Features ● ● ● ● ● ● ● ● ● ICE Technology* 115°C Maximum Case Temperature -40°C MinimumTemp. Built-in FCC/EN55022 Class B Filter 2:1 Wide Input Voltage Range 50 Watts Output Power Ribbed or Baseplate Case Styles Min. Efficiency 86% 3kVDC Isolation Low Quiescent Current Description The RPP50 series 2:1 input range DC/DC converters are ideal for high end industrial applications and COTS Military applications where a very wide operating temperature range of -45°C to +120°C is required. Although the case size is very compact, the converter contains a built-in filter EN55022 Class B / FCC Level B without the need for any external components. The RPP50 is available in two case styles: the ribbed case for active cooling and the baseplate case for high vibration, bulkhead-mounting or for passive heatsink cooling applications. They are UL-60950-1 certified. POWERLINE+ DC/DC-Converter with 3 year Warranty 50 Watt 2:1 Single Output Selection Guide 24V and 48V Input Types Part Number Input Range VDC Output Voltage VDC Output Current A Input(1) Current mA Efficiency(2) (Typ.) RPP50-243.3S 18-36 3.3 15 58/2405 86% RPP50-2405S 18-36 5 10 60/2315 89% RPP50-2412S 18-36 12 4.16 18/2370 87% RPP50-2415S 18-36 15 3.33 18/2315 88% RPP50-2424S 18-36 24 2.10 18/2315 88% RPP50-483.3S 36-75 3.3 15 42/1177 87% RPP50-4805S 36-75 5 10 37/1140 89% RPP50-4812S 36-75 12 4.16 11/1165 87% RPP50-4815S 36-75 15 3.33 11/1141 88% RPP50-4824S 36-75 24 2.10 11/1141 88% RoHS 2011/65/EU 6/6 UL-60950-1 Certified E224736 RPP50-S ** add suffix for case options * ICE Technology SUFFIX INFORMATION none = Standard Ribbed Case -B = Baseplate Case For other CTRL logic (-1), case style (-F) or low temperature options (-L, -M, -T) please contact RECOM for availability. www.recom-international.com REV: 0/2014 ICE (Innovation in Converter Excellence) uses state-of-the-art techniques to minimise internal power dissipation and to increase the internal temperature limits to extend the ambient operating temperature range to the maximum. Refer to Application Notes PP-37 RPP50-S Series POWERLINE+ DC/DC-Converter Specifications (typical at nominal input and 25°C unless otherwise noted) Input Voltage Range Under Voltage Lockout Input Filter Input Surge Voltage (100 ms max.) 24V nominal input 48V nominal input 24V input DC-DC ON (min.) DC-DC OFF (max.) 48V input DC-DC ON (min.) DC-DC OFF (max.) Common Mode EMC Filter 50VDC 100VDC 24V Input 48V Input Input Reflected Ripple Start Up Time nominal Vin and full load nominal Vin and constant resistor load Remote ON/OFF (3) Remote OFF input current Logic High Logic Low Nominal input Output Voltage Accuracy 10% Load and nominal Vin 300mAp-p 20ms typ., 50ms max. Open or 3.0V < Vr < 5.5V Short or 0V < Vr < 1.2V 2mA typ. Voltage Adjustability ±1% ±10% Minimum Load 0% Line Regulation low line, high line at full load Load Regulation Ripple and Noise (20MHz bandwith limited) (measured with 1µF capacitor across output) 10% to 100% full load 3.3V, 5V All others Temperature Coefficient RPP50 18-36VDC 36-75VDC 17.5VDC 17VDC 35VDC 34VDC ±0.3% ±0.5% 60mVp-p typ. 40mVp-p typ. ±0.04%/°C max. Transient Response 25% load step change Over Load Protection % of full load at nominal Vin Short Circuit Protection 200µs 120% typ. Hiccup, automatic recovery Output Over Voltage Protection (refer to block diagram in Application Notes) Converter shutdown if Vout > Vout nominal + 20% Isolation Voltage Rated at 2250VDC/1 minute, Flash tested at 3000VDC/1 second Isolation Resistance 10MΩ min. Isolation Capacitance (refer to block diagram in Application Notes) 3000pF