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TECHNICAL DATASHEET
Rev. A
DCBC60-48S05W
4:1 Ultra Wide Input Voltage Range: 18~75VDC
5VDC Single Output at 12A
2.0” x 2.0” x 0.5” Shielded Metal Case
60 Watt Isolated DC/DC Power Converter
FEATURES
 5VDC Single Output
 4:1 Ultra Wide Input Voltage Range: 18-75VDC
 60 Watts Output Power
 Fixed Switching frequency
 Industry Standard Pin-out
 1500VDC I/O Isolation
 No Minimum Load Requirement
 87% High Efficiency
 Short Circuit, Over Voltage, Over Load, and Over Temp. Protection
 Shielded Metal Case with Insulated Baseplate
 Lead Free Design, RoHS Compliant
APPLICATIONS
 Distributed Power Systems
 Wide Operating Temperature Range: -40°C to +85°C
 Process Control Equipment
 Synchronous Rectifier Topology
 Telecommunication Applications
 Remote ON/OFF
 Industrial Applications
 Adjustable Output Voltage
 Transportation Equipment
 Custom Designs Available
 Battery Powered Equipment
 Optional Heatsink Available (Suffix “HS”)
DESCRIPTION
The DCBC60-48S05W is an isolated DC/DC power converter that provides 60 Watts of continuous output power in a 2.0”
x 2.0” x 0.5” shielded metal case. This model has a 5VDC single output with 4:1 input voltage range of 18-75VDC. Some
features include 87% high efficiency, remote on/off, adjustable output voltage, 1500VDC I/O isolation, -40°C~+85°C
operating temperature range, and no minimum load requirement. The DCBC60-48S05W is RoHS compliant and has short
circuit, over load, over voltage, and over temperature protection. This converter is best suited for use in battery operated
equipment, distributed power systems, telecom, industry control systems, process control equipment, transportation
equipment, and anywhere where isolated, tightly regulated voltages and compact size are required.
05/17/2012
Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 1 of 5
Rev. A
TECHNICAL DATASHEET
DCBC60-48S05W
TECHNICAL SPECIFICATIONS
MODEL: DCBC60-48S05W
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
Input Surge Voltage
Under Voltage Shutdown
Input Reflected Ripple Current
Min
Nom
Max
Unit
18
48
75
100
VDC
VDC
V
mAp-p
100ms
Full load
Nominal Vin and full load
Nominal Vin and no load
Nominal Vin and full load
Nominal Vin and output shorted
Input Current
15
200
33
mA
1506
10
Pi Type
Open or 3.5V < Vr < 12V
Short (to -Vin) or 0V < Vr < 0.7V
0.2
mA
20
mA
Input Filter
Remote ON/OFF
Sourcing Current of Remote Control Pin
Idle Input Current (at Remote OFF State)
OUTPUT SPECIFICATIONS
Output Voltage
Voltage Accuracy
Output Current
Minimum Load
Maximum Capacitive Load
Start-up Time
Line Regulation
Load Regulation
Output Power
Ripple & Noise
Temperature Coefficient
Transient Response Overshoot
Transient Response Settling Time
Remote Sense
PROTECTION
Over Voltage Protection
Short Circuit Protection
Over Load Protection
Thermal Shutdown
GENERAL SPECIFICATIONS
Efficiency
Isolation Voltage
Isolation Resistance
Isolation Capacitance
Switching Frequency
ENVIRONMENTAL SPECIFICATIONS
Operating Temperature
Storage Temperature
Maximum Case Surface Temperature
Relative Humidity
Cooling
MTBF
PHYSICAL SPECIFICATIONS
Case Material
Base Material
Potting Material
Soldering Temperature
Weight
Dimensions (L x W x H)
SAFETY
Safety Approvals (pending)
05/17/2012
Converter ON
Converter: OFF
Nominal Vin
Nominal Vin
5
-1%
+1%
12
0
36000
Nominal Vin and full load
LL to HL at full load
25% load to full load
70
-0.5
-0.5
0
+0.5
+0.5
60
75
+0.02
+5
20MHz Bandwidth
-0.02
-5
di/dt=0.8A/µs
50% load step change
3
VDC
%
A
A
µF
ms
%
%
W
mVp-p
%/°C
% of Vo
ms
See page 4
Zener Diode Clamp
automatic recovery
% of full load at nominal input
6.2
Hiccup, continuous
110
110
Nominal Vin and full load
Input to Output
Input to Output (500VDC)
87
1500
10
1200
300
With derating (see derating curve)
Lead-free wave soldering
-40
-55
+85
+125
+105
95
Free air convection
888,000 hours
VDC
%
°C
%
VDC
GΩ
pF
KHz
°C
°C
°C
% RH
Nickel-coated copper
FR4 PCB
Silicon rubber (UL94V-0)
260°C/10sec max.
