TECHNICAL DATASHEET Rev. A DCBC60-24S05W 4:1 Ultra Wide Input Voltage Range: 9~36VDC 5VDC Single Output at 12A 2.0” x 2.0” x 0.5” Shielded Metal Case 60 Watt Isolated DC/DC Power Converter FEATURES 5VDC Single Output 4:1 Ultra Wide Input Voltage Range: 9-36VDC 60 Watts Output Power Fixed Switching frequency Industry Standard Pin-out 1500VDC I/O Isolation No Minimum Load Requirement 85% High Efficiency Short Circuit, Over Voltage, Over Load, and Over Temp. Protection Shielded Metal Case with Insulated Baseplate Lead Free Design, RoHS Compliant APPLICATIONS Distributed Power Systems Wide Operating Temperature Range: -40°C to +85°C Process Control Equipment Synchronous Rectifier Topology Telecommunication Applications Remote ON/OFF Industrial Applications Adjustable Output Voltage Transportation Equipment Custom Designs Available Battery Powered Equipment Optional Heatsink Available (Suffix “HS”) DESCRIPTION The DCBC60-24S05W is an isolated DC/DC power converter that provides 60 Watts of continuous output power in a 2.0” x 2.0” x 0.5” shielded metal case. This model has a 5VDC single output with 4:1 input voltage range of 9-36VDC. Some features include 85% high efficiency, remote on/off, adjustable output voltage, 1500VDC I/O isolation, -40°C~+85°C operating temperature range, and no minimum load requirement. The DCBC60-24S05W is RoHS compliant and has short circuit, over load, over voltage, and over temperature protection. This converter is best suited for use in battery operated equipment, distributed power systems, telecom, industry control systems, process control equipment, transportation equipment, and anywhere where isolated, tightly regulated voltages and compact size are required. 05/17/2012 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 1 of 5 Rev. A TECHNICAL DATASHEET DCBC60-24S05W TECHNICAL SPECIFICATIONS MODEL: DCBC60-24S05W 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 INPUT SPECIFICATIONS Input Voltage Range Input Surge Voltage Under Voltage Shutdown Input Reflected Ripple Current Min Nom Max Unit 9 24 36 50 VDC VDC V mAp-p 100ms Full load Nominal Vin and full load Nominal Vin and no load Nominal Vin and full load Nominal Vin and output shorted Input Current 8 200 80 mA 3086 10 Pi Type Open or 3.5V < Vr < 12V Short (to -Vin) or 0V < Vr < 0.7V 0.2 mA 20 mA Input Filter Remote ON/OFF Sourcing Current of Remote Control Pin Idle Input Current (at Remote OFF State) OUTPUT SPECIFICATIONS Output Voltage Voltage Accuracy Output Current Minimum Load Maximum Capacitive Load Start-up Time Line Regulation Load Regulation Output Power Ripple & Noise Temperature Coefficient Transient Response Overshoot Transient Response Settling Time Remote Sense PROTECTION Over Voltage Protection Short Circuit Protection Over Load Protection Thermal Shutdown GENERAL SPECIFICATIONS Efficiency Isolation Voltage Isolation Resistance Isolation Capacitance Switching Frequency ENVIRONMENTAL SPECIFICATIONS Operating Temperature Storage Temperature Maximum Case Surface Temperature Relative Humidity Cooling MTBF PHYSICAL SPECIFICATIONS Case Material Base Material Potting Material Soldering Temperature Weight Dimensions (L x W x H) SAFETY Safety Approvals (pending) 05/17/2012 Converter ON Converter: OFF Nominal Vin Nominal Vin 5 -1% +1% 12 0 36000 Nominal Vin and full load LL to HL at full load 25% load to full load 70 -0.5 -0.5 0 +0.5 +0.5 60 75 +0.02 +5 20MHz Bandwidth -0.02 -5 di/dt=0.8A/µs 50% load step change 1.2 