DCHB200 SERIES 165~255 Watts, Half-Brick DC/DC Power Converters Rev F Standards Models Size: 2.40 x 2.28 x 0.50 inches Terminal Block Models (“T” suffix) Terminal Block w/ EMC Filter (“TF” suffix) Terminal Block w/ EMC Filter (“TF1” suffix) Size: 3.35 x 2.40 x 1.27 inches Size: 3.35 x 2.40 x 1.47 inches Size: 3.35 x 2.40 x 1.53 inches OPTIONS FEATURES • • • • • • • • • Soft-Start • Single Outputs Ranging from 3.3VDC to 53VDC • 2:1 Wide Input Voltage Ranges • Input to Output Basic Insulation: 2250VDC • 165~255 Watts Output Power • Threaded Inserts and Thru-Hole Inserts Available • No Minimum Load Requirements • Short Circuit, Over Voltage, Over Current, & Over Temp. Pin Length Sync Pin Case Pin 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 • Adjustable Output Voltage Protection • Remote On/Off Control • -40°C to +115°C Operating Case Temperature • Industry Standard Half-Brick Footprint • Compliant to RoHS EU Directive 2011/65/EU • High Efficiency up to 93% • CE Mark Meets 2006/95/EC, 2011/95/EC, and 2004/108/EC • Six-Sided Shielding • UL60950-1, EN60950-1, & IEC60950-1 Safety Approvals • Several Mechanical Options Available APPLICATIONS DESCRIPTION • • • • • • • The DCHB200 series of DC/DC power converters provides up to 255 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 53VDC with 2:1 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 DCHB200 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 control, terminal block, pin length, heatsinks, sync pin, case pin, and thru-hole inserts. Wireless Networks Measurement Equipment Telecom / Datacom Industry Control Systems Distributed Power Architectures Semiconductor Equipment Military Applications MODEL SELECTION TABLE Model Number Input Voltage DCHB200-12S3.3 12 VDC (9 - 22 VDC) DCHB200-12S05 DCHB200-12S12 DCHB200-12S15 12 VDC DCHB200-12S24 (8.5 - 22 VDC) DCHB200-12S28 DCHB200-12S48 DCHB200-24S3.3 DCHB200-24S05 DCHB200-24S12 24 VDC DCHB200-24S15 (16.5 - 36 VDC) DCHB200-24S24 DCHB200-24S28 DCHB200-24S48 DCHB200-48S3.3 DCHB200-48S05 DCHB200-48S12 DCHB200-48S15 48 VDC DCHB200-48S24 (33 - 75 VDC) DCHB200-48S28 DCHB200-48S48 DCHB200-48S53 09/04/2014 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 53 VDC Output Current Min. load Full load 0mA 50A 0mA 36A 0mA 15A 0mA 12A 0mA 7.5A 0mA 6.5A 0mA 3.7A 0mA 50A 0mA 40A 0mA 18A 0mA 15A 0mA 9A 0mA 7.5A 0mA 4.5A 0mA 60A 0mA 46A 0mA 21A 0mA 17A 0mA 10.5A 0mA 9A 0mA 5.2A 0mA 4.7A No Load (2) Input Current 25mA 90mA 90mA 55mA 70mA 55mA 75mA 20mA 35mA 45mA 45mA 40mA 50mA 50mA 20mA 20mA 25mA 25mA 25mA 25mA 25mA 25mA Ripple & Noise (3) (4) 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 300mVp-p Output Power 165W 180W 180W 180W 180W 182W 177.6W 165W 200W 216W 225W 216W 210W 216W 198W 230W 252W 255W 252W 252W 249.6W 249.1W Maximum Efficiency (3) Capacitive Load (5) 151000µF 87% 72000µF 90% 12500µF 90% 8000µF 90% 3100µF 90% 2300µF 90% 770µF 89% 151000µF 88% 80000µF 91% 15000µF 91% 10000µF 91% 3700µF 93% 2600µF 93% 930µF 91% 181000µF 90% 92000µF 91% 17500µF 91% 11300µF 93% 4300µF 92% 3200µF 92% 1000µF 92% 880µF 92% 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 DCHB200 SERIES 165~255 Watts, Half-Brick DC/DC Power Converters Rev F SPECIFICATIONS: DCHB200 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 33 12 12 24 48 Max Unit INPUT SPECIFICATIONS 12VDC nominal input models Input Voltage Range Start-Up Voltage Shutdown Voltage Input Surge Voltage (1sec, max.) Input Current Input Filter (See Note 1) Sync Pin Signal (See Note 2) OUTPUT SPECIFICATIONS Output Voltage Voltage Accuracy Line Regulation Load Regulation Voltage Adjustability Remote Sense (See Note 3) Output Power Output Current Minimum Load Maximum Capacitive Load Ripple & Noise (20MHz bandwidth) Transient Response Recovery Time Start-Up