DATASHEET Rev. C DC100 SERIES 2:1 Wide Input Voltage Ranges 100 Watts, Single Outputs Industry Standard Half-Brick Footprint DC/DC Power Converters Standard FEATURES Soft-Start RoHS Compliant 2:1 Wide Input Voltage Ranges Up to 100 Watts Output Power Single Outputs Ranging from 3.3VDC to 48VDC Output Current up to 25A Terminal Block Under Voltage Lockout Six-Sided Shielding APPLICATIONS Wireless Networks Telecom / Datacom Industry Control Systems Semiconductor Equipment Distributed Power Architectures Military Applications OPTIONS Pin Length Heatsinks Thru-Hole Inserts Negative Logic Remote On/Off Terminal Block Terminal Block with EMC Filter High Efficiency up to 93% No Minimum Load Requirements Adjustable Output Voltage Industry Standard Half-Brick Footprint Remote On/Off Control Input to Output Basic Insulation: 2250VDC Threaded Inserts and Thru-Hole Inserts Available Input Reverse Protection Short Circuit, Over Voltage, Over Current, and Over Temperature Protection UL60950-1, EN60950-1, and IEC60950-1 Safety Approvals Several Mechanical Options Available DESCRIPTION The DC100 series of DC/DC power converters provides up to 100 Watts of output power in an industry standard half-brick package and footprint. This series consists of single output models ranging from 3.3VDC to 48VDC with 2:1 wide input voltage ranges of 9~18VDC, 18~36VDC and 36~75VDC. Some features include high efficiency up to 93%, adjustable output voltage, positive remote on/off control, and six-sided shielding. These converters also have short circuit, over voltage, over current, over temperature, and input reverse protection. The DC100 series is RoHS compliant and has UL60950-1, EN60950-1, and IEC60950-1 safety approvals. Several different options are available for this series including negative remote on/off, terminal block, pin length, heatsinks, and thru-hole inserts. Please call factory for more details. 10/23/2012 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 1 of 8 Rev. C DC100 Series 2:1 Input Voltage Ranges Up to 100 Watts, Single Outputs Half-Brick DC/DC Power Converters SPECIFICATIONS: DC100 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 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 9 18 36 12 24 48 18 36 75 9 18 36 Low line to high line at full load No load to full load Full load an nominal Vin -0.1 -0.1 -1 -20 Unit INPUT SPECIFICATIONS Input Voltage Range Start-up Voltage Shutdown Voltage Input Surge Voltage (100ms) Input Current Input Filter (See Note 11) Input Reverse Protection (See Note 14) OUTPUT SPECIFICATIONS Output Voltage Line Regulation Load Regulation Voltage Accuracy Voltage Adjustability (See Note 7) Output Power Output Current Minimum Load Ripple & Noise (peak to peak) Transient Response Recovery Time Power Up Start-Up Time Remote On/Off Remote Sense (See Note 8) Temperature Coefficient PROTECTION Over Voltage Protection Threshold Over Current Protection Threshold Short Circuit Protection Over Temperature Protection GENERAL SPECIFICATIONS Efficiency Switching Frequency I/P to O/P (Basic Insulation) Isolation