15 Watt TC Single Series DC/DC Converters Features -40 to +90C Case Operating Range Standard Dual Stage Output Filter for Low Noise Operation Very Low OFF Current, 1 mA Typically Water Washable Design Five Year Warranty Description Selection Chart These single output DC/DC converters are designed to provide a wide range of PCB mount power solutions. The extra wide 3:1 input voltage range covers the common American and European telecom standards along with 24 volt industrial control applications. MODEL INPUT RANGE VDC MIN For flexibility, a trim pin is included to adjust the output voltage. Use it to compensate for voltage drops in your system's wiring or to achieve non standard voltages. Use the remote ON/OFF function to maximize battery life. MAX OUTPUT VDC OUTPUT mA *48S5.3000TC 20 60 5.0 3000 48S12.1250TC 20 60 12.0 1250 48S15.1000TC 20 60 15.0 1000 * Agency Approval: UL 1459 The TC Single Series continues the CALEX tradition of reliable design by including transient overvoltage suppressor diode protection at the input and output terminals. Also provided as standard are overcurrent protection circuits. These features assure zero failure rate operation when using the TC Single Series. 15 Watt TC Single Series Block Diagram SHIELDED ISOLATION TRANSFORMER A 4 + OUTPUT + INPUT 3 -INPUT 2 5 CMN CURRENT MODE PWM 6 TRIM ISOLATED FEEDBACK ON/OFF 1 FIVE-SIDED SHIELDED COPPER CASE LOW TC BANDGAP REFERENCE 2401 Stanwell Drive * Concord, California 94520 * Ph: 925/687-4411 or 800/542-3355 * Fax: 925/687-3333 * www.calex.com * Email: sales@calex.com 1 eco# 041007-1 15 Watt TC Single Series DC/DC Converters Input Parameters* Model Voltage Range Input Current Full Load No Load Efficiency Switching Frequency Maximum Input Overvoltage, 100ms No Damage Turn-on Time, 1% Output Error MIN TYP MAX TYP TYP TYP 48S5.3000TC 48S12.1250TC 395 2 79 20.0 48.0 60.0 380 4 82 48S15.1000TC Units VDC 375 4 83 mA % TYP 120 kHz MAX 75 VDC TYP 5 10 Recommended Fuse ms (1) Output Parameters* Model Output Voltage Rated Load (3) Voltage Range 100% Load Load Regulation 25-100% Full Load Line Regulation Vin = Min-Max VDC MIN MAX MIN TYP MAX TYP MAX TYP MAX 48S5.3000TC 48S12.1250TC 48S15.1000TC Units 5 12 15 VDC 0 3000 4.950 5.000 5.050 0.5 0.75 0.1 0.15 0 1250 11.900 12.000 12.100 0.1 0.2 0.01 0.1 0 1000 14.900 15.000 15.100 0.1 0.2 0.01 0.1 Short Term Stability (4) TYP < 0.02 Long Term Stability TYP < 0.05 Transient Response (5) Dynamic Response (6) TYP TYP Input Ripple Rejection (7) TYP Noise, 0-20MHz bw (2) RMS Noise TYP TYP TYP MAX Temperature Coefficient 100 150 % % %/kHrs 200 170 s mV peak 60 2 mV P-P mV RMS > 60 dB 60 2 50 150 Short Circuit Protection to Common for all Outputs VDC %/24Hrs 600 200 75 3 mA ppm/C Current Limit NOTES * (1) (2) (3) (4) (5) The transient response is specified as the time required to settle from a 50 to 75% step load change (rise time of step = 2Sec) to a 1% error band. (6) Dynamic response is the peak overshoot voltage during the transient response time defined in note 5. (7) The input ripple rejection is specified for DC to 120Hz ripple with a modulation amplitude of 1% Vin. (8) The 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 +75VDC. (9) Case is tied to Pin 3, +Input. (10) The case thermal impedance is specified as the case temperature rise over ambient per package watt dissipated. (11) Specifications subject to change without notice. (12) Water Washability - Calex DC/DC converters are designed to withstand most solder/wash processes. Careful attention should be used when assessing the applicability in your specific manufacturing process. Converters are not hermetically sealed. All Parameters measured at Tc=25C, nominal input voltage and full rated load unless otherwise noted. Refer to the CALEX Application Notes for the definition of terms, measurement circuits and other information. See our application note for picking the correct fuse size. Noise is measured per CALEX Application Notes. Measurement bandwidth is 0-20 MHz. RMS noise is measured over a 0.01-1 MHz bandwidth. To simulate standard