Rev C DCQA100 SERIES Up to 108 Watts, Quarter-Brick DC/DC Converters FEATURES Size: 2.28 x 1.45 x 0.50 inches (57.9 x 36.8 x 12.7 mm) Applications: • Automation • Telecom/Datacom • Industry Control Systems • ICP • Measurement • Soft Start • Single Outputs • Input Under Voltage Protection • High Efficiency up to 93% • Remote ON/OFF Control • 2:1 Wide Input Voltage Ranges • No Minimum Load Required • 2250VDC I/O Basic Insulation • Voltage Adjustability • Low Stand-by Power Consumption • Industry Standard Quarter-brick Package • Up to 108 Watts Maximum Output Power • Short Circuit, Over Voltage, Over Load, & Over Temp. Protection • UL60950-1, EN60950-1, and IEC60950-1 Safety Approvals • CE Marked • RoHS & REACH Compliant • Optional Heatsinks Available (Suffix “HS”) • Threaded (Standard) or Thru-Hole (Optional) Inserts Available DESCRIPTION The DCQA100 series of DC/DC power converters provides up to 108 Watts of output power in a 2.28” x 1.45” x 0.5” industry standard quarter-brick package. This series has single output models with 2:1 wide input voltage ranges of 8.5-22VDC, 16.5-36VDC, and 33-75VDC. Some features include high efficiency up to 93%, 2250VDC I/O basic insulation, and remote ON/OFF control. These converters are also protected against input under voltage, short circuit, over voltage, over load, and over temperature conditions. All models are RoHS compliant and have UL60950-1, EN60950-1, and IEC60950-1 safety approvals. Several different options are available for this series including negative logic remote ON/OFF, heatsinks, and thruhole inserts. MODEL SELECTION TABLE Input Voltage Range Model Number DCQA100-12S33 DCQA100-12S05 DCQA100-12S12 DCQA100-12S15 DCQA100-12S24 DCQA100-12S30 DCQA100-12S48 DCQA100-24S33 DCQA100-24S05 DCQA100-24S12 DCQA100-24S15 DCQA100-24S24 DCQA100-24S30 DCQA100-24S48 DCQA100-48S33 DCQA100-48S05 DCQA100-48S12 DCQA100-48S15 DCQA100-48S24 DCQA100-48S30 DCQA100-48S48 12 VDC (8.5 - 22 VDC) 24 VDC (16.5 - 36 VDC) 48 VDC (33 - 75 VDC) Output Voltage 3.3 VDC 5 VDC 12 VDC 15 VDC 24 VDC 30 VDC 48 VDC 3.3 VDC 5 VDC 12 VDC 15 VDC 24 VDC 30 VDC 48 VDC 3.3 VDC 5 VDC 12 VDC 15 VDC 24 VDC 30 VDC 48 VDC Output Current Min Load Max Load 0mA 25A 0mA 18A 0mA 7.5A 0mA 6A 0mA 3.7A 0mA 3A 0mA 1.8A 0mA 25A 0mA 18A 0mA 7.5A 0mA 6A 0mA 3.7A 0mA 3A 0mA 1.8A 0mA 25A 0mA 21A 0mA 9A 0mA 7A 0mA 4.5A 0mA 3.5A 0mA 2.2A Output Ripple & Noise 75mVp-p 75mVp-p 100mVp-p 100mVp-p 200mVp-p 200mVp-p 300mVp-p 75mVp-p 75mVp-p 100mVp-p 100mVp-p 200mVp-p 200mVp-p 300mVp-p 75mVp-p 75mVp-p 100mVp-p 100mVp-p 200mVp-p 200mVp-p 300mVp-p No Load Input Current 50mA 50mA 50mA 50mA 50mA 50mA 50mA 25mA 25mA 25mA 25mA 25mA 25mA 25mA 15mA 15mA 15mA 15mA 15mA 15mA 15mA Output Power 82.5W 90W 90W 90W 88.8W 90W 86.4W 82.5W 90W 90W 90W 88.8W 90W 86.4W 82.5W 105W 108W 105W 108W 105W 105.6W Efficiency 89% 90% 91% 91% 90% 90% 89% 89% 90% 91% 91% 92% 91% 89% 89% 91% 90% 91% 93% 92% 91% Maximum Capacitive Load 75,000µF 36,000µF 6250µF 4000µF 1540µF 1000µF 380µF 75,000µF 36,000µF 6250µF 4000µF 1540µF 1000µF 380µF 75,000µF 42,000µF 7500µF 4600µF 1870µF 1160µF 460µF NOTES 1. Input Source Impedance: The