Voltage I/P to Case O/P to Case Isolation Resistance Isolation Capacitance Maximum Capacitive Load 10/23/2012 7.5 16 34 36 50 100 See Table Pi Type Parallel diode See Table +0.1 +0.1 +1 +10 See Table See Table 0 Nominal input and constant resistive load -0.02 115 110 Minimum input and constant resistive load Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 VDC VDC % % % % See Table 200 25 25 10 +0.02 µs ms ms % Vo %/°C 130 % Vo 140 % Io Hiccup, automatic recovery +115 °C Nominal input voltage and full load For 1 minute For 1 minute For 1 minute VDC % 20MHz Bandwidth 25% load step change Hiccup VDC 255 2250 1600 1600 1 See Table 300 330 2500 See Table KHz VDC VDC VDC GΩ pF Page 2 of 8 DC100 Series 2:1 Input Voltage Ranges Up to 100 Watts, Single Outputs Half-Brick DC/DC Power Converters Rev. C SPECIFICATIONS: DC100 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 REMOTE ON/OFF CONTROL (See Note 6) DC/DC ON Positive Logic (standard) DC/DC OFF DC/DC ON Negative Logic (optional) DC/DC OFF Input Current of Remote Control Pin Remote Off State Input Current ENVIRONMENTAL SPECIFICATIONS Operating Case Temperature Range Storage Temperature MTBF (See Note 1) Typ Max Unit Open or 3V < Vr < 12V Short or 0V < Vr < 1.2V Short or 0V < Vr < 1.2V Open or 3V < Vr < 12V -0.5 1 mA 3 mA Nominal Vin Nominal Vin Standard Terminal Block type Standard Terminal Block type -40 -40 -55 -40 5 Relative Humidity Thermal Shock Vibration Thermal Impedance (See Note 9) Min Standard With 0.24” Heatsink With 0.45” Heatsink BELLCORE TR-NWT-000332 MIL-HDBK-217F +115 +105 +125 +105 95 MIL-STD-810F MIL-STD-810F 6.7 5.4 4.7 1,010,000 hours 74,160 hours °C °C % RH °C/Watt PHYSICAL SPECIFICATIONS Weight Dimensions (L x W x H) Standard “T” suffix models “TF” suffix models “TF1” suffix models Standard “T” suffix models “TF” suffix models “TF1” suffix models Case Material Base Material Potting Material Shielding SAFETY & EMC CHARACTERISTICS Safety Approvals Standard EMI (See Note 11) TF or TF1 Option EN55022 EN55022 ESD EN61000-4-2 Radiated Immunity Fast Transient (See Note 11) Surge (See Note 11) Conducted Immunity EN61000-4-3 EN61000-4-4 EN61000-4-5 EN61000-4-6 10/23/2012 3.42oz (97g) 7.05oz (200g) 8.47oz (240g) 26.10oz (740g) 2.4x2.28x0.5 inches (61x57.9x12.7 mm) 3.35x2.4x1.1 inches (85x61x28 mm) 3.35x2.4x1.27 inches (85x61x32.3 mm) 4x3.5x3.5 inches (101.6x88.9x88.9 mm) Metal FR4 PCB Silicon (UL94-V0) Six-sided IEC60950-1, UL60950-1, EN60950-1 Class A Class A EN55024 Air ±8KV Contact ±6KV 10 V/m ±2KV ±1KV 10 Vrms Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Perf. Criteria A Perf. Criteria A Perf. Criteria A Perf. Criteria A Perf. Criteria A Page 3 of 8 DC100 Series 2:1 Input Voltage Ranges Up to 100 Watts, Single Outputs Half-Brick DC/DC Power Converters Rev. C MODEL SELECTION TABLE Output Voltage Min. load Full load No Load (2) Input Current Ripple & Noise (3) (4) Output Power Maximum Capacitive Load (5) DC100-12S3.3 3.3VDC 0mA 25A 155mA 75mVp-p 82.5W 75700µF 90% DC100-12S05 5 VDC 0mA 20A 150mA 75mVp-p 100W 40000µF 91% 12 VDC 0mA 8.4A 180mA 100mVp-p 100W 