DATASHEET Rev. E DCHBW75 SERIES 4:1 Ultra Wide Input Voltage Ranges Up to 76.8 Watts, Single Outputs Industry Standard Half-Brick Footprint DC/DC Power Converters Standard FEATURES Railway Applications Soft-Start RoHS Compliant 4:1 Ultra Wide Input Voltage Ranges Up to 76.8 Watts Output Power Single Outputs Ranging from 3.3VDC to 48VDC Terminal Block Output Current up to 20A Under Voltage Lockout APPLICATIONS Railway Systems Wireless Networks Telecom / Datacom Industry Control Systems Semiconductor Equipment Distributed Power Architectures Military Applications OPTIONS Pin Length Heatsinks Thru-Hole Inserts Negative Logic Remote On/Off Terminal Block Terminal Block with EMC Filter Six-Sided Shielding High Efficiency up to 90% No Minimum Load Requirements Adjustable Output Voltage Industry Standard Half-Brick Footprint Remote On/Off Control Threaded Inserts and Thru-Hole Inserts Available Short Circuit, Over Voltage, Over Current, and Over Temperature Protection UL60950-1, EN60950-1, IEC60950-1, & EN50155 Safety Approvals (Approvals Pending for 110VDC Input Models) DESCRIPTION The DCHBW75 series of DC/DC power converters provides up to 76.8 Watts of output power in an industry standard half-brick package and footprint. This series consists of single output models ranging from 3.3VDC to 48VDC with 4:1 ultra wide input voltage ranges of 9~36VDC, 18~75VDC and 43~160VDC. Some features include high efficiency up to 90%, adjustable output voltage, positive remote on/off control, and under voltage lockout. These converters also have short circuit, over voltage, over current, and over temperature protection. The DCHBW75 series is RoHS compliant and has UL60950-1, EN60950-1, IEC609501, and EN50155 safety approvals (safety approvals pending for 110VDC input models). Several different options are available for this series including negative remote on/off, terminal block, pin length, heatsinks, and thru-hole inserts. Please call factory for more details. 05/21/2013 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 1 of 8 Rev. E DCHBW75 Series 4:1 Input Voltage Ranges Up to 76.8 Watts, Single Outputs Half-Brick DC/DC Power Converters SPECIFICATIONS: DCHBW75 SERIES 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 Min Typ Max 24VDC nominal input models 48VDC nominal input models 110VDC nominal input models 24VDC nominal input models 48VDC nominal input models 110VDC nominal input models 24VDC nominal input models 48VDC nominal input models 110VDC nominal input models 24VDC nominal input models 48VDC nominal input models 110VDC nominal input models No Load 9 18 43 24 48 110 36 75 160 9 18 43 Low line to high line at full load No load to full load Full load an nominal Vin -0.1 -0.1 -1 -20 Unit INPUT SPECIFICATIONS Input Voltage Range Start-up Voltage Shutdown Voltage Input Surge Voltage (100ms) Input Current Input Filter (See Note 13) Input Reverse Protection (See Note 15) OUTPUT SPECIFICATIONS Output Voltage Line Regulation Load Regulation Voltage Accuracy