27 to 30 Watt LE Triple Series DC/DC Converters Features ! Triple Output ! Wide 4:1 Input Voltage Range (9-36 or 18-72 VDC) ! High Efficiency, up to 85% ! No Derating to 85°C Case Temperature ! LC Input Filter, Dual Section Output Filters ! PCB Mounting With Optional Heat Sink and Chassis Mounting Kit ! Five Year Warranty Description Selection Chart The 4:1 input range of the LE Triple Series makes them ideal for a wide variety of power requirements including battery and unregulated input applications. Each converter’s +5V is tightly regulated and useful for driving standard logic circuits. Model 12T5.12LE 12T5.15LE 48T5.12LE 48T5.15LE These 27-30 Watt converters have dual output filters. They provide a low output noise of 50 mV P-P typical and are fully specified and tested to the maximum specifications. Input filtering significantly reduces the reflected ripple noise. Input Range VDC Min Max 9 9 18 18 36 36 72 72 Outputs VDC Outputs mA 5, ±12 5, ±15 5, ±12 5, ±15 3000, ±500 3000, ±400 3000, ±625 3000, ±500 Unlike comparable converters, all inputs and outputs are protected from transient overvoltage conditions. Overload protection is provided by current sensing of the primary switching current and an independent thermal sensor. The 27-30 Watt Triple Series, like all CALEX converters, carries the full 5 Year CALEX Warranty. 27-30 Watt Triple Series Block Diagram A 2401 Stanwell Drive • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 1 3/2001 27 to 30 Watt LE Triple Series DC/DC Converters Input Parameters* Model 12T5.12LE Voltage Range Reflected Ripple (2), 0-20MHz bw Input Current Full Load No Load Efficiency Switching Frequency Maximum Input Overvoltage, 100ms No Damage Turn-on Time MIN MAX TYP TYP TYP TYP 12T5.15LE 48T5.12LE 9.0 36.0 200 2715 12 83 48T5.15LE 18.0 72.0 165 735 14 85 TYP VDC mA P-P mA % 100 MAX 45 TYP 60 kHz 85 VDC 45 Recommended Fuse Units mSec (3) AMPS Output Parameters* 12T5.12LE 48T5.12LE Model Output Voltage Rated Load (4) 12T5.15LE 48T5.15LE MIN MAX MIN TYP MAX +5 750 3000 4.950 5.000 5.050 TYP 12T5.12LE 48T5.12LE 12T5.15LE ±12 125 500 48T5.15LE ±15 160 625 100 400 Units VDC 125 500 mA 11.600 12.000 12.400 14.500 15.000 15.500 VDC N/A 0.3 0.3 % Cross Regulation (6) Line Regulation Vin = Min-Max VDC Short Term Stability (7) TYP MAX TYP TYP MAX TYP 1.2 2.0 0.3 0.1 0.5 < 0.02 1.5 3.0 3.1 0.3 1.0 < 0.1 1.1 3.0 3.1 0.3 1.0 < 0.1 % Long Term Stability TYP < 0.2 < 0.3 < 0.3 %/kHrs Transient Response (8) TYP 350 Never Exceeds 1% Never Exceeds 1% Dynamic Response (9) TYP TYP MAX TYP MAX TYP 130 50 100 50 150 6.8 Voltage Range 100% Load Output Balance (Plus to Minus Output, Full Load) Load Regulation Min-Max (5) Noise, 0-20MHz bw (10) Temperature Coefficient Overvoltage Clamp (11) Short Circuit Protection to CMN for all Outputs 60 60 35 35 70 70 50 50 200 200 15 18 Provides continuous protection with current limiting and thermal overload techniques NOTES parameters measured at Tc=25°C, nominal input voltage * All and full rated load unless otherwise noted. Refer to the CALEX Application Notes for the definition of terms, measurement circuits and other information. (2) Noise is measured per CALEX Application Notes found in the CALEX Power Conversion Design Guide & Catalog. Measurement bandwidth is 0 - 20 MHz. See the applications section of this note for more information. Input reflected ripple is measured with a 3.3 to 33µF, 0.5 to 5 ohm ESR, 100 Volt aluminum electrolytic capacitor connected directly across the input pins. (3) Refer to the CALEX Application Notes for information on fusing. (4) Optimum performance is obtained when this power supply is operated within the minimum to maximum load