7000µF 91% 15 VDC 0mA 6.7A 180mA 100mVp-p 100W 4460µF 91% Model Number DC100-12S12 DC100-12S15 DC100-12S24 Input Voltage 12 VDC (9 – 18 VDC) Output Current Efficiency (3) 24 VDC 0mA 4.2A 90mA 200mVp-p 100W 1750µF 90% DC100-12S28 28 VDC 0mA 3.6A 100mA 200mVp-p 100W 1280µF 90% DC100-12S48 48 VDC 0mA 2.1A 100mA 300mVp-p 100W 430µF 90% DC100-24S3.3 3.3VDC 0mA 25A 90mA 75mVp-p 82.5W 75700µF 91% DC100-24S05 5 VDC 0mA 20A 150mA 75mVp-p 100W 40000µF 93% 12 VDC 0mA 8.4A 185mA 100mVp-p 100W 7000µF 93% 15 VDC 0mA 6.7A 185mA 100mVp-p 100W 4460µF 93% DC100-24S12 DC100-24S15 DC100-24S24 24 VDC (18 – 36 VDC) 24 VDC 0mA 4.2A 85mA 200mVp-p 100W 1750µF 92% DC100-24S28 28 VDC 0mA 3.6A 85mA 200mVp-p 100W 1280µF 92% DC100-24S48 48 VDC 0mA 2.1A 85mA 300mVp-p 100W 430µF 92% DC100-48S3.3 3.3VDC 0mA 25A 80mA 75mVp-p 82.5W 75700µF 91% DC100-48S05 5 VDC 0mA 20A 90mA 75mVp-p 100W 40000µF 93% DC100-48S12 12 VDC 0mA 8.4A 90mA 100mVp-p 100W 7000µF 93% 15 VDC 0mA 6.7A 90mA 100mVp-p 100W 4460µF 93% DC100-48S15 DC100-48S24 48 VDC (36 – 75 VDC) 24 VDC 0mA 4.2A 40mA 200mVp-p 100W 1750µF 92% DC100-48S28 28 VDC 0mA 3.6A 40mA 200mVp-p 100W 1280µF 92% DC100-48S48 48 VDC 0mA 2.1A 40mA 300mVp-p 100W 430µF 92% NOTES 1. BELLCORE TR-NWT-000332. Case 1: 50% Stress, Temperature at 40°C. MIL-HDBK-217F Notice2 @Ta=25°C, Full load (Ground, Benign, controlled environment). 2. Typical value at nominal input voltage and no load. 3. Typical value at nominal input voltage and full load. 4. The ripple and noise of 48VDC output voltage models is measured with a 2.2μF/100V X7R 1812 MLCC; The ripple and noise of all other output voltages is measured with a 4.7μF/50V X7R 1812 MLCC. 5. Test by minimum input and constant resistive load. 6. The CTRL pin voltage is referenced to –INPUT. To order negative logic remote on/off control add the suffix “R” to the model number. 7. Output voltage is adjustable for 10% trim up or -20% trim down of nominal output voltage by connecting a single resistor between TRIM and +SENSE pins for trim up or between TRIM and -SENSE pins for trim down. To calculate the value of the resistor RU and RD for a particular output voltage see page 5. 8. Maximum output deviation is +10% inclusive of remote sense and trim. If remote sense is not being used the +SENSE should be connected to its corresponding +OUTPUT and likewise the -SENSE should be connected to its corresponding -OUTPUT. 9. (1) Thermal test conditions for vertical direction are by natural convection (20LFM). (2) Heat sink is optional. See the “Product Options” table on page 6 for suffix options. 10. The DC100 series can only meet EN55022 Class A or Class B with external components added. Please contact factory for more information. 11. An external input filter capacitor is required if the module has to meet EN61000-4-4, EN61000-4-5. We recommend connecting one aluminum electrolytic capacitor (Nippon chemi-con KY series, 220μF /100V, ESR 48mΩ) in parallel. 12. CASE GROUNDING: EMI can be reduced when you connect the four screw bolts to the shield plane. 