ETC AEV02C24

AEV 24V&48V Input Series
Te c h n i c a l R e f e r e n c e N o t e s
Single And Dual Output Series
25 Watt DC-DC Converter
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AEV 24V&48V Input Series DC-DC Converters
S i n g l e A n d D u a l O u t p u t , 2 5 Wa t t D C - D C C o n v e r t e r s
AEV Technical Description
The AEV series of switching DC-DC
converters is one of the most cost
effective options available in component power. The AEV uses an
industry standard package size and
pinout configuration, and provides
control and trim functions.
Note: CNT
must be tied
to -Vin for
operation.
AEV converters come in 24V or 48V
input versions, each of which uses a
2:1 input range. Outputs are isolated from the input and the converters are capable of providing up to
25 watts of output power.
At startup, input current passes
through an input filter designed to
help meet CISPR 22 level A radiated emissions, and Bellcore GR1089
conducted emissions. A fuse should
be used in line with the input.
Fig. 1. AEV Single Output Block Diagram
Note: CNT
must be tied
to -Vin for
operation.
The AEV converters are pulse width
modulated (PWM) and operate at a
Fig. 2. AEV Dual Output Block Diagram
nominal fixed frequency of 330 kHz.
Feedback to the PWM controller
uses an opto-isolator, maintaining complete isolation between primary and secondary. Caution
should be taken to avoid ground loops when connecting the converter to ground. Output power is
typically available within 10 ms after application of input power.
AEV Series Electrical Input
Input
The +Vin and -Vin pins are located as shown in the mechanical drawings at the end of this manual. AEV converters have a 2:1 input voltage range; 24 Vin converters can accept 18-36 Vdc,
and 48 Vin converters can accept 36-72 Vdc. Care should be taken to avoid applying reverse
polarity to the converters which can damage the converter.
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AEV 24V&48V Input Series DC-DC Converters
S i n g l e A n d D u a l O u t p u t , 2 5 Wa t t D C - D C C o n v e r t e r s
Input Reverse Voltage Protection
Under installation and cabling conditions where
reverse polarity across the input may occur, reverse
+Vin
+Vin
polarity protection is recommended. Protection can
-Vin
-Vin
easily be provided as shown in Figure 3. In both cases
the diode used is rated for 4A/100V. Placing the diode Fig. 3. Reverse Polarity Protection Circuits
across the inputs rather than in-line with the input
offers an advantage in that the diode only conducts in
a reverse polarity condition, which increases circuit efficiency and thermal performance.
Input Undervoltage Protection
The AEV is protected against undervoltage on the input. If the input voltage should drop below the
acceptable range, the converter will shut down. It will automatically restart when the undervoltage
condition is removed.
Input Overvoltage Protection
The AEV is protected against overvoltage on the input. If the input voltage should rise above the
acceptable range, the converter will shut down. It will automatically restart when the undervoltage
condition is removed.
Input Filter
Input filters are included in the converters to
+Vin
help achieve standard system emissions certifications. Some users however, may find that
C1
additional input filtering is necessary. The AEV
-Vin
series has an internal switching frequency of
330 kHz so a high frequency capacitor mountFig. 4. Ripple Rejection Input Filter
ed close to the input terminals produces the
best results. To reduce reflected noise, a capacitor can be added across the input as shown in
Figure 4, forming a π filter. A 47µF/100V electrolytic capacitor is recommended for C1.
For conditions where EMI is a concern, a different input filter can be used. Figure 5 shows
an input filter designed to reduce EMI effects.
L1 is a 1mH common mode inductor, C1 is a
47µF/100V electrolytic capacitor, and C2 is a
1µF/100V metal film or ceramic high frequency
capacitor, and Cy1 and Cy2 are each 4700 pF
high frequency ceramic capacitors.
L1
+Vin
Cy1
C2
C1
Cy2
-Vin
Fig. 5. EMI Reduction Input Filter
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AEV 24V&48V Input Series DC-DC Converters
S i n g l e A n d D u a l O u t p u t , 2 5 Wa t t D C - D C C o n v e r t e r s
When a filter inductor is connected in series with the power converter input, an input capacitor C1
should be added. An input capacitor C1 should also be used when the input wiring is long, since
the wiring can act as an inductor. Failure to use an input capacitor under these conditions can produce large input voltage spikes and an unstable output.
