TECHNICAL DATASHEET Rev A HP12S24-600 600W DC-DC Converter 10-36 Vdc Input 24Vdc Single Output at 25A FEATURES: High Power Density Low Input Voltage Capability Wide Input Range Fast Transient Response Remote Sense Enable/Disable Pin ±10% Trim Capability High Efficiency 100% Burn-in Synchronizable 1500VDC I/O Isolation APPLICATIONS Very Low Output Ripple Mobile/Vehicle Mounted Equipment Fixed Switching Frequency Telecommunications Equipment Active Current Sharing Option Network (LANs/WANs) Equipment Remote On/Off (Active High/Low) Industrial Equipment Short Circuit Protection Test Equipment Over Temperature Protection DESCRIPTION: The HP12S24-600 is a 600 watt dc/dc converter with a single 24VDC output and a 10~36VDC input voltage range. The HP12S24-600 is a model in our new HP series. The HP series is designed to compliment our LV and FA product lines. It is being introduced to answer the needs of higher power systems requiring low input voltages at higher power levels up to 600 watts. The HP12S24-600 is particularly suited for use in mobile/vehicle mounted equipment, telecommunications equipment, network (LANs/WANs) equipment, and industrial and test equipment. As specialists in modified standard and customized power solutions, Wall Industries is also capable of rapidly customizing the HP series to meet specific customer needs. (888) 597-WALL www.wallindustries.com 1 of 14 Rev A Technical Specifications TECHNICAL DATASHEET HP12S24-600 Model No. HP12S24-600 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 Switching Frequency INPUT (Vin) Operating Voltage Range UVLO Turn On at UVLO Turn Off at UVLO Hysterisis Maximum Input Current No Load Input Current Input Current under “Disable” Input Surge Voltage EFFICIENCY OUTPUT (Vo) Voltage Set Point Voltage Adjustment Load Regulation Line Regulation Temperature Drift Remote Sense Compensation Ripple Spikes Current Current Limit Maximum Admissible Output Capacitance DYNAMIC RESPONSE Load step / V Recovery Time Turn On Delay Turn On Overshoot Hold Up Time DISABLE SIGNAL (Logic enable) Off Condition On Condition ISOLATION Input-Output Isolation Resistance Isolation Capacitance THERMAL Case (Graph 2) Over Temperature Protection Storage Temperature MTBF MECHANICAL Weight (888) 597-WALL Related condition Min Nom Max Unit 10 8 7 - 12/24 8.5 7.5 0.5 0.1 10 92% 36 9 8 66 100 V V V V A A mA V 23.76 21.6 - 24 0.05 0.05 0.005 - 24.24 26.4 0.2 0.2 0.02 10 V V %Vo %Vo %/°C %Vo 0 TBD 32.5 25 - A A μF 50% to 100% load step change Recovery to within 1% Vo From Vin (min.) to Vout (nom.) Full load; resistive 0 0 1 0.4 10 - - V mS mS %Vo mS Pulled low = off, TTL compatible (ref. to –Vin) Open = on (internally pulled up), TTL 0 - 3.3 0.8 - V V 1500 1 1000 - - Vdc GΩ pF 100 °C °C °C 10Vin @ 600W Output 100mS Wavefront Sense pins connected to respective outputs Output limited to 600W and 25A Sense pins connected to respective outputs Sense pins connected to respective outputs Through operating temperature range Threshold Full load, resistive 1 minute -40 -55 Bellcore TR-332 Issue 6 - Calculated www.wallindustries.com 105 - 125 1,293,794.959 hours See Figure 1 19.4oz (550g) Page 2 of 14 TECHNICAL DATASHEET Rev A HP12S24-600 Figure 1: Mechanical Dimensions THREADED INSERTS (STANDARD) Unit: inches [mm] 6.00 152.4 SERIAL NO. 3.00 76 LABEL DATE CODE .112 (NO.4)-40UNC-2B 6X THREAD DEPTH .312 FROM SURFACE-A THRU HOLE .125 REMAINDER. MAX. APPLIED RECEIVING TORQUE: 3.8 LBF-IN [0.4 N-m] THERMAL INTERFACE SURFACE SEE NOTES-5 & 6. A PIN .69 17.4 .015 FIM .20 [5.1] MINIMUM PIN LENGTH FROM STANDOFF SEE NOTES- 2, 3 & 4. PIN DESIGNATIONS FOR REFERENCE ONLY 4.200 106.68 NON-METALLIC COUVENTURE 2.100 53.34 .55 14 9 5 9 5 9 5 8 4 2.400 60.96 2.300 58.41 2 6 1 6 6 1 1 .081 [2.06] 3-PLACES 2 + SENSE .040 [1.02] 3 TRIM .040 [1.02] 4 - SENSE .040 [1.02] 5 - OUTPUT .081 [2.06] 3-PLACES 6 + Vin .081 [2.06] 3-PLACES 7 SD .040 [1.02] 8 SYNC .040 [1.02] 9 - Vin .081 [2.06] 3-PLACES NOTES: 1. 