CG Series Single Output 2:1 Input Voltage Range 30 Watt DC/DC Converter FEATURES ● Soft Start ● Lead-Free Design ● Six-Sided Shielding ● Output Trim Function ● I/O Isolation 1500VDC ● MTBF > 600,000 hours ● 2:1 Input Voltage Range ● Very High Efficiency up to 88% ● Remote On/Off Control (Optional) ● Over Voltage and Short Circuit Protection ● EMI Complies with RN55022 Class A (Only for CG-A Series) Dimensions: 2.0 x 1.0 x 0.4 inches SPECIFICATIONS: CG Series All specifications are based on 25oC, 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 Nom Max INPUT (Vin) Input Voltage Range (24V input models) Input Voltage Range (48V input models) Start Voltage 24V input models) Start Voltage (48V input models) Under Voltage Shutdown (24V input models) Under Voltage Shutdown (48V input models) Over Voltage Shutdown (24V input models) Over Voltage Shutdown (48V input models) Reverse Polarity Input Current Input Surge Voltage (1000ms) (24V input models) Input Surge Voltage (1000ms) (48V input models) Reflected Ripple Current Short Circuit Input Power Input Filter OUTPUT (Vo) Output Voltage Range Output Voltage Accuracy Output Voltage Trim Load Regulation (2.5V,3.3V, and 5Vout) Load Regulation (12V and 15Vout) Line Regulation Output Power Output Current Range Ripple & Noise (20MHz) Ripple & Noise (20MHz) Ripple & Noise (20MHz) Transient Recovery Time Transient Response Deviation Maximum Capacitive Load Temperature Coefficient REMOTE ON/OFF CONTROL Supply On Supply Off Device Standby Input Current Control Input Current (On) Control Input Current (Off) Control Common PROTECTION Over Power Protection Short Circuit Protection Over Voltage Protection Input Fuse Recommendation (24V input models) Input Fuse Recommendation (48V input models) 18 36 17 34 16 32 40 80 All models -0.7 -0.7 All models All models % of nominal output voltage Io = No Load to 100% Load Io = 10% to 100% Load Vin = Min to Max ±9.0 Over Line, Load, and Temperature 25% Load Step Change 25% Load Step Change Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 200 24 48 17.5 35 16.5 33 42 82 36 75 18 36 17 34 44 84 2 50 100 See Table 4500 Pi Filter See Table ±0.5 ±1.0 ±10.0 ±11.0 ±0.5 ±1.0 ±0.5 ±1.0 ±0.1 ±0.3 30 See Table 75 100 120 10 500 ±2 ±5 See Table ±0.01 ±0.02 Unit VDC VDC VDC VDC VDC VDC VDC VDC A VDC VDC mW % % % % % W mVpk-pk mVpk-pk mVrms μs % %/°C 2.5 to 100VDC or Open Circuit -1 1 VDC 2 5 mA 5 μA -100 μA Referenced to Negative Input 110 160 % Continuous See table 3000mA Slow-Blow Type 1500mA Slow-Blow Type CG Series Single Output 2:1 Input Voltage Range 30 Watt DC/DC Converter SPECIFICATION TEST CONDITIONS GENERAL Efficiency Switching Frequency Isolation Voltage Rated Isolation Voltage Test Isolation Resistance Isolation Capacitance Internal Power Dissipation ENVIRONMENTAL Operating Temperature (Ambient) Operating Temperature (Case) Storage Temperature Lead Temperature Humidity Cooling RFI MTBF Conducted EMI PHYSICAL Weight Dimensions Case Material Min 280 1500 1650 1000 60 seconds Flash Tested for 1 second 500VDC 100KHz, 1V Nom Max See Table 350 400 1200 1500 5500 Unit KHz VDC VDC MΩ pF mW -40 -40 -55 +50 °C +105 °C +125 °C 260 °C 95 % Free air convection Six-sided shielded metal case 600,000 Hours EN55022 Class A 1.5mm from case for 10 seconds MIL-HDBK-217F @ 25°C, Ground Benign 32 grams 50.8(L) x 25.4(W) x 10.2(H) mm Aluminum anodizing treatment in black OUTPUT VOLTAGE / CURRENT RATING CHART Output Voltage Output Current Min Max CG24S2.5-6000 2.5 VDC 0mA 6000mA 50mA 744mA 3 VDC 6800μF 84% CG24S3.3-6000 3.3 VDC 0mA 6000mA 50mA 959mA 3.9 VDC 6800μF 86% 5 VDC 0mA 5000mA 70mA 1185mA 6.8 VDC 6800μF 88% Model Number Input Voltage CG24S5-5000 Input Current Reflected Over Voltage Max Capacitive Efficiency Load (Typ) No Load Max Load Ripple Current Protection 24 VDC (18 – 36 VDC) CG24S5.1-5000 5.1 VDC 0mA 5000mA 70mA 1207mA 6.8 VDC 6800μF 88% CG24S12-2500 12 VDC 166mA 2500mA 20mA 1420mA 15 VDC 680μF 88% CG24S15-2000 15 VDC 133mA 2000mA 20mA 1420mA 18 VDC 680μF 88% CG48S2.5-6000 2.5 VDC 0mA 6000mA 40mA 372mA 3 VDC 6800μF 84% CG48S3.3-6000 3.3 VDC 0mA 6000mA 40mA 480mA 3.9 VDC 6800μF 86% 5 VDC 0mA 5000mA 50mA 604mA 6.8 VDC 6800μF 88% CG48S5-5000 100mA (typ) 48 VDC CG48S5.1-5000 (36 – 75 VDC) 5.1 VDC 0mA 5000mA 50mA 604mA 6.8 VDC 6800μF 88% CG48S12-2500 12 VDC 166mA 2500mA 10mA 710mA 15 VDC 680μF 88% CG48S15-2000 15 VDC 133mA 2000mA 10mA 710mA 18 VDC 680μF 88% 50mA (typ) NOTES 1. 