Features ICE Technology* • +115°C Maximum Case Temperature • -45°C Minimum Case Temperature • Built-in EMC Filter • Ribbed Case Style • 2250VDC Isolation • Wide 4:1 Input Voltage Range • Built-in EMC Filter, EN-55022 Class B DC/DC Converter RPP40-2405SW Description 40 Watt 4:1 3 2“ x 1.2“ Ribbed Style Single Output 3Y The RPP40 series 4:1 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 +115°C is required. Although the case size is very compact, the converter contains a built-in EMC filter EN-55022 Class B without the need for any external components. The RPP40 is available in a ribbed case style for active cooling. They are UL-60950-1 certified. wa EAR rranty Selection Guide Part Input Input Output Output Efficiency Max. Capacitive Number Voltage RangeCurrentVoltageCurrent typ. Load (VDC) (mA)(VDC)(mA) (%) (µF) RPP40-2405SW 9-36 18905800089 2200 Notes: Note1: Typical values at nominal input voltage and full load. Specifications (measured at TA= 25°C, nominal input voltage, full load and after warm-up) BASIC CHARACTERISTICS Parameter Condition Input Voltage Range Transient Input Voltage Inrush Current Under Voltage Lockout Remote ON/OFF Remote OFF Input Voltage Start-up Time Max. 36VDC ≤100ms 50VDC 20A 40A DC-DC ON DC-DC OFF 8.5VDC ON / high logic OFF / low logic nominal input Open, 4.5V Short, 0V 5.5V 1.2V UL-60950-1 Certified EN-55022 Certified 5mA typ. Vin, full load Minimum Load Output Ripple and Noise E224736 8VDC when use CTRL function Efficiency 5ms 20ms 220kHz 260kHz 300kHz 88% 89% 0% 20MHz limited, 1µF output MLCC Efficiency VS. Load 9090 9090 8080 7070 9Vin 9Vin 24Vin 24Vin 36Vin 36Vin 1010 2020 3030 4040 5050 6060 7070 8080 9090 100 100 Load Load(%) (%) Efficiency (%) Efficiency (%) 100 100 6060 50mVp-p 100mVp-p Efficiency VS. Input Voltage 100 100 Efficiency (%) Efficiency (%) Typ. 24VDC with EMC Filter without EMC Filter Operating Frequency 5050 Min. 9VDC 8080 7070 * ICE Technology 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. 6060 5050 9 9 1212 1515 1818 2121 2424 2727 3030 3333 3636 Input InputVoltage Voltage(V)(V) 5555 perature (°C) perature (°C) Refer to Applications Notes 5050 www.recom-international.com 4545 REV.: 1/2015 RPP-1 RPP40-2405SW DC/DC Converter Series Specifications (measured at TA= 25°C, nominal input voltage, full load and after warm-up) REGULATIONS Parameter Condition Value Output Voltage Accuracy 50% load ±1.5% max. Line Voltage Regulation low line to high line ±0.3% max. Load Voltage Regulation 10% to 100% load ±0.5% max. Transient Response 25% load step change, ΔIo/Δt=2.5A/us 800µs typ. Transient Peak Deviation 25% load step change, ΔIo/Δt=2.5A/us ±2%Vout max. Trimming Output Voltage ±10% typ. Trimming Output Voltage Only the single output converters have a trim function that allows users to adjust the output voltage from +10% to -10%, please refer to the trim table that follow for details. Adjustment to the output voltage can be used with a simple fixed resistor as shown in Figures 1 and 2. A single fixed resistor can increase or decrease the output voltage depending on its connection. Resistor should be located close to the converter. If the trim function is not used, leave the trim pin open. Trim adjustments higher than the specified range can have an adverse effect on the converter´s performance and are not recommended. Excessive voltage differences between output voltage sense voltage, in conjunction with trim adjustment of the output voltage; can cause the OVP circuitry to activate. Thermal derating is based on maximum output current and voltage at the converter´s output pins. Use of the trim and sense function can cause output voltages to increase, thereby increasing