10 Watt TC Dual Series DC/DC Converters Features Description ! 3:1 Extra Wide Input Voltage Range, 20-60 VDC ! Low Noise, Highly Regulated Dual Outputs ! Efficiency > 72% for All Line Conditions These converters provide low noise bipolar outputs from a wide range of input voltages. The converters’ small 2.02" x 1.62" size makes them ideal for telecommunications, instrumentation or industrial control applications. ! No Derating to 80°C Case Temperature ! Six-sided Shielded Low Thermal Gradient Copper Case ! 700 VDC Minimum Input to Output Isolation ! Overvoltage Protected Input and Outputs ! Pulse-by-pulse Digital Current Limiting ! Overtemperature Protection Circuit ! 5 Year Warranty The dual outputs are cross regulated with a high loop gain current mode control method that provides good regulation with a true, high efficiency switching DC/DC topology. The large amount of loop gain insures excellent input ripple rejection and line transient response. Also included is a logic (open collector TTL / CMOS compatible) shutdown pin to control converter operation. The modules in the TC Dual Series are protected from output shorts by a high speed, pulse-by-pulse, digital current limit circuit and a thermal overload sensing circuit. The input and output are overvoltage protected. Selection Chart Model Input Range VDC MIN MAX Outputs VDC Outputs mA 48D12.400TC 20.0 60.0 ±12 400 48D15.350TC 20.0 60.0 ±15 350 10 Watt Dual Series Block Diagram SHIELDED ISOLATION TRANSFORMER THERMAL SHUTDOWN + INPUT 3 - INPUT 2 10µF A 10µF 10µF CURRENT MODE PWM 4 + OUTPUT 5 CMN 6 - OUTPUT 7 TRIM ON/OFF 1 LOW TC BANDGAP REFERENCE SIX-SIDED SHIELDED COPPER CASE Manufacturing Company, Inc. • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 1 10 Watt TC Dual Series DC/DC Converters Input Parameters* Model Voltage Range Reflected Ripple (2) (3), 0-20Mhz bw Input Current Full Load No Load Efficiency Switching Frequency Maximum Input Overvoltage, 100ms No Damage Turn-on Time, 1% Output Error MIN MAX TYP TYP TYP TYP 48D12.400TC 20.0 60.0 48D15.350TC 20.0 60.0 700 250 6 79 Units VDC mA RMS 285 6 75 mA % TYP 120 kHz MAX 75 VDC 10 ms TYP Recommended Fuse (4) Output Parameters* Model 48D12.400TC Output Voltage Rated Current (5) Voltage Range 100% Load Output Balance (Plus to Minus Output, Full Load) Load Regulation Min-Max Full Load (5) Cross Regulation, Min-Max Load (6) Line Regulation Vin = Min-Max VDC Short Term Stability (7) Long Term Stability Transient Response (8) Dynamic Response (6) Input Ripple Rejection (10) Noise, 0-20MHz bw (2) Temperature Coefficient Overvoltage Clamp (11) Short Circuit Protection to Common for all Outputs MIN MAX MIN TYP MAX TYP MAX TYP MAX TYP MAX TYP MAX TYP TYP TYP TYP TYP TYP MAX TYP MAX TYP 48D15.350TC Units ±12 ±15 VDC 100 90 mA 400 350 11.900 14.900 12.000 15.000 VDC 12.100 15.100 0.1 0.1 % 0.5 0.5 0.1 0.1 % 0.5 0.5 1.0 1.3 % 2.0 2.5 0.1 0.1 % 0.2 0.2 0.02 0.02 % 0.2 0.2 %/kHrs 200 200 µs 135 125 mV peak >60 >60 dB 20 20 mV P-P 50 50 50 50 ppm/°C 150 150 15 18 VDC Provides minimum of 8 hours continuous protection with current limiting and thermal overload protection 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 our Power conversion Design Guide and Catalog. (3) An external capacitor capable of withstanding at least 700 mA RMS of 120 kHz ripple current must be connected directly across the + and - inputs. Suggested capacitors are: Sprague Electric: 672D686H100DM3C, 68µF, 100V 672D127H100ET3C, 120µF, 100V Panasonic: ECEA2AFE101, 100µF, 100V ECEA2AFE121, 120µF, 100V United Chemi-Con: SXE100VB120M12.5X25LL, 120µF, 100V SXE100VB180M12.5X30LL, 180µF, 100V SXE100VB220M12.5X35LL, 220µF, 100V Note:All of the above capacitors are 105°C Rated. Multiple smaller sized capacitors may be used in parallel as long as their total ripple capability is above 700 mA RMS (see IRR curve). A (4) Determine the correct fuse size by calculating the maximum DC current drain at low line input, maximum load and then adding 20 to 25% to get the desired fuse size. A slow blow type fuse is recommended. (5) Load regulation for the outputs is specified as the voltage change when both outputs are changed from maximum to minimum load at the same time. Minimum load is required for specified regulation only. The converter can be run at no load on either or both outputs with no damage. (6) Cross regulation is defined as the change in one output when the other output is changed from maximum to minimum load. (7) Short term stability is specified after a 30 minute warm-up at full load, constant line and recording the drift over a 24 hour