power modules will operate to specifications without external components, assuming that the source voltage has very low impedance and reasonable input voltage regulation. Highly inductive source impedances can affect the stability of the power module. Since real-world voltage sources have finite impedance, performance is improved by adding an external filter capacitor. We recommend using Nippon Chemi-con KY series, 100µF/100V. 2. Maximum output deviation is +10% inclusive of remote sense and trim. If remote sense is not being used, sense pins should connect to the output pins with the same polarity. 3. The DCQA100 series can only meet EMI Class A or Class B with external components added. Please contact factory for more information. 4. An external input filter capacitor is required if the module has to meet EN61000-4-4, EN61000-4-5. We recommend connecting two pieces of aluminum electrolytic capacitors (Nippon chemi-con KY series, 220µF/100V). 5. Both positive logic and negative logic remote ON/OFF control is available. Positive logic remote ON/OFF comes standard; for negative logic remote ON/OFF add the suffix “R” to the model number (Ex: DCQA100-48S24R). 6. Optional heatsinks available. See page 5 for ordering details. 7. M3 x 0.5 threaded-thru inserts come standard. For Ø.126 thru-hole inserts add the suffix “TH” to the model number (Ex: DCQA100-48S24TH). Models with thru-hole inserts cannot be equipped with a heatsink. 8. BASE-PLATE GROUNDING: EMI can be reduced when two screw bolts connected to shield plane. CAUTION: This power module is not internally fused. An input line fuse must always be used. 11/14/2013 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 7 DCQA100 SERIES Up to 108 Watts, Quarter-Brick DC/DC Converters Rev C SPECIFICATIONS: DCQA100 SERIES All specifications are based on 25°C, Nominal Input Voltage, and Full Load unless otherwise noted. We reserve the right to change specifications based on technological advances. SPECIFICATION TEST CONDITIONS Min Typ 8.5 16.5 33 12 24 48 Max Unit INPUT SPECIFICATIONS Input Voltage Range Start-Up Voltage Shutdown Voltage Input Surge Voltage (1sec, max.) Input Current Input Filter (See Note 1) 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 No Load 7.3 15.5 31.6 22 36 75 9 18 36 7.7 8.1 15.9 16.3 32 32.5 30 50 100 See Table Pi type VDC VDC VDC VDC OUTPUT SPECIFICATIONS Output Voltage Voltage Accuracy Line Regulation Low line to high line at full load Load Regulation No load to full load Voltage Adjustability Remote Sense (See Note 2) Output Power Output Current Minimum Load Maximum Capacitive Load Ripple & Noise (20MHz BW) Transient Response Recovery Time Start-Up Time 3.3V & 5V Output Models Others Maximum output deviation is inclusive of remote sense % of Vo (nom) -1.0 -0.1 -0.2 -0.1 -20 See Table +1.0 +0.1 +0.2 +0.1 +10 10 See Table See Table 0 Minimum input and constant resistive load Measured with a 22µF/25V X7R MLCC 3.3V & 5V Output Models Measured with a 22µF/25V X7R MLCC 12V & 15V Output Models Measured with a 4.7µF/50V X7R MLCC 24V & 30V Output Models Measured with a 2.2µF/100V X7R MLCC 48V Output