output power beyond the converter´s specified rating. Therefore: (Vout at Pins) X (Iout) ≤ rated output power. +VIN +VOUT CTRL TRIM LOAD +VIN +VOUT CTRL TRIM LOAD RTRIMUP RTRIMDOWN -VOUT -VIN -VOUT -VIN Figure 1. Trim connections to increase output voltage using fixed resistors Figure 2. Trim connections to decrease output voltage using fixed resistors Trim up resistor value (KW) Vout 1% 5VDC 109.7 Trim down resistor value (KW) 2% 3% 4% 5% 6% 7% 8% 9% 10% Vout -4% -5% -6% -7% -8% -9% -10% 51 31.2 20.3 14.2 9.87 7.1 5.0 3.38 2.08 5VDC 127.6 55.8 32.96 20.2 14.2 9.46 5.97 3.6 1.77 -1% -2% -3% 0.28 PROTECTIONS Parameter Condition Output Power Protection (OPP) (2) Value Hiccup Mode Over Voltage Protection (OVP) 120% typ. 10% load Over Temperature Protection (OTP) 120% typ. case temperature 120°C, auto-recovery Isolation Voltage I/P to O/P, at 70% RH I/P to Case, O/P to Case 2250VDC / 1 Minute 1500VDC / 1 Minute Isolation Resistance I/P to O/P , at 70% RH 100MW min. Isolation Capacitance I/P to O/P 1500pF typ. Notes: Note2: Note3: RPP-2 combines Over Load Protection and Short Circuit Protection This Power Module is not internally fused. A input fuse must be always used. Recommended Fuse: T6.3A REV.: 1/2015 www.recom-international.com RPP40-2405SW DC/DC Converter Series Specifications (measured at TA= 25°C, nominal input voltage, full load and after warm-up) ENVIRONMENTAL Parameter Condition Value Relative Humidity 95%, non condensing Temperature Coefficient ±0.04% / °C max. natural convection, mounting at FR4 100 (254x254mm) PCB 90 Efficiency (%) Operating Temperature Range Maximum Case Temperature Storage Temperature Range MTBF vertical horizontal 90 start up at -45°C 80 70 9Vin 60according to MIL-HDBK-217F (+50°C 24Vin G.B.) according to BellCore-TR-332 (+50°C 36Vin G.B.) 50 10 20 30 40 Derating Graph 50 60 4.6°C/W 6.4°C/W 100 Efficiency (%) Thermal Impedance 70 80 90 100 -45°C to (see calculation) 80 +115°C 70 -55°C to +125°C 609 x 103 hours 1541 x 103 hours 60 50 9 12 15 Load (%) 18 21 24 27 30 33 Input Voltage (V) (Ta= +25°C, natural convection, typ. Vin and vertical mounting) Case Temperature (°C) 55 50 45 40 35 30 0 10 20 30 40 50 60 70 80 90 100 Load (%) Calculation Rthcase-ambient = 4.6°C/W (vertical) Rthcase-ambient = 6.4°C/W (horizontal) Rthcase-ambient = Tambient = Environment Temperature Tcase - Tambient PIN Pdissipation POUT = Case Temperature Pdissipation = Internal losses Tcase Pdissipation = PIN - POUT = = Input Power = Output Power h = Efficiency under given Operating Conditions POUTapp - POUTappRthcase-ambient = Thermal Impedance h Practical Example: Take the RPP40-2405SW with 50% load. What is the maximum ambient operating temperature? Use converter vertical in application. Effmin = 88% @ Vnom POUT = 40W POUTapp = 40 x 0.5 = 20W Pdissipation = POUTapp T -T - POUTappRth = casemax ambient h P dissipation --> 4.6°C/W = 115°C - Tambient 1.98W h = ~91% (from Eff vs Load Graph) 20 - 20 = 1.98W 0.91 Tambientmax = 105.9°C Pdissipation = continued on next page www.recom-international.com REV.: 1/2015 RPP-3 36 RPP40-2405SW DC/DC Converter Series Specifications (measured at TA= 25°C, nominal input voltage, full load and after warm-up) Soldering Hand Soldering Hand Soldering is the least preferred method because the amount of solder applied, the time the soldering iron is held on the joint, the temperature of the iron and the temperature of the solder joint are variable. The recommended hand soldering guideline is listed in Table 1. The suggested soldering process must keep the power module’s internal temperature below the critical temperature of 217°C continuously. Wave Soldering High temperature and long soldering