13. This series comes with several different options: negative remote on/off control, heatsinks, pin length, thru-hole inserts, and terminal blocks. See the “Product Options” table on page 6 for more ordering information. 14. CAUTION: This power converter is not internally fused. An input line fuse must always be used. 10/23/2012 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 4 of 8 DC100 Series 2:1 Input Voltage Ranges Up to 100 Watts, Single Outputs Half-Brick DC/DC Power Converters Rev. C DERATING CURVES DC100-48S05 Derating Curve With 0.24” Height Heatsink (See Note 9) 20 60 Natural Convection (20LFM) 100LFM 200LFM 300LFM 400LFM 500LFM 40 20 40 80 60 100 20 0 -40 120 Natural Convection (20LFM) 100LFM 200LFM 300LFM 400LFM 500LFM 40 ~ ~ 20 60 ~ ~ 0 -40 80 Output Power (%) Output Power (%) 80 ~ ~ 0 100 ~ ~ Natural Convection (20LFM) 100LFM 200LFM 300LFM 400LFM 500LFM 40 ~ ~ 60 120 ~ ~ 100 80 DC100-48S05 Derating Curve With 0.45” Height Heatsink (See Note 9) ~ ~ 100 120 ~ ~ 120 ~ ~ Output Power (%) DC100-48S05 Derating Curve 20 40 Ambient Temperature (°C) 60 80 100 120 -40 20 Ambient Temperature (°C) 40 60 80 100 120 Ambient Temperature (°C) EFFICIENCY GRAPHS DC100-48S05 Efficiency vs Input Voltage DC100-48S05 Efficiency vs Output Load 94.00 95.0 92.75 92.5 91.50 90.0 87.5 85.0 90.25 Efficiency (%) Efficiency (%) 89.00 87.75 86.50 85.25 84.00 82.5 80.0 77.5 75.0 72.5 70.0 82.75 80.25 Vin Vin Vin Vin 67.5 65.0 62.5 Iout = 100% F.L. Iout = 50% F.L. Iout = 25% F.L. 81.50 79.00 = 18V = 24V = 48V = 75V 60.0 36 40 44 48 52 56 60 64 68 72 75 Input Voltage (VDC) 10 20 30 40 50 60 70 80 90 100 % of Full Load 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 between the TRIM and -SENSE pin, the output voltage set point increases. Maximum output deviation is +10% inclusive of remote sense. The value of the external resistor can be obtained by the equations below. The external TRIM resistor needs to be at least 1/8W resistor. V 100 % 100 2% RU OUT K % 1.225% TRIM UP 10/23/2012 100 RD 2K % TRIM DOWN Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 5 of 8 DC100 Series 2:1 Input Voltage Ranges Up to 100 Watts, Single Outputs Half-Brick DC/DC Power Converters Rev. C MECHANICAL DRAWING Unit: inches (mm) SIDE VIEW 2.000 (50.80) 1.400 (35.56) 1.000 (25.40) 0.700 (17.78) 9 0.400 (10.16) 8 7 BOTTOM VIEW 6 1 2 3 4 0.400 (10.16) EXTERNAL OUTPUT TRIMMING Output can be externally trimmed by using the method shown below. TRIM UP 0.20 (5.1) 2.28 (57.9) TRIM DOWN 6 RD RU 8 1.900 (48.26) PIN CONNECTIONS DEFINE DIAMETER - INPUT 0.04 in. CASE 0.04 in. CTRL 0.04 in. + INPUT 0.04 in. - OUTPUT 0.08 in. - SENSE 0.04 in. TRIM 0.04 in. + SENSE 0.04 in. + OUTPUT 0.08 in. 7 0.50 (12.7) 1.000 (25.40) 0.700 (17.78) 2.40 (61.0) 1.400 (35.56) 0.02 (0.6) 5 Threaded (Standard) 4-M3X0.5 Thru-Hole (“TH” suffix) 4-Ø0.126 (Ø3.2) The screw locked torque: MAX 0.49N.M (5.0kgf.cm) See Note 12 PIN 1 2 3 4 5 6 7 8 9 Product Options 0.200” pin length 0.145” pin length 0.200” pin length Positive Remote ON/OFF Logic 0.145” pin length Thru-Hole Inserts (No Thread) (1) Ø0.126 thru-hole (no thread) inserts Negative Remote ON/OFF