DCHBW100 SERIES 82.5~100.8 Watts Half-Brick DC/DC Power Converters Single Output Rev D 24V & 48V Input Models 110V Input Models Terminal Block Models (“T” suffix) Terminal Block w/ EMC Filter (“TF” suffix) Terminal Block w/ EMC Filter (“TF1” suffix) Size: 2.40 x 2.28 x 0.50in Size: 2.40 x 2.28 x 0.50in Size: 3.35 x 2.40 x 1.27in Size: 3.35 x 2.40 x 1.47in Size: 3.35 x 2.40 x 1.53in OPTIONS FEATURES • • • • • • Pin Length Heatsinks Thru-Hole Inserts Negative Logic Remote On/Off Terminal Block Terminal Block with Aluminum Base-plate and EMC Filter • Terminal Block with Anodized Aluminum Base-plate and EMC Filter, Can be Connected to PE • • • • • • • • • • • APPLICATIONS DESCRIPTION Railway Systems Wireless Networks Telecom / Datacom Industry Control Systems Distributed Power Architectures • Semiconductor Equipment • Military Applications The DCHBW100 series of DC/DC power converters provides up to 100.8 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. Some features include high efficiency up to 93%, adjustable output voltage, and remote on/off control. These converters also have short circuit, over voltage, over current, and over temperature protection. The DCHBW100 series is RoHS II 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 control, terminal block, pin length, heatsinks, and thru-hole inserts. • • • • • Railway Applications Soft-Start 4:1 Ultra Wide Input Voltage Ranges 82.5~100.8 Watts Output Power High Efficiency up to 93% Under Voltage Lockout No Minimum Load Requirements Adjustable Output Voltage Remote On/Off Control Industry Standard Half-Brick Footprint Single Outputs Ranging from 3.3VDC to 48VDC • 2250VDC Basic Insulation for 24VIN & 48VIN • 3000VAC Reinforced Insulation for 110VDC Nominal Input Models • Threaded Inserts and Thru-Hole Inserts Available • Short Circuit, Over Voltage, Over Current, and Over Temp. Protection • Compliant to RoHS II & REACH • CE Mark Meets 2006/95/EC, 2011/95/EC, and 2004/108/EC • UL60950-1, EN60950-1, & IEC60950-1 Safety Approvals MODEL SELECTION TABLE Model Number DCHBW100-24S3.3 DCHBW100-24S05 DCHBW100-24S12 DCHBW100-24S15 DCHBW100-24S24 DCHBW100-24S28 DCHBW100-24S48 DCHBW100-48S3.3 DCHBW100-48S05 DCHBW100-48S12 DCHBW100-48S15 DCHBW100-48S24 DCHBW100-48S28 DCHBW100-48S48 DCHBW100-110S3.3 DCHBW100-110S05 DCHBW100-110S12 DCHBW100-110S15 DCHBW100-110S24 DCHBW100-110S28 DCHBW100-110S48 04/30/2014 Input Voltage Range 24 VDC (9 - 36 VDC) 24 VDC (8.5 - 36 VDC) 48 VDC (16.5 - 75 VDC) 110 VDC (43 - 160 VDC) Output Voltage 3.3 VDC 5 VDC 12 VDC 15 VDC 24 VDC 28 VDC 48 VDC 3.3 VDC 5 VDC 12 VDC 15 VDC 24 VDC 28 VDC 48 VDC 3.3 VDC 5 VDC 12 VDC 15 VDC 24 VDC 28 VDC 48 VDC Output Current No Load Ripple & Noise Input Current Min Load Max Load 0mA 25A 75mVp-p 20mA 0mA 20A 75mVp-p 25mA 0mA 8.4A 100mVp-p 25mA 0mA 6.7A 100mVp-p 25mA 0mA 4.2A 200mVp-p 25mA 0mA 3.6A 200mVp-p 25mA 0mA 2.1A 300mVp-p 35mA 0mA 25A 75mVp-p 15mA 0mA 20A 75mVp-p 15mA 0mA 8.4A 100mVp-p 20mA 0mA 6.7A 100mVp-p 20mA 0mA 4.2A 200mVp-p 20mA 0mA 3.6A 200mVp-p 20mA 0mA 2.1A 300mVp-p 25mA 0mA 25A 75mVp-p 10mA 0mA 20A 75mVp-p 10mA 0mA 8.4A 100mVp-p 10mA 0mA 6.7A 100mVp-p 10mA 0mA 4.2A 200mVp-p 10mA 0mA 3.6A 200mVp-p 10mA 0mA 2.1A 300mVp-p 10mA Output Power Maximum Capacitive Load Efficiency 82.5W 100W 100.8W 100.5W 100.8W 100.8W 100.8W 82.5W 100W 100.8W 100.5W 100.8W 100.8W 100.8W 82.5W 100W 100.8W 100.5W 100.8W 100.8W 100.8W 75,700µF 40,000µF 7000µF 4460µF 1750µF 1280µF 430µF 75,700µF 40,000µF 7000µF 4460µF 1750µF 1280µF 430µF 75,700µF 40,000µF 7000µF 4460µF 1750µF 1280µF 430µF 91% 93% 90% 91% 90% 90% 90% 91% 93% 90% 91% 90% 92% 91% 87% 90% 90% 90% 90% 90% 91% 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 9 DCHBW100 SERIES 82.5~100.8 