DCHBW75 SERIES Up to 76.8 Watts DC/DC Power Converter Single Outputs Rev G Standard Terminal Block with EMC Filter Terminal Block Size: 2.4in x 2.28in x 0.5in (61mm x 57.9mm x 12.7in) OPTIONS • • • • • • FEATURES Pin Length Heatsinks Thru-Hole Inserts Negative Logic Remote On/Off Terminal Block Terminal Block with EMC Filter • • • • • • • • Soft-Start • RoHS II and REACH Compliant • 4:1 Ultra Wide Input Voltage Ranges • Up to 76.8 Watts of Output Power • Single Outputs Ranging from 3.3VDC to 48VDC • Output Current up to 20A • Under Voltage Lockout • UL60950-1, EN60950-1, IEC60950-1, • EN45545-2 and EN50155 Safety Approvals Six-Sided Shielding High Efficiency up to 91% No Minimum Load Requirements Adjustable Output Voltage Industry Standard Half-Brick Footprint Remote On/Off Control Threaded Inserts and Thru-Hole Inserts Available Short Circuit, Over Voltage, Over Load, and Over Temperature Protection APPLICATIONS DESCRIPTION • • • • • • The DCHBW75 series of DC/DC power converters provides up to 76.8 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 4:1 ultra wide input voltage ranges of 9~36VDC, 18~75VDC and 43~160VDC. Some features include high efficiency up to 91%, adjustable output voltage, positive remote on/off control, and under voltage lockout. These converters also have short circuit, over voltage, over load, and over temperature protection. The DCHBW75 series is RoHS compliant and has UL60950-1, EN60950-1, IEC60950-1, EN45545-2 and EN50155 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. Railway Systems Wireless Networks Telecom/Datacom Industry Control Systems Semiconductor Equipment Distributed Power Architectures • Military Applications 2/6/2018 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 1 of 9 DCHBW75 SERIES Up to 76.8 Watts DC/DC Power Converter Single Outputs Rev G MODEL SELECTION TABLE Input Voltage Range Model Number DCHBW75-24S3.3 DCHBW75-24S05 DCHBW75-24S12 DCHBW75-24S15 DCHBW75-24S24 DCHBW75-24S28 DCHBW75-24S48 DCHBW75-48S3.3 DCHBW75-48S05 DCHBW75-48S12 DCHBW75-48S15 DCHBW75-48S24 DCHBW75-48S28 DCHBW75-48S48 DCHBW75-110S3.3 DCHBW75-110S05 DCHBW75-110S12 DCHBW75-110S15 DCHBW75-110S24 DCHBW75-110S28 DCHBW75-110S48 24VDC (9~36VDC) 48VDC (18~75VDC) 110VDC (43~160VDC) Output Voltage 3.3VDC 5VDC 12VDC 15VDC 24VDC 28VDC 48VDC 3.3VDC 5VDC 12VDC 15VDC 24VDC 28VDC 48VDC 3.3VDC 5VDC 12VDC 15VDC 24VDC 28VDC 48VDC Output Current No Load Ripple & Noise Input Current(1) Min Load Max Load 0mA 20A 75mVp-p 85mA 0mA 15A 75mVp-p 120mA 0mA 6.3A 100mVp-p 185mA 0mA 5A 100mVp-p 185mA 0mA 3.2A 200mVp-p 85mA 0mA 2.7A 200mVp-p 85mA 0mA 1.6A 300mVp-p 85mA 0mA 20A 75mVp-p 60mA 0mA 15A 75mVp-p 60mA 0mA 6.3A 100mVp-p 90mA 0mA 5A 100mVp-p 50mA 0mA 3.2A 200mVp-p 50mA 0mA 2.7A 200mVp-p 50mA 0mA 1.6A 300mVp-p 50mA 0mA 20A 75mVp-p 10mA 0mA 15A 75mVp-p 10mA 0mA 6.3A 100mVp-p 10mA 0mA 5A 100mVp-p 10mA 0mA 3.2A 200mVp-p 10mA 0mA 2.7A 200mVp-p 10mA 0mA 1.6A 300mVp-p 10mA Output Power 66W 75W 75.6W 75W 76.8W 75.6W 76.8W 66W 75W 75.6W 75W 76.8W 75.6W 76.8W 66W 