PCB decoupling practices, output noise is measured with a 0.1F, ceramic capacitor located 1 inch away from the converter. Minimum load required for rated regulation only. Dynamic response may degrade if run at less than 25% full load. Short term stability is specified after a 30 minute warm-up at full load, and with constant line, load and ambient conditions. A 2401 Stanwell Drive * Concord, California 94520 * Ph: 925/687-4411 or 800/542-3355 * Fax: 925/687-3333 * www.calex.com * Email: sales@calex.com 2 eco# 041007-1 15 Watt TC Single Series DC/DC Converters General Specifications* All Models ON/OFF Function (8) ON Logic Level or Leave Pin Open OFF Logic Level Input Resistance Converter Idle Current, ON/OFF Pin Low Isolation (9) Isolation Voltage 10A Leakage Input-Output Input to Output Capacitance Output Trim Function Input Resistance Programming Range Environmental Case Operating Range No Derating Storage Range Thermal Impedance (10) Units MIN 8.0 VDC MAX TYP 2.0 100 VDC kohms TYP <1 mA MIN 700 VDC TYP 300 pF TYP MIN 20 5 kohms % BOTTOM VIEW Mechanical tolerances unless otherwise noted: X.XX dimensions: 0.020 inches MIN MAX MIN MAX TYP -40 90 -55 100 10 TYP 2 X.XXX dimensions: 0.005 inches Seal around terminals is not hermetic. Do not immerse units in any liquid. C Pin 1 2 3 4 5 6 C C/Watt General Unit Weight SIDE VIEW oz Chassis Mounting Kit MS8 Function ON/OFF -INPUT +INPUT +OUTPUT CMN TRIM 15 Watt TC Single Typical Application Figure 1 shows the recommended connections for the 15 Watt TC Singles. Capacitor C1 is required for proper operation (see below). The trim and ON/OFF pins can be safely left floating if they are not used. The input fuse should not be omitted. The fuse serves two purposes: 1) It prevents unlimited current from flowing in the case of a catastrophic system failure 2) UL regulations for telecom equipment require the use of a fuse. See CALEX Application Notes for more info on sizing the input fuse. A SIZE TRACES FOR 1 AMP DC MAXIMUM FUSE TO INPUT SOURCE 3 + INPUT SIZE TRACES APPROPRIATELY FOR LOAD REQUIREMENTS + OUTPUT 4 LOAD C1 * 2 - INPUT CMN 5 1 ON/OFF TRIM 6 * * PINS 1 AND 6 MAY BE LEFT FLOATING IF NOT USED FIGURE 1. Recommended application circuit for TC Single Series 2401 Stanwell Drive * Concord, California 94520 * Ph: 925/687-4411 or 800/542-3355 * Fax: 925/687-3333 * www.calex.com * Email: sales@calex.com 3 eco# 041007-1 15 Watt TC Single Series DC/DC Converters Sizing The Input Capacitor Solution For maximum reliability the TC Single Series must use a capacitor of sufficient ripple handling capability connected across the input pins. The probable result of undersizing (over stressing) this capacitor is increased self heating, shortening of the capacitors and hence shortening of your systems' life. Oversizing the capacitor can have a negative effect on your product's cost and size, although this kind of overdesign does not result in shorter life of any components. There is no one optimum value for this capacitor. The size and capacity are dependent on the following factors: According to the 15 Watt TC Single Series "Reflected Input Ripple vs. Line Input" curve at 40 VDC input and 2.25 Amps output (75% of rated load), the reflected input ripple can be read as 650 mA RMS. From the derating guidelines the capacitor's rated voltage and ripple current can be determined. Capacitor voltage rating is calculated as: 1 V= x Maximum Expected Input Voltage Derating Factor V= 1) expected ambient temperature and your temperature derating guidelines 2) your ripple current derating guidelines I= 3) the maximum load expected on the converter = 4) the minimum input voltage expected on the converter 1 x 52 = 74 Volts or greater 0.7 1 x Reflected Ripple Current Derating Factor 1 0.7 x 650 mA = 0.93 A RMS or greater at 45C (40C ambient + 5C for self heating) 5) the statistical probability that your system will spend a significant amount of time at any worst case extreme A capacitor selection can now be made. Look only at controlled low ESR types (where the ESR is specified as a maximum) because these usually have the highest ripple current capability per unit volume. Factors 1 and 2 are determined by your system design guidelines. These can range from 50% to 100% of the manufacturer's rated maximum, although a usual derating factor is 70% of manufacturer's maximum limit. 