time will result in IMC layer increasing in thickness and thereby shorten the solder joint lifetime. Therefore the peak temperature over 245°C is not suggested due to the potential reliability risk of components under continuous hightemperature. In the meanwhile, the soldering time of temperature above 217°C should be less than 90 seconds. Please refer to the soldering profile below for recommended temperature profile parameters. Temp Table 1 Hand-Soldering Guideline Parameter Single-side Circuit Boad Double-side Circuit Board Multi-layers Circuit Board Peak Temp. 240 - 245°C 217°C Soldering Iron Wattage 90W 90W 90W 200°C Tip Temperature 385 ±10°C 420 ±10°C 420 ±10°C 150°C Soldering Time 2-6 seconds Ramp downmax. 4°C/sec Time Limited 90sec.above 217°C Preheat time100-140 sec. 4-10 seconds 25°C 4-10 seconds Ramp upmax. 3°C/sec Time SAFETY AND CERTIFICATIONS Certificate Type Report / File Number UL General Safety E224236 UL-60950-1, 1st Edition Conditions Standard / Criterion ±8kV Air Discharge, ±6kV Contact Discharge Level 3, 10V/m ±4kV Applied ±4kV Applied Level 3, 10V rms 50-150Hz, along X,Y and Z 12 cycles 5g / 30ms EN-55022, Class B EN-61000-4-2, Criteria B EN-61000-4-3, Criteria A EN-61000-4-4, Criteria B EN-61000-4-5, Criteria B EN-61000-4-6, Criteria A EN-60068-2-6 EN-60068-2-14 EN-60068-2-27 Certificate Type (Environmental) EMI ESD Radiated Immunity Fast Transient Surge Conducted Immunity Vibration Thermal Cycling (complies with MIL-STD-810F) Shock Standard / Edition EMC Filtering - Suggestions D1 +VIN C2 C4 C1 UR1 Load C3 C5 It is recommended to add UR1, D1 and C1 in railway application. To meet EN61000-4-2, module case should be earth grounded. We offer independent case pin option on request, the location is upon pin 1. RPP -VIN RPP-4 Standard UR1 D1 C1 C2, C3, C4, C5 EN61000-4-2, 3, 4, 5, 6 MOV 14D361K 100V / 3A 680µF / 250V 471pF / 3kV REV.: 1/2015 www.recom-international.com RPP40-2405SW DC/DC Converter Series Specifications (measured at TA= 25°C, nominal input voltage, full load and after warm-up) DIMENSIONS AND PHYSICAL CHARACTERISTICS Parameter Material Value Aluminium (4) Dimensions (LxWxH) 50.8 x 30.5 x 12.7mm Weight 39g Packaging Dimensions (LxWxH) 160 x 55 x 20mm Packaging Quantity 4pcs / Tube Mechanical Dimensions (mm) 30.5 50.8 2.54 11.68 10.16 Sandoff =1.02 4.06 dia. 1.0 45.72 Pin Connections Pin # Single 5.08 Bottom View 2 10.16 5 10.16 10.16 3 4 7.62 Notes: Note4: 1 +Vin 2 -Vin 3 CTRL 4 Trim 5 -Vout 6 +Vout Tolerance: ±0.5mm 6 1 To ensure a good all-round electrical contact, the bottom plate is pressed firmly into place into the aluminium case.The hydraulic press can leave tooling marks and deformations to both the case and plate. 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. Test Set-up + 5µH in DC Power Source - Printed Circuit Board 50Ω LISN out 50 Ohm temination rcvr Filter (if used) 5µH in 50Ω LISN out 1m Twisted Pair Resistive Load rcvr Optional Connection to Earth Ground 50 Ohm input EMC Reciever Computer The product information and specifications are subject to change without prior notice. RECOM products are not authorized for use in safety-critical applications (such as life support) without RECOM’s explicit written consent. A safety-critical application is defined as an application where a failure of a RECOM product may reasonably be expected to endanger or cause loss of life, inflict bodily harm or damage property. The buyer shall indemnify and hold harmless RECOM, its affiliated companies and its representatives against any damage claims in connection with the unauthorized use of RECOM products in such safety-critical applications. www.recom-international.com REV.: 1/2015 RPP-5