ETC 48S12.500EC

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: sales@calex.com
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: sales@calex.com
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: sales@calex.com
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: sales@calex.com
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: sales@calex.com
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: sales@calex.com
6