Logic 0.200 (5.08) Suffix R RL None S TH Heatsink (1) Terminal Block (2)(3) 0.50 (12.7) 7 NOTES 1. Tolerance: x.xx±0.02 (x.x±0.5) x.xxx±0.01 (x.xx±0.25) 2. Pin Pitch Tolerance: ±0.01 (±0.25) 3. Pin Dimension Tolerance: ±0.004 (±0.1) Product Options H = 0.45” Vertical H = 0.24” Horizontal H = 0.24” Vertical H = 0.45” Horizontal Wall Mounted Wall Mounted with EMC Filter (2) (2)(3) Wall Mounted with Fin Type Heatsink and EMC Filter Suffix H H1 H2 H3 T TF TF1 NOTES 1. Models with thru-hole inserts cannot be equipped with a heatsink. 2. Models with EMC filter (suffix “TF” and “TF1”) meet EN55011, EN55022 Class A. 3. “TF1” models have an ambient operating temperature of -40°C to +85°C (without derating). HEATSINK OPTIONS Vertical Fin Orientation (Suffixes “H”, “H2”) Horizontal Fin Orientation (Suffixes “H1”, “H3”) 2.28 (57.9) H Unit: inches (mm) Heatsink Options Heatsink Options H = 0.24 inches (“H2” suffix) H = 0.45 inches (“H” suffix) H = 0.24 inches (“H1” suffix) H = 0.45 inches (“H3” suffix) 2.40 (61.0) Unit: inches (mm) H 2.40 (61.0) 2.28 (57.9) 10/23/2012 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 6 of 8 DC100 Series 2:1 Input Voltage Ranges Up to 100 Watts, Single Outputs Half-Brick DC/DC Power Converters Rev. C TERMINAL BLOCK OPTIONS Wall Mounted without EMC Filter (Suffix “T”) Wall Mounted with EMC Filter (Suffix “TF”) TF (2) TF1 (2) (3) Terminal Block Type T Weight 7.05oz (200g) 8.47oz (240g) 26.10oz (740g) Dimensions 3.35 x 2.4 x 1.1 inches (85 x 61 x 28 mm) 3.35 x 2.4 x 1.27 inches (85 x 61 x 32.3 mm) 4.0 x 3.5 x 3.5 inches (101.6 x 88.9 x 88.9 mm) Thru-Hole Inserts (WxL) 2.126 x 3.071 inches (54.00 x 78.00 mm) 2.126 x 3.071 inches (54.00 x 78.00 mm) 2.126 x 3.071 inches (54.00 x 78.00 mm) MODEL NUMBER SETUP DC 100 - Series Name Output Power 100: 100 Watts 24 S 12 Input Voltage Single Output Output Voltage S: single 3.3: 3.3 VDC 12: 9~18 VDC 24: 18~36 VDC 05: 5 VDC 48: 36~75 VDC 12: 12 VDC 15: 15 VDC 24: 24 VDC 28: 28 VDC 48: 48 VDC R Remote On/Off & Pin Length None: positive Logic, 0.200” pin length S: positive Logic, 0.145” pin length R: negative Logic, 0.200” pin length RL: negative Logic, 0.145” pin length TH Thru-Hole Inserts H (1) Heatsink None: threaded inserts TH: Ø0.126 thru-hole inserts TF (1) None: no heatsink (1) H: 0.45” vertical H1: 0.24” horizontal H2: 0.24” vertical H3: 0.45” horizontal Terminal Block (2) (3) None: no terminal block T: wall mounted TF: wall mounted with EMC filter (2) TF1: wall mounted with fin type heatsink and (2) (3) EMC filter NOTES 1. Models with thru-hole inserts cannot be equipped with a heatsink. 2. Models with EMC filter (suffix “TF” and “TF1”) meet EN55011, EN55022 Class A. 3. “TF1” models have an ambient operating temperature of -40°C to +85°C (without derating). 10/23/2012 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 7 of 8 Rev. C DC100 Series 2:1 Input Voltage Ranges Up to 100 Watts, Single Outputs Half-Brick DC/DC Power Converters 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: 10/23/2012 (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 8 of 8