1000 WATT FXW SERIES DC/DC CONVERTERS Features Description The 4:1 Input Voltage 1000 Watt Single FXW DC/DC converter provides a precisely regulated dc output. The output voltage is fully isolated from the input, allowing the output to be positive or negative polarity and with various ground connections. The 1000 Watt FXW meets the most rigorous performance standards in an industry standard footprint for mobile (12Vin), process control (24Vin), and military COTS (28Vin) applications. The 4:1 Input Voltage 1000W FXW includes trim and remote ON/OFF. Threaded through holes are provided to allow easy mounting or addition of a heatsink for extended temperature operation. The converters high efficiency and high power density are accomplished through use of high-efficiency synchronous rectification technology, advanced electronic circuit, packaging and thermal design thus resulting in a high reliability product. Converter operates at a fixed frequency and follows conservative component de-rating guidelines. Product is designed and manufactured in the USA. 4:1 Input voltage range High power density Small size 2.5" x 4.7" x 0.52" Efficiency up to 96% Excellent thermal performance with metal case Over-Current and Short Circuit Protection Over-Temperature protection Auto-restart Monotonic startup into pre bias Constant frequency Remote ON/OFF Good shock and vibration damping Temperature Range -40C to +105C Available. RoHS Compliant UL60950 Approved* (except 24S12.84FXW (RoHS)) Input Range VDC Model Vout VDC Iout ADC Min Max 24S12.84FXW (ROHS)* 9 36 12 84 24S24.42FXW (ROHS) 9 36 24 42 24S28.36FXW (ROHS) 9 36 28 36 24S48.21FXW (ROHS) 9 36 48 21 24S53.19FXW (ROHS) 9 36 53 19 * The 24S12.84FXW is under evaluation but not currently UL60950 Approved. 1. Negative Logic ON/OFF feature available. Add "-N" to the part number when ordering. i.e. 24S24.42FXW-N (ROHS) 2. Designed to meet MIL-STD-810G for functional shock and vibration. The unit must be properly secured to the interface medium (PCB/Chassis) by use of the threaded inserts of the unit. 3. A thermal management device, such as a heatsink, is required to ensure proper operation of this device. The thermal management medium is required to maintain baseplate < 105C for full rated power. 4. Non-Standard output voltages are available. Please contact the factory for additional information. 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Page 1 of 24 Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS Electrical Specifications Conditions: TA = 25 C, Airflow = 300 LFM (1.5 m/s), Vin = 24VDC, unless otherwise specified. Specifications are subject to change without notice. All Models Parameter Notes Min Typ Max Units 40 50 V V -40 105 C -55 125 C Absolute Maximum Ratings Input Voltage Continuous 0 Transient (100ms) Operating Temperature Baseplate (100% load) Storage Temperature Isolation Characteristics and Safety Isolation Voltage Input to Output 2250 Input to Baseplate & Output to Baseplate 1500 Isolation Capacitance Isolation Resistance V V 9000 pF 20 M 10 Insulation Safety Rating Basic Designed to meet UL/cUL 60950, IEC/EN 60950-1 Feature Characteristics Fixed Switching Frequency 200 Input Current and Output Voltage Ripple Output Voltage Trim Range Adjustable via TRIM (Pin 12) Remote Sense Compensation Between SENSE+ and +OUT pins kHz kHz 400 60 110 % 1 V Output Overvoltage Protection Non-latching 114 122 130 % Overtemperature Shutdown (Baseplate) Non-latching (Vin=9V; 12V, 24/36V) 108 112 115 C Auto-Restart Period Applies to all protection features Time from UVLO to Vo=90%VOUT(NOM) Resistive load 1.7 2 2.3 s 480 517 530 ms Turn-On Delay Time from Vin 24S24.42FXW & 24S28.36FXW 20 27 35 ms 24S48.21FXW & 24S53.19FXW 20 35 50 24S24.42FXW & 24S28.36FXW 4 7 11 ms ms 24S48.21FXW & 24S53.19FXW 7 15 25 ms ON state Pin open = ON or 2 Control Current Leakage current Turn-On Delay Time from ON/OFF Control (From ON to 90%VOUT(NOM) Resistive load) Rise Time (Vout from 10% to90%) ON/OFF Control - Positive Logic OFF state Control current Sinking 12 V 0.16 mA 0 0.8 V 0.3 0.36 mA ON/OFF Control - Negative Logic ON state Pin shorted to - ON/OFF pin or 0 0.8 V OFF state Pin open = OFF or 2 12 V Thermal Characteristics Thermal resistance Baseplate to Ambient 2401 Stanwell Drive, Concord Ca. 94520 Converter soldered to 5" x 3.5" x 0.07", 3.3 4 layers/ 2Oz copper FR4 PCB. Ph: 925-687-4411 Page 2 of 24 Fax: 925-687-3333 www.calex.com C/W Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS Electrical Specifications (Continued): Conditions: TA = 25 C, Airflow = 300 LFM (1.5 m/s) and 0.9" heatsink, Vin = 14VDC, unless otherwise specified. Specifications are subject to change without notice. 