specifications. With other load currents the output voltage may be outside of the specification limits. Tests should be run for the specific application. (5) Dual output regulation is specified by simultaneously changing both ±12V or ±15V outputs from minimum to maximum load and noting the change in each output. (6) Cross regulation is defined as the change in one output when only one of the other outputs is changed from maximum to minimum load. (7) (8) (9) (10) (11) (12) (13) (14) % % % µSec mV peak mV P-P ppm/°C VDC A Short term stability is specified after a 30 minute warm up at full load, constant line, load and ambient conditions. Transient response is defined as the time for the output to settle from a 50 to 75% step load change to a 1% error band (rise time of step = 2µs). Dynamic response is defined as the peak overshoot during a transient as defined in note 8 above. A 1µF 35V Tantalum capacitor is connected from each output pin to the CMN pin, directly at the converter. Noise is measured per CALEX application notes. Measurement bandwidth is 0 20MHz. 500 Watt peak pulse power transient suppression diodes used. The functional temperature range is intended to give an additional data point for use in evaluating this power supply. At the low functional temperature the power supply will function with no side effects. Sustained operation at the high functional temperature will reduce the expected operational life. The data sheet specifications are not guaranteed over the functional temperature range. The case thermal impedance is specified as the case temperature rise over ambient per package watt dissipated. Specifications subject to change without notice. 2401 Stanwell Drive • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 2 3/2001 27 to 30 Watt LE Triple Series DC/DC Converters General Specifications* All Models Units Isolation Isolation Voltage Input to Output 12T Input to Output 48T 10µA Leakage MIN MIN 700 1544 VDC Input to Output Capacitance TYP 350 pF MIN MAX MIN Case Functional Range (12) MAX MIN Storage Range MAX Thermal Impedance (13) TYP Thermal Shutdown TYP Case Temperature -25 85 -40 90 -40 105 4.4 °C/Watt 95 °C Environmental Case Operating Range No Derating °C °C °C BOTTOM VIEW SIDE VIEW Mechanical tolerances unless otherwise noted: X.XX dimensions: ±0.020 inches General Unit Weight 7 X.XXX dimensions: ±0.005 inches oz Seal around terminals is not hermetic. Do not immerse units in any liquid. Mounting Options MS9 Chassis Mounting Kit - I Suffix on Part Number - HS Pin 1 2 3 4 5 6 Inserts In Case Heat Sink Option Heat Sink Option The 27-30 Watt Triple can be ordered with a “-I” configuration which provides 3 inserts on the top surface of the case for attaching a heat sink. When ordered with an “-HS” configuration, CALEX will ship the converter with the heat sink attached. The CALEX heat sink was specially developed for this model and will reduce the case temperature rise to below 3.3°C/W with natural convection and even lower with moving air. Function +INPUT -INPUT +12/15V CMN -12/15V +5V Customer installed heat sinks may also be used. It is recommended that only liquid heat sink compound be used on the heat sink interface. Avoid so called “Dry” pad heat sink materials. In our experience these materials are actually worse than using no compound at all. A Chassis Mounting Kit - MS9 C1-C3=1µF/35V, TANTALUM The MS9 chassis mounting kit allows for direct wire connection through two barrier strips. The MS9 may be conveniently attached to a chassis by using the 4-0.156 inch diameter mounting holes provided in each corner. Although the MS9 comes with solderless sockets, it is recommended that the converter be soldered to the mounting kit for improved reliability under severe environmental or vibration conditions. Typical Application Figure 1 shows the recommended connections for the 27-30 Watt Triple DC/DC converter. A fuse is recommended to prevent unlimited current flow in the event of a system failure and to protect the DC/DC converter input circuit. 