55 Watt K Triple Series DC/DC Converters Features Description n Very Low Noise, < 50 mV P-P Maximum n PCB Mounting with Optional Heat Sink or Chassis Mount Versions n Efficiencies to 87% n Common and Differential Mode Input Filtering n Remote Sense On +5 Volt Output n Single and Dual Outputs are Isolated From Each Other The 55 Watt Triple Series consists of separate power sections for the single and dual outputs. These power sections are operated in anti-phase to each other to reduce the ripple current stress on the input components and the reflected input ripple. The main benefit of two separate power sections is the excellent regulation achieved by all outputs. An order of magnitude regulation improvement is obtained over competitive designs. There is no cross regulation between +5 output and the dual outputs. This means that the dual output voltages are independent of the +5 Volt loading and visa versa. n No derating to 80°C Case Temperature n Five Year Warranty Excellent noise performance is attained by using a 0.040 inch thick aluminum case, pot core and toroidal magnetics, double shielded transformers and both normal mode and common mode input filtering. The input and outputs are protected from overvoltage by transient voltage suppressor diodes. The outputs are protected from faults with pulse by pulse digital current limiting. Selection Chart Model Input Range VDC Min Max Outputs VDC Outputs mA 12T5.12K 9.0 18.0 5, ±12 5000, ±1250 12T5.15K 9.0 18.0 5, ±15 5000, ±1000 24T5.12K 18.0 36.0 5, ±12 5000, ±1250 24T5.15K 18.0 36.0 5, ±15 5000, ±1000 48T5.12K 36.0 72.0 5, ±12 5000, ±1250 48T5.15K 36.0 72.0 5, ±15 5000, ±1000 55 Watt Triple Series Block Diagram DOUBLE SHIELDED ISOLATION TRANSFORMER SINGLE SECTION 10 +5V OUTPUT THERMAL SHUTDOWN ) + INPUT 4 + INPUT 5 - INPUT 2 COMMON & DIFFERENTIAL MODE INPUT FILTER 9 +5 CMN 11 +5V SENSE ANTI-PHASE DUAL PWM CONTROLLER ISOLATION BARRIER 8 +5V CMN SENSE 14 +DUAL OUTPUT - INPUT 3 13 DUAL CMN ON/OFF 6 1.5M || 0.01µF 12 -DUAL OUTPUT CASE 7 SHIELDED, LOW THERMAL GRADIENT ALUMINUM 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 D-134 DUAL SECTION 55 Watt K Triple Series DC/DC Converters Input Parameters* Model 12T5.12K 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, 1% Output Error MIN MAX TYP MAX TYP TYP TYP 12T5.15K 9.0 18.0 110 250 5630 50 81 24T5.12K 24T5.15K 18.0 36.0 60 150 2715 35 85 TYP 38T5.12K 48T5.15K 36.0 72.0 35 80 1325 30 87 80 MAX 23 TYP VDC mA P-P mA % kHz 45 Recommended Fuse Units 85 VDC 70 ms (3) AMPS Output Parameters* 12T5.12K 24T5.12K 48T5.12K Output Voltage Rated Current (4) Voltage Range 100% Load (5) Output Balance (Plus to Minus Output, Full Load) Load Regulation 25%-100% 1-100% Cross Regulation (6) Line Regulation Vin = Min-Max VDC Short Term Stability (7) Long Term Stability Transient Response (8) Dynamic Response (9) Input Ripple Rejection (10) Noise, 0-20MHz bw 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 MAX TYP TYP TYP TYP TYP TYP MAX TYP MAX TYP 12T5.15K 24T5.15K 48T5.15K 12T5.12K 24T5.12K 48T5.12K 12T5.15K 24T5.15K 48T5.15K ±12 310 1250 11.925 12.000 12.075 0.5 0.7 0.8 1.2 2.0 4.0 0.8 1.2 0.02 0.2 0.02 ±15 250 1000 14.925 15.000 15.075 0.5 0.7 0.7 1.2 2.0 4.0 0.7 1.2 +5 50 5000 4.950 5.000 5.050 N/A 0.02 0.2 0.02 0.2 N/A N/A Units VDC mA VDC % % % % % 0.2 %/kHrs 500 400 400 µs 250 250 200 mV peak 25 15 15 dB 15 mV P-P 50 50 50 50 ppm/°C 100 200 200 6.8 15 18 VDC Provides minimum of 8 hours continuous protection with current limiting and thermal overload techniques ) NOTES parameters measured at Tc = 25 °C, nominal input * All voltage 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. Measurement bandwidth