max. Operating Frequency 260kHz ± 40kHz Maximum Case Temperature +115°C Storage Temperature Range -55°C to +125°C Over Temperature Protection (refer to block diagram in Application Notes) internal thermistor RPP50 Operating Temperature Range Ambient, Free Convection Thermal Impedance (Natural convection Ribbed Case: Vertical Ribbed Case: Horizontal Relative Humidity Case Material -40°C to see Calculation (Note 7) 7.3°C/Watt 10°C/Watt 5% to 95% RH (6) Aluminium Potting Material Silicone (UL94-V0) Weight Ribbed Case Baseplate Case 39g 43g Packing Quantity Ribbed Case Baseplate Case 4 pcs per Tube Single packed PP-38 REV: 0/2014 www.recom-power.com RPP50-S Series POWERLINE+ DC/DC-Converter Specifications (typical at nominal input and 25°C unless otherwise noted) Safety Standards certified UL-60950-1, 1st Edition Thermal Cycling complies with MIL-STD-810F Vibration 10-55Hz, 12G, 30 Min. along X, Y and Z Conducted Emissions Radiated Emissions ESD Radiated Immunity Fast Transient (4) Surge (4) Conducted Immunity EN55022 EN55022 EN61000-4-2 EN61000-4-3 EN61000-4-4 EN61000-4-5 EN61000-4-6 MTBF calculated according to BELLCORE TR-NWT-000332 (5) Class B Class B Perf. Criteria B Perf. Criteria A Perf. Criteria B Perf. Criteria B Perf. Criteria A 1989 x 103 hours Notes : Pdissipation = Pin-Pout = Pout Ƞ RPP50 1. Typical values at nominal input voltage and no load/full load. 2. Typical values at nominal input voltage and full load. 3. The ON/OFF pin voltage is referenced to negative input. The pin is pulled high internally. ON/OFF control is standard with positive logic: e.g.RPP50-4805S. Positive logic: 0= OFF, 1 = ON. The converter will be ON if the CTRL is left open. 4. Requires an external 100µF low ESR capacitor to meet EN61000-4-4 and EN61000-4-5 5. Case l: 50% Stress, Temperature at 50°C (Ground Benign). 6. To ensure a good all-round electrical contact, the baseplate is pressed firmly into place within the aluminium housing.The hydraulic press can leave tooling marks and deformations to both the housing and baseplate. The case is anodised aluminium, so there will be natural variations in the case colour and the aluminium is not scratch resistant. Any resultant marks, scratches and colour varations are cosmetic only and do not affect the operation or performance of the converters. 7. Example: Tcase = Case Temperature Rthcase-ambient = 7.3°C/W (vertical) Tambient = Environment Temperature Rthcase-ambient = 11°C/W (horizontal) Pdissipation = Internal losses Tcase - Tambient Pin = Input Power Rthcase-ambient = Pdissipation Pout = Output Power Pout Ƞ = Efficiency under given Operating Conditions Pdissipation = Pin-Pout = Ƞ - Pout Rthcase-ambient = Thermal Impedance - Pout Practical Example: Take the RPP50-4805SW with 90% load. What is the maximum ambient operating temperature? Use converter vertical in application. Effmin = 89% @ Vnom Pout = 50W Poutapp = 50 x 0.9 = 45W Pdissipation = Ƞ Pout Ƞ - Pout = ~90% (from Eff vs Load Graph) Rth = 115°C - Tambient Tcasemax - Tambient --> 7.3°C/W = 5W Pdissipation Tambient = 78.5°C 45 Pdissipation = - 45 = 5W 0.9 www.recom-international.com REV: 0/2014 PP-39 RPP50-S Series POWERLINE+ DC/DC-Converter Typical Characteristics External Output Trimming -Vout -Vout Trim Up Refer to Application Notes for suggested Resistor Values 10kW Trimpot Trim Trim Trim Down 10kW Trimpot +Vout 10kW Trimpot +Vout RPP50-4805S Efficiency VS Load Vnom RPP50 Efficiency (%) 100 90 80 70 60 50 40 30 20 10 0 20 0 40 60 80 100 Output Load (%) Recommended PCB Layout Ribbed Case Single Output C1 Fuse PP-40 C2 Top View