Nominal
Input
Fuse
24V
5A
48V
2.5A
Input Fusing
Standard safety agency regulations require input fusing.
Recommended fuse ratings for the AEV Series are shown in Table 1.
Table 1. Fuse Ratings
AEV Series Electrical Output
Output Connections (+Vout, -Vout)
Outputs on the AEV series are isolated from the input and can therefore be left to float or can be
grounded. Pin connections for +Vout, and -Vout are shown in the mechanical drawings at the end
of this manual.
Sharing Power Between Dual Outputs
Each output of a dual output AEV is limited
to one half of the total power capacity of the
converter. For example, if the positive output of an AEV01cc48 only draws 5W, the
negative output will still be limited to 12.5W.
Voltage regulation performance is best
when the outputs are balanced. Figure 6
shows typical cross regulation for a 15 volt
output.
AEV01CC24
AEV01CC48
AEV01CC24
AEV01CC48
Fig. 6. Cross Regulation
Overcurrent Protection (OCP)
AEV series DC/DC converters feature foldback current limiting as part of their
Overcurrent Protection (OCP) circuits.
When output current exceeds 115 to 150%
of rated current, such as during a short circuit condition, the output will shutdown
immediately, and can tolerate short circuit
conditions indefinitely. When the overcurrent condition is removed, the converter will
automatically restart.
AEV02B24
AEV02C24
Fig. 7. Overcurrent Performance
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AEV 24V&48V Input Series DC-DC Converters
S i n g l e A n d D u a l O u t p u t , 2 5 Wa t t D C - D C C o n v e r t e r s
Overvoltage Protection (OVP)
The AEV series provides overvoltage protection on the output, which will shut the output off if the
voltage exceeds 120 to 140% of the nominal output voltage. If the OVP circuit activates, power to
the converter should be cycled to turn the converter back on.
Trim
The output voltage of the AEV series can be trimmed using the trim pin provided. Applying a voltage to the trim pin through a voltage divider from the output will cause the output to increase or
decrease by up to 10%. Trimming up by more
+Vout
than 10% of the nominal output may activate the
R1
Load
-Vout
OVP circuit or damage the converter. Trimming
R2
down more than 10% can cause improper reguRT = 100k Ω
Trim
lation. When trimming a dual output converter,
both outputs trim simultaneously.
Single Output Converters
Dual Output Converters
10%
R1 R2
Fixed and variable trim circuits are shown in
Figures 7 to 9. Note that resistor values will
change depending on the converter used. For
trim ranges not listed, contact the factory for
assistance.
5%
R1 R2
10%
R1 R2
5%
R1 R2
3.3V out
5V out
33
12
63
5V out
12V out
120
11
200 20
15V out
150 10
270 20
12V out
47
12
86
15V out
68
12
120 22
22
22
All resistor values in kΩ
Fig. 8. Variable Trim
+Vout
+Vout
Load
R1
Load
-Vout
-Vout
R2
Trim
Trim
Single Output Converters
Dual Output Converters
5V out:
2.08
R1 = y - 2.2
1.87
y -1
12V out:
R1 =
R1 =
1.97
y -1
15V out:
R1 =
R1 =
2.08
- 2.2
y
3.3V out:
1.55
R1 = y - 2.2
5V out:
R1 =
12V out:
15V out:
where
where
3.3V out:
2.54
R1 = y - 5.08
2.23
y - 2.2
5V out:
R1 =
5.6
y
2.28
y - 2.2
12V out:
R1 =
7.49
y - 10.66
15V out:
R1 =
10.38
y - 13.65
y = Vo - Ve
Ve
y = Vo - Ve
Ve
Dual Output Converters
Single Output Converters
where
- 8.67
5.6
y
5V out:
R1 =
12V out:
R1 =
19.18
y - 23.61
15V out:
R1 =
25.11
y - 29.59
where
- 9.67
y = Ve - Vo
Ve
y = Ve - Vo
Ve
All resistor values in kΩ
All resistor values in kΩ
Fig. 9. Fixed Trim Up
Fig. 10. Fixed Trim Down
Control Function
The AEV provides a control function allowing the user to turn the output on and off using an external circuit. Applying a voltage greater than 7V to the CNT pin will disable the output, while applying a voltage less than 3.5V will enable it. The performance of the converter between these two
points will depend on the individual converter and whether the control voltage is increasing or
Page 4
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AEV 24V&48V Input Series DC-DC Converters
S i n g l e A n d D u a l O u t p u t , 2 5 Wa t t D C - D C C o n v e r t e r s
decreasing. The CNT pin must be connected to -Vin for operation. If the CNT pin is left open, the
converter will default to “control off” and the output will not turn on. The maximum voltage that can
be applied to the control pin is 80 volts.