2. 3. 4. 5. 6. 7. 8. Specifications typical at +25°C, resistive load, nominal input voltage, rated output current unless otherwise noted. Transient Recovery Time is measured to within 1% error band for a step change in output load of 75% to 100%. Ripple & Noise measurement bandwidth is 0- 20MHz. These power converters require a minimum output loading to maintain specified regulation. Operation at no-load will not damage these devices, however they may not meet all listed specifications. All DC/DC converters should be externally fused at the front end for protection. Other input and output voltages may be available, please contact factory. Specifications subject to change without notice. To order the converter with Remote On/Off function, please add suffix ”-RC” (Ex: CG48S5-5000(A)-RC). Due to advances in technology, specifications subject to change without notice. Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 CG Series Single Output 2:1 Input Voltage Range 30 Watt DC/DC Converter BLOCK DIAGRAM Input Voltage Transient Rating Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 CG Series Single Output 2:1 Input Voltage Range 30 Watt DC/DC Converter MECHANICAL DRAWING Connecting Pin Patterns Top View (2.54 mm / 0.1 inch grids) Pin 1 2 3 4 5 6 PIN CONNECTIONS Function +Vin -Vin *Remote On/Off (option) +Vout -Vout Trim * See Note 8 1. All dimensions in mm [inches] Tolerance: X.X±0.25 [X.XX±0.01] X.XX±0.13 [X.XXX±0.005] 2. Pin: ±0.05 [±0.002] Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 CG Series Single Output 2:1 Input Voltage Range 30 Watt DC/DC Converter DESIGN & FEATURE CONSIDERATIONS Remote On/Off Positive logic remote on/off turns the module on during a logic high voltage on the remote on/off pin and off during a logic low. Negative logic remote on/off turns the module off during a logic low and on during a logic high. To turn the power module on and off, the user must supply a switch to control the voltage between the on/off terminal and the -Vin terminal. The switch can be an open collector or equivalent. A logic low is -0.7V to 1.0V. A logic high is 2.5V to 100V. The maximum sink current at the On/Off terminal (Pin 3) during a logic low is 100 mA. The maximum allowable leakage current of a switch connected to the On/Off terminal (Pin 3) at logic high (2.5V to 100V) is 5uA. Output Voltage Trim Output voltage trim allows the user to increase or decrease the output voltage set point of a module. The output voltage can be adjusted by placing an external resistor (Radj) between the Trim and +Vout or -Vout terminals. By adjusting Radj, the output voltage can be changed by ±10% of the nominal output voltage. A 10K, 1 or 10 Turn trimpot is usually specified for continuous trimming. Trim pin may be safely left floating if it is not used. Connecting the external resistor (Radj (up)) between the Trim and -Vout pins increases the output voltage set point as defined by the following equation: Radj (up ) = (33 ∗ Vout ) − (30 ∗ Vadj ) Vadj − Vout Connecting the external resistor (Radj (down)) between the Trim and +Vout pins decreases the output voltage set point as defined by the following equation: Radj ( down ) = Vout: Vadj: Units: (36.667 ∗ Vadj ) − (33 ∗ Vout ) Vout − Vadj Nominal Output Voltage Adjusted Output Voltage VDC/KΩ Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 CG Series Single Output 