6 Watt EC Single Series DC/DC Converters Features Description ! Few External Parts Required for Operation ! Efficiencies to 80 Percent ! Overcurrent Protected for Long, Reliable Operation ! Water Washable, Non-conductive Case Design ! Low Input to Output Capacitance These 6 Watt DC/DC converters were designed expressly for fast integration with your systems power needs. With few external components or filtering needed for all but the most critical applications, these converters drop onto your board and provide power instantly. This saves you costly engineering time needed to design your system around the power converter, “We’ve done the engineering for you”. ! Isolation Voltage Raised to 700 VDC as Per the Requirements of UL1459 ! Five Year Warranty Saving space in today’s modern designs is also critical. The EC Series converters replace narrow input voltage range 2 x 2 inch converters with a space saving 1 x 2 inch design. This series has the highest isolation of any high power density 1 x 2 inch DC/DC converter on the market - we guarantee the full UL1459 mandated value of 700 VDC. Reliability is the most important design criteria for the CALEX design team. To this end we reduced the component count 50% from our last generation of 6 Watt devices and reduced the case footprint. Selection Chart Model Input Range VDC Min Max Output VDC Output mA 12S5.1000EC 9 27 5 1000 12S12.500EC 9 27 12 500 12S15.400EC 9 27 15 400 48S5.1000EC 20 60 5 1000 48S12.500EC 20 60 12 500 48S15.400EC 20 60 15 400 CALEX reliability is backed by our 5 year warranty. We can offer a 5 year warranty where others can’t because with a CALEX DC/DC it’s rarely needed. 6 Watt EC Single Series Block Diagram ISOLATION TRANSFORMER + INPUT 1 - INPUT 2 A 3 + OUTPUT 4 CMN CURRENT MODE PWM ISO AMP LOW TC BANDGAP REFERENCE Manufacturing Company, Inc. • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 1 6 Watt EC Single Series DC/DC Converters Input Parameters* Model 12S5.1000EC Voltage Range 12S12.500EC MIN MAX 12S15.400EC 48S5.1000EC 48S12.500EC 9 27 48S15.400EC Units 20 60 VDC Reflected Ripple (1) With External Capacitor Reflected Ripple (1) without Capacitor Input Current Full Load No Load TYP 4 3 mA RMS TYP TYP TYP TYP 1.8 0.93 0.85 0.44 A P-P A RMS 507 6 Efficiency TYP 82 Switching Frequency Maximum Input Overvoltage 100ms Maximum 12S models 48S Models Turn-on Time, 1% Output Error Recommended Fuse TYP 600 12 83 83 130 5 154 6 82 82 80 125 MAX % kHz VDC 34 72 TYP mA 6 ms (2) AMPS Output Parameters* Model 12S5.1000EC Output Voltage Output Voltage Accuracy Rated Load Range 48S5.1000EC 12S12.500EC 48S12.500EC 12S15.400EC 48S15.400EC Units MIN TYP MAX MIN MAX 5 4.95 5.00 5.05 0.0 1.0 12 11.90 12.00 12.10 0.0 0.5 15 14.90 15.00 15.10 0.0 0.4 VDC VDC A Load Regulation 25% - 100% of Rated Load Line Regulation Vin = Min to Max VDC Short Term Stability (3) TYP MAX 0.1 0.3 0.2 0.4 0.2 0.4 % TYP MAX TYP 0.02 0.2 0.2 0.8 < 0.05 0.2 0.8 % Long Term Stability TYP Transient Response (4) TYP 250 300 µs Dynamic Response (5) TYP 75 250 mV peak Input Ripple Rejection (6) TYP > 40 Noise, Peak - Peak (1) TYP TYP 50 mV P-P 8 50 150 mV RMS RMS Noise Temperature Coefficient %/24Hrs < 0.1 TYP MAX Short Circuit Protection to Common for all Outputs %/kHrs A Continuous, Current Limit Protection NOTES parameters measured at Tc=25°C, nominal input voltage * All and full rated load unless otherwise noted. Refer to the CALEX Application Notes for the definition of terms, measurement circuits and other information. (1) Noise is measured per CALEX Application Notes. Measurement bandwidth is 0-20 MHz for peak-peak measurements, 10 kHz to 1 MHz for RMS measurements. Output noise is measured with a 0.1µF / 50V ceramic capacitor in parallel with a 1µf / 35V Tantalum capacitor, 1 inch from the output pins to simulate standard PCB decoupling capacitance. Reflected Ripple is measured with the appropriate input capacitor, and into a 10 µH source impedance. See application notes for input capacitor requirements. (2) To determine the correct fuse size, see CALEX Application Notes. (3) (4) (5) (6) (7) dB ppm/°C Short term stability is specified after a 30 minute warmup at full load, constant line and recording the drift over a 24 hour period. The transient response is specified as the time required to settle from a 50 to 75% step load change (rise time of step = 2 µs) to a 1% error band. Dynamic response is the peak overshoot during a transient as defined in note 4 above. The input ripple rejection is specified for DC to 120 Hz ripple with a modulation amplitude of 1% of Vin. The case thermal impedance is specified as the case temperature rise over ambient per package watt