CNT
-Vin
Fig. 11. Simple Control
Circuit
CNT
CNT
CNT
-Vin
-Vin
Fig. 12. Transistor
Control Circuit
-Vin
Fig. 13. Isolated Control
Circuit
Fig. 14. Relay Control
Circuit
Output Filters
When the load is sensitive to ripple and noise, an output filter
+Vout
C1
can be added to minimize the effects. A simple output filter to
Load
reduce output ripple and noise can be made by connecting a
-Vout
capacitor across the output as shown in Figure 15. The recFig. 15. Output Ripple Filter
ommended value for the output capacitor is 470µf / 10V for single outputs up to 5 volts, 100µf / 25V for 12 and 15 volt single
outputs, and 220µf / 25V on each output for dual output converters.
Extra care should be taken when long leads or traces are used
to provide power to the load. Long lead lengths increase the
chance for noise to appear on the lines. Under these conditions
C2 can be added across the load as shown in Figure 16. The
recommended component for C2 is 1µf ceramic capacitor.
+Vout
C1
C2
Load
-Vout
Fig. 16. Output Ripple Filter for a
Distant Load
Decoupling
Noise on the power distribution system is not always created by the converter. High speed analog
or digital loads with dynamic power demands can cause noise to cross the power inductor back
onto the input lines. Noise can be reduced by decoupling the load. In most cases, connecting a
10 µF tantalum capacitor in parallel with a 0.1µF ceramic capacitor across the load will decouple
it. The capacitors should be connected as close to the load as possible.
Series Operation
When converters are connected in series to increase the output
voltage, diodes should be added as shown in Figure 16. Choose
low forward voltage drop diodes, such as shottky diodes. The
reverse voltage of the diode should be greater than the output
voltage, and the diode’s turn-on current should be greater than
the series load current. The maximum operating output current
of the series connection should not be greater than the maximum output current of any single converter.
+Vin
-Vin
+Vout
-Vout
Load
+Vin
-Vin
+Vout
-Vout
Fig. 17. Series Operation
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AEV 24V&48V Input Series DC-DC Converters
S i n g l e A n d D u a l O u t p u t , 2 5 Wa t t D C - D C C o n v e r t e r s
Parallel Operation
Under most circumstances, paralleling converters is not desirable. When more power is required,
a higher power converter will usually use less space and will cost less than using two lower power
converters. One common exception is when redundancy or graceful degradation is required. In
this case, multiple converters should be used. Please see the discussion on Redundant Operation
in the Design Considerations section for further information.
Design Considerations
Parallel Power Distribution
Figure 18 shows a typical parallel power distribution
design. Such designs, sometimes called daisy chains, can
be used for very low output currents, but are not normally
recommended. The voltage across loads far from the
source can vary greatly depending on the IR drops along
the leads and changes in the loads closer to the source.
Dynamic load conditions increase the potential problems.
Radial Power Distribution
Radial power distribution is the preferred method of providing power to the load. Figure 19 shows how individual
loads are connected directly to the power source. This
arrangement requires additional power leads, but it avoids
the voltage variation problems associated with the parallel power distribution technique.
Mixed Distribution
In the real world a combination of parallel and radial
power distribution is often used. Dynamic and high current loads are connected using a radial design, while static and low current loads can be connected in parallel.
This combined approach minimizes the drawbacks of a
parallel design when a purely radial design is not feasible.