24S12.84FXW Parameter Notes Min Typ Max 9 14 36 V 8.2 8.5 8.8 V Turn-off Threshold 7.7 V 0.4 8.0 0.55 8.3 Lockout Hysteresis Voltage 0.7 V 89 A Units Input Characteristics Operating Input Voltage Range Input Under Voltage Lockout Turn-on Threshold Maximum Input Current Non-latching Vin = 9V, 80% Load Vin = 12V, 100% Load 92 600 Vin = 14V, Output Shorted Input Stand-by Current Converter Disabled Input Current @ No Load Converter Enabled 450 2 Minimum Input Capacitance (external)1) See Table 1 1000 550 Inrush Transient Input Terminal Ripple Current, iC mA 4 690 mA 0.19 F 2 A s ARMS 3.65 25 MHz bandwidth, 100% Load (Fig. 2) A mARMS Output Characteristics Output Voltage Range Output Voltage Set Point Accuracy (No load) 11.64 12.00 12.36 V 11.90 12.00 12.10 V % Output Regulation Over Line Vin = 9V to 36V 0.05 0.10 Over Load Vin = 14V, Load 0% to 100% 0.05 0.150 % 0.005 0.015 %/C 15.6 V Temperature Coefficient 14 Overvoltage Protection 120 mVPK-PK 40 mVrms Output Ripple and Noise - 20 MHz bandwidth 100% Load, See Table 1 for external components External Load Capacitance1) See Table 1 Output Current Range (See Fig. A) Vin = 12V - 36V 0 84 A Vin = 9V 0 67.2 A 109.2 A Current Limit Inception RMS Short-Circuit Current Vin = 12V - 36V 92.4 9V Vin < 12V 73.5 100.8 109.2 A 7 Arms 500 mV 800 s Vin = 14V 93.0 % Vin = 12V 92.3 % Vin = 14V 95.4 % Vin = 12V 95.0 % Non-latching, Continuous Dynamic Response Load Change 50%-100%-50%, di/dt =0 .5A/s See Table 1 for external capacitors Settling Time to 1% of VOUT Efficiency 100% Load 50% Load 1) Section "Input and Output Capacitance" 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Page 3 of 24 Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS Electrical Specifications (Continued): Conditions: TA = 25 C, Airflow = 300 LFM (1.5 m/s), Vin = 24VDC, unless otherwise specified. Specifications are subject to change without notice. 24S24.42FXW Parameter Notes Min Typ Max 9 24 36 V 8.2 8.5 8.8 V Turn-off Threshold 7.7 V 0.4 8.0 0.55 8.3 Lockout Hysteresis Voltage 0.7 V 89 A Units Input Characteristics Operating Input Voltage Range Input Under Voltage Lockout Turn-on Threshold Maximum Input Current Non-latching Vin = 9V, 80% Load Vin = 12V, 100% Load 92 350 Vin = 24V, Output Shorted Input Stand-by Current Converter Disabled Input Current @ No Load Converter Enabled 330 Minimum Input Capacitance (external)1) ESR < 0.1 1000 2 4 mA 420 530 mA 0.19 F 2 A s Inrush Transient Input Terminal Ripple Current, iC ARMS 3.65 25 MHz bandwidth, 100% Load (Fig. 5) A mARMS Output Characteristics Output Voltage Range Output Voltage Set Point Accuracy (No load) 23.62 24.00 24.36 V 23.90 24.00 24.10 V % Output Regulation Over Line Vin = 9V to 36V 0.05 0.10 Over Load Vin = 24V, Load 0% to 100% 0.05 0.10 % 0.005 0.015 %/C 31.2 V 200 320 mVPK-PK 50 80 mVrms Temperature Coefficient 27.36 Overvoltage Protection Output Ripple and Noise - 20 MHz bandwidth External Load Capacitance1) Output Current Range (See Fig. A) Current Limit Inception RMS Short-Circuit Current 100% Load, See Table 1 for external components Full Load (resistive) (over operating temp range) CEXT ESR 1000 4700 F 10 100 m Vin = 12V - 36V 0 42 A Vin = 9V 0 33.5 A Vin = 12V - 36V 46 50.2 54.6 A 9V Vin < 12V 37 49 54.6 A Non-latching, Continuous 2.0 3.1 6.5 Arms Co = 2 x 470 F/70m 400 600 mV Co = 2 x 470 F/70m 700 mV 500 s Dynamic Response Load Change 50%-75%-50%, di/dt = 1A/s Load Change 50%-100%-50%, di/dt = 1A/s Settling Time to 1% of VOUT Efficiency 100% Load 50% Load 1) Vin = 24V 93.6 94.6 95.3 % Vin = 12V 92.4 93.4 94 % Vin = 24V 95.0 96 96.4 % Vin = 12V 94.7 95.7 96.3 % Section "Input and Output Capacitance" 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Page 4 of 24 Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS Electrical Specifications (Continued): Conditions: TA = 25 C, Airflow = 300 LFM (1.5 m/s), Vin = 24VDC, unless otherwise specified. Specifications are subject to change without notice. 