DH50 SERIES 50 Watt DC/DC Power Converters Rev E Standard Models FEATURES • RoHS & UL 94V-0 Compliant • 2.0” x 1.0” x 0.43” Package Size • Smallest Encapsulated 50W Converter • Trimmable Output Voltage • 2:1 Wide Input Voltage Ranges • Shielded Metal Case with Isolated Base- • Single Outputs plate • Remote ON/OFF Control • 1500VDC I/O Isolation Size: 2.00 x 1.00 x 0.43 inches (50.8 x 25.4 x 11.0 mm) • No Minimum Load Requirements • High Efficiency up to 92% • Over Load, Short Circuit, Over Voltage, & Over Temperature Protection • -40°C to +80°C Operating Temperature Range • UL/cUL/IEC/EN 60950-1 Safety Approvals Heatsink Models (Suffix “HS”) • Heatsink (Optional) DESCRIPTION Size: 2.00 x 1.22 x 0.71 inches (50.8 x 31.0 x 18.0 mm) The DH50 series is the latest generation of high performance DC/DC converters setting a new standard concerning power density. These converters offer 50 Watts of continuous output power in a 2.0” x 1.0” x 0.43” encapsulated, shielded metal package. All models have a 2:1 wide input voltage range and a precisely regulated single output. Advanced circuit topology provides a very high efficiency up to 92% and an operating temperature range of 40°C to +80°C. Further features include remote on/off, trimmable output voltage, under voltage lockout as well as over load, over voltage, short circuit, and over temperature protection. These converters are RoHS compliant and are ideal for use in battery operated equipment, instrumentation, distributed power architectures in communication and industrial electronics and many other space critical applications. MODEL SELECTION TABLE Model Number DH12S3.3-33 DH12S5-50 DH12S12-50 DH12S15-50 DH12S24-50 DH24S3.3-33 DH24S5-50 DH24S12-50 DH24S15-50 DH24S24-50 DH48S3.3-33 DH48S5-50 DH48S12-50 DH48S15-50 DH48S24-50 Input Voltage 12 VDC (9 – 18 VDC) 24 VDC (18 – 36 VDC) 48 VDC (36 – 75 VDC) Output Voltage 3.3 VDC 5 VDC 12 VDC 15 VDC 24 VDC 3.3 VDC 5 VDC 12 VDC 15 VDC 24 VDC 3.3 VDC 5 VDC 12 VDC 15 VDC 24 VDC Output Current 10A 10A 4.17A 3.33A 2.08A 10A 10A 4.17A 3.33A 2.08A 10A 10A 4.17A 3.33A 2.08A Input Current Reflected Ripple Over Voltage Protection No Load Max Load Current (Typ) 85mA 3090mA 3.9 VDC 110mA 4630mA 6.2 VDC 160mA 4580mA 50mA 15 VDC 160mA 4580mA 18 VDC 250mA 4570mA 30 VDC 50mA 1550mA 3.9 VDC 70mA 2260mA 6.2 VDC 85mA 2260mA 40mA 15 VDC 85mA 2260mA 18 VDC 110mA 2290mA 30 VDC 35mA 770mA 3.9 VDC 45mA 1130mA 6.2 VDC 50mA 1130mA 30mA 15 VDC 50mA 1130mA 18 VDC 60mA 1150mA 30 VDC Output Power 33W 50W 50W 50W 50W 33W 50W 50W 50W 50W 33W 50W 50W 50W 50W Efficiency 89% 90% 91% 91% 91% 89% 92% 92% 92% 91% 89% 92% 92% 92% 91% Maximum Capacitive Load 25800μF 17000μF 2900μF 1900μF 750µF 25800μF 17000μF 2900μF 1900μF 750µF 25800μF 17000μF 2900μF 1900μF 750µF NOTES 1. Transient recovery time is measured to within 1% error band for a step change in output load from 75% to 100%. 2. We recommend protecting the converter by a slow blow fuse in the input supply line. 3. The DH50 series can meet EN55022 Class A with external capacitors in parallel with the input pins. • 12Vin Models: 22µF/25V 1210 MLCC • 24Vin Models: 3.3µF/50V 1210 MLCC • 48Vin Models: 2.2µF/100V 1210 MLCC 4. To meet EN61000-4-4 & EN61000-4-5 an external capacitor across the input pins is required. Suggested capacitor: CHEMI-CON KY 330µF/100V 5. Do not exceed maximum power specifications when adjusting the output voltage. 6. To order the converter with a heatsink, please add the suffix “HS” to the model number. (Ex: DH12S12-50HS). Due to advances in technology, specifications subject to change without notice. 