REV: 0/2014 www.recom-power.com RPP50-S Series POWERLINE+ DC/DC-Converter Recommended PCB Layout Baseplate Case- suggested PCB layout Single Output Dual Output C2 No tracks in this area (42 x 30mm) C1 C3 C3 Fuse Top View Input Fuse is recommended. Recommended fuse rating = double maximum input current, time delay type. Input Capacitor, C1, is required to meet EN61000 Surge and Fast Transient, otherwise it is not required for normal operation. Output Capacitors C2/C3 are recommended, but not required for normal operation. Typical capacitor values are 1µF MLCC To ensure optimum thermal performance, use large areas of copper on the PCB to assist with heat dissipation and mount the converter vertically. Package Style and Pinning (mm) RPP50 Ribbed Case (Standard - no Suffix) 51.4 31.1 11.70 dia. 1.0 5.1 +/- 0.9 Standoff = 1.3 45.70 3.3 Pin Connections 5.10 1 2 10.20 Bottom View 3 10.20 4 10.20 6 7.6 www.recom-international.com 5 5.0 REV: 0/2014 Pin # 1 2 3 4 5 6 Single +Vin -Vin +Vout -Vout Trim CTRL Dual +Vin -Vin +Vout Com -Vout CTRL Pin Pitch Tolerance ±0.35 mm PP-41 RPP50-S Series POWERLINE+ DC/DC-Converter Typical Characteristics Baseplate Case (-B Suffix) 45.7 3.0 1.0 dia. 1.0 2.8 1.7 4.0 8.7 11.4 50.8 17.8 6x 3.55 (use M3 screws) 2.54 5.10 25.4 17.8 3.3 Pin Connections 1 Bottom View 2 10.20 3 4 6 5 Pin # 1 2 3 4 5 6 30.9 10.20 32.6 10.20 36.0 38.0* Single +Vin -Vin +Vout -Vout Trim CTRL Dual +Vin -Vin +Vout Com -Vout CTRL 40.6 RPP50 Pin Pitch Tolerance ±0.35 mm *Recommended Fixing Centres Baseplate Case Fixing - Mounting onto Heatsink/Bulkhead PCB Baseplate Case Fixing - Anti Vibration Mounting onto PCB Use 10mm Spacers PCB PP-42 REV: 0/2014 www.recom-power.com POWERLINE+ Application Notes DC/DC-Converter ICE Technology ICE Technology I.C.E Technology ICE (Innovation in Converter Excellence) Technology uses a combination of techniques to minimise internal heat dissipation and maximise the heat transfer to ambient to create a new converter series which offers high end performance at a price which is significantly lower than conventional specialist converters. The exact details of this technology must remain secret, but the following brief resume describes the main features of this technological breakthrough: Minimising internal heat dissipation Maximising heat transfer The rate of heat transfer between a hot body and its cooler surroundings is given by Fourier’s Law: q=-k.ΔT where q = rate of heat transfer k = thermal conductivity and ΔT = temperature difference If k can be made larger, then the rate of heat transfer can still match or exceed the rate of heat generation at lower temperature differences ΔT and the converter will have an extended operating temperature range. www.recom-international.com ICE Technology splits the thermal conductivity problem into two areas and attacks each area seperately using different techniques. Firstly, the internal heat transfer to the case is maximised by a combination of novel converter construction and clever thermal design. ICE converters use a construction where the hottest components (the switching FET, the transformer and the synchronous rectification FETs) are placed closest to the case wall. This method of construction makes the manufacture of the converter more difficult, but this lack of compromise reduces greatly the internal thermal impedance. Secondly, the rate of transfer of heat to the surroundings is improved by a novel case construction which incorporates a built-in heat sink. The case is also made from thick aircraft grade aluminium rather than thin nickel-plated