period. (8) The transient response is specified as the time required to settle from a 50 to 75 % step load change (rise time of step = 2 µSec) to a 50 mV error band. (9) Dynamic response is the peak overshoot during a transient as defined in note 8 above. (10) The input ripple rejection is specified for DC to 120 Hz ripple with a modulation amplitude of 1% of Vin. Manufacturing Company, Inc. • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 2 10 Watt TC Dual Series DC/DC Converters General Specifications * All Models ON/OFF Function (12) ON Logic Level or Leave Pin Open Off Logic Level Input Resistance Converter Idle Current ON/OFF Pin Low Isolation (13) Isolation Voltage 10µA Leakage Input-Output Input to Output Capacitance Output Trim Function Input Resistance Programming Range Units MIN 8.0 VDC MAX TYP 2.0 100 VDC kohms TYP 1 mA MIN 700 VDC BOTTOM VIEW TYP 60 SIDE VIEW pF Mechanical tolerances unless otherwise noted: TYP MIN 35 ±10 MIN MAX MIN Case Functional Range (14) MAX MIN Storage Range MAX Thermal Impedance (15) TYP Thermal Shutdown TYP Case Temperature General -25 80 -40 90 -55 105 10 °C/Watt 90 °C Unit Weight 1.9 oz Environmental Case Operating Range No Derating TYP X.XX dimensions: ±0.020 inches kohms % X.XXX dimensions: ±0.005 inches Seal around terminals is not hermatic. Do not immerse unts in any liquid. °C °C Pin 1 2 3 4 5 6 7 °C Function ON/OFF -INPUT +INPUT +OUTPUT OUTPUT CMN -OUTPUT TRIM (11) For module protection only, see also note 4. (12) The logic ON/OFF pin is Open Collector TTL, CMOS, and relay compatible. The input to this pin is referenced to Pin 2, -Input and is protected to +100 VDC. (13) Case is tied to Pin 3, + Input. (14) 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, however, sustained operation at the high functional temperature will reduce expected operational life. The data sheet specifications are not guaranteed over the functional temperature range. (15) The case thermal impedance is specified as the case temperature rise over ambient per package watt dissipated. Low Noise Input Circuit Connections for Output Trim See note 3 for capacitor recommendations and note 4 for fuse sizing. The circuit shown below will reduce reflected ripple to 50 mA P-P. Keep all components as close to the converter as possible The inductor is 35 turns on a Micro-Metals T50-26 Iron Powder Core. A Use one resistor for either trim up or trim down. The values can range from infinity to zer ohms with zero ohms giving the most trim. + OUT 4 TRIM 7 - OUT 6 USING TRIMPOT + OUT 4 100K TRIM 7 - OUT 6 THIS CAPACITOR IS REQUIRED FOR PROPER OPERATION FUSE TRIM DOWN 40µH, 700mA 3 + INPUT TRIM UP TO INPUT SOURCE USING FIXED RESISTORS SEE NOTE 3 2 - INPUT Manufacturing Company, Inc. • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 3 10 Watt TC Dual Series DC/DC Converters Typical Performance (Tc=25°C; Vin=48VDC, Full Rated Load 48D12.400TC EFFICIENCY Vs LINE INPUT 48D12.400TC INPUT CURRENT Vs LINE INPUT VOLTAGE 48D12.400TC EFFICIENCY Vs LOAD 85 83 0.70 82 EFFICIENCY (%) EFFICIENCY (%) 80 79 100% FULL LOAD 78 LINE = 20VDC 80 FULL LOAD 77 76 75 LINE = 48VDC INPUT CURRENT (AMPS) 50% 81 LINE = 60VDC 70 65 74 60 20 25 30 35 40 45 50 55 60 100% FULL LOAD 0.40 0.30 0.20 50% FULL LOAD 0.00 20 40 LINE INPUT (VOLTS) 60 80 100 0 10 20 LOAD (%) 48D15.400TC EFFICIENCY Vs LINE INPUT 30 40 50 60 LINE INPUT (VOLTS) 48D15.350TC INPUT CURRENT Vs LINE INPUT VOLTAGE 48D15.350TC EFFICIENCY Vs LOAD 85 81 0.80 80 EFFICIENCY (%) 78 100% FULL LOAD 77 50% FULL LOAD 76 75 74 INPUT CURRENT (AMPS) 0.70 80 79 EFFICIENCY (%) 0.50 0.10 75 LINE = 20VDC 75 LINE = 48VDC 70 LINE = 60VDC 65 0.60 0.50 100% FULL LOAD 0.40 0.30 0.20 50% FULL LOAD 0.10 73 72 60 20 25 30 35 40 45 50 55 60 0.00 20 40 LINE INPUT (VOLTS) 60 80 100 0 10 20 LOAD (%) INPUT RIPPLE Vs. LINE INPUT 30 40 50 60 LINE INPUT (VOLTS) OUTPUT VOLTAGE Vs. LOAD OUTPUT IMPEDANCE Vs. FREQUENCY 10 110 1.0 100 0.6 0.4 0.2 90 IMPEDANCE (OHMS) 0.8 NOMINAL OUTPUT (%) REFLECTED RMS RIPPLE (A) 0.60 80 70 60 50 40 30 1.0 0.1 20 10 0.01 0 0.0 20 25 30 35 40 45 50 55 60 0 100 200 300 400 500 600 700 10 100 LOAD (%) LINE INPUT (VOLTS) 1K 10K 100K 1MEG FREQUENCY (Hz) A TC SERIES POWER DERATING OUTPUT VOLTAGE Vs CASE TEMPERATURE 0.10 INFINITE HEAT SINK ↓ 10 NORMALIZED OUTPUT (%) OUTPUT POWER (WATTS) 12 STILL AIR 8 ↑ 6 ←SAFE OPERATING AREA→ ↓ 4 2 0 0.05 0.00 -0.05 -0.10 -0.15 -0.20 -25 -15 -5 5 15 25 35 45 55 65 75 85 -40 AMBIENT TEMPERATURE (Deg C) -20 0 20 40 60 80 CASE TEMPERATURE (Deg C) Manufacturing Company, Inc. • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 4