08/25/2014 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-7789797 website: www.wallindustries.com • e-mail: [email protected] Page 1 of 11 Rev E DH50 SERIES 50 Watt DC/DC Power Converters SPECIFICATIONS: DH50 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 9 18 36 -0.7 -0.7 -0.7 12 24 48 18 36 75 25 50 100 9 18 36 Unit INPUT SPECIFICATIONS Input Voltage Range Input Surge Voltage (100ms max.) Start-up Threshold Voltage Under Voltage Lockout (UVLO) Start-up Time 12VDC nominal input models 24VDC nominal input models 48VDC nominal input models 12VDC nominal input models 24VDC nominal input models 48VDC nominal input models 12VDC nominal input models 24VDC nominal input models 48VDC nominal input models 12VDC nominal input models 24VDC nominal input models 48VDC nominal input models Nominal Vin and constant resistive load VDC VDC VDC 8.3 16.5 33 VDC Power Up 30 Remote On/Off 30 Input Current ms See Table Reflected Ripple Current (Page 10) See Table Conducted EMI for EN55022 Class A and FCC level A compliance see Note 3 Short Circuit Current Hiccup mode Internal LC Filter 24VDC output models 0.3 Others 1.5 Hz OUTPUT SPECIFICATIONS Output Voltage See Table Line Regulation Low line to high line at full load ±0.5 % Load Regulation Minimum load to full load ±0.5 % Output Voltage Setting Accuracy At 50% load and nominal Vin ±1.0 %Vnom Output Voltage Trim (Page 5) % of nominal output voltage 24VDC output models -10 +20 Others -10 +10 Output Power % See Table Output Current See Table Minimum Load No minimum load required Ripple & Noise (0-20MHz) (Page 10) Transient Recovery Time (Note 1) 3.3V & 5V output models Measured with a 1µF MLCC and a 10µF tantalum capacitor in parallel 12V, 15V, & 24V output models 25% load step change 100 mVp-p 150 250 Transient Recovery Deviation (Note 1) 25% load step change µs ±3 Temperature Coefficient ±5 % ±0.02 %/°C PROTECTION Input Polarity Protection none Over Voltage Protection (page 10) For shutdown voltage see table Over Current Protection Hiccup Thermal Protection Shutdown temperature Current limitation at 150% typ. of Iout max. 110 Short Circuit Protection °C Hiccup, automatic recovery GENERAL SPECIFICATIONS Efficiency Switching Frequency (see efficiency curves on pages 7-9) 24VDC output models Others See Table 285 320 Isolation Voltage (Input to Output) 60 seconds 1500 Isolation Resistance 500VDC 1000 Isolation Capacitance 100kHz, 1V Maximum Capacitive Load 08/25/2014 KHz VDC MΩ 2200 pF See Table Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-7789797 website: www.wallindustries.com • e-mail: [email protected] Page 2 of 11 Rev E DH50 SERIES 50 Watt DC/DC Power Converters SPECIFICATIONS: DH50 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 Unit REMOTE ON/OFF (Page 10) Converter On Converter Off On Vctrl = 5.0V Off Vctrl = 0V Positive Logic Control Input Current Control Common Stand-by Input Current 3.5 ~ 12V or open circuit 0V ~ 1.2 or short circuit 0.5 mA -0.5 Referenced to negative input 2.5 mA Nominal Vin ENVIRONMENTAL SPECIFICATIONS Natural air convection Operating Temperature (W/O (20LFM) Heatsink) (see derating curves on pages 6-7) Nominal Vin and full load Operating Temperature (W/ Natural air convection Heatsink) (20LFM) (see derating curves on pages 6-7) Nominal Vin and full load Thermal Impedance (W/O Heatsink) Thermal Impedance (W/ Heatsink) Case Temperature Storage Temperature Humidity (non-condensing) RFI Cooling Lead Temperature MTBF (calculated) 3.3VDC Output Models DH24S5-50, DH24S12-50 DH24S15-50, DH48S5-50 DH48S12-50, DH48S15-50 