dissipated. Manufacturing Company, Inc. • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 2 6 Watt EC Single Series DC/DC Converters General Specifications* All Models Units Isolation Isolation Voltage Input to Output 10µA Leakage Input to Output Capacitance MIN 700 VDC TYP 400 pF Thermal Impedance (7) MIN MAX MIN MAX TYP -40 100 -55 105 20 °C/Watt General Unit Weight TYP 1 oz Environmental Case Operating Range No Derating Storage Range Chassis Mounting Kits Agency Approvals °C BOTTOM VIEW SIDE VIEW °C Mechanical tolerances unless otherwise noted: X.XX dimensions: ±0.040 inches X.XXX dimensions: ±0.010 inches MS6, MS8, MS15 CSA/UL 60950 Pin 1 2 3 4 Function +INPUT -INPUT +OUTPUT CMN Application Information General Information Applying the Input The 125 kHz operating frequency of the 6 Watt EC Single series allows an increased power density over the last generation of 2 X 2 inch converters. The input to the 6 Watt EC single series should be buffered with a high ripple current capacitor (C1 in Figure 1) if it is an appreciable distance from your input source. A capacitor capable of handling the input ripple current of the EC series should be used (see the input reflected ripple current curves for exact values). Use the minimum size required for your output power level and minimum input voltage to keep your system small and cost effective. The series is also mindful of battery operation for industrial, medical control and remote data collection applications. The no-load input current draws typically less than 7 mA from the input source. Full overload protection is provided by independent pulseby-pulse current limiting. These protection features assure you that our 6 Watt single will provide you with zero failure rate operation. Applicable capacitor types for worst case applications are detailed below. Worst case is defined as continuous operation at full load, minimum line and high ambient temperatures. The capacitor that you will need will probably be smaller if one or all of the worst case conditions listed is relaxed. A A fully sealed, water washable, non-conductive case is standard along with specified operation over the full commercial temperature range of -40 to +100 °C. General Operation Figure 1 shows the recommended connections for the 6 Watt EC Single DC/DC converter. A fuse is recommended to protect the input circuit and should not be omitted. The fuse prevents unlimited current from flowing in the case of a catastrophic system failure. No external capacitance on the output is required for normal operation, in fact it can degrade the converters performance. See our application note “Understanding DC/ DC Converters Output Impedance” and the low noise circuits later in this data sheet for more information. The usual 10 µF and 0.1 to 0.001 µF bypasses may be used around your PCB as required for local bypassing without harm. Figure 1. Standard connections for the 6 Watt EC Single. The input fuse should not be omitted. The overvoltage diodes D1 and D2 may be added to the circuit directly at the converter to provide transient protection to your circuit. In some circuits capacitor C1 may be required, see the section “Applying The Input” for more information. Manufacturing Company, Inc. • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 3 6 Watt EC Single Series DC/DC Converters Suggested Capacitors 12 Volt Inputs Panasonic Suggested Part: HFQ Series ECA1HFQ271 270µF, 50V, 105°C Rated 10 x 25 mm ESR=0.090 Ohms Allowable Ripple=1.040 A @ 105°C Nichicon Suggested Part: PF or PL Series UPL1H221MPH6 220µF, 50V, 105°C Rated 10 x 25 mm ESR=0.075 Ohms Allowable Ripple=1.040 A @ 105°C Figure 2. For very low noise applications the circuits shown above can be used. The input current ripple will be reduced approximately 30 dB of the original value while the output noise will be reduced to below 10 mV p-p. Do not use the biggest lowest ESR capacitors that you can find in these circuits. These types of capacitors will cause severe peaking in the filters transfer function and may actually make the conducted noise worse. United Chemi-Con LXF, KMF, or SXE Series Suggested Part: LXF50VB221M10X25LL 220µF, 50V, 105°C Rated 10 x 25 mm ESR=0.063 Ohms Allowable Ripple=1.150 A @ 105°C converter it is suggested that a 1 to 10µF, 0.5 to 5 Ohm ESR capacitor bypass be used directly at the converter output pins. This capacitor prevents any common mode switching currents from showing up at the converters output as normal mode output noise. Do not use the lowest ESR, biggest value capacitor that you can find! This can only lead to reduced system performance or oscillation. See our application note “Understanding Output Impedance For Optimum Decoupling” for more information. 