75W 75.6W 75W 76.8W 75.6W 76.8W Maximum Capacitive Efficiency(3) Load(2) 60600µF 30000µF 5250µF 3330µF 1330µF 960µF 330µF 60600µF 30000µF 5250µF 3330µF 1330µF 960µF 330µF 60600µF 30000µF 5250µF 3330µF 1330µF 960µF 330µF 87% 88% 88% 88% 87% 87% 87% 88% 90% 90% 89% 88% 88% 87% 89% 91% 91% 91% 90% 90% 90% SPECIFICATIONS 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 43 24 48 110 36 75 160 9 18 43 Unit INPUT SPECIFICATIONS Input Voltage Range Start-Up Voltage Shutdown Voltage Input Surge Voltage (1 sec max.) Input Current Input Filter(4) OUTPUT SPECIFICATIONS Output Voltage Voltage Accuracy Line Regulation Load Regulation Voltage Adjustability(5) Remote Sense(6) Output Power Output Current Minimum Load Maximum Capacitive Load Ripple & Noise (20MHz bandwidth) Transient Response Recovery Time 110VDC Input Models Start-Up Time Others Temperature Coefficient 2/6/2018 24VDC Nominal Input Models 48VDC Nominal Input Models 110VDC Nominal Input Models 24VDC Nominal Input Models 48VDC Nominal Input Models 110VDC Nominal Input Models 24VDC Nominal Input Models 48VDC Nominal Input Models 110VDC Nominal Input Models 24VDC Nominal Input Models 48VDC Nominal Input Models 110VDC Nominal Input Models No Load Low Line to High Line at Full Load No Load to Full Load 7.5 16 36 50 100 185 See Table Pi Type -1.0 -0.1 -0.1 -20 See Table +1.0 +0.1 +0.1 +10 10 See Table See Table 0 Minimum Input and Constant Resistive Load 4.7µF/50V X7R MLCC 3.3V and 5V Models 4.7µF/50V X7R MLCC 12V and 15V Models 4.7µF/50V X7R MLCC 24V and 28V Models 2.2µF/100V X7R MLCC 48V Models 25% Load Step Change Nominal Input and Constant Resistive Load Power Up or Remote On/Off -0.02 VDC VDC VDC VDC % % % % %Vo % See Table 75 100 100 125 200 250 300 350 200 250 60 25 +0.02 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] mVp-p µs Ms %/ºC Page 2 of 9 DCHBW75 SERIES Up to 76.8 Watts DC/DC Power Converter Single Outputs Rev G SPECIFICATIONS 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 CONTROL(7) Positive Logic (Standard) Negative Logic (Optional) DC-DC ON DC-DC OFF DC-DC ON DC-DC OFF Input Current of CTRL Pin Remote OFF Input Current PROTECTION Short Circuit Protection Over Load Protection Over Voltage Protection Over Temperature Protection ENVIRONMENTAL SPECIFICATIONS Operating Case Temperature Storage Temperature Thermal Impedance(8) Relative Humidity Thermal Shock Shock Vibration MTBF GENERAL SPECIFICATIONS Efficiency Switching Frequency -0.5 110Vin (Nominal) % of lout rated; Hiccup mode Others % of Vout (nominal); Hiccup Mode Base-Plate Standard Terminal Block Type Standard With 0.24” Heatsink With 0.45” Heatsink Nominal Input Voltage and Full Load Isolation Resistance Isolation Capacitance PHYSICAL SPECIFICATIONS 1 minute (basic insulation) 500VDC Standard Terminal Block (“T” Suffix) Dimensions (L x W x H) Terminal Block with EMC Filter (“TF” suffix) Terminal Block with EMC Filter, connected to PE (“TF1” suffix) Case Material Base Material Potting Material Shielding SAFETY & EMC CHARACTERISTICS