copper to provide a better thermal junction between the case and the high thermal conductivity silicone potting material used inside the converter. Maximising high performance temperature The final technique used in the construction of ICE Technology converters is to use high temperature internal components. The maximum operating temperature of a converter is dependent on the lowest maximum permissible operating temperature of any the components used. If the capacitors are rated up to +85°C and the FETs are rated at +160°C, then the limiting factor is the capacitor temperature of +85°C. The temperature of the ferrite core used in the transformer is also an important limiting factor. If the transformer core temperature exceeds the Curie temperature of the ferrite, then the transformer rapidly loses performance. ICE Technology converter uses high temperature grade components to permit a case temperature of +115°C maximum. This allows operation at up to +85°C ambient without the need for fans to blow air over the converter. REV: 0/2014 Electromagnetic Compatibility Although high temperature performance is a significant feature of ICE Technology design, it does not end there. ICE Technology also addresses the need for electromagnetic compatibility by incorporating a built-in EN55022 Class B grade filter inside the converter. The converter has been designed from the ground up to meet EMC requirements rather than a conventional design process where first the converter is optimised for performance and then an external filter is added to combat the conducted interference. By including the filter on the main PCB of the converter, the track path lengths and impedances between the filter and the noisegenerating components are reduced to the minimum and consequently smaller value filter components can be used that fit into the compact case dimensions of the Powerline+ converters without compromising on filter performance. Safety and Protection ICE Technology converters are fully protected from output short circuits, overload, output over-voltage and over-temperature. In addition, they feature under-voltage lockout that will automatically disable the converter if the input voltage falls below the minimum level. The output is current limited which means that temporary overloads can occur without the converter shutting down. When overloaded, the output voltage will decrease to keep the maximum power constant. For the 40W and 50W converters, if the overload is too high, the converter will go into hiccup short circuit protection mode. In this mode, the converter will attempt to reconnect power every 10-20 milliseconds. Output overvoltage protection is monitored by a separate and independent feedback circuit and an internal thermistor sensor is used to protect the converter against overheating. PP-43 ICE The difference between the input power and the output power is the internal power dissipation which generates heat within the converter. If the converter is inefficient at converting power, then adding external heat sinks, baseplates or fans are remedies that cure the symptoms rather than address the illness. First and foremost, the converter must have the highest possible efficiency over the entire input voltage range and load conditions. Most power converters are designed to be most efficient at 25°C, full load and nominal input voltage and thus offer a compromise performance when lightly loaded or operated at the maximum ambient temperature. ICE Technology uses state-of-the-art techniques to improve power convertion efficiency by