3D MODEL ML106261 AVAILABLE FOR REFERENCE. 2. PIN TO PIN TOLERANCE: .01 [0.25]. 3. PIN DIAMETER TOLERANCE: .005 [0.31]. 4. PIN FINISH: LEAD-FREE, RoHS COMPLIANT. 5. CASE MATERIAL: ALUMINUM. 6. CASE FINISH: ANODIZE. 2.050 52.07 1.450 36.83 1.150 29.21 UNLESS OTHERWISE SPECIFIED DIM ARE IN INCHES, TOLERANCE ON: .850 21.58 ANGLES ±1° .500 12.69 125 .XX= ±.01 .XXX= ±.005 .250 6.35 REMOVE ALL BURRS AND BREAK SHARP EDGES. 0 0 INTERPRET DIMENSION AND TOLERANCE PER ASME Y14.5M - 1994 .35 8.9 THIRD ANGLE PROJECTION 0 0 .35 8.9 5.300 134.63 .05 1.3 PIN + OUTPUT 1.800 45.72 3 7 DESIGNATION 1 THRU-HOLE INSERTS (“TH” SUFFIX) Unit: inches [mm] 6.00 152.4 SERIAL NO. 3.00 76 LABEL DATE CODE .125 [3.18] THRU HOLE 6X MAX. APPLIED RECEIVING TORQUE: 3.8 LBF-IN [0.4 N-m] THERMAL INTERFACE SURFACE SEE NOTES-5 & 6. PIN .69 17.4 .015 FIM 1 .13 [3.2] MINIMUM PIN LENGTH FROM STANDOFF SEE NOTES- 2, 3 & 4. PIN DESIGNATIONS FOR REFERENCE ONLY 4.200 106.68 NON-METALLIC COUVENTURE 2.100 53.34 .55 14 9 5 9 5 9 5 8 4 2.400 60.96 2.300 58.41 2.050 52.07 2 6 1 6 6 1 1 + SENSE .040 [1.02] 3 TRIM .040 [1.02] 4 - SENSE .040 [1.02] 5 - OUTPUT .081 [2.06] 3-PLACES 6 + Vin .081 [2.06] 3-PLACES 7 SD .040 [1.02] 8 SYNC .040 [1.02] 9 - Vin .081 [2.06] 3-PLACES 1. 3D MODEL ML106261 AVAILABLE FOR REFERENCE. 2. PIN TO PIN TOLERANCE: .01 [0.25]. 3. PIN DIAMETER TOLERANCE: .005 [0.13]. 4. PIN FINISH: LEAD-FREE, RoHS COMPLIANT. 5. CASE MATERIAL: ALUMINUM. 6. CASE FINISH: ANODIZE. .850 21.58 .250 6.35 0 0 5.300 134.63 UNLESS OTHERWISE SPECIFIED DIM ARE IN INCHES, TOLERANCE ON: ANGLES ±1° .500 12.69 125 .XX= ±.01 .XXX= ±.005 REMOVE ALL BURRS AND BREAK SHARP EDGES. INTERPRET DIMENSION AND TOLERANCE PER ASME Y14.5M - 1994 0 0 THIRD ANGLE PROJECTION .35 8.9 .05 1.3 2 NOTES: 1.450 36.83 1.150 29.21 .35 8.9 (888) 597-WALL PIN .081 [2.06] 3-PLACES 1.800 45.72 3 7 DESIGNATION + OUTPUT www.wallindustries.com Page 3 of 14 TECHNICAL DATASHEET Rev A HP12S24-600 TR-332 Issue 6, Dec 1997 Reliability Prediction Procedure Form/Worksheet Exhibits and Preparation Instructions Device Reliability Prediction Worksheet Black Bock Estimates (50% Stress, Temperature = 40°C, No Device Burn-in) E = 0.9 . Date 4/22/09 Page 1 of 1 Unit: HP12S24-600 Device Type* Part Number Circuit Ref. Symbol Manufacturer: Wall Industries Qty. (NI) Failure Rate** (G1) Quality Factor (Q1) Total Device Failure Rate (N1GI, QI) (f) 64 2 5 5 74 1 3 1 14 1 18 9 1 3 3 6 0.5 7 19 15 20 4 19 0.2 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 57.6 5.4 13.5 27 33.3 6.3 51.3 13.5 252 3.6 307.8 1.62 CERAMIC CAP ZENER DIODE<1A DIODE1-20A RESISTOR<1 MEG LOAD COIL POWER FILTER OPTOCOUPLER MOSFET PNP TRANS IC 1-32 TRANS PC PINS 772.92 SUBTOTAL TOTAL = (lSS) = pE S NI lG pQ = 772.92 MTBF = (10^9) / (lSS) = 1293794.96 HRS. * Similar parts having the same failure rate, base part number, and quality factor may be combined and entered on one line. Part descriptions should be sufficient to verify that correct failure rate assignment has been made. ** Failure rates come from Table A. If Method II is applied to devices, instead use failure rate (j) from Form 9 (l*GI ). (888) 597-WALL www.wallindustries.com Page 4 of 14 Rev A TECHNICAL DATASHEET HP12S24-600 DESIGN CONSIDERATIONS Under Voltage Lock Out (UVLO) The converter output is disabled until the input voltage exceeds the UVLO turn-on limit. The converter will remain ON until the input voltage falls below the UVLO turn-off limit. There is approximately 0.5V hysteresis in the UVLO circuit. Over Current Protection The converter is internally protected from short circuit and over current conditions. During these fault conditions, the converter output will “hiccup”- (short) or “fold back” - (over current). The converter output will recover once the short or over current fault is removed. Over Temperature