Models 25% load step change Power Up Constant resistive load Remote On/Off Temperature Coefficient -0.02 % % % % % % See Table 75 100 200 300 250 75 100 75 100 +0.02 mVp-p µs ms %/°C PROTECTION Short Circuit Protection Over Load Protection Over Voltage Protection Over Temperature Protection Continuous, automatic recovery 110 140 % 115 130 % +110 °C % of rated Iout; hiccup mode % of Vo (nom); hiccup mode GENERAL SPECIFICATIONS Efficiency Switching Frequency Nominal input voltage and full load Isolation Voltage 1 minute (basic insulation) Isolation Resistance Isolation Capacitance 500VDC Input to Output Input/Output to Base-plate 270 2250 2250 1 See Table 300 330 1500 kHz VDC VDC GΩ pF REMOTE ON/OFF (See Note 5) Positive Logic (standard) Referenced to –Input pin Negative Logic (optional) Referenced to –Input pin Input Current of Remote Control Pin Remote OFF State Input Current Nominal Vin Nominal Vin 11/14/2013 DC/DC ON DC/DC OFF DC/DC ON DC/DC OFF Open or 3~12 VDC Short or 0~1.2VDC Short or 0~1.2 VDC Open or 3~12VDC -0.5 1 3 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] VDC VDC mA mA Page 2 of 7 Rev C DCQA100 SERIES Up to 108 Watts, Quarter-Brick DC/DC Converters SPECIFICATIONS: DCQA100 SERIES All specifications are based on 25°C, Nominal Input Voltage, and Full Load unless otherwise noted. We reserve the right to change specifications based on technological advances. SPECIFICATION TEST CONDITIONS Min ENVIRONMENTAL SPECIFICATIONS Operating Base-Plate Temperature Storage Temperature Range Thermal Impedance (See Note 6) Relative Humidity Thermal Shock Vibration MTBF Typ -40 -55 Vertical direction by natural convection (20LFM) Without Heatsink With 0.24” Height Heatsink With 0.5” Height Heatsink Mounted on 2U iron base-plate Unit +105 +125 °C °C 9 7.1 5.5 2.8 5 MIL-HDBK-217F, full load Max °C/W 95 MIL-STD-810F MIL-STD-810F 387,300 Hours % RH PHYSICAL SPECIFICATIONS Weight 2.26oz (64g) 2.28x1.45x0.50 inch (57.9x36.8x12.7 mm) Aluminum base-plate with plastic case Silicon (UL94-V0) Dimensions (L x W x H) Case Material Potting Material SAFETY & EMC CHARACTERISTICS Safety Approvals EMI (See Note 3) EN55032 ESD EN61000-4-2 Radiated Immunity Fast Transient (See Note 4) Surge (See Note 4) Conducted Immunity Power Frequency Magnetic Field EN61000-4-3 EN61000-4-4 EN61000-4-5 EN61000-4-6 EN61000-4-8 IEC60950-1, UL60950-1, EN60950-1 Class A, Class B Air ±8kV Contact ±6kV 20 V/m ±2kV EN55024: ±2kV 10 Vrms 100A/m continuous; 1000A/m 1 sec Perf. Criteria A Perf. Criteria A Perf. Criteria A Perf. Criteria A Perf. Criteria A Perf. Criteria A CHARACTERISTIC CURVES DCQA100-48S05 Derating Curve DCQA100-48S05 Derating Curve w/ 0.24” Heatsink DCQA100-48S05 Efficiency vs Input Voltage DCQA100-48S05 Efficiency vs Output Load 11/14/2013 DCQA100-48S05 Derating Curve w/ 0.5” Heatsink 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 7 Rev C DCQA100 SERIES Up to 108 Watts, Quarter-Brick DC/DC Converters OUTPUT VOLTAGE ADJUSTMENT Output is adjustable for 10% trim up or -20% trim down of nominal output voltage by connecting an external resistor between the TRIM pin and either the +SENSE or -SENSE pins. With an external resistor between the TRIM and -SENSE pin, the output voltage set decreases. With an external resistor between the TRIM and +SENSE pin, the output voltage set point increases. Maximum output deviation is +10% inclusive of remote sense. The external trim resistor needs to be at least 1/8 of rated powerThe value of the external resistor can be obtained by the equations below. Trim Up Equation 5.11VOUT(100 + ∆%) (511+ 10.22∆%) RU = − KΩ ∆% 1.225∆% Trim Down Equation 511 RD = − 10.22KΩ ∆% TRIM UP 3.3V Output Models ΔV (%) 1 Vout (V) 3.333 RU (kΩ) 869.117 2 3.366 436.331 3 3.399 292.07 4 3.432 219.939 5 3.465 176.66 6 3.498 147.808 7 3.531 127.198 8 3.564 111.742 9 3.597 99.72 10 3.630 90.103 5V Output Models ΔV (%) 1 Vout (V) 5.05 RU (kΩ) 1585.35 2 5.10 797.994 3 5.15 535.542 4 5.20 404.316 5 5.25 325.58 6 5.30 273.09 7 5.35 235.596 8 5.40 207.479 9 5.45 185.605 10 5.50 168.109 9 13.08 539.25 10 13.20 489.309 12V Output Models ΔV (%) 1 Vout (V) 12.12 RU (kΩ) 4534.55 2 12.24 2287.19 3 12.36 1538.08 4 12.48 1163.52 5 12.60 938.78 6 12.72 788.956 7 12.84 681.939 8 12.96 601.676 15V Output Models ΔV (%) 1 Vout (V) 15.15 RU (kΩ) 5798.49 2 15.30 2925.42 3 15.45 1967.73 4 15.60 1488.89 5 15.75 1201.58 6 15.90 1010.04 7 16.05 873.229 8 16.20 770.619 9 16.35 690.812 10 16.50 626.966 24V Output Models ΔV (%) 1 Vout (V) 24.24 RU (kΩ) 9590.32 2 24.48 4840.11 3 24.72 3256.7 4 24.96 2465 5 25.20 1989.98 6 25.44 1673.3 7 25.68 1447.1 8 25.92 1277.45 9 26.16 1145.5 10 26.40 1039.94 30V Output Models ΔV (%) 1 Vout (V) 30.3 RU (kΩ) 12118.2 2 30.6 6116.57 3 30.9 4116.02 4 31.2 3115.74 5 31.5 2515.58 6 31.8 2115.47 7 32.1 1829.68 8 32.4 1615.33 9 32.7 1448.62 10 33 1315.25 48V Output Models ΔV (%) 1 Vout (V) 48.48 RU (kΩ) 19701.9 2 48.96 9945.94 3 49.44 6693.96 4 49.92 5067.97 5 50.40 4092.38 6 50.88 3441.99 7 51.36 2977.42 8 51.84 2628.99 9 52.32 2357.99 10 52.80 2141.19 TRIM DOWN 11/14/2013 All Outputs ΔV (%) RD (kΩ) 1 500.78 2 245.28 3 160.113 4 117.53 5 91.98 6 74.947 7 62.78 8 53.655 9 46.558 10 40.88 ΔV (%) RD (kΩ) 11 36.235 12 32.363 13 29.088 14 26.28 15 23.847 16 21.718 17 19.839 18 18.169 19 16.675 20 15.33 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 7 Rev C DCQA100 SERIES Up to 108 Watts, Quarter-Brick DC/DC Converters MECHANICAL DRAWING PIN 1 2 3 4 5 6 7 8 PIN CONNECTION DEFINE -Vin Ctrl +Vin -Vout -Sense Trim +Sense +Vout DIAMETER 0.04 Inch 0.04 Inch 0.04 Inch 0.06 Inch 0.04 Inch 0.04 Inch 0.04 Inch 0.06 Inch Notes: 1. All dimensions in inch [mm] 2. Tolerance: x.xx±0.02 [x.x±0.5] x.xxx±0.01 [x.xxx±0.25] 3. Pin pitch tolerance: ±0.01 [0.25] 4. Pin dimension tolerance ±0.004 [0.10] 5. The screw locked torque: MAX 3.5kgf-cm [0.34N-m] RECOMMENDED PAD LAYOUT Notes: All dimensions in inch [mm] Pad size (lead free recommended) Through Hole 1.2.3.5.6.7: Ø0.051 [1.30] Through Hole 4.8: Ø0.075 [1.90] Through Hole of Mounting: Ø0.126 [3.20] Top View Pad 1.2.3.5.6.7: Ø0.064 [1.63] Top View Pad 4.8: Ø0.094 [2.38] Top View Pad of Mounting: Groove R0.065 [1.65] L0.157 [4.00] Bottom View Pad 1.2.3.5.6.7: Ø0.102 [2.60] Bottom View Pad 8: Ø0.150 [3.80] Bottom