70% derating means that if the capacitor manufacturer says their capacitor can do 1 A RMS and 100 VDC you would not use the part over 700 mA RMS and 70 VDC. Surge voltage rating should also be evaluated against any expected voltage surges when selecting a capacitor working voltage. Be careful to compare apples to apples. Some manufacturers specify their capacitors at 85C and others specify at 105C. The manufacturers give temperature derating guidelines, so all capacitors should be normalized to your maximum ambient (plus 5C to account for self heating) before making a selection. Since the 15 Watt TC Single Series operates at 120 kHz the frequency usually does not have to be derated since most modern low ESR capacitors are rated at 100 kHz. Factors 3 and 4 realistically determine the worst case ripple current. The reflected ripple current increases with output load and increases as the input voltage decreases. So if you are running with a solid 48 VDC input and at 50% load your capacitors required ripple current rating would decrease by more than 2:1 from what would be required for operation at 20 VDC with full load (see the "Input Reflected Ripple" curve). One note: The temperature derating multipliers are based on the capacitor's expected life at 105C. The life of a capacitor operating at a significantly lower temperature will not be greater if the ripple current in the part is increased over the 105C rating. This means that a capacitor rated for 1 A RMS current at 105C and 2 A RMS at 50C will have the same life if used at either point while the same capacitor used at 1 A RMS and 50C will have a longer life. Factor 5 is not easy to quantify. At CALEX, we can make no assumptions about a customer's system so we design for continuous operation at worst case extremes. A Example Of Capacitor Sizing Suggested Capacitor Sources Given the following conditions, select the minimum size capacitor needed to provide reliable performance: Suitable capacitors can be acquired from the following sources: Converter ......................................... 48S5.3000TC Minimum Input Voltage .................... 40 VDC United Chemi-Con Suggested Part: SXE, RXC, RZ and RZA Series SXE100VB221M12.5X35LL 220F, 100V, 105C Rated ESR=0.087 ohms Allowable Ripple=1.45 A @ 105C Nichicon Suggested Part: PR and PF UPR2A102MPH 1000F, 100V, 105C Rated ESR=0.047 ohms Allowable Ripple=1.32 A @ 105C Maximum Input Voltage ................... 52 VDC Maximum Load ................................ 2.25 Amps Maximum Ambient Temperature ..... 40C Your Capacitor Voltage Derating Guideline ........................... 70% of Maximum Specification Your Capacitor Current Derating Guideline ........................... 70% of Maximum Specification 2401 Stanwell Drive * Concord, California 94520 * Ph: 925/687-4411 or 800/542-3355 * Fax: 925/687-3333 * www.calex.com * Email: sales@calex.com 4 eco# 041007-1 15 Watt TC Single Series DC/DC Converters Panasonic Suggested Part: HFE Series ECEA2AFE221L 220F, 100V, 105C Rated ESR=0.089 ohms Allowable Ripple=1.04 A @ 105C Use one resistor for either trim up or trim down. The values can range from infinity to zero ohms with zero ohms providing the most trim. USING TRIMPOT The suggested capacitors will work for any line and load condition, however, they may be oversized for your application. + OUT 4 Low Noise Input Filtering Circuit To reduce the input reflected ripple to less than 50 mA peak to peak the circuit shown in Figure 2 may be used. Toroid core inductors have theoretically lower radiated noise than a rod core. Use reasonable caution when selecting an inductor other than the one specified. Nearly any 105C rated capacitor can be used for the 10F / 100V part. To prevent input filter peaking the ESR should be in the range of 