24S28.36FXW Notes Parameter Operating Input Voltage Range Input Under Voltage Lockout Min Typ Max Units 9 24 36 V Non-latching Turn-on Threshold 8.2 8.5 8.8 V Turn-off Threshold 7.7 8.3 V Lockout Hysteresis Voltage 0.4 8.0 0.55 0.7 V Vin = 9V, 80% Load 89 A Vin = 12V, 100% Load 92 A Maximum Input Current 330 Vin = 24V, Output Shorted Input Stand-by Current Converter Disabled Input Current @ No Load Converter Enabled 400 ESR < 0.1 1000 1) Minimum Input Capacitance (external) Inrush Transient Input Reflected-Ripple Current, iC mARMS 2 4 mA 480 600 mA 0.19 F 2 A s ARMS 2.5 25 MHz bandwidth, 100% Load (Fig. 6) Output Characteristics Nominal Output Voltage Output Voltage Set Point Accuracy (No load) 27.56 28.00 28.42 V 27.9 28.00 28.1 V 0.05 0.1 0.1 % 0.015 %/C Output Regulation Over Line Over Load Vin = 9V to 36V Vin = 24V, Load 0% to 100% 0.05 0.005 Temperature Coefficient 31.9 Overvoltage Protection Output Ripple and Noise - 20 MHz bandwidth External Load Capacitance1) Output Current Range (See Fig. A) Current Limit Inception RMS Short-Circuit Current 220 100% Load, See Table 1 for external components Full Load (resistive) (over operating temp range) 50 CEXT ESR % 36.4 V 360 mVPK-PK 80 mVRMS 1000 4700 F 10 100 m Vin = 12V - 36V 0 36 A Vin = 9V 0 28.8 A Vin = 12V - 36V 39.6 46.8 A 9V Vin < 12V 31.7 46.8 Non-latching 1.7 A ARMS 2.5 6.4 See Table 1 for external components 330 430 See Table 1 for external components 600 mV 500 s Dynamic Response Load Change 50%-75%-50%, di/dt = 1A/s Load Change 50%-100%-50%, di/dt = 1A/s Settling Time to 1% of VOUT mV Efficiency 100% Load 50% Load 1) Vin = 24V 94.5 95.5 96.2 % Vin = 12V 93.0 93.8 94.5 % Vin = 24V 95.5 96.2 97 % Vin = 12V 94.3 95.4 96.2 % Section "Input and Output Capacitance" 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Page 5 of 24 Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS Electrical Specifications (Continued): Conditions: TA = 25 C, Airflow = 300 LFM (1.5 m/s), Vin = 24VDC, unless otherwise specified. Specifications are subject to change without notice. 24S48.21FXW Notes Parameter Operating Input Voltage Range Input Under Voltage Lockout Min Typ Max Units 9 24 36 V Non-latching Turn-on Threshold 8.2 8.5 8.8 V Turn-off Threshold 7.7 8.3 V Lockout Hysteresis Voltage 0.4 8.0 0.55 0.7 V Vin = 9V, 80% Load 89 A Vin = 12V, 100% Load 92 A Maximum Input Current 400 Vin = 24V, Output Shorted Input Stand-by Current Converter Disabled Input Current @ No Load Converter Enabled 370 ESR < 0.1 1000 1) Minimum Input Capacitance (external) Inrush Transient Input Reflected-Ripple Current, iC mARMS 2 4 mA 470 560 mA 0.19 F 2 A s ARMS 0.9 25 MHz bandwidth, 100% Load (Fig. 6) Output Characteristics Nominal Output Voltage Output Voltage Set Point Accuracy (No load) 47.28 48.00 48.92 V 47.80 48.00 48.20 V 0.05 0.1 0.1 % 0.015 %/C Output Regulation Over Line Over Load Vin = 9V to 36V Vin = 24V, Load 0% to 100% 0.05 0.005 Temperature Coefficient 54.7 Overvoltage Protection Output Ripple and Noise - 20 MHz bandwidth External Load Capacitance1) Output Current Range (See Fig. B) Current Limit Inception RMS Short-Circuit Current 100 100% Load, See Table 1 for external components Full Load (resistive) (over operating temp range) 25 CEXT ESR % 62.4 V 150 mVPK-PK 50 mVRMS 470 3000 F 10 100 m Vin = 12V - 36V 0 21 A Vin = 9V 0 16.8 A Vin = 12V - 36V 23.1 25.2 27.3 A 9V Vin < 12V 18.48 20.16 27.3 1.0 1.6 3.3 A ARMS Non-latching Dynamic Response Load Change 50%-75%-50%, di/dt = 1A/s Load Change 50%-100%-50%, di/dt = 1A/s See Table 1 for external components 480 560 mV See Table 1 for external components 880 1150 mV 500 Settling Time to 1% of VOUT s Efficiency 100% Load 50% Load 1) Vin = 24V 94.3 95.0 95.7 % Vin = 12V 93.2 93.9 94.6 % Vin = 24V 95.3 96 96.7 % Vin = 12V 94.9 95.6 96.3 % Section "Input and Output Capacitance" 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Page 6 of 24 Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS Electrical Specifications (Continued): Conditions: TA = 25 C, Airflow = 300 LFM (1.5 m/s), Vin = 24VDC, unless otherwise specified. Specifications are subject to change without notice. 