2:1 Input Voltage Range 30 Watt DC/DC Converter Input Source Impedance The power module should be connected to a low ac-impedance input source. Highly inductive source impedances can affect the stability of the power module. In applications where power is supplied over long lines and output loading is high, it may be necessary to use a capacitor at the input to ensure startup. A capacitor mounted close to the power module helps ensure stability of the unit, it is recommended to use a good quality low Equivalent Series Resistance (ESR < 1.0Ω at 100 KHz) capacitor of 10uF for the 24V and 48V input devices. Maximum Capacitive Load The CG Series has a limitation of maximum connected capacitance at the output. The power module may be operated in current limiting mode during start-up, affecting the ramp-up and the startup time. The maximum capacitance can be found in the “Output Voltage / Current Rating Chart.” Over Current Protection To provide protection in a fault (output overload) condition, the unit is equipped with internal current limiting circuitry and can endure current limiting for an unlimited duration. At the point of current-limit inception, the unit shifts from voltage control to current control. The unit operates normally once the output current is brought back into its specified range. Output Over Voltage Protection The output over voltage clamp consists of control circuitry, which is independent of the primary regulation loop that monitors the voltage on the output terminals. The control loop of the clamp has a higher voltage set point than the primary loop. This provides a redundant voltage control that reduces the risk of output over voltage. The OVP level can be found in the “Output Voltage / Current Rating Chart.” Thermal Considerations Many conditions affect the thermal performance of the power module, such as orientation, airflow over the module, and board spacing. To avoid exceeding the maximum temperature rating of the components inside the power module, the case temperature must be kept below 105°C. The derating curves are determined from measurements obtained in an experimental apparatus. Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 CG Series Single Output 2:1 Input Voltage Range 30 Watt DC/DC Converter Efficiency vs Input Voltage Efficiency vs Output Load DERATING CURVE Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 CG Series Single Output 2:1 Input Voltage Range 30 Watt DC/DC Converter TEST CONFIGURATIONS Input Reflected-Ripple Current Test Setup Input reflected-ripple current is measured with an inductor Lin (4.7uH) and Cin (220uF, ESR < 1.0Ω at 100 KHz) to simulate source impedance. Capacitor Cin offsets possible battery impedance. Current ripple is measured at the input terminals of the module. Measurement bandwidth is 0-500 KHz. Peak-to-Peak Output Noise Measurement Test Use Cout = 1.0uF ceramic capacitor. Scope measurement should be made by using a BNC socket, measurement bandwidth is 0-20MHz. Position the load between 50mm and 75mm from the DC/DC Converter. Output Ripple Reduction A good quality low ESR capacitor placed as close as possible across the load will give the best ripple and noise performance. To reduce output ripple, it is recommended to use 4.7uF capacitors at the output. Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 CG Series Single Output 2:1 Input Voltage Range 30 Watt DC/DC Converter COMPANY INFORMATION Wall Industries, Inc. has created custom and modified units for over 40 years. Our in-house research and development engineers will provide a solution that exceeds your performance requirements on time and on budget. Our ISO9001-2000 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: (603)778-2300 (888)587-9255 (603)778-9797 [email protected] www.wallindustries.com 5 Watson Brook Rd. Exeter, NH 03833 Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797