Time 3.3Vout & 5Vout models Other 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 -0.3 Low line to high line at full load No load to full load Maximum output deviation is inclusive of remote sense % of nominal Vout Constant resistive load Referenced to –Input pin Negative Logic (optional) Referenced to –Input pin 75 12Vout & 15Vout 100 24Vout & 28Vout 48Vout & 53Vout 200 300 200 75 75 Power Up Remote On/Off DC/DC ON DC/DC OFF DC/DC ON DC/DC OFF 09/04/2014 -0.5 VDC VDC VDC % % % % % mVp-p 250 µs +0.02 %/°C ms Open or 3~12 VDC Short or 0~1.2VDC Short or 0~1.2VDC Open or 3~12 VDC 1 3 mA mA Continuous, automatic recovery 120 150 % 115 130 % +120 °C -40 -40 -55 Module without assembly option Only mounted on iron base-plate 0.24” height heatsink 0.45” height heatsink +115 +105 +125 6.1 2.8 5.1 4.6 5 MIL-HDBK-217F, full load VDC % 3.3Vout & 5Vout Input Current of CTRL Pin Remote OFF Input Current PROTECTION Short Circuit Protection Over Load Protection % of rated Iout; hiccup mode 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 and natural convection (20LFM) VDC See Table -0.02 Positive Logic (standard) Relative Humidity Thermal Shock Vibration MTBF 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 Temperature Coefficient REMOTE ON/OFF CONTROL Thermal Impedance (See Note 4) -1.0 -0.1 -0.1 -20 22 22 36 75 9 18 34 8.1 16.3 32.5 30 50 100 See Table Pi type 5.6 95 MIL-STD-810F MIL-STD-810F 318,200 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] °C °C °C/W % RH hours Page 2 of 9 DCHB200 SERIES 165~255 Watts, Half-Brick DC/DC Power Converters Rev F SPECIFICATIONS: DCHB200 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 Isolation Voltage 1 minute (basic insulation) Isolation Resistance Isolation Capacitance PHYSICAL SPECIFICATIONS 500VDC Weight Dimensions (L x W x H) Min 225 2250 1600 1600 1 Input to Output Input to Case Output to Case Typ Max Unit See Table 250 275 kHz VDC GΩ pF 2500 Standard models “T” suffix models “TF” suffix models “TF1” suffix models Standard models “T” suffix models “TF” suffix models “TF1” suffix models 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 FR4 PCB Silicon (UL94-V0) Six-sided Case Material Base Material Potting Material Shielding SAFETY & EMC CHARACTERISTICS Safety Approvals EMI (See Note 5) EN55022 ESD Radiated Immunity Fast Transient (See Note 6) Surge (See Note 6) Conducted Immunity EN61000-4-2 EN61000-4-3 EN61000-4-4 EN61000-4-5 EN61000-4-6 Air ±8kV and Contact ±6kV 20 V/m ±2kV EN55024 ±2kV 10 Vrms IEC60950-1, UL60950-1, EN60950-1 Class A Class B 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. We recommend Nippon chemi-con KY series, 100μF/100V. 2. (1) Multiple DCHB200 series modules can be synchronized together simply by connecting the module SYNC pins together. Care should be taken to ensure the ground potential differences between the modules are minimized. (2) In this configuration all of the modules will be synchronized to the highest frequency module. (3) Up to three modules can be synchronized using this technique. (4) More relevant information in the application notes. 3. 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. 4. (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 7 for suffix options. 5. The DCHB200 standard models (without assembly options) can only meet EN55022 Class A or Class B with external components added. 6. An external input filter capacitor is required if the module has to meet EN61000-4-4, EN61000-4-5. We recommend connecting two aluminum electrolytic capacitors (Nippon chemi-con KY series, 220μF/100V) in parallel. 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 7. 