24S53.19FXW Notes Parameter Operating Input Voltage Range Input Under Voltage Lockout Min Typ Max Units 9 24 36 V Non-latching Turn-on Threshold 8.2 8.5 8.8 V Turn-off Threshold 7.7 8.3 V Lockout Hysteresis Voltage 0.4 8.0 0.55 0.7 V Vin = 9V, 80% Load 89 A Vin = 12V, 100% Load 92 A Maximum Input Current 300 Vin = 24V, Output Shorted Input Stand-by Current Converter Disabled Input Current @ No Load Converter Enabled 360 ESR < 0.1 1000 1) Minimum Input Capacitance (external) Inrush Transient Input Reflected-Ripple Current, iC mARMS 2 4 mA 460 560 mA 0.19 F 2 A s ARMS 0.8 25 MHz bandwidth, 100% Load (Fig. 6) Output Characteristics Nominal Output Voltage Output Voltage Set Point Accuracy (No load) 52.20 53.00 54.02 V 52.780 53.00 53.220 V 0.05 Output Regulation Over Line Over Load Vin = 9V to 36V Vin = 24V, Load 0% to 100% Temperature Coefficient 60.4 Overvoltage Protection Output Ripple and Noise - 20 MHz bandwidth External Load Capacitance1) Output Current Range (See Fig. B) Current Limit Inception RMS Short-Circuit Current 0.1 0.1 % 0.05 0.005 0.015 %/C 64.7 69.4 V 70 140 mVPK-PK 50 mVRMS 100% Load, See Table 1 for external components Full Load (resistive) (over operating temp range) 16 CEXT ESR % 470 2200 F 10 100 m Vin = 12V - 36V 0 19 A Vin = 9V 0 15.2 A Vin = 12V - 36V 20.9 22.8 24.7 A 9V Vin < 12V 16.7 18.2 24.7 Non-latching 0.8 1.8 3.0 A ARMS Dynamic Response Load Change 50%-75%-50%, di/dt = 1A/s Load Change 50%-100%-50%, di/dt = 1A/s See Table 1 for external components 420 510 mV See Table 1 for external components 850 1100 mV 500 Settling Time to 1% of VOUT s Efficiency 100% Load 50% Load 1) Vin = 24V 94.9 95.7 96.4 % Vin = 12V 93.4 94.1 95 % Vin = 24V 95.3 96.2 96.9 % Vin = 12V 95.1 95.4 96.5 % Section "Input and Output Capacitance" 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Page 7 of 24 Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS Environmental and Mechanical Specifications. Specifications are subject to change without notice. Parameter Note Min Typ Max Units Environmental Operating Humidity Non-condensing 95 % Storage Humidity Non-condensing 95 % 1 ROHS Compliance See Calex Website http://www.calex.com/RoHS.html for the complete RoHS Compliance statement Shock and Vibration Designed to meet MIL-STD-810G for functional shock and vibration. Water washability Not recommended for water wash process. Contact the factory for more information. Mechanical Weight Through Hole Pins Diameter Pins 3, 3A, 4, 4A, 5, 6, 8 and 9 Pins 1, 2, 10, 11 and 12 Through Hole Pins Material Pins 3, 3A, 4, 4A, 5, 6 , 8 and 9 Through Hole Pin Finish All pins 8.55 Ounces 242 Grams 0.079 0.081 0.083 Inches 2.006 2.057 2.108 mm 0.038 0.04 0.042 Inches 0.965 1.016 1.667 mm 14500 or C1100 Copper Alloy Pins 1, 2, 10, 11 and 12 TB3 or "Eco Brass" 10" Gold over nickel Case Dimension 4.7 x 2.5 x 0.52 Inches 119.38 x 63.50 x 13.21 mm Plastic: Vectra LCP FIT30: 1/2-16 EDM Finish Case Material Aluminum Material Baseplate Flatness 0.010 Inches 0.25 mm 5.4 MHrs Reliability MTBF Telcordia SR-332, Method I Case 1 50% electrical stress, 40C components Agency Approvals UL60950 Approved EMI and Regulatory Compliance Conducted Emissions Additional Notes: The RoHS marking is as follows \ Output Power vs. Input Voltage 1200 Output Power [W] 1 MIL-STD 461F CE102 with external EMI filter network (See Figs. 57 and 58) 1000 800 600 400 200 0 9 12 15 18 21 24 27 30 33 36 Input Voltage [V] Figure A: Output Power as function of input voltage. 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Page 8 of 24 Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS Operations When converter is started by applying the input voltage with ON/OFF pin active there is delay of 500msec that was intentionally provided to prevent potential startup issues especially at low input voltages Input Fusing The FXW converters do not provide internal fusing and therefore in some applications external input fuse may be required. Use of external fuse is also recommended if there is possibility for input voltage reversal. For greatest safety, it is recommended to use fast blow fuse in the ungrounded input supply line. Input Reverse Polarity Protection The FXW converters do not have input reverse polarity. If input voltage polarity is reversed, internal diodes will become forward biased and draw excessive current from the