Safety Approvals EMI(9) ESD Radiated Immunity Fast Transient(10) Surge(10) Conducted Immunity Power Frequency Magnetic Field 2/6/2018 270 3000 1500 2250 24VDC and 48VDc Nominal Input Voltage Models 110VDC Nominal Input Voltage Models 24VDC and 48VDC Nominal Input Voltage Models 24VDC and 48VDC Nominal Input Models ºC ºC ºC/W 95 %RH MIL-STD-810F EN61373, MIL-STD-810F EN61373, MIL-STD-810F 336,200 hours See Table 300 330 kHz VAC VDC 1600 1 2500 Standard Terminal Block (“T” Suffix) Terminal Block with EMC Filter (“TF” suffix) Terminal Block with EMC Filter, connected to PE (“TF1” suffix) Weight +105 +125 +105 6.7 5.4 4.7 MIL-HDBK-217F, Full Load Isolation Voltage Others -40 -55 -40 Input to Output Input (Output) to Case Input to Output Input (Output) to Case mA mA Continuous, Automatic Recovery 150 % 110 140 115 130 % +115 ºC 5 110VDC Input Models 1 minute (reinforced insulation) Short or 0~1.2VDC Open or 3~12VDC Open or 3~12VDC Short or 0~1.2VDC 1 3 GΩ pF 3.42oz (97g) 7.05oz (200g) 9.88oz (280g) 10.12oz (287g) 2.4in x 2.28in x 0.5in (61mm x 57.9mm x 12.7mm) 3.35in x 2.4in x 1.17in (85mm x 61mm x 28mm) 3.35in x 2.4in x 1.54in (85mm x 61mm x 32.3mm) 3.35in x 2.40in x 1.59in (85.0mm x 61.0mm x 40.5mm) Metal Aluminum Base-Plate with Plastic Case FR4 PCB Silicone (UL94 V-0) Six-Sided UL60950-1, EN60905-1, IEC60950-1, EN50155, EN45545-2 EN55011, EN55022 Air ±8KV EN61000-4-2 Contact ±6KV EN61000-4-3 20 V/m EN61000-4-4 ±2KV EN55024 ±2KV EN61000-4-5 EN50155 ±2KV EN61000-4-6 10Vr.m.s EN61000-4-8 100A/m continuous; 1000A/m 1 second Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Class A, Class B Perf. Criteria A Perf. Criteria A Perf. Criteria A Perf. Criteria A Perf. Criteria A Perf. Criteria A Page 3 of 9 DCHBW75 SERIES Up to 76.8 Watts DC/DC Power Converter Single Outputs Rev G NOTES (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Typical Value at Nominal Input Voltage and No Load. Test by minimum input and constant resistive load. Typical Value at Nominal Input Voltage and Full Load. Input source impedance: The power module will operate as specifications without external components, assuming that the source voltage has a very low impedance and reasonable input voltage regulation. Highly inductive source impedances can affect the stability of the power module. An external input capacitor is recommended for 24VDC nominal input models. We suggest 4.7µF/50V X7R MLCC or Nippon chemi-con KY series, 68µF/100V, ESR 110mΩ or better capacitor. For terminal block versions, the capacitor is included as standard and an external capacitor is not necessary. Output voltage is adjustable for 10% trim up or -20% 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 5/6. 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. The CTRL pin voltage is referenced to –INPUT. To order negative logic remote on/off control add the suffix “R” to the model number. 