I1 + I2 + I3
I2 + I3
I3
RL2
RL1
RL3
+Vout
Load 1
Load 2
Load 3
-Vout
RG2
RG1
RG3
RL = Lead Resistance
RG = Ground Lead Resistance
Fig. 18. Parallel Power Distribution
+Vout
RL3
RL1
RL2
Load 1
Load 2
Load 3
RG2
RG1
RG3
-Vout
RL = Lead Resistance
RG = Ground Lead Resistance
Fig. 19. Radial Distribution
+Vout
RL3
RL1
RL4
RL2
Load 1
RG1
Load 2
Load 3
Load 4
RG2
RG3
-Vout
RG4
RL = Lead Resistance
RG = Ground Lead Resistance
Fig. 20. Mixed Distribution
Redundant Operation
A common requirement in high reliability systems is to provide redundant power supplies. The
easiest way to do this is to place two converters in parallel, providing fault tolerance but not load
sharing. Oring diodes should be used to ensure that failure of one converter will not cause failure
of the second. Figure 21 shows such an arrangement. Upon application of power, one of the converters will provide a slightly higher output voltage and will support the full load demand. The sec-
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AEV 24V&48V Input Series DC-DC Converters
S i n g l e A n d D u a l O u t p u t , 2 5 Wa t t D C - D C C o n v e r t e r s
ond converter will see a zero load condition and will
“idle”. If the first converter should fail, the second converter will support the full load. When designing redundant converter circuits, Shottky diodes should be used to
minimize the forward voltage drop. The voltage drop
across the Shottky diodes must also be considered when
determining load voltage requirements.
+Vout
-Vout
Load
+Vout
-Vout
Fig 21. Redundant Operation
Ground Loops
Ground loops occur when different circuits are given multiple paths to common or earth ground,
as shown in Figure 22. Multiple ground points can have slightly different potential and cause
current flow through the circuit from one point to another. This can result in additional noise in all
the circuits. To eliminate the problem, circuits should be designed with a single ground connection as shown in Figure 23.
RLine
RLine
RLine
+Vout
RLine
+Vout
Load
Load
RLine
-Vout
Load
-Vout
RLine
Load
RLine
RLine
RLine
Ground
Loop
RLine
RLine
Fig. 22 Ground Loops
Fig. 23. Single Point Ground
Hot Plugging
When a power source or load is inserted or removed from a system while the system is operational, it is called “hot plugging”. Designing a system for hot plug operation is challenging and several issues should be considered.
The input to a converter is largely capacitive and it will draw a high inrush current when power is
first applied. This will place a large demand on the power bus which must be designed to handle
the current spike. It also presents the risk of arcing when the converter is connected.
A common way to minimize inrush current is to disable the output until after the inrush current has
subsided. Disabling the output eliminates power draw from the converter and reduces capacitor
charge times. The output only has to be disabled for a very short time and can usually be done
through mechanical connections. Making the input connections physically longer lets them connect first and initiate the inrush current. When the shorter output or output enable connections are
made, the inrush has already subsided.
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AEV 24V&48V Input Series DC-DC Converters
S i n g l e A n d D u a l O u t p u t , 2 5 Wa t t D C - D C C o n v e r t e r s
AEV Series Mechanical Considerations
Maximum Case Temperature
Percent maximum output power
Thermal Derating
AEV single and dual output converters are rated
100
for full power up to a case temperature of 90°C.
80
Under typical conditions this equates to an ambiSafe Operating Area
60
ent temperature of 70°C. For operation above
40
ambient air temperatures of 70°C, output power
20
must be derated as shown in Figure 24, or airflow
0
over the converter must be provided. When air-20 -10 0 10 20 30 40 50 60 70 80 90
Ambient Temperature in degrees C
flow is provided, the case temperature should be
Fig. 24. Temperature Derating
used to determine maximum temperature limits.
The minimum operating temperature for the AEV is -25°C. Operation at temperatures as low as 40°C is possible, but output performance below -25°C is not specified.
Installation
AEV series converters can be mounted in any orientation, but care should be taken to allow for
free airflow. Common placement techniques put heat sources such as power components at the
end of the airflow path or provide separate airflow paths. This arrangement keeps other system
equipment cooler and increases component life spans.
Soldering
AEV series converters are compatible with standard wave soldering techniques. When wave
soldering, the converter pins should be preheated for 20-30 seconds at 110°C, and wave soldered at 260°C for less than 15 seconds.