power source. If the power source is not current limited or input fuse not used, the converter could be permanently damaged. Input Undervoltage Protection Input undervoltage lockout is standard with this converter. The FXW converter will start and regulate properly if the ramping-up input voltage exceeds Turn-on threshold of typ. 8.5V (See Specification) and remains at or above Turn-on Threshold. The converter will turn off when the input voltage drops below the Turn-off Threshold of typical 8V (See specification) and converter enters hiccup mode and will stay off for 2 seconds. The converter will restart after 2 seconds only if the input voltage is again above the Turnon Threshold. The built-on hysteresis and 2 second hiccup time prevents any unstable on/off operation at the low input voltage near Turn-on Threshold. User should take into account for IR and inductive voltage drop in the input source and input power lines and make sure that the input voltage to the converter is always above the Turn-off Threshold voltage under ALL OPERATING CONDITIONS. Because of the switching nature and negative input impedance of DC/DC converters, the input of these converters must be driven from the source with both low AC impedance and DC input regulation. The FXW converters are designed to operate without external components as long as the source voltage has very low impedance and reasonable voltage regulation. However, since this is not the case in most applications an additional input capacitor is required to provide proper operations of the FXW converter. Specified values for input capacitor are recommendation and need to be adjusted for particular application. Due to large variation between applications some experimentation may be needed. In many applications, the inductance associated with the distribution from the power source to the input of the converter can affect the stability and in some cases, if excessive, even inhibit operation of the converter. This becomes of great consideration for input voltage at 12V or below. The DC input regulation, associated with resistance between input power source and input of the converter, plays significant role in particular in low input voltage applications such as 12V battery systems. Note that input voltage at the input pins of the connector must never degrade below Turn-off threshold under all load operating conditions. Note that in applications with high pulsating loads additional input as well as output capacitors may be needed. In addition, for EMI conducted measurement, due to low input voltage it is recommended to use 5H LISNs instead of typical 50H LISNs. Input/ Output Filtering Input Capacitor Start-Up Time The start-up time is specified under two different scenarios: a) Startup by ON/OFF remote control (with the input voltage above the Turn-on Threshold voltage) and b) Start-up by applying the input voltage (with the converter enabled via ON/OFF remote control). The startup times are measured with maximum resistive load as: a) the interval between the point when the ramping input voltage crosses the Turn-on Threshold and the output voltage reaches 90% of its nominal value and b) the interval between the point when the converter is enabled by ON/OFF remote control and time when the output voltage reaches 90% of its nominal value. 2401 Stanwell Drive, Concord Ca. 94520 Input Source Impedance Ph: 925-687-4411 Page 9 of 24 Minimum required input capacitance, mounted close to the input pins of the converter, is 1000F with ESR < 0.1. Several criteria need to be met when choosing input capacitor: a) type of capacitor, b) capacitance to provide additional energy storage, c) RMS current rating, d) ESR value that will ensure that output impedance of the input filter is lower than input impedance of the converter and its variation over the temperature. Since inductance of the input power cables could have significant voltage drop due to rate of change of input current di(in)/dt during transient load operation, an external capacitor on the output of the converter is Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS required to reduce di(in)/dt. Another constraint is minimum rms current rating of the input capacitors which is application dependent. One component of input