approximately 2% compared to standard converters. A two per cent improvement may not sound much, but the difference between a converter with 88% efficiency and one with 90% efficiency is a 17% reduction in the dissipated power. In addition, when lightly loaded, the converters enter a power saving mode and draw only a few milliamps from the supply. Techniques to improve thermal conductivity POWERLINE+ Application Notes Trim Tables DC/DC-Converter Powerline Plus Output Trim Tables Single output Powerline Plus converters offer the feature of trimming the output voltage over a certain range around the nominal value by using external trim resistors. No general equation can be given for calculating the trim resistors, but the Output Voltage Trimming: following trimtables give typical values for chosing these trimming resistors. If voltages between the given trim points are required, extrapolate between the two nearest given values to work out the resistor required or use a variable resistor to set the output voltage. RPPxx-xx3.3S (all types) Trim up Vout = RU = 1 3,333 72.8 2 3,366 34.4 3 3,399 21.2 4 3,432 14.4 5 3,465 9.9 6 3,498 7.2 7 3,531 5.3 8 3,564 3.88 9 3,597 2.74 10 3,63 1.84 % Volts KOhms Trim down Vout = RD = 1 3,267 101.3 2 3,234 36.2 3 3,201 21.0 4 3,168 13.65 5 3,135 9.2 6 3,102 6.0 7 3,069 4.12 8 3,036 2.56 9 3,003 1.34 10 2,97 0.87 % Volts KOhms App Notes RPPxx-xx05S (all types) Trim up Vout = RU = 1 5,05 109.7 2 5,1 51 3 5,15 31.2 4 5,2 20.3 5 5,25 14.2 6 5,3 9.87 7 5,35 7.1 8 5,4 5.0 9 5,45 3.38 10 5,5 2.08 % Volts KOhms Trim down Vout = RD = 1 4,95 127.6 2 4,9 55.8 3 4,85 33.0 4 4,8 20.2 5 4,75 14.2 6 4,7 9.46 7 4,65 5.97 8 4,6 3.6 9 4,55 1.77 10 4,5 0.28 % Volts KOhms RPPxx-xx12S (all types) Trim up Vout = RU = 1 12,12 270 2 12,24 120 3 12,36 70 4 12,48 45.2 5 12,6 30.1 6 12,72 19.8 7 12,84 12.8 8 12,96 7.52 9 13,08 3.31 10 13,2 0 % Volts KOhms Trim down Vout = RD = 1 11,88 270 2 11,76 120 3 11,64 70 4 11,52 45.2 5 11,4 30.1 6 11,28 19.8 7 11,16 12.8 8 11,04 7.52 9 10,92 3.31 10 10,8 0 % Volts KOhms RPPxx-xx15S (all types) Trim up Vout = RU = 1 15,15 337 2 15,3 150 3 15,45 87 4 15,6 56.2 5 15,75 37.5 6 15,9 24.7 7 16,05 16 8 16,2 9.4 9 16,35 4.16 10 16,5 0 % Volts KOhms Trim down Vout = RD = 1 14,85 337 2 14,7 150 3 14,55 87 4 14,4 56.2 5 14,25 37.5 6 14,1 24.7 7 13,95 16 8 13,8 9.4 9 13,65 4.16 10 13,5 0 % Volts KOhms PP-44 REV: 0/2014 www.recom-power.com Block Diagrams POWERLINE+ Application Notes DC/DC-Converter Powerline Plus Output Trim Tables RPPxx-xx24S (all types) Trim up Vout = RU = 1 24,24 270 2 24,48 120 3 24,72 70 4 24,96 45.2 5 25,20 30.1 6 25,44 19.8 7 24,68 12.8 8 25,92 7.52 9 26,16 3.31 10 26,4 0 % Volts KOhms Trim down Vout = RD = 1 23,76 270 2 23,52 120 3 23,28 70 4 23,04 45.2 5 22,80 30.1 6 22,56 19.8 7 22,32 12.8 8 22,08 7.52 9 21,84 3.31 10 21,6 0 % Volts KOhms Block Diagrams Single Output - 3.3V and 5V Outputs App Notes Single Output - all other outputs +Vin +Vout Com -Vin ON/OFF Control Overtemp. Sensor www.recom-international.com PWM Controller Isolation Overvoltage Sensor Isolation Reference & Error AMP REV: 0/2014 Trim PP-45 POWERLINE+ Application Notes DC/DC-Converter Block Diagrams Block Diagrams App Notes Dual Output The product information and specifications are subject to change without prior notice. All products are designed for non-safety critical commercial and industrial applications. The Buyer agrees to implement safeguards that anticipate the consequences of any failures that might cause harm, loss of life and/or damage property. PP-46 REV: 0/2014 www.recom-power.com