0.5 to 2 ohms. Do not use the lowest ESR capacitor available for this part. This will render the filter ineffective. TRIM 6 CMN 5 LOAD USING FIXED RESISTORS + OUT 4 THIS CAPACITOR IS REQUIRED FOR PROPER OPERATION TRIM DOWN TRIM 6 CMN FUSE 10 K TRIM UP 5 LOAD 50 H, 1000 mA 3 + INPUT Figure 3. Output trim methods TO INPUT SOURCE 10 F 100 V Temperature Derating Guidelines Care must be taken in the application of all power devices. Be sure to account for the self heating in your instrument due to the power converter and the loads. For minimum temperature gradient, the hottest components should be mounted at the bottom of your system (bottom of a vertical PCB) and the coolest components at the top of the system. This will help to even the temperature of the entire system and prevent temperature gradients. 2 - INPUT FIGURE 2. Low noise input filter circuit Remote ON/OFF Circuit Operation The 15 Watt TC Single Series has a thermal impedance of 10C per package watt dissipated. During normal operation the 15 Watt TC Single Series can be expected to run at 80% efficiency at 48 VDC and full load. This means that the 15 Watt TC Single Series is dissipating nearly 4 Watts internally at full load. This, therefore, translates to a package temperature rise of about 40C (10C/watt x 4 watts dissipated). The remote ON/OFF pin is best applied as follows: To turn the unit off, the ON/OFF pin should be tied to the Input pin. This is best done by an open collector arrangement or contact closure. To turn the unit on, let the ON/OFF pin float. If the remote ON/OFF pin is not used, it may be safely left floating. There is a 100K internal pull-up resistor inside the unit to +9 volts DC. A Other applications of the ON/OFF function can be found in the application note, "Understanding the Remote ON/OFF Function". The maximum rated case temperature for the 15 Watt TC Series is 90C. This means that, in the absence of other heat sources (including the load that the converter is powering) and with at least 3 inches of clearance, the 15 Watt TC Single Series can be expected to operate at an ambient of 50C. Proper Application Of The Trim Pin Additional heat sinks or cooling air flow can extend the ambient temperature of operation significantly. The trim pin is used to adjust the output voltage slightly to compensate for voltage drops in the system's wiring. Figure 3 shows the proper application of the trim pin. Either a 10K trimpot or fixed resistors may be used. Other applications for the TRIM function can be found in the CALEX application note: "Applying the Remote Sense and Trim Functions on DC/DC Converters." 2401 Stanwell Drive * Concord, California 94520 * Ph: 925/687-4411 or 800/542-3355 * Fax: 925/687-3333 * www.calex.com * Email: sales@calex.com 5 eco# 041007-1 15 Watt TC Single Series DC/DC Converters Typical Performance (Tc=25C, Vin=Nom VDC, Rated Load, 48S12.1250TC) EFFICIENCY Vs. LINE INPUT VOLTAGE EFFICIENCY Vs. LOAD INPUT RIPPLE Vs. LINE INPUT 90 85 1.00 REFLECTED RMS RIPPLE (AMPS) 50% FULL LOAD LINE = 20VDC 85 EFFICIENCY (%) EFFICIENCY(%) 82 100% FULL LOAD 80 80 LINE = 48VDC 75 70 77 65 LINE = 60VDC 75 60 20 25 30 35 40 45 50 55 60 100% FULL LOAD 0.80 75% FULL LOAD 0.60 50% FULL LOAD 0.40 0.20 0 10 20 30 40 LINE INPUT(VOLTS) 50 60 70 80 90 100 20 25 30 LOAD (%) INPUT CURRENT Vs. LINE INPUT VOLTAGE 35 40 45 50 55 60 LINE INPUT (VOLTS) OUTPUT IMPEDANCE Vs. FREQUENCY OUTPUT VOLTAGE Vs. OUTPUT LOAD 1.2 1 OUTPUT IMPEDANCE (OHMS) OUTPUT VOLTAGE (%) 1.0 0.8 0.6 100% LOAD 0.4 0.2 100 80 60 40 20 50% LOAD 0.0 10 20 30 40 50 60 48S15.1000TC .1 48S5.3000TC .01 0 0 0 20 40 60 LINE INPUT (VOLTS) 80 100 120 140 160 180 10 100 1000 10000 100000 1000000 FREQUENCY (Hz) OUTPUT LOAD (%) OUTPUT VOLTAGE Vs CASE TEMPERATURE 0.2 NORMALIZED OUTPUT (%) INPUT CURRENT (AMPS) 120 0.1 -0.0 -0.1 -0.2 -0.3 -0.4 -0.5 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 CASE TEMPERATURE (Deg C) A 2401 Stanwell Drive * Concord, California 94520 * Ph: 925/687-4411 or 800/542-3355 * Fax: 925/687-3333 * www.calex.com * Email: sales@calex.com 6 eco# 041007-1