Voltage Adjustability (See Note 7) Output Power Output Current Minimum Load Ripple & Noise (peak to peak) Transient Response Recovery Time 110VDC Input Models Start-Up Time Others Remote Sense (See Note 8) Temperature Coefficient PROTECTION Over Voltage Protection Threshold Over Current Protection Threshold 50 100 185 See Table Pi Type Parallel diode See Table +0.1 +0.1 +1 +10 See Table See Table 0 20MHz Bandwidth 25% load step change Nominal input and constant resistive load Power Up or Remote On/Off -0.02 Hiccup 110VDC nominal input models Others Short Circuit Protection Over Temperature Protection REMOTE ON/OFF CONTROL (See Note 6) DC/DC ON Positive Logic (standard) DC/DC OFF DC/DC ON Negative Logic (optional) DC/DC OFF Input Current of Remote Control Pin Nominal Vin Remote Off State Input Current Nominal Vin 05/21/2013 7.5 16 36 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 VDC VDC VDC VDC % % % % % See Table 200 60 25 10 +0.02 µs ms ms % Vo %/°C 115 130 % Vo 150 % Io 110 140 Hiccup, automatic recovery +115 °C Open or 3V < Vr < 12V Short or 0V < Vr < 1.2V Short or 0V < Vr < 1.2V Open or 3V < Vr < 12V -0.5 1 mA 3 mA Page 2 of 8 DCHBW75 Series 4:1 Input Voltage Ranges Up to 76.8 Watts, Single Outputs Half-Brick DC/DC Power Converters Rev. E SPECIFICATIONS: DCHBW75 SERIES 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 GENERAL SPECIFICATIONS Efficiency Switching Frequency TEST CONDITIONS Min Nominal input voltage and full load 110VDC Input Models 1 minute (reinforced insulation) Others 1 minute (basic insulation) Isolation Voltage Input to Output Input (Output) to Case Input to Output Input (Output) to Case 270 4242 2121 2250 1600 1 Typ Max See Table 300 330 Unit KHz VDC VDC Isolation Resistance GΩ Isolation Capacitance 2500 pF Maximum Capacitive Load Minimum input and constant resistive load See Table ENVIRONMENTAL SPECIFICATIONS Base-plate -40 +105 Operating Case Temperature Range °C Terminal Block type -40 +105 Standard -55 +125 Storage Temperature °C Terminal Block type -40 +105 Relative Humidity 5 95 % RH Thermal Shock EN61373, MIL-STD-810F Vibration EN61373, MIL-STD-810F Standard 6.7 Thermal Impedance (See Note 9) °C/Watt With 0.24” Heatsink 5.4 With 0.45” Heatsink 4.7 BELLCORE TR-NWT-000332 1,010,000 hours MTBF (See Note 1) MIL-HDBK-217F 74,160 hours PHYSICAL SPECIFICATIONS Standard 3.42oz (97g) Weight Terminal Block (“T” suffix) 7.05oz (200g) Terminal Block with EMC Filter (“TF” suffix) 8.47oz (240g) Standard 2.4x2.28x0.5 inches (61x57.9x12.7 mm) Dimensions (L x W x H) Terminal Block (“T” suffix) 3.35x2.4x1.1 inches (85x61x28 mm) Terminal Block with EMC Filter (“TF” suffix) 3.35x2.4x1.27 inches (85x61x32.3 mm) 24VDC and 48VDC nominal input models Metal Case Material 110VDC nominal input voltage models Aluminum base-plate with plastic case Base Material 24VDC and 48VDC nominal input models FR4 PCB Potting Material Silicon (UL94-V0) Shielding 24VDC and 48VDC nominal input models Six-sided SAFETY & EMC CHARACTERISTICS Safety Approvals