2.96oz (84g)
2.0 x 2.0 x 0.5 inches (50.8 x 50.8 x 12.7 mm)
EN60950-1: 2006 + A11:2009+A1:2010, IEC 60950-1: 2005 (2nd Edition)+A1
Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 2 of 5
TECHNICAL DATASHEET
DCBC60-48S05W
Rev. A
DERATING CURVES
DCBC60-48S05W Power Derating Curve (With Heatsink)
120
100
100
Output Power (%)
Output Power (%)
DCBC60-48S05W Power Derating Curve (Without Heatsink)
120
80
60
40
20
80
60
40
20
0
-40
-20
0
20
33 40
60
80
100
0
-40
120
-20
0
Ambient Temperature (°C)
40 44
20
60
80
100
120
Ambient Temperature (°C)
EFFICIENCY
DCBC60-48S05W Output Current vs. Efficiency
95
90
85
85
80
80
Efficiency (%)
Efficiency (%)
DCBC60-48S05W Input Voltage vs. Efficiency
95
90
75
70
65
75
70
65
60
60
55
55
50
18
24
30
36
42
48
54
60
66
75
50
1.2
2.4
3.6
4.8
6.0
7.2
8.4
9.6
10.8
12.0
Output Current (A)
Input Voltage (VDC)
CHARACTERISTICS
DCBC60-48S05W
Transient Response at 50%~100% Max Load
05/17/2012
DCBC60-48S05W
Loop Gain & Phase at Vi=48V, Full Load
Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 3 of 5
TECHNICAL DATASHEET
DCBC60-48S05W
Rev. A
REMOTE SENSE APPLICATION CIRCUIT
The remote sense function is used to compensate for the voltage drop incurred when the load is located physically far away
from the DC/DC converter providing its power. The remote sense pins are connected as close to the load as possible. The
DC/DC converter’s regulation specifications are maintained across the points where the remote sense wires are connected at
the load. This will remove the effect of the voltage drop caused by the resistance of the wires used to conduct the power from
the DC/DC converter to the load. This is represented by RCL1 and RCL2. With the use of remote sense, the effects of RCL1 and
RCL2 are eliminated.
If the Remote Sense function is not used, the +Sense has to be connected to +Vout and the -Sense has to be connected to
-Vout as close to the DC/DC converter as possible.
+Vout
RCL1
+Sense
+Vin
Load
-Vin
-Sense
-Vout
R CL1 and R CL2 are line resistors
RCL2
MECHANICAL DRAWING
Standard
Unit: inches (mm)
Ø0.04 (Ø1.0) x 8
8
3
2
5
1
4
2.0 (50.8)
6
0.4 0.2
(10.16)(5.08)
7
PIN CONNECTIONS
0.5
(12.70)
0.3 0.2 0.3 0.2 0.3
(7.62) (5.08) (7.62) (5.08) (7.62)
2.0 (50.8)
Ø1.0 (Ø0.04)
BOTTOM VIEW
0.2
(5.0)
Pin
Assignment
1
+Vin
2
-Vin
3
Remote On/Off
4
-Sense
5
+Sense
6
+Vout
7
-Vout
8
Trim
Tolerance: X.XX±0.02 (X.X±0.5)
0.5 (12.7)
0.10 (2.5)
1.8 (45.7)
Pin Pitch Tolerance: ±0.014 (0.35)
All dimensions are for reference only
05/17/2012
Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 4 of 5
TECHNICAL DATASHEET
DCBC60-48S05W
Rev. A
Heatsink Option (Suffix “HS”)
Unit: inches (mm)
2.0 (50.8)
Material: Aluminum
Weight: 0.67oz (19g) (without converter)
Tolerance: X.XX±0.02 (X.X±0.5)
2.0 (50.8)
Note:
The product label on the converter has to be
removed before mounting the heatsink.
For volume orders, converters will be supplied
with heatsink already mounted. Please contact
factory for more details.
0.76 (19.2)
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:
05/17/2012
(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 5 of 5