is 0 - 20 MHz. (3) 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. For reverse voltage protection on the input this fuse must be used. (4) Minimum load is required for rated regulation only, no module damage will occur if the output is run at less than minimum load. Maximum output power on the dual section is 30 Watts (i.e. one output can draw 30 Watts and the other 0 Watts). Regulation degrades with substantial loading unbalance. (5) The remote sense pins must be connected to their respective output pins for proper output voltage and regulation. The combined drop on each output line to it’s respective remote sense pin must be less than 0.3 volts or 0.6 volts for both sense lines combined. (6) Cross regulation is defined as the change in one output when the other output is changed from minimum to maximum load. (7) Short term stability is specified after a 30 minute warm-up at full load, constant line, load and ambient conditions. (8) Transient response is defined as the time for the output to settle from a 50 to 75% step load change to a 2% error band (rise time of step = 2µ Sec). (9) Dynamic response is defined as 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 D-134 Model 55 Watt K Triple Series DC/DC Converters Heat Sink Option (-HS suffix) General Specifications* All Models Unit Weight Mounting Kits 4.5 VDC 1.2 2 VDC k ohms 25 mA 1544 700 250 1544 VDC BOTTOM VIEW 100 150 75 pF -25 80 -40 90 -40 100 °C 2.7 1.8 (14) °C/Watt 90 °C 14 oz. °C °C Chassis Mount Option (-CM suffix) See Case Options (11) For module protection only, see also note 3. (12) The ON/OFF pin is Open Collector TTL, CMOS, and relay compatible. The input to this pin is referenced to -Input (pin 2). (13) 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. (14) The case thermal impedance is specified as the case temperature rise over ambient per package watt dissipated. The thermal resistance of the Chassis Mount version depends on the mounting surface. If the mounting surface is a poor thermal conductor the thermal resistance can be as high as 2.7° C/watt. If the mounting surface is an excellent thermal conductor the thermal resistance can be below 1°C/watt. ) Mechanical tolerances unless otherwise noted: X.XX dimensions: ±0.020 inches X.XXX dimensions: ±0.005 inches Seal around terminals is not hermetic. Do not immerse units in any liquid. Pin 1 2 3 4 5 6 7 Mounting Configuration Options To order the optional heat sink on the pin mount version place a “-HS” suffix on the part number. To order the chassis mount version place a “-CM” suffix on the part number. The heat sink and chassis mount options cannot be used together. Function NO PIN -INPUT -INPUT +INPUT +INPUT ON/OFF CASE Pin 8 9 10 11 12 13 14 Function +5V CMN SENSE +5V CMN +5V OUTPUT +5V SENSE -DUAL OUTPUT DUAL CMN +DUAL OUTPUT 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 D-134 ON/OFF Function (12) ON Logic Level MIN or Leave Pin Open OFF Logic Level MAX Input Resistance TYP Converter Idle Current, TYP ON/OFF Pin Low Isolation Isolation Voltage Input to Either Output MIN Single to Dual Output MIN Input-Case MIN Either Output to Case MIN 10µA Leakage Input to Output Capacitance Input to Single Output TYP Input to Dual Output TYP Single to Dual Output TYP Environmental Case Operating Range MIN No Derating MAX MIN Case Funtional Range (13) MAX MIN Storage Range MAX Thermal Impedance (14) Pin Mount Version TYP Option -HS (Heat Sink) TYP Option -CM (Chassis Mount) Thermal Shutdown TYP Case Temperature General Units 55 Watt K Triple Series DC/DC Converters Application Guidelines Dual Output Inputs The dual outputs are cross regulated to each other but