IEC60950-1, UL60950-1, EN60950-1, EN50155 (pending for 110VDC nominal input models) Standard EN55011, EN55022 Class A EMI (See Note 11) TF Option EN55011, EN55022 Class A Air ±8KV ESD EN61000-4-2 Perf. Criteria A Contact ±6KV Radiated Immunity EN61000-4-3 20 V/m Perf. Criteria A Fast Transient (See Note 11) EN61000-4-4 ±2KV Perf. Criteria A EN55024 ±1KV Perf. Criteria A Surge (See Note 11) EN61000-4-5 EN50155 ±2KV Perf. Criteria A Conducted Immunity EN61000-4-6 10 Vrms Perf. Criteria A 05/21/2013 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 3 of 8 DCHBW75 Series 4:1 Input Voltage Ranges Up to 76.8 Watts, Single Outputs Half-Brick DC/DC Power Converters Rev. E MODEL SELECTION TABLE Model Number Input Voltage Output Voltage Output Current Min. load Full load 0mA 20A No Load (2) Input Current Ripple & Noise (3) (4) Output Power Maximum Capacitive Load (5) Efficiency (3) DCHBW75-24S3.3 3.3VDC 85mA 75mVp-p 66W 60600µF 87% DCHBW75-24S05 5 VDC 0mA 15A 120mA 75mVp-p 75W 30000µF 88% DCHBW75-24S12 12 VDC 0mA 6.3A 185mA 100mVp-p 75.6W 5250µF 88% 15 VDC 0mA 5A 185mA 100mVp-p 75W 3330µF 88% DCHBW75-24S15 DCHBW75-24S24 24 VDC (9 – 36 VDC) 24 VDC 0mA 3.2A 85mA 200mVp-p 76.8W 1330µF 87% DCHBW75-24S28 28 VDC 0mA 2.7A 85mA 200mVp-p 75.6W 960µF 87% DCHBW75-24S48 48 VDC 0mA 1.6A 85mA 300mVp-p 76.8W 330µF 87% DCHBW75-48S3.3 3.3VDC 0mA 20A 60mA 75mVp-p 66W 60600µF 88% DCHBW75-48S05 5 VDC 0mA 15A 60mA 75mVp-p 75W 30000µF 90% DCHBW75-48S12 12 VDC 0mA 6.3A 90mA 100mVp-p 75.6W 5250µF 90% 15 VDC 0mA 5A 50mA 100mVp-p 75W 3330µF 89% 24 VDC 0mA 3.2A 50mA 200mVp-p 76.8W 1330µF 88% DCHBW75-48S28 28 VDC 0mA 2.7A 50mA 200mVp-p 75.6W 960µF 88% DCHBW75-48S48 48 VDC 0mA 1.6A 50mA 300mVp-p 76.8W 330µF 87% DCHBW75-110S3.3 3.3VDC 0mA 20A 25mA 75mVp-p 66W 60600µF 89% DCHBW75-110S05 5 VDC 0mA 15A 25mA 75mVp-p 75W 30000µF 91% DCHBW75-110S12 12 VDC 0mA 6.3A 40mA 100mVp-p 75.6W 5250µF 91% 15 VDC 0mA 5A 40mA 100mVp-p 75W 3330µF 91% DCHBW75-48S15 DCHBW75-48S24 DCHBW75-110S15 DCHBW75-110S24 48 VDC (18 – 75 VDC) 110 VDC (43 – 160 VDC) 24 VDC 0mA 3.2A 25mA 200mVp-p 76.8W 1330µF 90% DCHBW75-110S28 28 VDC 0mA 2.7A 25mA 200mVp-p 75.6W 960µF 90% DCHBW75-110S48 48 VDC 0mA 1.6A 25mA 300mVp-p 76.8W 330µF 90% NOTES 1. BELLCORE TR-NWT-000332. Case 1: 50% Stress, Temperature at 40°C. MIL-HDBK-217F Notice2 @Ta=25°C, Full load (Ground, Benign, controlled environment). 2. Typical value at nominal input voltage and no load. 3. Typical value at nominal input voltage and full load. 4. The ripple and noise of 48VDC output voltage models is measured with a 2.2μF/100V X7R 1812 MLCC; The ripple and noise of all other output voltages is measured with a 4.7μF/50V X7R 1812 MLCC. 5. Test by minimum input and constant resistive load. 6. The CTRL pin voltage is referenced to –INPUT. To order negative logic remote on/off control add the suffix “R” to the model number. 