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CG Series
Single Output
2:1 Input Voltage Range
30 Watt DC/DC Converter
FEATURES
● Soft Start
● Lead-Free Design
● Six-Sided Shielding
● Output Trim Function
● I/O Isolation 1500VDC
● MTBF > 600,000 hours
● 2:1 Input Voltage Range
● Very High Efficiency up to 88%
● Remote On/Off Control (Optional)
● Over Voltage and Short Circuit Protection
● EMI Complies with RN55022 Class A (Only for CG-A Series)
Dimensions: 2.0 x 1.0 x 0.4 inches
SPECIFICATIONS: CG Series
All specifications are based on 25oC, 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
Nom
Max
INPUT (Vin)
Input Voltage Range (24V input models)
Input Voltage Range (48V input models)
Start Voltage 24V input models)
Start Voltage (48V input models)
Under Voltage Shutdown (24V input models)
Under Voltage Shutdown (48V input models)
Over Voltage Shutdown (24V input models)
Over Voltage Shutdown (48V input models)
Reverse Polarity Input Current
Input Surge Voltage (1000ms) (24V input models)
Input Surge Voltage (1000ms) (48V input models)
Reflected Ripple Current
Short Circuit Input Power
Input Filter
OUTPUT (Vo)
Output Voltage Range
Output Voltage Accuracy
Output Voltage Trim
Load Regulation (2.5V,3.3V, and 5Vout)
Load Regulation (12V and 15Vout)
Line Regulation
Output Power
Output Current Range
Ripple & Noise (20MHz)
Ripple & Noise (20MHz)
Ripple & Noise (20MHz)
Transient Recovery Time
Transient Response Deviation
Maximum Capacitive Load
Temperature Coefficient
REMOTE ON/OFF CONTROL
Supply On
Supply Off
Device Standby Input Current
Control Input Current (On)
Control Input Current (Off)
Control Common
PROTECTION
Over Power Protection
Short Circuit Protection
Over Voltage Protection
Input Fuse Recommendation (24V input models)
Input Fuse Recommendation (48V input models)
18
36
17
34
16
32
40
80
All models
-0.7
-0.7
All models
All models
% of nominal output voltage
Io = No Load to 100% Load
Io = 10% to 100% Load
Vin = Min to Max
±9.0
Over Line, Load, and Temperature
25% Load Step Change
25% Load Step Change
Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
200
24
48
17.5
35
16.5
33
42
82
36
75
18
36
17
34
44
84
2
50
100
See Table
4500
Pi Filter
See Table
±0.5
±1.0
±10.0
±11.0
±0.5
±1.0
±0.5
±1.0
±0.1
±0.3
30
See Table
75
100
120
10
500
±2
±5
See Table
±0.01
±0.02
Unit
VDC
VDC
VDC
VDC
VDC
VDC
VDC
VDC
A
VDC
VDC
mW
%
%
%
%
%
W
mVpk-pk
mVpk-pk
mVrms
μs
%
%/°C
2.5 to 100VDC or Open Circuit
-1
1
VDC
2
5
mA
5
μA
-100
μA
Referenced to Negative Input
110
160
%
Continuous
See table
3000mA Slow-Blow Type
1500mA Slow-Blow Type
CG Series
Single Output
2:1 Input Voltage Range
30 Watt DC/DC Converter
SPECIFICATION
TEST CONDITIONS
GENERAL
Efficiency
Switching Frequency
Isolation Voltage Rated
Isolation Voltage Test
Isolation Resistance
Isolation Capacitance
Internal Power Dissipation
ENVIRONMENTAL
Operating Temperature (Ambient)
Operating Temperature (Case)
Storage Temperature
Lead Temperature
Humidity
Cooling
RFI
MTBF
Conducted EMI
PHYSICAL
Weight
Dimensions
Case Material
Min
280
1500
1650
1000
60 seconds
Flash Tested for 1 second
500VDC
100KHz, 1V
Nom
Max
See Table
350
400
1200
1500
5500
Unit
KHz
VDC
VDC
MΩ
pF
mW
-40
-40
-55
+50
°C
+105
°C
+125
°C
260
°C
95
%
Free air convection
Six-sided shielded metal case
600,000 Hours
EN55022 Class A
1.5mm from case for 10 seconds
MIL-HDBK-217F @ 25°C, Ground Benign
32 grams
50.8(L) x 25.4(W) x 10.2(H) mm