When hand soldering, the iron temperature should be maintained at 450°C and applied to the
converter pins for less than 5 seconds. Longer exposure can cause internal damage to the converter. Cleaning can be performed with cleaning solvent IPA or with water.
Page 8
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AEV 24V&48V Input Series DC-DC Converters
S i n g l e A n d D u a l O u t p u t , 2 5 Wa t t D C - D C C o n v e r t e r s
Electrical Specs
Nominal Output Output Short Circuit
Input Voltage Current
Current
Ripple
(V)
(V)
(A)
(A)
(mV rms)
typ
typ max
24
3.3
5
6.7
10 20
24
5
4
5.3
10 20
24
12
2.1
2.9
10 20
24
15
1.7
2.6
10 20
AEV05F24
AEV04A24
AEV02B24
AEV02C24
Noise
(mV pp)
typ max
50 75
50 75
75 100
75 100
Efficiency
(%)
min typ
78 80
82 83
83 85
83 86
80
83
86
86
Overvoltage
Lockout
(V)
min max
3.96 5.0
5.75 7.0
13.8 15.5
17.0 19.5
AEV05F48
AEV04A48
AEV02B48
AEV02C48
48
48
48
48
3.3
5
12
15
5
4
2.1
1.7
6.7
5.3
2.9
2.6
10
10
10
10
20
20
20
20
50 75
50 75
75 100
75 100
78
82
84
84
3.96 5.0
5.75 7.0
13.8 15.5
17.0 19.5
AEV02AA24
AEV01BB24
AEV01CC24
24
24
24
±5
±12
±15
±2
±1.05
±0.85
6.6
3.4
3.2
10
10
10
20
20
20
50 75
75 100
75 100
82 83
84 86
84 86
12
27
33.5
14
33
42
AEV02AA48
AEV01BB48
AEV01CC48
48
48
48
±5
±12
±15
±2
±1.05
±0.85
6.2
2.9
2.7
10
10
10
20
20
20
50 75
75 100
75 100
82 83
84 86
84 86
12
27
33.5
14
33
42
5.08 (0.20)
5.08 (0.20)
+Vin
50.0 (1.97)
+Vo
7.62 (0.30)
-Vo
-Vin
Trim
CNT
5.08 (0.20)
50.0 (1.97)
+Vo
COM
15.24 (0.60)
15.24 (0.60)
5.08 (0.20)
+Vin
7.62 (0.30)
5.08 (0.20)
15.24 (0.60)
-Vo
-Vin
Trim
CNT
5.44 (0.21)
5.08 (0.20)
5.44 (0.21)
3.81 (0.15)
3.81 (0.15)
55.88 (2.20)
55.88 (2.20)
65.0 (2.56)
65.0 (2.56)
8.5 (0.33)
8.5 (0.33)
0.5 (0.02)
0.5 (0.02)
STANDOFF
TYP, 4 PLACES
6.6 (0.26)
6-φ1.0 (0.039)
2.4 (0.09)
3.0 (0.12)
STANDOFF
TYP, 4 PLACES
6.6 (0.26)
7-φ1.0 (0.039)
2.4 (0.09)
3.0 (0.12)
AEV Single and Dual Outputs
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AEV 24V&48V Input Series DC-DC Converters
S i n g l e A n d D u a l O u t p u t , 2 5 Wa t t D C - D C C o n v e r t e r s
Input
Input Voltage
Isolation
Input-Output
Input-Case
Output-Case
I/O Isolation Resistance
Control Voltage
Control Logic
Logic Low = On
Logic High = Off
Control Current
Undervoltage Shutdown
24 Vin
48 Vin
Overvoltage Shutdown
24 Vin
48 Vin
Min
18
36
Nom
24
48
Common Specs
Max
Units
36
Vdc
72
Vdc
500
500
500
300
80
3.5
0.6
Vdc
Vdc
mA
7
14
30
16
33
18
36
Vdc
Vdc
36
72
38
76
42
82
Vdc
Vdc
±1
±0.1
±0.5
+10
W
%Vo
%Vo
%Vo
%Vo
4
200
4
200
±0.02
%Vo
µs
%Vo
µs
%Vo/°C
Output
Power
Voltage Setpoint Accuracy
Line Regulation
Load Regulation
Trim Range
-10
Dynamic Response
50-75% load
25
±0.05
±0.35
50-25% load
Temperature Regulation
General
MTBF
Case Temperature
Storage Temperature
Switching Frequency
Pin solder temperature
Hand Soldering Time
Weight
Vdc
Vdc
Vdc
MΩ
Vdc
2,030
-25
-40
90
105
330
260
5
63
k Hrs
°C
°C
kHz
°C
s
grams
Notes
50 Vdc max < 100 ms
100 Vdc max < 100 ms
absolute maximum
Both outputs trim together.