7. Output voltage is adjustable for 10% trim up or -20% trim down of nominal output voltage by connecting a single resistor between TRIM and +SENSE pins for trim up or between TRIM and -SENSE pins for trim down. To calculate the value of the resistor RU and RD for a particular output voltage see page 5. 8. Maximum output deviation is +10% inclusive of remote sense and trim. If remote sense is not being used the +SENSE should be connected to its corresponding +OUTPUT and likewise the -SENSE should be connected to its corresponding -OUTPUT. 9. (1) Thermal test conditions for vertical direction are by natural convection (20LFM). (2) Heat sink is optional. See the “Product Options” table on page 6 for suffix options. 10. The DCHBW75 series can only meet EN55022 Class A or Class B with external components added. Please contact factory for more information. 11. An external input filter capacitor is required if the module has to meet EN61000-4-4, EN61000-4-5. For 24 & 48VDC nominal input models, we recommend connecting one aluminum electrolytic capacitor (Nippon chemi-con KY series, 220μF /100V, ESR 48mΩ) in parallel. For 110VDC nominal input models, we recommend connecting three aluminum electrolytic capacitors (Ruby-con BXF series, 100μF / 250V) in parallel. 12. CASE GROUNDING: EMI can be reduced when you connect the four screw bolts to the shield plane. 13. An external input capacitor is recommended for 24VDC nominal input models. We suggest 4.7μF/50V X7R MLCC or Nippon chemi-con KY series, 68μF/100V, ESR 110mΩ or better capacitor. For terminal block versions, the capacitor is included as standard and an external capacitor is not necessary. 14. This series comes with several different options: negative remote on/off control, heatsinks, pin length, thru-hole inserts, and terminal blocks. See the “Product Options” table on page 6 for more ordering information. 15. CAUTION: This power converter is not internally fused. An input line fuse must always be used. 05/21/2013 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 4 of 8 DCHBW75 Series 4:1 Input Voltage Ranges Up to 76.8 Watts, Single Outputs Half-Brick DC/DC Power Converters Rev. E DERATING CURVES DCHBW75-48S05 Derating Curve With 0.24” Height Heatsink (See Note 9) 20 80 60 20 20 40 80 60 100 0 -40 120 20 20 40 Ambient Temperature (°C) Natural Convection (20LFM) 100LFM 200LFM 300LFM 400LFM 500LFM 40 80 60 100 0 -40 120 ~ ~ -40 60 ~ ~ ~ ~ 0 Natural Convection (20LFM) 100LFM 200LFM 300LFM 400LFM 500LFM 40 80 Output Power (%) Output Power (%) 40 100 ~ ~ Natural Convection (20LFM) 100LFM 200LFM 300LFM 400LFM 500LFM ~ ~ 60 120 ~ ~ 100 80 DCHBW75-48S05 Derating Curve With 0.45” Height Heatsink (See Note 9) ~ ~ 100 120 ~ ~ 120 ~ ~ Output Power (%) DCHBW75-48S05 Derating Curve 20 Ambient Temperature (°C) 40 60 80 100 120 Ambient Temperature (°C) EFFICIENCY GRAPHS DCHBW75-48S05 Efficiency vs Input Voltage DCHBW75-48S05 Efficiency vs Output Load 95.0 92.5 90.0 87.5 82.5 Efficiency (%) Efficiency (%) 85.0 80.0 77.5 75.0 72.5 70.0 67.5 Iout = 100% F.L. Iout = 50% F.L. Iout = 25% F.L. 65.0 62.5 60.0 18 24 30 36 42 48 54 60 66 72 95.0 92.5 90.0 87.5 85.0 82.5 