DH12S12-50, DH12S15-50, DH12S24-50, DH24S24-50, DH48S24-50 DH12S5-50 3.3VDC Output Models DH24S5-50, DH24S12-50 DH24S15-50, DH48S5-50 DH48S12-50, DH48S15-50 DH12S12-50, DH12S15-50, DH12S24-50, DH24S24-50, DH48S24-50 DH12S5-50 Natural convection (20LFM) 100LFM convection 200LFM convection 400LFM convection Natural convection (20LFM) 100LFM convection 200LFM convection 400LFM convection -40 +56 °C -40 +53 °C -40 +46 °C -40 -40 +38 +64 °C °C -40 +62 °C -40 +56 °C -40 12.1 9.2 7.8 5.2 9.8 5.4 4.5 3.0 +49 °C °C/W °C/W Natural convection is about 20LFM but is not equal to still air (0LFM) 1.5mm from case for 10 seconds MIL-HDBK-217F at 25°C, Ground Benign +105 °C +125 °C 95 % RH Six-sided shielding, metal case natural convection 260 °C 224,700 hours “HS” suffix 1.06oz (30g) 2.00 x 1.00 x 0.43 inches (50.8 x 25.4 x 11.0 mm) Aluminum alloy, black anodized coating FR4 PCB (flammability to UL 94V-0 rated) Epoxy (UL94-V0) Copper alloy with gold plate over nickel subplate See page 4 -50 PHYSICAL SPECIFICATIONS Weight Dimensions (L x W x H) Case Material Base Material Potting Material Pin Material Heatsink (optional) SAFETY & EMC UL/cUL 60950-1 recognition (CSA certificate) IEC/EN 60950-1 (CB-scheme) Class A Safety Approvals EMI (See Note 3) EMS 08/25/2014 EN55022, FCC part 15 EN55024 ESD EN61000-4-2 Radiated Immunity Fast Transient (See Note 4) Surge (See Note 4) Conducted Immunity EN61000-4-3 EN61000-4-4 EN61000-4-5 EN61000-4-6 Air: ±8KV, Contact: ±6KV 10V/m ±2KV ±1KV 10V/m A A A A A Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-7789797 website: www.wallindustries.com • e-mail: [email protected] Page 3 of 11 Rev E DH50 SERIES 50 Watt DC/DC Power Converters MECHANICAL DRAWINGS Standard Models Heatsink Models (“HS” Suffix) 08/25/2014 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-7789797 website: www.wallindustries.com • e-mail: [email protected] Page 4 of 11 Rev E DH50 SERIES 50 Watt DC/DC Power Converters OUTPUT VOLTAGE ADJUSTMENT Output voltage trim allows the user to increase or decrease the output voltage of a module. This is accomplished by connecting an external resistor between the Trim pin and either the +Vout or –Vout pins. With an external resistor between the Trim and –Vout pins, the output voltage increases. With an external resistor between the Trim and +Vout pins, the output voltage set-point decreases. Trim Up Trim Down Trim 1% 2% 3% 4% 5% 6% 7% 8% 9% 10% DHXXS3.3-33 Vout,up Rup 3.333V 60.84kΩ 3.366V 27.40kΩ 3.399V 16.25kΩ 3.432V 10.68kΩ 3.465V 7.34kΩ 3.498V 5.11kΩ 3.531V 3.51kΩ 3.564V 2.32kΩ 3.597V 1.39kΩ 3.630V 0.65kΩ Trim 1% 2% 3% 4% 5% 6% 7% 8% 9% 10% DHXXS5-50 Vout,up Rup 5.05V 106.87kΩ 5.10V 47.76kΩ 5.15V 28.06kΩ 5.20V 18.21kΩ 5.25V 12.30kΩ 5.30V 8.36kΩ 5.35V 5.55kΩ 5.40V 3.44kΩ 5.45V 1.79kΩ 5.50V 0.48kΩ Trim 1% 2% 3% 4% 5% 6% 7% 8% 9% 10% DHXXS3.3-33 Vout,down Rdown 3.267V 72.61kΩ 3.234V 32.55kΩ 3.201V 19.20kΩ 3.168V 12.52kΩ 3.135V 8.51kΩ 3.102V 5.84kΩ 3.069V 3.94kΩ 3.036V 2.51kΩ 3.003V 1.39kΩ 2.970V 0.50kΩ Trim 1% 2% 3% 4% 5% 6% 7% 8% 9% 10% DHXXS5-50 Vout,down Rdown 4.95V 138.88kΩ 4.90V 62.41kΩ 4.85V 36.92kΩ 4.80V 24.18kΩ 4.75V 16.53kΩ 4.70V 11.44kΩ 4.65V 7.79kΩ 4.60V 5.06kΩ 4.55V 2.94kΩ 4.50V 1.24kΩ Trim 1% 2% 3% 4% 5% 6% 7% 8% 9% 10% DHXXS12-50 Vout,up Rup 12.12V 351.00kΩ 12.24V 157.50kΩ 12.36V 93.00kΩ 12.48V 60.75kΩ 12.60V 41.40kΩ 12.72V 28.50kΩ 12.84V 19.29kΩ 12.96V 12.37kΩ 13.08V 7.00kΩ 13.20V 2.70kΩ Trim 1% 2% 3% 4% 5% 6% 7% 8% 9% 10% DHXXS15-50 Vout,up Rup 15.15V 427.77kΩ 15.30V 189.89kΩ 15.45V 112.26kΩ 15.60V 73.44kΩ 15.75V 50.15kΩ 15.90V 34.63kΩ 16.05V 23.54kΩ 16.20V 