See page 3 Zener Diode Clamp automatic recovery % of full load at nominal input 6.2 Hiccup, continuous 110 110 Nominal Vin and full load Input to Output Input to Output (500VDC) 85 1500 10 1200 300 With derating (see derating curve) Lead-free wave soldering -40 -55 +85 +125 +105 95 Free air convection 888,000 hours VDC % A A µF ms % % W mVp-p %/°C % of Vo ms VDC % °C % VDC GΩ pF KHz °C °C °C % RH Nickel-coated copper FR4 PCB Silicon rubber (UL94V-0) 260°C/10sec max. 2.96oz (84g) 2.0 x 2.0 x 0.5 inches (50.8 x 50.8 x 12.7 mm) EN60950-1: 2006 + A11:2009+A1:2010, IEC 60950-1: 2005 (2nd Edition)+A1 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 2 of 5 TECHNICAL DATASHEET DCBC60-24S05W Rev. A DERATING CURVES DCBC60-24S05W Power Derating Curve (With Heatsink) 120 100 100 Output Power (%) Output Power (%) DCBC60-24S05W Power Derating Curve (Without Heatsink) 120 80 60 40 20 80 60 40 20 0 -40 -20 0 20 31 40 60 80 100 0 -40 120 -20 0 Ambient Temperature (°C) 20 40 60 80 100 120 Ambient Temperature (°C) EFFICIENCY DCBC60-24S05W Output Current vs. Efficiency 95 90 85 85 80 80 Efficiency (%) Efficiency (%) DCBC60-24S05W Input Voltage vs. Efficiency 95 90 75 70 65 75 70 65 60 60 55 55 50 1.2 50 9 12 15 18 21 24 27 30 33 36 2.4 3.6 4.8 6.0 7.2 8.4 9.6 10.8 12.0 Output Current (A) Input Voltage (VDC) REMOTE SENSE APPLICATION CIRCUIT The remote sense function is used to compensate for the voltage drop incurred when the load is located physically far away from the DC/DC converter providing its power. The remote sense pins are connected as close to the load as possible. The DC/DC converter’s regulation specifications are maintained across the points where the remote sense wires are connected at the load. This will remove the effect of the voltage drop caused by the resistance of the wires used to conduct the power from the DC/DC converter to the load. This is represented by RCL1 and RCL2. With the use of remote sense, the effects of RCL1 and RCL2 are eliminated. If the Remote Sense function is not used, the +Sense has to be connected to +Vout and the -Sense has to be connected to -Vout as close to the DC/DC converter as possible. RCL1 +Vout +Vin +Sense Load -Vin -Sense -Vout R CL1 and R CL2 are line resistors 05/17/2012 RCL2 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 3 of 5 TECHNICAL DATASHEET DCBC60-24S05W Rev. A MECHANICAL DRAWINGS Standard Unit: inches (mm) Ø0.04 (Ø1.0) x 8 8 3 2 5 1 4 2.0 (50.8) 6 0.4 0.2 (10.16)(5.08) 7 PIN CONNECTIONS 0.5 (12.70) 0.3 0.2 0.3 0.2 0.3 (7.62) (5.08) (7.62) (5.08) (7.62) 2.0 (50.8) Ø1.0 (Ø0.04) BOTTOM VIEW 0.2 (5.0) Pin Assignment 1 +Vin 2 -Vin 3 Remote On/Off 4 -Sense 5 +Sense 6 +Vout 7 -Vout 8 Trim Tolerance: X.XX±0.02 (X.X±0.5) 0.5 (12.7) 1.8 (45.7) 0.10 (2.5) Pin Pitch Tolerance: ±0.014 (0.35) All dimensions are for reference only Heatsink Option (Suffix “HS”) Unit: inches (mm) 2.0 (50.8) Material: Aluminum Weight: 0.67oz (19g) (without converter) Tolerance: X.XX±0.02 (X.X±0.5) 2.0 (50.8) Note: The product label on the converter has to be removed before mounting the heatsink. For volume orders, converters will be supplied with heatsink already mounted. Please contact factory for more details. 0.76 (19.2) 05/17/2012 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 4 of 5 Rev. A TECHNICAL DATASHEET DCBC60-24S05W 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: 05/17/2012 (603)778-2300 (888)587-9255 (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 5 of 5