T=25°C, DI/Dt=1A/10µs
T=25°C, DI/Dt=1A/10µs
T=25°C, DI/Dt=1A/10µs
T=25°C, DI/Dt=1A/10µs
Bellcore TR332, 25°C
wave solder < 15 s
iron temperature 450°C
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Asia
852-2437-9662
852-2402-4426
www.astec.com
AEV 24V&48V Input Series DC-DC Converters
S i n g l e A n d D u a l O u t p u t , 2 5 Wa t t D C - D C C o n v e r t e r s
AEV Single Performance Curves
AEV05F48
AEV04A48
AEV02B48
AEV02C48
AEV05F24
AEV04A24
AEV02B24
AEV02C24
AEV05F24
AEV04A24
AEV02B24
AEV02C24
AEV Single Output Typical Startup Delay from CNT On
AEV05F48
AEV04A48
AEV02B48
AEV02C48
AEV Single Output Typical Shutdown Delay from CNT Off
Page 11
TEL:
FAX:
USA
1-760-930-4600
1-760-930-0698
Europe
44-(0)1384-842-211
44-(0)1384-843-355
Asia
852-2437-9662
852-2402-4426
www.astec.com
AEV 24V&48V Input Series DC-DC Converters
S i n g l e A n d D u a l O u t p u t , 2 5 Wa t t D C - D C C o n v e r t e r s
AEV Single Performance Curves
AEV05F48
AEV04A48
AEV05F24
AEV04A24
AEV02B48
AEV02C48
AEV02B24
AEV02C24
Typical step up load response from 50% to 75% load.
AEV04A48
Typical step down load response from 50% to 25% load.
AEV04A48
Page 12
TEL:
FAX:
USA
1-760-930-4600
1-760-930-0698
Europe
44-(0)1384-842-211
44-(0)1384-843-355
Asia
852-2437-9662
852-2402-4426
www.astec.com
AEV 24V&48V Input Series DC-DC Converters
S i n g l e A n d D u a l O u t p u t , 2 5 Wa t t D C - D C C o n v e r t e r s
90
90
80
80
70
70
60
60
Efficiency (%)
Efficiency (%)
AEV Dual Performance Curves
50
40
50
40
30
30
20
20
AEV02AA24
AEV01BB24
AEV01CC24
10
AEV02AA48
AEV01BB48
AEV01CC48
10
0
0
0
0.5
1
1.5
2
2.5
0
0.5
1.5
2
2.5
AEV02AA48
AEV01BB48
AEV01CC48
AEV02AA24
AEV01BB24
AEV01CC24
AEV Dual Output Typical Startup Delay from CNT On
1
Output Current (amps)
Output Current (amps)
AEV Dual Output Typical Shutdown Delay from CNT Off
Page 13
TEL:
FAX:
USA
1-760-930-4600
1-760-930-0698
Europe
44-(0)1384-842-211
44-(0)1384-843-355
Asia
852-2437-9662
852-2402-4426
www.astec.com
AEV 24V&48V Input Series DC-DC Converters
S i n g l e A n d D u a l O u t p u t , 2 5 Wa t t D C - D C C o n v e r t e r s
AEV Dual Performance Curves
AEV02AA24
AEV02AA48
AEV02AA24
AEV02AA48
AEV02AA24
AEV02AA48
AEV01BB24
AEV01BB48
AEV01BB24
AEV01BB48
AEV01BB24
AEV01CC24
AEV01CC24
AEV01CC48
AEV01CC24
AEV01CC48
Page 14
TEL:
FAX:
USA
1-760-930-4600
1-760-930-0698
Europe
44-(0)1384-842-211
44-(0)1384-843-355
Asia
852-2437-9662
852-2402-4426
www.astec.com