15.22kΩ 16.35V 8.75kΩ 16.50V 3.58kΩ Trim 1% 2% 3% 4% 5% 6% 7% 8% 9% 10% DHXXS12-50 Vout,down Rdown 11.88V 413.55kΩ 11.76V 184.55kΩ 11.64V 108.22kΩ 11.52V 70.05kΩ 11.40V 47.15kΩ 11.28V 31.88kΩ 11.16V 20.98kΩ 11.04V 12.80kΩ 10.92V 6.44kΩ 10.80V 1.35kΩ Trim 1% 2% 3% 4% 5% 6% 7% 8% 9% 10% DHXXS15-50 Vout,down Rdown 14.85V 530.73kΩ 14.70V 238.61kΩ 14.55V 141.24kΩ 14.40V 92.56kΩ 14.25V 63.35kΩ 14.10V 43.87kΩ 13.95V 29.96kΩ 13.80V 19.53kΩ 13.65V 11.41kΩ 13.50V 4.92kΩ Trim 2% 4% 6% 8% 10% 12% 14% 16% 18% 20% DHXXS24-50 Vout,up Rup 24.48V 243.70kΩ 24.96V 108.50kΩ 25.44V 63.43kΩ 25.92V 40.90kΩ 26.40V 27.38kΩ 26.88V 18.37kΩ 27.36V 11.93kΩ 27.84V 7.10kΩ 28.32V 3.34kΩ 28.80V 0.34kΩ Trim 1% 2% 3% 4% 5% 6% 7% 8% 9% 10% DHXXS24-50 Vout,down Rdown 23.760V 333.39kΩ 23.520V 148.80kΩ 23.280V 87.26kΩ 23.040V 56.50kΩ 22.800V 38.04kΩ 22.560V 25.73kΩ 22.320V 16.94kΩ 22.080V 10.35kΩ 21.840V 5.22kΩ 21.600V 1.12kΩ 08/25/2014 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-7789797 website: www.wallindustries.com • e-mail: [email protected] Page 5 of 11 Rev E DH50 SERIES 50 Watt DC/DC Power Converters DERATING CURVES DH12S3.3-33, DH24S3.3-33, DH48S3.3-33 Derating Curve Without Heatsink DH12S3.3-33, DH24S3.3-33, DH48S3.3-33 Derating Curve With Heatsink DH24S5-50, DH24S12-50, DH24S15-50, DH48S5-50, DH48S1250, DH48S15-50 Derating Curve Without Heatsink DH24S5-50, DH24S12-50, DH24S15-50, DH48S5-50, DH48S1250, DH48S15-50 Derating Curve With Heatsink DH12S12-50, DH12S15-50, DH12S24-50, DH24S24-50, DH48S24-50 Derating Curve Without Heatsink DH12S12-50, DH12S15-50, DH12S24-50, DH24S24-50, DH48S24-50 Derating Curve With Heatsink 08/25/2014 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-7789797 website: www.wallindustries.com • e-mail: [email protected] Page 6 of 11 Rev E DH50 SERIES 50 Watt DC/DC Power Converters DERATING CURVES DH12S5-50 Derating Curve Without Heatsink DH12S5-50 Derating Curve With Heatsink EFFICIENCY CURVES 08/25/2014 DH12S3.3-33 Efficiency vs Load Current DH12S5-50 Efficiency vs Load Current DH12S12-50 Efficiency vs Load Current DH12S15-50 Efficiency vs Load Current Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-7789797 website: www.wallindustries.com • e-mail: [email protected] Page 7 of 11 Rev E DH50 SERIES 50 Watt DC/DC Power Converters EFFICIENCY CURVES 08/25/2014 DH12S24-50 Efficiency vs Load Current DH24S3.3-33 Efficiency vs Load Current DH24S5-50 Efficiency vs Load Current DH24S12-50 Efficiency vs Load Current DH24S15-50 Efficiency vs Load Current DH24S24-50 Efficiency vs Load Current Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-7789797 website: www.wallindustries.com • e-mail: [email protected] Page 8 of 11 Rev E DH50 SERIES 50 Watt DC/DC Power Converters EFFICIENCY CURVES DH48S3.3-33 Efficiency vs Load Current DH48S5-50 Efficiency vs Load Current DH48S12-50 Efficiency vs Load Current DH48S15-50 Efficiency vs Load Current DH48S24-50 Efficiency vs Load Current 08/25/2014 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-7789797 website: www.wallindustries.com • e-mail: [email protected] Page 9 of 11 Rev E DH50 SERIES 50 Watt DC/DC Power Converters DESIGN CONSIDERATIONS Input Reflected-Ripple Current Test Setup Input reflected-ripple current is measured with an inductor Lin (4.7µH) and Cin (220µF, ESR < 1.0Ω at 100 KHz) to simulate source impedance. Capacitor Cin offsets possible battery impedance. Current ripple is measured at the input terminals of the module. Measurement bandwidth is 0-500 KHz. Peak-to-Peak Output Noise Measurement Test Use a 1µF ceramic capacitor and a 10µF tantalum