80.0 77.5 75.0 72.5 70.0 67.5 65.0 62.5 60.0 57.5 55.0 52.5 50.0 75 Input Voltage (VDC) Vin Vin Vin Vin 10 20 30 40 50 60 70 80 90 = 18V = 24V = 48V = 75V 100 % of Full Load OUTPUT VOLTAGE ADJUSTMENT Output is adjustable for 10% trim up or -20% trim down of nominal output voltage by connecting an external resistor between the TRIM pin and either the +SENSE or -SENSE pins. With an external resistor between the TRIM and -SENSE pin, the output voltage set decreases. With an external between the TRIM and -SENSE pin, the output voltage set point increases. Maximum output deviation is +10% inclusive of remote sense. The value of the external resistor can be obtained by the equations below. The external TRIM resistor needs to be at least 1/8W resistor. V 100 % 100 2% RU OUT K % 1.225% TRIM UP 05/21/2013 100 RD 2K % TRIM DOWN Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 5 of 8 DCHBW75 Series 4:1 Input Voltage Ranges Up to 76.8 Watts, Single Outputs Half-Brick DC/DC Power Converters Rev. E MECHANICAL DRAWING METAL CASE (24VDC & 48VDC Nominal Input Models) Unit: inches (mm) SIDE VIEW 2.000 (50.80) 1.400 (35.56) 1.000 (25.40) 0.400 (10.16) 0.700 (17.78) 6 7 8 9 BOTTOM VIEW 1 2 3 4 0.400 (10.16) PIN CONNECTIONS DEFINE DIAMETER - INPUT 0.04 in. CASE 0.04 in. CTRL 0.04 in. + INPUT 0.04 in. - OUTPUT 0.08 in. - SENSE 0.04 in. TRIM 0.04 in. + SENSE 0.04 in. + OUTPUT 0.08 in. EXTERNAL OUTPUT TRIMMING Output can be externally trimmed by using the method shown below. TRIM UP 0.20 (5.1) 2.28 (57.9) RD RU 7 8 1.900 (48.26) TRIM DOWN 6 7 0.50 (12.7) 1.000 (25.40) 0.700 (17.78) 2.40 (61.0) 1.400 (35.56) 0.02 (0.6) 5 Threaded (Standard) 4-M3X0.5 Thru-Hole (“TH” suffix) 4-Ø0.126 (Ø3.2) The screw locked torque: MAX 0.49N.M (5.0kgf.cm) See Note 12 PIN 1 2 3 4 5 6 7 8 9 0.200 (5.08) NOTES 1. Tolerance: x.xx±0.02 (x.x±0.5) x.xxx±0.01 (x.xx±0.25) 2. Pin Pitch Tolerance: ±0.01 (±0.25) 3. Pin Dimension Tolerance: ±0.004 (±0.1) 0.50 (12.7) PLASTIC CASE (110VDC Nominal Input Models) Unit: inches (mm) SIDE VIEW 2.000 (50.80) 1.400 (35.56) 1.000 (25.40) 0.400 (10.16) 0.700 (17.78) 6 7 8 9 BOTTOM VIEW 1 2 3 4 0.400 (10.16) EXTERNAL OUTPUT TRIMMING TRIM UP Product Options 0.200” pin length 0.145” pin length 0.200” pin length Positive Remote ON/OFF Logic 0.145” pin length 0.200 (5.08) Suffix R RL None S Negative Remote ON/OFF Logic Ø0.126 thru-hole (no thread) inserts RD RU 0.20 (5.1) 2.28 (57.9) TRIM DOWN 6 7 8 1.900 (48.26) Thru-Hole Inserts (No Thread) (1) PIN CONNECTIONS DEFINE DIAMETER - INPUT 0.04 in. CASE 0.04 in. CTRL 0.04 in. + INPUT 0.04 in. - OUTPUT 0.08 in. - SENSE 0.04 in. TRIM 0.04 in. + SENSE 0.04 in. + OUTPUT 0.08 in. Output can be externally trimmed by using the method shown below. 