Aluminum anodizing treatment in black
OUTPUT VOLTAGE / CURRENT RATING CHART
Output
Voltage
Output Current
Min
Max
CG24S2.5-6000
2.5 VDC
0mA
6000mA
50mA
744mA
3 VDC
6800μF
84%
CG24S3.3-6000
3.3 VDC
0mA
6000mA
50mA
959mA
3.9 VDC
6800μF
86%
5 VDC
0mA
5000mA
70mA
1185mA
6.8 VDC
6800μF
88%
Model Number Input Voltage
CG24S5-5000
Input Current
Reflected
Over Voltage Max Capacitive Efficiency
Load
(Typ)
No Load Max Load Ripple Current Protection
24 VDC
(18
– 36 VDC)
CG24S5.1-5000
5.1 VDC
0mA
5000mA
70mA
1207mA
6.8 VDC
6800μF
88%
CG24S12-2500
12 VDC
166mA
2500mA
20mA
1420mA
15 VDC
680μF
88%
CG24S15-2000
15 VDC
133mA
2000mA
20mA
1420mA
18 VDC
680μF
88%
CG48S2.5-6000
2.5 VDC
0mA
6000mA
40mA
372mA
3 VDC
6800μF
84%
CG48S3.3-6000
3.3 VDC
0mA
6000mA
40mA
480mA
3.9 VDC
6800μF
86%
5 VDC
0mA
5000mA
50mA
604mA
6.8 VDC
6800μF
88%
CG48S5-5000
100mA (typ)
48 VDC
CG48S5.1-5000 (36 – 75 VDC)
5.1 VDC
0mA
5000mA
50mA
604mA
6.8 VDC
6800μF
88%
CG48S12-2500
12 VDC
166mA
2500mA
10mA
710mA
15 VDC
680μF
88%
CG48S15-2000
15 VDC
133mA
2000mA
10mA
710mA
18 VDC
680μF
88%
50mA (typ)
NOTES
1.
2.
3.
4.
5.
6.
7.
8.
Specifications typical at +25°C, resistive load, nominal input voltage, rated output current unless otherwise noted.
Transient Recovery Time is measured to within 1% error band for a step change in output load of 75% to 100%.
Ripple & Noise measurement bandwidth is 0- 20MHz.
These power converters require a minimum output loading to maintain specified regulation. Operation at no-load
will not damage these devices, however they may not meet all listed specifications.
All DC/DC converters should be externally fused at the front end for protection.
Other input and output voltages may be available, please contact factory.
Specifications subject to change without notice.
To order the converter with Remote On/Off function, please add suffix ”-RC” (Ex: CG48S5-5000(A)-RC).
Due to advances in technology, specifications subject to change without notice.
Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
CG Series
Single Output
2:1 Input Voltage Range
30 Watt DC/DC Converter
BLOCK DIAGRAM
Input Voltage Transient Rating
Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
CG Series
Single Output
2:1 Input Voltage Range
30 Watt DC/DC Converter
MECHANICAL DRAWING
Connecting Pin Patterns
Top View (2.54 mm / 0.1 inch grids)
Pin
1
2
3
4
5
6
PIN CONNECTIONS
Function
+Vin
-Vin
*Remote On/Off (option)
+Vout
-Vout
Trim
* See Note 8
1. All dimensions in mm [inches]
Tolerance: X.X±0.25 [X.XX±0.01]
X.XX±0.13 [X.XXX±0.005]
2. Pin: ±0.05 [±0.002]
Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
CG Series
Single Output
2:1 Input Voltage Range
30 Watt DC/DC Converter
DESIGN & FEATURE CONSIDERATIONS
Remote On/Off
Positive logic remote on/off turns the module on during a logic high voltage on the remote on/off pin and
off during a logic low. Negative logic remote on/off turns the module off during a logic low and on during
a logic high. To turn the power module on and off, the user must supply a switch to control the voltage
between the on/off terminal and the -Vin terminal. The switch can be an open collector or equivalent.
A logic low is -0.7V to 1.0V.
A logic high is 2.5V to 100V.
The maximum sink current at the On/Off terminal (Pin 3) during a logic low is 100 mA. The maximum
allowable leakage current of a switch connected to the On/Off terminal (Pin 3) at logic high (2.5V to
100V) is 5uA.