Protection The converter is protected from over temperature conditions. Upon exceeding this temperature, the converter will shut down. The converter will automatically recover once it has sufficiently cooled. Input Filter A 4,700μF low ESR capacitor across the input pins is recommended for most system level designs. No additional input capacitance is needed for the power supply to operate with low impedance inputs. However, most “real world” system level integration will have some amount of trace or wiring lengths – raising the inductive impedance. The added input capacitor will bring the impedance back towards unity. Output Filter No additional output capacitor is needed for the power supply to operate within stated specifications. However, if it is a requirement to reduce the ripple and noise on the output, additional capacitance may be added. Usually, ceramic MLCC’s capacitor works best for reducing H.F. spike noise. Also, capacitance in the form of a tantalum or aluminum electrolytic capacitor may also be placed across the output in order reduce base ripple, and improve the load transient peak-to-peak voltage deviation. Remote Sense To improve the voltage regulation at the load, route the connections from the -Sense and the +Sense pins to the –Vout and +Vout connections AT the load. This will force the converter to regulate the voltage at the load and not at the pins of the converter. If it is not desired to use the Remotes Sense feature, the –Sense and +Sense pins should be connected to the -Vout and +Vout pins respectively. Fusing It is required that the input to the converter be supplied with a maximum 100 A, 250 V rated fuse. Safety The HP series is CE pending and pending approval of the following: UL1950, CUL950, TUV60950 FILE 155800. The isolation provided by the HP Series is a Basic insulation in accordance with EN60950. SELV output reliability is maintained only if the input to the HP converter is an SELV source. (888) 597-WALL www.wallindustries.com Page 5 of 14 Rev A TECHNICAL DATASHEET HP12S24-600 Remote ON/OFF The HP Series has Remote ON/OFF (Enable/Disable) capability using TTL logic levels. This function is offered as either Active=TTL High (no suffix) or Active=TTL Low (R suffix), see order details on page 14. For Remote ON/OFF limits, see page 2. Figure 2. Remote (L/E) Synchronization The HP series provides synchronization of switching frequencies between multiple HP series power supplies. The synchronization function is accomplished without the need for any added external circuitry. By tying the SYNC pin between HP modules, they will all automatically synchronize. If synchronization is not used, the pin should be tied to –Vin. (888) 597-WALL www.wallindustries.com Page 6 of 14 Rev A TECHNICAL DATASHEET HP12S24-600 Output Voltage Trim The following information is provided to allow quick calculation of the trim resistor value for a desired output voltage. The general procedure for calculating a trim resistor is as follows: 1. Determine the desired output voltage deviation %. 2. To trim down, solve for resistor value using the “Rtlow” equation. 3. To trim up, solve for resistor value using the “Rthi” equation. 4. Solved resistor values are in K ohms. Figure 3 510 10.2 Rtlow % Figure 4 5.1 Vo (100 %) 510 Rthi 10.2 1 . 2225 % % Notes: 1. 2. 3. 4. Maximum trim range is ±10%. This includes remote sense drops if applicable. Output current is limited to specified current when trimming down. Output power is limited to specified power when trimming up. Trim resistors should be placed close to the module. 