0.50 (12.7) 1.000 (25.40) 0.700 (17.78) 2.40 (61.0) 1.400 (35.56) 0.02 (0.6) 5 Threaded (Standard) 4-M3X0.5 Thru-Hole (“TH” suffix) 4-Ø0.126 (Ø3.2) The screw locked torque: MAX 0.49N.M (5.0kgf.cm) See Note 12 PIN 1 2 3 4 5 6 7 8 9 TH NOTES 1. Tolerance: x.xx±0.02 (x.x±0.5) x.xxx±0.01 (x.xx±0.25) 2. Pin Pitch Tolerance: ±0.01 (±0.25) 3. Pin Dimension Tolerance: ±0.004 (±0.1) 0.50 (12.7) Heatsink (1) Terminal Block (2)(3) 7 Product Options H = 0.45” Vertical H = 0.24” Horizontal H = 0.24” Vertical H = 0.45” Horizontal Wall Mounted Wall Mounted with EMC Filter (3) Suffix H H1 H2 H3 T TF NOTES 1. Models with thru-hole inserts cannot be equipped with a heatsink. 2. Terminal block models have 0.200” pin lengths. 0.145” pin lengths are not available for terminal block models. 3. EMI filter meets EN55011, EN55022 Class A. 05/21/2013 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 6 of 8 DCHBW75 Series 4:1 Input Voltage Ranges Up to 76.8 Watts, Single Outputs Half-Brick DC/DC Power Converters Rev. E HEATSINK OPTIONS Vertical Fin Orientation (Suffixes “H”, “H2”) Horizontal Fin Orientation (Suffixes “H1”, “H3”) 2.28 (57.9) H Unit: inches (mm) Heatsink Options Heatsink Options H = 0.24 inches (“H2” suffix) H = 0.45 inches (“H” suffix) H = 0.24 inches (“H1” suffix) H = 0.45 inches (“H3” suffix) 2.40 (61.0) Unit: inches (mm) H 2.40 (61.0) 2.28 (57.9) TERMINAL BLOCK OPTIONS Wall Mounted without EMC Filter (Suffix “T”) Wall Mounted with EMC Filter (Suffix “TF”) Terminal Block Type T TF Weight 7.05oz (200g) 8.47oz (240g) Dimensions 3.35 x 2.40 x 1.10 inches (85.0 x 61.0 x 28.0 mm) 3.35 x 2.40 x 1.27 inches (85.0 x 61.0 x 32.3 mm) Thru-Hole Inserts (WxL) 2.126 x 3.071 inches (54.00 x 78.00 mm) 2.126 x 3.071 inches (54.00 x 78.00 mm) NOTES 1. Terminal block models have 0.200” pin lengths. 0.145” pin lengths are not available for terminal block models. 2. Models with EMC filter (suffix “TF”) meet EN55011, EN55022 Class A. 05/21/2013 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 7 of 8 DCHBW75 Series 4:1 Input Voltage Ranges Up to 76.8 Watts, Single Outputs Half-Brick DC/DC Power Converters Rev. E MODEL NUMBER SETUP DCHBW 75 Series Name - 48 S 05 Output Power Input Voltage Single Output Output Voltage 75: 75 Watts 24: 9~36 VDC S: single 3.3: 3.3 VDC 48: 18~75 VDC 05: 5 VDC 110: 43~160 VDC 12: 12 VDC 15: 15 VDC 24: 24 VDC 28: 28 VDC 48: 48 VDC R TH H TF Remote On/Off & Pin Length Thru-Hole Inserts (1) Heatsink (1) Terminal Block (2) None: positive Logic, 0.200” pin length S: positive Logic, 0.145” pin length None: threaded inserts TH: Ø0.126 thru-hole inserts R: negative Logic, 0.200” pin length None: no heatsink (1) H: 0.45” vertical H1: 0.24” horizontal RL: negative Logic, 0.145” pin length None: no terminal block T: wall mounted TF: wall mounted with EMC filter (3) H2: 0.24” vertical H3: 0.45” horizontal NOTES 1. Models with thru-hole inserts cannot be equipped with a heatsink. 2. Terminal block models have 0.200” pin lengths. 0.145” pin lengths are not available for terminal block models. 3. Models with EMC filter (suffix “TF”) meet EN55011, EN55022 Class A. 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: 05/21/2013 (603)778-2300 (888)597-9255 (603)778-9797 [email protected] 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 8 of 8