ripple current (Irc). The input ripple voltage is also measured at the pins with the following input filter. If there is a need to reduce input ripple current/voltage then additional ceramic capacitors can be added to the input of the converter. Ripple Current Setup Irrc SCOPE PROBE Irc 12µH +Vin Low Impedance Source 07/11/2013 6800µF 1µF electrolytic capacitor ceramic capacitor LV200 SERIES -Vin Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 10 of 12 Wall Industries, Inc. LV200 SERIES 200 Watt Half-Brick DC/DC Power Converters Advanced Publication Converter Thermal Consideration The converter is designed to operate without convective cooling if the derating curves are followed. The converter can operate at higher temperatures if airflow is applied. Airflow should be aligned lengthwise to the converter for optimum heat transfer. Airflow Orientation AIRFLOW +Vin +Vout Pins Facing Down LV200 SERIES ON/OFF -V in -Vout Paralleling Converters The LV200 series converters may be paralleled both for redundancy and for higher output current. However, in order to do this, a high-current, low Vf, schottky diode must be placed at the +Vo pin of each supply as shown below. To improve sharing, tie the two TRIM pins together. The converters may be trimmed by adding a resistor value from each TRIM pin to ±RS pin, or alternatively, a single resistor of half the value from the common TRIM pins to the common ±RS pins. Paralleling Converters -VO -VO +VIN -RS ON/OFF CONVERTER B CHGND TRIM -VIN +VO R (Up or Down) (OPTIONAL) +RS RLOAD +5V +VIN -VO +RS VIN ON/OFF CHGND TRIM CONVERTER A R (Up or Down) (OPTIONAL) -RS -VIN -VO -VIN -VO 07/11/2013 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 11 of 12 Advanced Publication Wall Industries, Inc. LV200 SERIES 200 Watt Half-Brick DC/DC Power Converters MODEL NUMBER SETUP CM LV 12 S 15 Chassis Mount Series Name Input Voltage Output Quantity Ouptut Voltage None: CM: Standard 12: 9-36VDC S: Single Output Chassis Mount R TH HS Remote ON/OFF Inserts Heatsink None: Active High None: Threaded None: R: Active Low TH: Thru-hole H: 3.3: 3.3 VDC 05: 5 VDC 12: 12 VDC 15: 15 VDC 24: 24 VDC 28: 28 VDC 48: 48 VDC - 200 200: 200 Watts No heatsink Heatsink Note: Models with thru-hole inserts cannot be equipped with a heatsink. 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: 07/11/2013 (603)778-2300 (888)597-9255 (603)778-9797 [email protected] www.wallindustries.com 37 Industrial Drive Exeter, NH 03833 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 12 of 12