5. If the trim function is not used, it is advised to leave the trim pin floating / not connected. (888) 597-WALL www.wallindustries.com Page 7 of 14 TECHNICAL DATASHEET Rev A HP12S24-600 Graph 1: HP12S24-600 Efficiency vs. Output Current 100% 99% 98% 97% 96% Efficiency (%) 95% 94% 93% 92% 91% 90% 89% Vin=10V 88% Vin=24V 87% Vin=36V 86% 85% 5 10 15 20 25 Io (A) Graph 2: Projected HP12S24-600 Output Power vs Ambient Temperature (888) 597-WALL www.wallindustries.com Page 8 of 14 Rev A TECHNICAL DATASHEET HP12S24-600 Pdiss(W) Graph 3: HP12S24-600 Power Dissipation vs. Input Voltage 60 57 54 51 48 45 42 39 36 33 30 27 24 21 18 15 12 9 6 3 0 Io=6.25A Io=12.5A Io=18.75A Io=25A 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Vin(V) Graph 4: HP12S24-600 Input Current vs. Input Voltage 70 65 Io=6.25A 60 55 Io=12.5A 50 Io=17.75A 45 Iin (A) 40 Io=25A 35 30 25 20 15 10 5 0 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Vin(V) (888) 597-WALL www.wallindustries.com Page 9 of 14 Rev A TECHNICAL DATASHEET HP12S24-600 Photo 1: No load output startup. Ch.1 = Vin (5V/div) Photo 2: Full load output startup. Ch.1 = Vin (5V/div) Photo 3: Full load (resistive) startup. Ch.1 = Vin (5V/div) Photo 4: Output ripple, 24Vin, full load. 100mV / div. 20MHz BW Photo 5: Transient Response 50% to 100% Vin=24V, Iout = 12.5A to 25A @ 2V/ Div Cout=0.1μF Ceramic + 10μF Tantalum (888) 597-WALL www.wallindustries.com Page 10 of 14 Rev A TECHNICAL DATASHEET HP12S24-600 TEST SETUP: The HP12S24-600 specifications are tested with the following configurations: Regulation and Efficiency Setup To ensure that accurate measurement are taken, the voltage measurements are taken directly at the terminals of the module. This minimizes errors due to contact and trace lengths between the load and the output of the supply. The following diagram is of the test setup. Figure 5: Regulation and Efficiency Probe Setup Output Ripple Voltage Setup The module is tested with a 0.1μF ceramic capacitor in parallel with a 10μF tantalum capacitor across the output terminals. Unless otherwise specified, bandwidth is limited to 20MHZ. Figure 6: Ripple Voltage Probe Setup (888) 597-WALL www.wallindustries.com Page 11 of 14 Rev A TECHNICAL DATASHEET HP12S24-600 Input Reflected Ripple Current and Input Ripple Voltage Setup The module is tested for input reflected ripple current (Irrc). The input ripple voltage is also measured at the pins with and without an additional 4,700μF electrolytic capacitor. To reduce either the input ripple current or voltage additional capacitors and/or an inductor may be added to the input of the converter. Figure 7: Ripple Current Setup Converter Thermal Consideration The converter is designed to operate without convective cooling if the de-rating curves are followed. The converter can operate at higher temperatures and higher output currents if airflow and/or a heatsink are applied. See Graph 2 for de-rating curves or contact factory for additional thermal information. (888) 597-WALL www.wallindustries.com Page 12 of 14 Rev A TECHNICAL DATASHEET HP12S24-600 Paralleling Converters The HP series converters may be paralleled both for redundancy and for higher output current. However, in order to do this, a high-current, low Vf, Schottky diode must be placed at the +Vo pin of each supply as shown in Figure 8. To improve sharing, tie the two TRIM pins together. The converters may be trimmed by adding a resistor value from each TRIM pin to ±RS pin, or alternatively, a single resistor of half the value from the common TRIM pins to the common ±RS pins. Figure 8: Paralleling Converters (888) 597-WALL www.wallindustries.com Page 13 of 14 TECHNICAL DATASHEET Rev A HP12S24-600 Ordering Information: Part Number Example: HP 12 S 24 – 600 R TH Series Designation Nominal Input Voltage Single Output Nominal Output Voltage Maximum Output Power Options Blank R Options Blank TH Threaded Hole Through Hole Active High Enable Active Low Enable 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: (888) 597-WALL (603)778-2300 (888)587-9255 (603)778-9797 [email protected] www.wallindustries.com 5 Watson Brook Rd. Exeter, NH 03833 www.wallindustries.com Page 14 of 14