View Pad 4: Ø0.130 [3.30] Bottom View Pad of Mounting: Groove R0.065 [1.65] L0252 [6.40] 11/14/2013 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 7 Rev C DCQA100 SERIES Up to 108 Watts, Quarter-Brick DC/DC Converters HEATSINK OPTIONS Horizontal Fin Orientation (Suffix Option: H) 7G-0029B-F Horizontal Fin Orientation (Suffix Option: H1) 7G-0030B-F Vertical Fin Orientation (Suffix Option: H2) 7G-0031B-F Vertical Fin Orientation (Suffix Option: H3) 7G-0032B-F Note: Models with thru-hole inserts cannot be equipped with a heatsink All dimensions in inch [mm] Tolerance: x.xx±0.02 [x.x±0.5] FUSE CONSIDERATION This power module is not internally fused. An input line fuse must always be used. This encapsulated power module can be used in a wide variety of applications, ranging from simple stand-alone operation to an integrated part of sophisticated power architecture. To maximum flexibility, internal fusing is not included; however, to achieve maximum safety protection, always use an input line fuse. The input line fuse suggestions are below: Model 12VDC nominal input models 24VDC nominal input models 48VDC nominal input models Fuse Rating 20A 10A 6.3A Fuse Type Fast-Acting Fast-Acting Slow-Blow The table is based on the information provided in this data sheet on inrush energy and maximum DC input current at low Vin. 11/14/2013 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 7 DCQA100 SERIES Up to 108 Watts, Quarter-Brick DC/DC Converters Rev C THERMAL CONSIDERATION This power module operates in a variety of thermal environments. However, sufficient cooling should be provided to help ensure reliable operation of the unit. Heat is removed by conduction, convection, and radiation to the surrounding environment. Proper cooling can be verified by measuring the point in the figure below. The temperature at this location should not exceed 105ºC. When operating, adequate cooling must be provided to maintain the test point temperature at or below 105ºC. Although the maximum point, temperature of the power modules is 105ºC, you can limit this temperature to a lower value for extremely high reliability. ■ Thermal test condition with vertical direction by national convection (20LFM) ■ The iron base-plate dimension is 19” x 3.5” x 0.063” (the height is EIA standard 2U) ■ The heat-sink is optional and P/N: 7G-0029B-F, 7G-0030B-F, 7G-0031B-F, 7G-0032B-F BASE PLATE MODEL NUMBER SETUP DCQA 100 Series Name Output Power 100: 100 Watts - 48 S 05 R H (1) Input Voltage Output Quantity Output Voltage Remote ON/OFF Hole Thread & Heatsink Options 12: 8.5~22 VDC S: Single Output 33: 3.3 VDC 24: 16.5~36 VDC 05: 5 VDC 48: 33~75 VDC 12: 12 VDC M3x0.5 Threaded-thru Inserts TH: Ø.126 Thru-hole Inserts (1) None: Positive Logic None: R: Negative Logic H: 0.24” Horizontal Heatsink 15: 15 VDC H1: 0.5” Horizontal Heatsink 24: 24 VDC H2: 0.24” Vertical Heatsink 30: 30 VDC H3: 0.5” Vertical Heatsink 48: 48 VDC (1) Models with thru-hole inserts cannot be equipped with a heatsink. 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: 11/14/2013 (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 7 of 7