independent of the loading on the single output. The dual output uses a cross regulation scheme where the plus and minus output voltage is regulated as an average voltage. This allows improved regulation on both outputs. If the outputs are loaded equally and the regulation is checked, then the apparent regulation is much closer to 0.5%. This data shows the worst case result of changing each output independently. The output common on the dual section is electrically isolated from the +5 volt section to aid in proper system grounding. If 24 volts or 30 volts are required, then the appropriate output can be connected to the system ground and the output current can be taken from the other output. In this situation the dual section’s common pin (Pin 13) should be left unconnected. Full output power (30 watts) is available in this configuration. Figure 3 shows the dual output connections. The input should be fused as per note number 3. The case is connected to the -INPUT pins through 1.5 Megohms in parallel with 0.01µF. The case may be left floating in most applications. The noise performance of the converter may improve or degrade with the case connected to other inputs or outputs depending on your system grounding. The remote ON/OFF pin may be left floating if it is not used. See “Understanding the Remote ON/OFF Function” application note for more information on this feature. The dual input pins (2,3 and 4,5) should be paralleled to share the input current. Figure 1 shows the recommended input connections. FUSE 4 +INPUT 5 +DUAL OUTPUT 14 SOURCE +LOAD 2 -INPUT DUAL CMN 13 3 -LOAD Figure 1. Parallel both + and -INPUT pins. Fusing the input is recommended. -DUAL OUTPUT 12 Single Output Figure 3. The single output is independent of the loading on the dual output section. The single output also features provisions for remote sense connections. These allow the power supply to correct for line drops of up to 0.3 volts per leg or 0.6 volts total. The remote sense connections should be made with twisted pair wire or closely coupled PCB traces. There is approximately 2mA of current flowing in the remote sense lines. If the remote sense is not to be used, these pins must be connected to their respective output pins for proper output voltage accuracy and regulation. See “Applying the Remote Sense and Trim Functions On DC/DC Converters” application note for more information. The output common on the single section is electrically isolated from the dual section to aid in proper system grounding. Figure 2 shows the single output connections with remote sense. The dual outputs can also be used with substantial unbalance and as single-ended outputs by leaving Pin 13 unconnected. Mounting Guidelines The 55 Watt Triple Series can be supplied in either a pin mount version or a chassis mount (screw terminal) version. It is suggested that when using the pin mount version, the 4-40 hold down screws provided in the bottom of the case be used to secure the unit to the PCB. These screws should be tightened before soldering to avoid solder joint stress. The chassis mount version can be mounted on its back with the four 4-40 hold down screws provided. The mounting surface should be flat to within 0.01 inches to prevent warping the case. The mounting can then serve as additional heat sinking. For optimum heat sinking, silicone grease is recommended over the so called “dry pads.” Additional heat sinking will lower internal temperatures and increase the expected life. When chassis mounting remember that the case is connected to the - INPUT pins through 1.5 Megohms in parallel with 0.01µF. The breakthrough voltage of this connection is greater than 250VDC. ) +5V OUTPUT 10 +5V SENSE 11 LOAD +5V CMN SENSE 8 +5V CMN 9 Figure 2. The remote sense pins must be connected to their respective outputs. If the remote sense feature is not used, connect the sense pins to their outputs directly at the converter. 