2401 Stanwell Drive • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 3 3/2001 27 to 30 Watt LE Triple Series DC/DC Converters Figure 3. Low Noise Input Filter Circuit Case Grounding L1-L3 =5µH C1-C3 =1µF/35V, TANTALUM C4-C6 =10µF/35V, TANTALUM C7-C9 = 0.01µF, CERAMIC The case serves not only as a heat sink but also as an EMI shield. The case/header shield is tied to the +Input pin as shown in the block diagram. Figure 2. Low Noise Output Filter Circuit Temperature Derating / Mounting Options Extra output filtering can be added to further reduce the noise. The optional circuit shown in Figure 2 can reduce the +5V noise to less than 10 mV P-P, and the ±V output noise to less than 15 mV P-P. Use an inductor for L1 that is rated for 3 Amps DC minimum, and 650 mA DC minimum for L2 and L3. The LE Triple Series can operate up to 85°C case temperature without derating. The case temperature may be roughly calculated from ambient by knowing that the LE Triple’s case temperature rise is 4.4°C per package Watt dissipated. For example, if the converter was functioning at an output of 30 Watts, at what ambient could it expect to run with no moving air and no additional heat sinks? Low Noise Input Filtering Circuit Efficiency is approximately 85% which calculates to an input power of 35 Watts. 35 - 30 = 5 Watts dissipated internally in the package. The case temperature rise would be 5 Watts x 4.4 = 22°C. The 22°C is subtracted from the maximum case temperature of 85°C so, in this example, the unit can operate up to a 63°C ambient. The circuit of Fig 3 can be added to reduce the input reflected ripple current to less than 50 mA P-P (12V models) and less than 30 mA P-P (48V models). For L4, use a 5µH-4 Amp DC inductor for 12V models, and a 20µH-2 Amp DC inductor for 48V models. C10 and C11 are 10µF/100V and can be nearly any 105°C rated capacitor. To prevent input filter peaking the ESR should be in range of 0.5 to 2 ohms. Do not use a low ESR capacitor for this part as peaking of the filter’s transfer function may occur and render the filter ineffective. This is a rough approximation of the maximum ambient temperature. Because of the difficulty of defining ambient and the possibility that the load’s dissipation may actually increase the local ambient temperature significantly, these calculations should be verified by actual measurement before committing to a production design. Typical Performance (Tc=25°C, Vin=Nom VDC, Rated Load). 12 VOLT EFFICIENCY Vs. LOAD 12 VOLT EFFICIENCY Vs. LINE INPUT VOLTAGE 12 VOLT INPUT CURRENT Vs. LINE INPUT VOLTAGE 90 90 5 85 100% LOAD 85 INPUT CURRENT(AMPS) EFFICIENCY(%) EFFICIENCY(%) LINE = 12VDC 50% LOAD LINE = 9VDC LINE = 36VDC 80 75 80 5 10 15 20 25 30 35 10 20 30 40 50 60 70 80 90 100 100% LOAD 80 85 80 LINE INPUT(VOLTS) 70 80 20 25 30 35 40 2 100% LOAD 1 50% LOAD LINE = 72VDC 75 75 15 48 VOLT INPUT CURRENT Vs. LINE INPUT VOLTAGE LINE = 18VDC LINE = 48VDC 60 10 3 INPUT CURRENT(AMPS) EFFICIENCY(%) 85 50 5 LINE INPUT(VOLTS) 50% LOAD EFFICIENCY(%) 0 90 40 50% LOAD 1 48 VOLT EFFICIENCY Vs. LOAD 48 VOLT EFFICIENCY Vs. LINE INPUT VOLTAGE 90 30 100% LOAD 2 LOAD(%) LINE INPUT(VOLTS) 20 A 3 0 0 40 4 0 0 10 20 30 40 50 60 LOAD(%) 70 80 90 100 0 10 20 30 40 50 60 70 80 LINE INPUT(VOLTS) 2401 Stanwell Drive • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 4 3/2001