Output Voltage Trim
Output voltage trim allows the user to increase or decrease the output voltage set point of a module.
The output voltage can be adjusted by placing an external resistor (Radj) between the Trim and +Vout
or -Vout terminals. By adjusting Radj, the output voltage can be changed by ±10% of the nominal output
voltage.
A 10K, 1 or 10 Turn trimpot is usually specified for continuous trimming. Trim pin may be safely left
floating if it is not used.
Connecting the external resistor (Radj (up)) between the Trim and -Vout pins increases the output voltage
set point as defined by the following equation:
Radj (up ) =
(33 ∗ Vout ) − (30 ∗ Vadj )
Vadj − Vout
Connecting the external resistor (Radj (down)) between the Trim and +Vout pins decreases the output
voltage set point as defined by the following equation:
Radj ( down ) =
Vout:
Vadj:
Units:
(36.667 ∗ Vadj ) − (33 ∗ Vout )
Vout − Vadj
Nominal Output Voltage
Adjusted Output Voltage
VDC/KΩ
Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
CG Series
Single Output
2:1 Input Voltage Range
30 Watt DC/DC Converter
Input Source Impedance
The power module should be connected to a low ac-impedance input source. Highly inductive source
impedances can affect the stability of the power module.
In applications where power is supplied over long lines and output loading is high, it may be necessary
to use a capacitor at the input to ensure startup.
A capacitor mounted close to the power module helps ensure stability of the unit, it is recommended to
use a good quality low Equivalent Series Resistance (ESR < 1.0Ω at 100 KHz) capacitor of 10uF for the
24V and 48V input devices.
Maximum Capacitive Load
The CG Series has a limitation of maximum connected capacitance at the output. The power module
may be operated in current limiting mode during start-up, affecting the ramp-up and the startup time.
The maximum capacitance can be found in the “Output Voltage / Current Rating Chart.”
Over Current Protection
To provide protection in a fault (output overload) condition, the unit is equipped with internal current
limiting circuitry and can endure current limiting for an unlimited duration. At the point of current-limit
inception, the unit shifts from voltage control to current control. The unit operates normally once the
output current is brought back into its specified range.
Output Over Voltage Protection
The output over voltage clamp consists of control circuitry, which is independent of the primary
regulation loop that monitors the voltage on the output terminals. The control loop of the clamp has a
higher voltage set point than the primary loop. This provides a redundant voltage control that reduces
the risk of output over voltage. The OVP level can be found in the “Output Voltage / Current Rating
Chart.”
Thermal Considerations
Many conditions affect the thermal performance of the power module, such as orientation, airflow over
the module, and board spacing. To avoid exceeding the maximum temperature rating of the components
inside the power module, the case temperature must be kept below 105°C. The derating curves are
determined from measurements obtained in an experimental apparatus.
Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
CG Series
Single Output
2:1 Input Voltage Range
30 Watt DC/DC Converter
Efficiency vs Input Voltage
Efficiency vs Output Load
DERATING CURVE
Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
CG Series
Single Output
2:1 Input Voltage Range
30 Watt DC/DC Converter
TEST CONFIGURATIONS
Input Reflected-Ripple Current Test Setup
Input reflected-ripple current is measured with an inductor Lin (4.7uH) and Cin (220uF, ESR < 1.0Ω at
100 KHz) to simulate source impedance.
Capacitor Cin offsets possible battery impedance.
Current ripple is measured at the input terminals of the module. Measurement bandwidth is 0-500 KHz.
Peak-to-Peak Output Noise Measurement Test
Use Cout = 1.0uF ceramic capacitor.
Scope measurement should be made by using a BNC socket, measurement bandwidth is 0-20MHz.
Position the load between 50mm and 75mm from the DC/DC Converter.
Output Ripple Reduction
A good quality low ESR capacitor placed as close as possible across the load will give the best ripple
and noise performance. To reduce output ripple, it is recommended to use 4.7uF capacitors at the
output.
Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
CG Series
Single Output
2:1 Input Voltage Range
30 Watt DC/DC Converter
COMPANY INFORMATION
Wall Industries, Inc. has created custom and modified units for over 40 years. Our in-house research
and development engineers will provide a solution that exceeds your performance requirements on time
and on budget. Our ISO9001-2000 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:
(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. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797