capacitor. Scope measurement should be made by using a BNC socket, measurement bandwidth is 0-20MHz. Position the load between 50mm and 75mm from the DC/DC converter. TEST SETUP Remote On/Off Positive logic remote on/off turns the module on during a logic high voltage on the remote on/off pin and off during a logic low. To turn the module on and off, the user must supply a switch to control the voltage between the on/off terminal and the –Vin terminal. The switch can be an open collector or equivalent. A logic low is 0V to 1.2V. A logic high is 3.5V to 12V. The maximum sink current at on/off terminal (Pin 3) during a logic low is -100µA. Over Current Protection To provide protection in a fault (output overload) condition, the unit is equipped with internal current limiting circuitry and can endure overload for an unlimited duration. Over Voltage Protection The output over voltage clamp consists of control circuitry which is independent of the primary regulation loop that monitors the voltage on the output terminals. The control loop of the clamp has a higher voltage set point than the primary loop. This provides a redundant voltage control that reduces the risk of output over voltage. The OVP level can be found in the model selection table. Input Source Impedance The power module should be connected to a low ac-impedance input source. Highly inductive source impedances can affect the stability of the power module. In applications where power is supplied over long lines and output loading is high, it may be necessary to use a capacitor at the input to ensure startup. Capacitor mounted close to the power module helps ensure stability of the unit, it is recommended to use a good quality low Equivalent Series Resistance (ESR < 1.0Ω at 100 KHz) capacitor of 33µF for the 12VDC input models and a 10µF for the 24VDC and 48VDC input models. 08/25/2014 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-7789797 website: www.wallindustries.com • e-mail: [email protected] Page 10 of 11 DH50 SERIES 50 Watt DC/DC Power Converters Rev E Output Ripple Reduction A good quality low ESR capacitor placed as close as possible across the load will give the best ripple and noise performance. To reduce output ripple, it is recommended to use 4.7µF capacitors at the output. Maximum Capacitive Load The DH50 series has a limitation of maximum connected capacitance on the output. The power module may be operated in current limiting mode during start-up, affecting the ramp-up and the start-up time. The maximum capacitance can be found in the Model Selection Table. Thermal Considerations Many conditions affect the thermal performance of the power module, such as orientation, airflow over the module, and board spacing. To avoid exceeding the maximum temperature rating of the components inside the power module, the case temperature must be kept below 105°C. The derating curves are determined from measurements obtained in a test setup. MODEL NUMBER SETUP DH 24 S 12 Series Name Input Voltage Output Quantity 12: 9 - 18 VDC S: Single Output - 50 HS Ouptut Voltage Output Power Heatsink 3.3: 3.3 VDC 33: 33 Watts None: No Heatsink 24: 18 - 36 VDC 5: 5 VDC 50: 50 Watts HS: Heatsink 48: 36 - 75 VDC 12: 12 VDC 15: 15 VDC 24: 24 VDC 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: 08/25/2014 (603)778-2300 (888)597-9255 (603)778-9797 [email protected] www.wallindustries.com 37 Industrial Drive Exeter, NH 03833 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-7789797 website: www.wallindustries.com • e-mail: [email protected] Page 11 of 11