1. The thermal test conditions for vertical direction are by natural convection (20LFM) 2. Heat sink is optional. See the “Product Options” table for suffix options. The standard module meets EMI Class A or Class B with external components. An external input filter capacitor is required if the module has to meet EN61000-4-4, EN61000-4-5. For 24 & 48VDC nominal input models, we recommend connecting one aluminum electrolytic capacitor (Nippon chemi-con KY series, 220µF/100V, ESR 48mΩ) in parallel. For 110VDc nominal input models, we recommend connecting three aluminum electrolytic capacitors (Ruby-con BXF series, 100µF/250V) in parallel. CASE GROUNDING: EMI can be reduced when you connect the four screw bolts to the shield plane. 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. CAUTION: This power converter is not internally fused. An input line fuse must always be used. DERATING CURVES DCHBW75-48S05 Derating Curve DCHBW75-48S05 Derating Curve With 0.24” Height Heatsink (See Note 8) DCHBW75-48S05 Derating Curve With 0.45” Height Heatsink (See Note 8) 2/6/2018 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 4 of 9 DCHBW75 SERIES Up to 76.8 Watts DC/DC Power Converter Single Outputs Rev G EFFICIENCY GRAPHS DCHBW75-48S05 Efficiency vs. Input Voltage DCHBW75-48S05 Efficiency vs. Output Load MECHANICAL DRAWINGS METAL CASE (24VDC & 48VDC Nominal Input Models) PIN 1 2 3 4 5 6 7 8 9 PIN CONNECTION DEFINE DIAMETER -Vin 0.04 Inch Case 0.04 Inch Ctrl 0.04 Inch +Vin 0.04 Inch -Vout 0.08 Inch -Sense 0.04 Inch Trim 0.04 Inch +Sense 0.04 Inch +Vout 0.08 Inch EXTERNAL OUTPUT TRIMMING Output can be externally trimmed by using the method shown below Notes: 1. 2. 3. 4. 5. 6. 2/6/2018 All dimensions in inch (mm) Tolerance: x.xx±0.02 (x.x±0.5) x.xxx±0.01 (x.xx±0.25) Pin Pitch Tolerance ±0.01 (0.25) Pin Dimension Tolerance ±0.004 (0.1) Mounting Screws should always be used The screw locked torque: MAX 5.0kgf-cm(049N-m) Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 5 of 9 DCHBW75 SERIES Up to 76.8 Watts DC/DC Power Converter Single Outputs Rev G PLASTIC CASE (110VDC Nominal Input Models) PIN 1 2 3 4 5 6 7 8 9 PIN CONNECTION DEFINE DIAMETER -Vin 0.04 Inch Case 0.04 Inch Ctrl 0.04 Inch +Vin 0.04 Inch -Vout 0.08 Inch -Sense 0.04 Inch Trim 0.04 Inch +Sense 0.04 Inch +Vout 0.08 Inch EXTERNAL OUTPUT TRIMMING Output can be externally trimmed by using the method shown below Notes: 1. 2. 3. 4. 5. 6. Product Options Negative Remote ON/OFF Logic Positive Remote ON/OFF Logic Thru-Hole Inserts (No Thread)(1) Notes: 1. 2. 3. 2/6/2018 0.200” pin length 0.145” pin length 0.200” pin length 0.145” pin length 00.126 thru-hold (no thread) inserts Suffix R RL None S All dimensions in inch (mm) Tolerance: x.xx±0.02 (x.x±0.5) x.xxx±0.01 (x.xx±0.25) Pin Pitch Tolerance ±0.01 (0.25) Pin Dimension Tolerance ±0.004 (0.1) Mounting screws should always be used. The screw locked torque: MAX 3.5kgf-cm(0.34N-m) Heatsink(1) TH Terminal Block(2) (3) Product Options H = 0.45” Vertical H = 0.24” Horizontal H = 0.24” Vertical H = 0.45” Horizontal Suffix H H1 H2 H3 Wall Mounted T Wall Mounted with EMC Filter Wall mounted with EMC Filter can be connected to PE TF TF1 Models with thru-hole inserts cannot be equipped with heatsink. Terminal block models have 0.200” pin lengths. 