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 D-134 The “-HS” heat sink option lowers the thermal resistance from 2.7 to 1.8°C/Watt dissipated. It also increases the heat removing efficiency of any cooling air flow. If the 55 Watt Triple is to be placed in a small enclosure where the power delivered to the load or the power dissipated in the 55 Watt Triple converter can raise the ambient temperature then care must be taken to insure that the case temperature does not exceed the 80°C limit for proper operation. 55 Watt K Triple Series DC/DC Converters Typical Performance (Tc=25°C, Vin=48 VDC, Rated Load). 12T5.XXK EFFICIENCY Vs. LOAD 86 12T5.XXK EFFICIENCY Vs. LINE INPUT 85 LINE = 12VDC 84 84 EFFICIENCY (%) EFFICIENCY (%) 82 80 LINE = 78 LINE = 18VDC 76 9VDC 74 50% FULL LOAD 83 82 100% FULL LOAD 81 80 79 72 70 78 10 20 30 40 50 60 70 80 90 100 9 10 11 12 LOAD (%) 14 15 16 17 18 LINE INPUT (VOLTS) 12T5.XXK INPUT CURRENT Vs. LINE INPUT VOLTAGE 24T5.XXK EFFICIENCY Vs. LOAD 90 9 LINE = 24VDC 8 LINE = 18VDC 85 7 6 EFFICIENCY (%) INPUT CURRENT (AMPS) 13 100% FULL LOAD 5 4 50% FULL LOAD 3 80 75 LINE = 36VDC 2 70 1 0 65 6 8 10 12 14 16 18 10 20 30 40 LINE INPUT (VOLTS) 24T5.XXK EFFICIENCY Vs. LINE INPUT 60 70 80 90 100 24T5.XXK INPUT CURRENT Vs. LINE INPUT VOLTAGE 4.0 INPUT CURRENT (AMPS) 87 50% FULL LOAD 86 85 100% FULL LOAD 84 83 ) 3.0 100% FULL LOAD 50% FULL LOAD 2.0 1.0 0.0 18 20 22 24 26 28 30 32 34 36 5 LINE INPUT (VOLTS) 10 15 20 25 30 35 40 LINE INPUT (VOLTS) Manufacturing Company, Inc. • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 5 D-134 EFFICIENCY (%) 50 LOAD (%) 55 Watt K Triple Series DC/DC Converters Typical Performance (Tc=25°C, Vin=48 VDC, Rated Load). 48T5.XXK EFFICIENCY Vs. LOAD 48T5.XXK EFFICIENCY Vs. LINE INPUT 90 88 87 80 LINE = 36VDC 100% FULL LOAD LINE = 48VDC EFFICIENCY (%) EFFICIENCY (%) 85 75 LINE = 72VDC 70 65 86 85 84 50% FULL LOAD 83 82 60 81 10 20 30 40 50 60 70 80 90 100 35 40 45 50 LOAD (%) 55 60 65 70 75 LINE INPUT (VOLTS) 5 VOLT OUTPUT VOLTAGE Vs. OUTPUT LOAD 48T5.XXK INPUT CURRENT Vs. LINE INPUT VOLTAGE 120 2.0 OUTPUT VOLTAGE (%) INPUT CURRENT (AMPS) 2.5 100% FULL LOAD 1.5 50% FULL LOAD 1.0 0.5 100 80 60 40 20 0.0 0 0 10 20 30 40 50 60 70 80 0 20 40 LINE INPUT (VOLTS) 60 80 100 120 140 OUTPUT LOAD (%) DUAL OUTPUT VOLTAGE Vs. OUTPUT LOAD OUTPUT IMPEDANCE Vs. FREQUENCY 1 +/-DUAL OUTPUT 100 IMPEDANCE (OHMS) 80 60 40 ) .1 5V OUTPUT .01 20 0 .001 0 50 100 150 200 250 300 350 10 OUTPUT LOAD (%) 100 1K 10K 100K 1M FREQUENCY (Hz) Manufacturing Company, Inc. • Concord, California 94520 • Ph: 925/687-4411 or 800/542-3355 • Fax: 925/687-3333 • www.calex.com • Email: [email protected] 6 D-134 OUTPUT VOLTAGE (%) 120 55 Watt K Triple Series DC/DC Converters Typical Performance (Tc=25°C, Vin=48 VDC, Rated Load). DUAL OUTPUT VOLTAGE Vs CASE TEMPERATURE 5 VOLT OUTPUT Vs CASE TEMPERATURE 0.15 MINUS OUTPUT 0.15 0.10 NORMALIZED OUTPUT (%) 0.05 +5V OUTPUT -0.00 -0.05 -0.10 -0.15 -0.20 -0.25 0.05 PLUS OUTPUT -0.00 -0.05 -0.10 -0.15 -0.20 -0.25 -0.30 -0.30 -0.35 -0.35 -30 -20 -10 0 10 20 30 40 50 60 70 -30 80 -20 -10 0 10 20 30 40 50 60 70 80 CASE TEMPERATURE (Deg C) CASE TEMPERATURE (Deg C) DERATING 120 â INFINITE 100 OUTPUT POWER (%) NO HEAT SINK 80 HEAT SINK 60 á 40 ß à SAFE OPERATING AREA 20 â 0 -40 -20 0 20 40 60 80 100 AMBIENT 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] 7 D-134 NORMALIZED OUTPUT (%) 0.10