Watts Half-Brick DC/DC Power Converters Single Output Rev D SPECIFICATIONS: DCHBW100 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 9 8.5 16.5 43 24 24 48 110 Max Unit INPUT SPECIFICATIONS 3.3Vout & 5Vout Others 24VDC nominal input models Operating Input Voltage Range Start-Up Voltage Shutdown Voltage Input Surge Voltage (1sec, max.) Input Current Input Filter (See Note 1) OUTPUT SPECIFICATIONS Output Voltage Voltage Accuracy Line Regulation Load Regulation Voltage Adjustability (See Note 6) Remote Sense (See Note 2) Output Power Output Current Minimum Load Maximum Capacitive Load Ripple & Noise (See Note 7) Transient Response Recovery Time Start-Up Time 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 7.3 15.5 33.0 -1.0 -0.1 -0.1 -20 Low line to high line at full load No load to full load Maximum output deviation is inclusive of remote sense % of nominal Vout VDC VDC VDC VDC See Table +1.0 +0.1 +0.1 +10 10 See Table See Table % % % % % 0 Minimum input and constant resistive load With a 1µF/25V X7R MLCC and a 22µF/25V POS-CAP With a 1µF/25V X7R MLCC and a 22µF/25V POS-CAP With a 4.7µF/50V X7R MLCC With a 2.2µF/100V X7R MLCC 25% load step change 3.3Vout & 5Vout 12Vout & 15Vout 24Vout & 28Vout 48Vout Constant resistive load Power Up Remote On/Off Temperature Coefficient REMOTE ON/OFF CONTROL -0.02 Positive Logic (standard) Referenced to –Vin pin Negative Logic (optional) Referenced to –Vin pin Input Current of CTRL Pin Remote OFF Input Current PROTECTION Short Circuit Protection Nominal Vin Nominal Vin Over Load Protection % of rated Iout; hiccup mode DC/DC ON DC/DC OFF DC/DC ON DC/DC OFF -0.5 24VDC & 48VDC Input Models 110VDC Input Models Over Voltage Protection % of nominal Vout; hiccup mode Over Temperature Protection ENVIRONMENTAL SPECIFICATIONS Operating Case Temperature Base-plate Terminal block types Storage Temperature Others Vertical direction by natural convection (20LFM) Module without assembly options Thermal Impedance (See Note 3) 0.24” height heatsink 0.45” height heatsink Relative Humidity Thermal Shock Shock Vibration MTBF MIL-HDBK-217F Ta=25°C, full load 04/30/2014 36 36 75 160 9 18 43 8.1 16.3 36.0 50 100 185 See Table Pi type % See Table 75 100 200 300 200 250 75 75 +0.02 Open or 3 ~ 12VDC Short or 0 ~ 1.2VDC Open or 3 ~ 12VDC Short or 0 ~ 1.2VDC 1 3 mVp-p µs ms %/°C mA mA Continuous, automatic recovery 120 150 % 150 115 130 % +115 °C -40 -40 -55 +115 +105 +125 °C °C 6.7 5.4 4.7 °C/W 5 95 % RH MIL-STD-810F EN61373, MIL-STD-810F EN61373, MIL-STD-810F 408,700 hours 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 9 DCHBW100 SERIES 82.5~100.8 Watts Half-Brick DC/DC Power Converters Single Output Rev D SPECIFICATIONS: DCHBW100 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 GENERAL SPECIFICATIONS Efficiency Switching Frequency TEST CONDITIONS Nominal input voltage and full load 24VDC & 48VDC nominal input models 110VDC nominal input models 1 minute (reinforced insulation) 110VDC nominal input models Isolation Voltage 1 minute (basic insulation) 24VDC & 48VDC nominal input models Isolation Resistance Isolation Capacitance PHYSICAL SPECIFICATIONS Weight Dimensions (L x W x H) Case Material Base Material Potting Material SAFETY & EMC CHARACTERISTICS Safety Approvals EMI (See Note 4) ESD Radiated Immunity Fast Transient (See Note 5) Surge (See Note 5) Conducted Immunity Power Frequency Magnetic Field Min Input to Output Input to Case Output to Case Input to Output Input to Case Output to Case 500VDC 225 270 3000 1500 1500 2250 1600 1600 1 Typ Max See Table 250 275 300 330 2500 Standard models “T” suffix models “TF” suffix models “TF1” suffix models Standard models “T” suffix models “TF” suffix models “TF1” suffix models 24VDC & 48VDC nominal input models 110VDC nominal input models 24VDC & 48VDC nominal input models EN55011, EN55022 EN61000-4-2 Air ±8kV and Contact ±6kV EN61000-4-3 20 V/m EN61000-4-4 ±2kV EN61000-4-5 EN55024 ±2kV and EN50155 ±2kV EN61000-4-6 10 Vrms EN61000-4-8 100A/m Continuous; 1000A/m 1 Second Unit kHz kHz VAC VAC VAC VDC VDC VDC GΩ pF 3.70oz (105g) 8.29oz (235g) 9.88oz (280g) 10.12oz (287g) 2.40 x 2.28 x 0.50 inches (61.0 x 57.9 x 12.7 mm) 3.35 x 2.40 x 1.27 inches (85.0 x 61.0 x 32.3 mm) 3.35 x 2.40 x 1.47 inches (85.0 x 61.0 x 37.3 mm) 3.35 x 2.40 x 1.53 inches (85.0 x 61.0 x 38.8 mm) Metal Aluminum base-plate with plastic case FR4 PCB Silicon (UL94-V0) UL60950-1, EN60950-1, EN50155 Class A, Class B Perf. Criteria A Perf. Criteria A Perf. Criteria A Perf. Criteria A Perf. Criteria A Perf. Criteria A NOTES 1. Input Source Impedance: These converters will operate under all listed 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 converter. Since real world voltage sources have finite impedance, performance can be improved by adding an external filter capacitor. - For 24VDC & 48VDC nominal input models, we recommend Nippon chemi-con KY series, 100μF/100V. - For 110VDC nominal input models, we recommend Ruby-con BXF series, 68µF/200V. 2. 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. 3. (1) Thermal test conditions for vertical direction are by natural convection (20LFM). (2) The iron base-plate dimensions are 19” x 3.5” x 0.063” (the height is EIA standard 2U). (3) Heat sink is optional. See the “Model Number Setup” table on page 8 for suffix options. 4. The DCHBW100 standard models (no assembly options) can meet EN55011, EN55022 Class A or Class B with additional external components. 5. An external input filter capacitor is required if the module has to meet EN61000-4-4, EN61000-4-5. For 24VDC & 48VDC nominal input models, we recommend connecting two aluminum electrolytic capacitors (Nippon chemi-con KY series, 220μF/100V) in parallel. For 110VDC nominal input models, we recommend connecting three aluminum electrolytic capacitors (Nippon chemi-con KXJ series, 150μF/200V) in parallel. 6. 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 6. 7. Measured by 20MHz bandwidth. 8. CASE GROUNDING: EMI can be reduced when you connect the four screw bolts to the shield plane. 9. This series comes with several different options: negative remote on/off control, heatsinks, case pin, sync pin, pin length, terminal block, and thru-hole inserts. See the “Model Number Setup” table on page 8 for more ordering information. CAUTION: This power converter is not internally fused. An input line fuse must always be used. Due to advances in technology, specifications are subject to change without notice. 04/30/2014 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 3 of 9 DCHBW100 SERIES 82.5~100.8 Watts Half-Brick DC/DC Power Converters Single Output Rev D DERATING CURVES DCHBW100-48S05 Derating Curve (Note 3) DCHBW100-48S05 Derating Curve (Note 3) With 0.24” Height Heat-Sink DCHBW100-48S05 Derating Curve (Note 3) With 0.45” Height Heat-Sink EFFICIENCY GRAPHS DCHBW100-48S05 Efficiency vs Input Voltage 04/30/2014 DCHBW100-48S05 Efficiency vs Output Load 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 9 DCHBW100 SERIES 82.5~100.8 Watts Half-Brick DC/DC Power Converters Single Output Rev D MECHANICAL DRAWINGS 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 * Screw locked torque: MAX 5.0kgf-cm (0.49N-m) 110VDC Nominal Input Models 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. Pin pitch tolerance ±0.01 (0.25) 4. Pin dimension tolerance ±0.004 (0.1) 5. Mounting Screws should always be used. * Screw locked torque: MAX 3.5kgf-cm (0.34N-m) 04/30/2014 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 9 DCHBW100 SERIES 82.5~100.8 Watts Half-Brick DC/DC Power Converters Single Output Rev D TERMINAL BLOCK OPTIONS Terminal Block Models (“T” suffix) Terminal Block w/ EMC Filter (“TF” suffix) Terminal Block w/ EMC Filter that Can be Connected to PE(“TF1” suffix) 04/30/2014 PIN 1 2 3 4 5 6 7 8 9 PIN CONNECTION DEFINE -Vin NC Ctrl +Vin -Vout -Sense Trim +Sense +Vout 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 locked torque: MAX 12.0kgf-cm/1.18N-m 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 9 DCHBW100 SERIES 82.5~100.8 Watts Half-Brick DC/DC Power Converters Single Output Rev D HEATSINK OPTIONS Vertical Fin Orientation (Suffixes “H”, “H2”) Horizontal Fin Orientation (Suffixes “H1”, “H3”) Notes HS: HS1: HS2: HS3: Height H=0.45” Vertical fin, 7G-0021A-F Height H=0.24” horizontal fin, 7G-0022A-F Height H=0.24” vertical fin, 7G-0023A-F Height H=0.45” horizontal fin, 7G-0024A-F 1. All dimensions in inch (mm) 2. Tolerance: x.xx (x.x±0.5) x.xxx±0.01 (x.xx±0.25) TERMINAL BLOCK OPTIONS Terminal Block with Al Base-plate (Suffix T) Terminal Block Type Weight Dimensions Thru-Hole (WxL) T Terminal Block with Al Base-plate and EMC Filter (Suffix TF) TF 8.29oz (235g) 9.88oz (280g) 3.35 x 2.40 x 1.27 inches 3.35 x 2.40 x 1.47 inches (85.0 x 61.0 x 32.3 mm) (85.0 x 61.0 x 37.3 mm) 2.126 x 3.071 inches (54.00 x 78.00 mm), 4-Ø0.17 inches (Ø4.3mm) Terminal Block with Anodized Al Base-plate and EMC Filter (Suffix TF1) TF1 10.12oz (287g) 3.35 x 2.40 x 1.53 inches (85.0 x 61.0 x 38.8 mm) NOTES 1. Terminal block models (suffix “T”, “TF”, and “TF1”) cannot be equipped with a heatsink. 2. Only 0.200” pin length is available with terminal block options. 3. Models with EMC filter (suffix “TF” and “TF1”) meet EN55011, EN55022 Class A. 04/30/2014 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 7 of 9 Rev D DCHBW100 SERIES 82.5~100.8 Watts Half-Brick DC/DC Power Converters Single Output 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 V (100 + ∆%) (100 + 2∆%) RU = OUT − KΩ ∆% 1.225∆% 100 RD = − 2 KΩ ∆% APPLICATION NOTES Assembly 04/30/2014 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 8 of 9 DCHBW100 SERIES 82.5~100.8 Watts Half-Brick DC/DC Power Converters Single Output Rev D MODEL NUMBER SETUP DCHBW 100 24 S 12 R Series Name Output Power - Input Voltage Output Quantity Ouptut Voltage Remote On/Off & Pin Length 100: 100 Watts 24: 8.5-36 VDC S: Single 3.3: 3.3 VDC None: Positive Logic, 0.200” pin length 9-36 VDC 05: 5 VDC S: Positive Logic, 0.145” pin length 48: 16.5-75 VDC 12: 12 VDC R: Negative Logic, 0.200” pin length 110: 43-160 VDC 15: 15 VDC RL: Negative Logic, 0.145” pin length 24: 24 VDC 28: 28 VDC 48: 48 VDC TH Thru-Hole Inserts H (1) None: Threaded Inserts TH: Ø0.126 Thru-Hole Inserts (1) Heatsink TF (1) (2) None: No Heatsink Terminal Block (2) (3) (4) None: No Terminal Block H: 0.45” Vertical 7G-0021A-F H1: 0.24” Horizontal 7G-0022A-F H2: 0.24” Vertical 7G-0023A-F H3: 0.45” Horizontal 7G-0024A-F T: Terminal block with aluminum base-plate TF: Terminal block with aluminum base-plate and EMC filter TF1: Terminal block with anodized aluminum base-plate and EMC filter, can be connected to Protective Earth (PE) NOTES 1. Models with thru-hole inserts cannot be equipped with a heatsink. 2. Terminal block models (suffix “T”, “TF”, and “TF1”) cannot be equipped with a heatsink. 3. Only 0.200” pin length is available with terminal block options. 4. Models with EMI filter (suffix “TF” and “TF1”) meet EN55011, EN55022 Class A. 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: 04/30/2014 (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 9 of 9