0.145” pin lengths are not available for terminal block models EMI filter meets EN55011, EN55022 Class A/ Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 6 of 9 DCHBW75 SERIES Up to 76.8 Watts DC/DC Power Converter Single Outputs Rev G HEATSINK OPTIONS Vertical Fin Orientation, Suffixes: “HS”, “HS2” Horizontal Fin Orientation, Suffixes: “H1”, “H3” Unit: Inches (mm) Tolerance: x.xx±0.02 (x.x±0.5) Unit: Inches (mm) Tolerance: x.xx±0.02 (x.x±0.5) Heatsink Options H= 0.24 Inches (“H2” Suffix) H= 0.45 Inches (“H” Suffix) Heatsink Options H= 0.24” (“H1” Suffix) H= 0.45” (“H3” Suffix) TERMINAL BLOCK OPTIONS Wall Mounted without EMC Filter (Suffix “T”) TERMINAL CONNECTION: -T, -TF NO. DEFINE 1 -Vin 2 Case 3 Ctrl 4 +Vin 5 -Vout 6 -Sense 7 Trim 8 +Sense 9 +Vout Wall Mounted with EMC Filter (Suffix “TF”) EXTERNAL OUTPUT TRIMMING Output can be externally trimmed by using the method shown below. Wall Mounted with EMC Filter can be connected to PE (Suffix “TF1”) TERMINAL CONNECTION: -TF1 NO. DEFINE 1 -Vin 2 NC 3 Ctrl 4 +Vin 5 -Vout 6 -Sense 7 Trim 8 +Sense 9 +Vout Notes: 1. All dimensions in inch (mm) 2. Tolerance: x.xx±0.02 (x.x±0.5) x.xxx±0.01 (x.xx±0.25) 3. Screw 1 locked torque: MAX 11.2kgf-cm/ 1.10N-m 4. Screw 2 locked torque: MAX 5.2kgf-cm/ 0.51N-m 5. Screw 3.4 locked torque: MAX 12.0kgf-cm/ 1.18N-m 2/6/2018 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 7 of 9 DCHBW75 SERIES Up to 76.8 Watts DC/DC Power Converter Single Outputs Rev G 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. TRIM UP TRIM DOWN MODEL NUMBER SETUP DCHBW 75 Series Name Output Power 75: 75 Watts - 48 S 05 Input Voltage Output Quantity Output Voltage 24: 9~36VDC S: Single 3.3: 3.3VDC 48: 18~75VDC 05: 5VDC 110: 43~160VDC 12: 12VDC 15: 15VDC 24: 24VDC 28: 28VDC 48: 48VDC R TH H TF Remote On/Off & Pin Length Thru-Hole Inserts(1) Heatsink (1) Terminal Block (2) None: Positive Logic, 0.200” pin length S: Positive Logic, 0.145” pin length None: Threaded Inserts TH: Ø0.126 thru-hole inserts R: Negative Logic, 0.200” pin length RL: Negative Logic, 0.145” pin length (1) None: No Heatsink 0.45” Vertical 7GH: 0021A-F 0.24” Horizontal H1: 7G-0022A-F 0.24” Vertical H2: 7G0023A-F 0.45” Horizontal H3: 7G-0024A-F None: No Terminal Block T: Wall Mounted TF: Wall Mounted with EMC Filter (3) T1: Wall Munted with EMC filter can be connected to PE (3) NOTES 1. Models with thru-hole inserts cannot be equipped with a heatsink. 2. Only 0.200” pin length is available with terminal block options. 3. EMI Filter meets EN55011, EN55022 Class A 2/6/2018 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 8 of 9 Rev G DCHBW75 SERIES Up to 76.8 Watts DC/DC Power Converter Single Outputs 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: 2/6/2018 (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 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 9 of 9