48 Volt Inputs Panasonic Suggested Part: HFE Series ECEA2AFE680, 68µF, 100V, 105°C Rated 12.5 x 15 mm ESR=0.28 Ohms Allowable Ripple=0.511 A @ 105°C Nichicon Suggested Part: PR Series UPR2A101MRH 100µF, 100V, 105°C Rated 12.5 x 20 mm Allowable Ripple=0.577 A @ 105°C Temperature Derating The EC Single series can operate up to 100°C case temperature without derating. Case temperature may be roughly calculated from ambient by knowing that the 6 Watt EC Singles case temperature rise is approximately 20°C per package watt dissipated. United Chemi-Con KMF, SXE Suggested Part: KMF100VB470M10X16LL 47µF, 100V, 105°C Rated 10 x 16 mm ESR=0.32 Ohms Allowable Ripple=0.500 A @ 105°C For example: If a 48 volt input converter was delivering 4 Watts, at 48 volts input at what ambient could it expect to run with no moving air and no extra heatsinking? Efficiency for a EC Single is approximately 78%. A little less for some - a little more for others, check the product curves for exact information. This leads to an input power of about 5 Watts. Therefore the case dissipation is 5 Watts (input power) minus 4 Watts (output power) or 1 Watt. The case temperature rise would be 1 Watt x 20°C/W = 20°C. This number is subtracted from the maximum case temperature of 100°C to get: 80°C. A Applying the Output The output is simply connected to your application circuit and away you go. If extra low output noise is required in your application the circuit shown in Figure 2 may be used to reduce the output noise to below 10 mV peak-peak. This is a rough approximation to the maximum ambient temperature. Because of the difficulty of defining ambient temperature and the possibility that the loads dissipation may actually increase the local ambient temperature significantly or that convection cooling is suppressed by physical placement of the module, these calculations should be verified by actual measurement of operating temperature and your circuits exact efficiency (efficiency depends on both line input and load value) before committing to a production design. Grounding The input and output sections are fully floating from each other. They may be operated fully floating or with a common ground. If the input and output sections are connected either directly at the converter or at some remote location from the Manufacturing Company, Inc. • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 4 6 Watt EC Single Series DC/DC Converters Typical Performance (Tc=25°C, Vin=Nom VDC, Rated Load). Data for 12 Volt Input Models 12 VOLT EFFICIENCY Vs. LOAD 12 VOLT INPUT CURRENT Vs. LINE INPUT VOLTAGE 85 80 LINE = 9VDC LINE = 12VDC 75 EFFICIENCY(%) INPUT CURRENT(AMPS) 1.00 70 65 LINE = 27VDC 60 55 0.75 100% LOAD 0.50 50% LOAD 0.25 50 45 0.00 0 10 20 30 40 50 60 70 80 90 100 0 5 10 LOAD(%) 12 VOLT EFFICIENCY Vs. LINE INPUT VOLTAGE 20 25 30 12 VOLT CAPACITOR CURRENT Vs. LOAD CAPACITOR CURRENT (AMPS RMS) 85 100% LOAD EFFICIENCY(%) 15 LINE INPUT(VOLTS) 80 50% LOAD 75 70 1.00 0.80 0.60 12V & 15V OUTPUT 0.40 5V OUTPUT 0.20 5 10 15 20 25 30 0 20 40 60 80 100 LOAD (%) LINE INPUT(VOLTS) Data for 48 Volt Input Models 48 VOLT EFFICIENCY Vs. LOAD 48 VOLT INPUT CURRENT Vs. LINE INPUT VOLTAGE 90 0.5 . EFFICIENCY(%) 80 LINE = 20VDC INPUT CURRENT(AMPS) 85 LINE = 48VDC 75 70 65 LINE = 60VDC 60 55 50 0.4 100% LOAD 0.3 0.2 50% LOAD 0.1 A 45 40 0.0 0 10 20 30 40 50 60 70 80 90 100 0 10 LOAD(%) 48 VOLT EFFICIENCY Vs. LINE INPUT VOLTAGE 30 40 50 60 48 VOLT CAPACITOR CURRENT Vs. LOAD CAPACITOR CURRENT (AMPS RMS) 90 100% LOAD 85 EFFICIENCY(%) 20 LINE INPUT(VOLTS) 80 50% LOAD 75 70 65 0.50 0.40 0.30 12V & 15V OUTPUT 0.20 5V OUTPUT 0.10 20 30 40 50 60 0 20 40 60 80 100 LOAD (%) LINE INPUT(VOLTS) Manufacturing Company, Inc. • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 5 6 Watt EC Single Series DC/DC Converters Typical Performance (Tc=25°C, Vin=Nom VDC, Rated Load). Data for All Models DERATING OUTPUT VOLTAGE Vs. OUTPUT LOAD 120 120 NORMALIZED OUTPUT (%) INFINITE HEAT SINK OUTPUT POWER (%) 100 80 NO HEAT SINK 60 SAFE OPERATING AREA 40 20 100 80 CURRENT LIMIT MODE -> 60 40 20 "HICKUP" MODE -> 0 0 -40 -20 0 20 40 60 80 100 120 0 20 40 AMBIENT TEMPERATURE (Deg C) 80 100 120 140 160 180 200 OUTPUT LOAD (%) OUTPUT VOLTAGE Vs. CASE TEMPERATURE OUTPUT IMPEDANCE Vs. FREQUENCY 10 OUTPUT IMPEDANCE (OHMS) 0.2 NORMALIZED OUTPUT (%) 60 0.1 0.0 -0.1 -0.2 -0.3 -0.4 12 AND 15 VOLT 1 .1 5 VOLT .01 .001 .0001 -40 -20 0 20 40 60 80 100 10 CASE TEMPERATURE (Deg C) 100 1000 10000 100000 1000000 FREQUENCY (Hz) A Manufacturing Company, Inc. • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 6

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