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 7 for more ordering information. CAUTION: This power converter is not internally fused. An input line fuse must always be used. 09/04/2014 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 Rev F DCHB200 SERIES 165~255 Watts, Half-Brick DC/DC Power Converters DERATING CURVES DCHB200-48S05 Derating Curve (Note 4) DCHB200-48S05 Derating Curve with 0.24” Height Heatsink (Note 4) DCHB200-48S05 Derating Curve with 0.45” Height Heatsink (Note 4) EFFICIENCY GRAPHS DCHB200-48S05 Efficiency vs Input Voltage 09/04/2014 DCHB200-48S05 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 Rev F DCHB200 SERIES 165~255 Watts, Half-Brick DC/DC Power Converters MECHANICAL DRAWING Standard Models Product Options Suffix Negative Remote ON/OFF Logic 0.200” pin length 0.145” pin length RL Positive Remote ON/OFF Logic 0.200” pin length None Thru-Hole Inserts(1) 0.145” pin length Ø0.126 thru-hole (no thread) inserts Product Options H = 0.45” Vertical Fin R Heatsinks (1)(2) S TH Sync Pin(3) SY Case Pin(3) CP Suffix P/N: 7G-0021A-F H = 0.24” Horizontal Fin P/N: 7G-0022A-F H1 H = 0.24” Vertical Fin P/N: 7G-0023A-F H2 H = 0.45” Horizontal Fin P/N: 7G-0024A-F H3 Terminal Block Terminal Block(2)(3)(4)(5) H Terminal Block with Aluminum Base-plate and EMC Filter Terminal block with anodized aluminum base-plate and EMC filter, can be connected to protective earth (PE) T TF TF1 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. No “SY” or “CP” functions for terminal block types. 4. Only 0.200” pin length is available with terminal block options. 5. Models with EMC filter (suffix “TF” and “TF1”) meet EN55011, EN55022 Class A. 09/04/2014 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 Rev F DCHB200 SERIES 165~255 Watts, Half-Brick DC/DC Power Converters TERMINAL BLOCK OPTIONS Terminal Block with Aluminum Base-plate - Suffix “T” Terminal Block with Aluminum Base-plate and EMC Filter (EN55022 Class A) - Suffix “TF” Terminal Block with Anodized Aluminum Base-plate and EMC Filter (EN55022 Class A) and can be Connected to PE - Suffix “TF1” 09/04/2014 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 6 of 9 DCHB200 SERIES 165~255 Watts, Half-Brick DC/DC Power Converters Rev F HEATSINK OPTIONS Vertical Fin Orientation (Suffixes “H”, “H2”) Horizontal Fin Orientation (Suffixes “H1”, “H3”) 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 ∆% MODEL NUMBER SETUP DCHB 200 Series Name Output Power - 200: 200 Watts 24 S 12 R Input Voltage Output Quantity Ouptut Voltage Remote On/Off & Pin Length 12: 8.5 - 22 VDC 9 - 22 VDC 24: 16.5 - 36 VDC 48: 33 - 75 VDC S: Single 3.3: 05: 12: 15: 24: 28: 48: 53: 3.3 VDC 5 VDC 12 VDC 15 VDC 24 VDC 28 VDC 48 VDC 53 VDC None: S: R: RL: positive Logic, 0.200” pin length positive Logic, 0.145” pin length negative Logic, 0.200” pin length negative Logic, 0.145” pin length Y C TH H TF Sync Pin (3) Case Pin (3) Thru-Hole Inserts (1) Heatsink (1) (2) Terminal Block (2) (3) (4) (5) SY: sync pin CP: case pin None: threaded inserts TH: Ø0.126 thru-hole inserts None: no heatsink H: 0.45” vertical H1: 0.24” horizontal H2: 0.24” vertical H3: 0.45” horizontal None: no terminal block T: Terminal block with aluminum base-plate Terminal block with aluminum base-plate and EMC TF: 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. No “SY” or “CP” functions for terminal block types. 4. Only 0.200” pin length is available with terminal block options. 5. Models with EMC filter (suffix “TF” and “TF1”) meet EN55011, EN55022 Class A. 09/04/2014 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 F DCHB200 SERIES 165~255 Watts, Half-Brick DC/DC Power Converters APPLICATION NOTES Assembly 09/04/2014 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 Rev F DCHB200 SERIES 165~255 Watts, 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: 09/04/2014 (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