rms current handled by input capacitor is high frequency component at switching frequency of the converter (typ. 400kHz) and is specified under "Input terminal ripple current" iC. Typical values at full rated load and 24 Vin are provided in Section "Characteristic Waveforms" for each model and are in range of 2.5A- 3.6A . It is recommended to use ceramic capacitors for attenuating this component for input terminal ripple current, which is also required to meet requirement for conducted EMI (See EMI Section). The second component of the input ripple current is due to pulsating load current being reflected to the input and electrolytic capacitors usually used for this purpose need to be selected accordingly. Using several electrolytic capacitors in parallel on the input is recommended. ESR of the electrolytic capacitors, need to be carefully chosen taken into account temperature dependence. Output Capacitor Similar considerations apply for selecting external output capacitor. For additional high frequency noise attenuation use of ceramic capacitors is recommended while in order to provide stability of the converter during high pulsating load high value electrolytic capacitor is required. It is recommended to use several electrolytic capacitors in parallel in order to reduce effective ESR. Note that external output capacitor also reduces slew rate of the input current during pulsating load transients as discussed above. Table 1 shows recommend external output capacitance. ON/OFF (Pins 1 and 2) The ON/OFF pin is used to turn the power converter on or off remotely via a system signal and has positive logic. A typical connection for remote ON/OFF function is shown in Fig. 1. applied between ON/OFF pin and - INPUT pin. See the Electrical Specifications for logic high/low definitions. The negative logic version turns on when the ON/OFF pin is at logic low and turns off when at logic high. The converter is on when the ON/OFF pin is either shorted to - INPUT pin or kept below 0.8V. The converter is off when the ON/OFF pin is either left open or external voltage not more than 12V is applied between ON/OFF pin and - INPUT pin. See the Electrical Specifications for logic high/low definitions. The ON/OFF pin is internally pulled up to typically 4.5V via resistor and connected to internal logic circuit via RC circuit in order to filter out noise that may occur on the ON/OFF pin. A properly de-bounced mechanical switch, open-collector transistor, or FET can be used to drive the input of the ON/OFF pin. The device must be capable of sinking up to 0.36mA at a low level voltage of 0.8 V. During logic high, the typical maximum voltage at ON/OFF pin (generated by the converter) is 4.5V, and the maximum allowable leakage current is 160A. If not using the remote on/off feature leave the ON/OFF pin open. TTL Logic Level - The range between 0.81V and 2V is considered the dead-band. Operation in the dead-band is not recommended. External voltage for ON/OFF control should not be applied when there is no input power voltage applied to the converter. Output Overcurrent Protection (OCP) The converter is protected against overcurrent or short circuit conditions. Upon sensing an overcurrent condition, the converter will switch to constant current operation and thereby begin to reduce output voltage. When the output voltage drops below approx. 50% of the nominal value of output voltage, the converter will shut down. Once the converter has shut down, it will attempt to restart nominally every 2 seconds. The attempted restart will continue indefinitely until the overload or short circuit conditions are removed or the output voltage rises above 50% of its nominal value. Once the output current is brought back into its specified range, the converter automatically exits the hiccup mode and continues normal operation. During initial startup if output voltage does not exceed typical 50% of nominal output voltage within 500 msec after the converter is enabled, the converter will be shut down and will attempt to restart after 2 seconds. Fig. 1: Circuit configuration for ON/OFF function. The positive logic version turns on when the ON/OFF pin is at logic high and turns off when at logic low. The converter is on when the ON/OFF pin is either left open or external voltage greater than 2V and not more than 12V is 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Page 10 of 24 In case of startup into short circuit, internal logic detects short circuit condition and shuts down converter typical 5 msec after condition is detected. The converter will attempt to restart after 2 seconds until short circuit condition exists. Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS Output Overvoltage Protection (OVP) The converter will shut down if the output voltage across +OUT (Pins 5 and 6) and -OUT (Pins 8 and 9) exceeds the threshold of the OVP circuitry. The OVP circuitry contains its own reference, independent of the output voltage regulation loop. Once the converter has shut down, it will attempt to restart every 2 seconds until the OVP condition is removed. Note that OVP threshold is set for nominal output voltage and not trimmed output voltage value or remote sense voltage. Overtemperature Protection (OTP) Fig. 2: Circuit configuration for Remote sense function. The FXW converters have non-latching overtemperature protection. It will shut down and disable the output if temperature at the center of the base plate exceeds a threshold of typical 108C for 9Vin, 112 C for 12Vin and 115 C for 24Vin/36Vin. Measured with FXW converter soldered to 5" x 3.5" x 0.07" 4 layers/ 2 Oz Cooper FR4 PCB. The converter will automatically restart when the base temperature has decreased by approximately 20C. Safety Requirements The sense input and power Vout pins are internally connected through 100 (SENSE+ to +OUT) and 10 (SENSE- to -OUT) resistors enabling the converter to operate without external connection to the Sense. If the Sense function is not used for remote regulation, the user should connect SENSE- (Pin 10) to -OUT (Pins 8 and 9) and SENSE+ (Pin 11) to +OUT (Pins 5 and 6) at the converter pins. Sense lines must be treated with care in PCB layouts and should run adjacent to DC signals. If cables and discrete wiring is used, it is recommended to use twisted pair, shielded tubing or similar techniques. Basic Insulation is provided between input and the output. The converters have no internal fuse. To comply with safety agencies requirements, a fast-acting or time-delay fuse is to be provided in the unearthed lead. Recommended fuse values are: The maximum voltage difference between Sense inputs and corresponding power pins should be kept below 1V, i.e.: a) 140A for 9V<Vin<18V V(-OUT) - V(SENSE-) 1V b) 90A for 18V<Vin<36V. Note that maximum output power is determined by maximum output current and highest output voltage at the output pins of the converter: Electromagnetic Compatibility (EMC) EMC requirements must be met at the end-product system level, as no specific standards dedicated to EMC characteristics of board mounted component dc-dc converters exist. With the addition of a two stage external filter, the FXW converters will pass the requirements of MILSTD-461F CE102 Base Curve for conducted emissions. Note that 5uH LISN should be used in order to enable operation of the converter at low input voltage. Remote Sense Pins (Pins 10 and 11) Sense inputs compensate for output voltage inaccuracy delivered at the load. 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Page 11 of 24 V(SENSE+) - V(+OUT) 1V [V(+OUT) - V(-OUT)]x Iout Pout rated Output Voltage Adjust/TRIM (Pin 12) The TRIM (Pin 12) allows user to adjust output voltage 10% up or -40% down relative to rated nominal voltage by addition of external trim resistor. Trim resistor should be mounted close to the converter and connected with short leads. Internal resistor in the converter used for the TRIM is high precision 0.1% with temperature coefficient 25 ppm/ C. The accuracy of the TRIM is therefore determined by tolerance of external Trim resistor. If trimming is not used, the TRIM pin should be left open. Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS To trim the output voltage up, for example 24V to 26.4V, =10 and required external resistor is: Trim Down - Decrease Output Voltage Trimming down is accomplished by connecting an external resistor, Rtrim-down, between the TRIM (pin 12) and the SENSE- (pin 10), with a value of: - 9.98 [k] Rtrim-down = Where, Rtrim-down = Required value of the trim-down resistor [k] VO(NOM) = Nominal value of output voltage [V] VO(REQ) = Required value of output voltage [V] = ( ) ( ( ) ) [%] Rtrim-up = 4.99 24 100+10 1.2510 - 100+210 10 = 1015 k Note that trimming output voltage more than 10% is not recommended and OVP may be tripped. Active Voltage Programming In applications where output voltage need to be adjusted actively, an external voltage source, such as for example a Digital-to-Analog converter (DAC), capable of both sourcing and sinking current can be used. It should be connected across with series resistor Rg across TRIM (Pin 12) and SENSE- (Pin 10). External trim voltage should not be applied before converter is enabled in order to provide proper startup output voltage waveform and prevent tripping overvoltage protection. Please contact Calex technical representative for more details. Thermal Consideration Fig. 3: Circuit configuration for Trim-down function To trim the output voltage 10% (=10) down, required external trim resistance is: Rtrim-down = - 9.98 = 39.92 k 10 Trim Up - Increase Output Voltage Trimming up is accomplished by connecting an external resistor, Rtrim-up, between the TRIM (pin 12) and the SENSE+ (pin 11), with a value of: Rtrim-up = 4.99 VO NOM (100+) 1.25 - (100+2) [k] The FXW converter can operate in a variety of thermal environment. However, in order to ensure reliable operation of the converter, sufficient cooling should be provided. The FXW converter is encapsulated in plastic case with metal baseplate on the top. In order to improve thermal performance, power components inside the unit are thermally coupled to the baseplate. In addition, thermal design of the converter is enhanced by use of input and output pins as heat transfer elements. Heat is removed from the converter by conduction, convection and radiation. There are several factors such as ambient temperature, airflow, converter power dissipation, converter orientation how converter is mounted as well as the need for increased reliability that need to be taken into account in order to achieve required performance. It is highly recommended to measure temperature in the middle of the baseplate in particular application to ensure that proper cooling of the converter is provided. A reduction in the operating temperature of the converter will result in an increased reliability. Thermal Derating There are two most common applications: 1) the FXW converter is thermally attached to a cold plate inside chassis without any forced internal air circulation; 2) the FXW converter is mounted in an open chassis on system board with forced airflow with or without an additional heatsink attached to the base plate of the FXW converter. Fig. 4: Circuit configuration for Trim-up function 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Page 12 of 24 The best thermal results are achieved in application 1) since the converter is cooled entirely by conduction of heat Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS from the top surface of the converter to a cold plate and temperature of the components is determined by the temperature of the cold plate. There is also some additional heat removal through the converter's pins to the metal layers in the system board. It is highly recommended to solder pins to the system board rather than using receptacles. Typical derating output power and current are shown in Figs. 17-26 for various baseplate temperatures up to 105C. Note that operating converter at these limits for prolonged time will affect reliability. FXW converters are not recommended for water wash process. Contact the factory for additional information if water wash is necessary. Test Configuration Soldering Guidelines The ROHS-compliant through-hole FXW converters use Sn/Ag/Cu Pb-free solder and ROHS-compliant component. They are designed to be processed through wave soldering machines. The pins are 100% matte tin over nickel plated and compatible with both Pb and Pbfree wave soldering processes. It is recommended to follow specifications below when installing and soldering FXW converters. Exceeding these specifications may cause damage to the FXW converter. Fig. 5: Test setup for measuring input reflected ripple currents ic . Wave Solder Guideline For Sn/Ag/Cu based solders Maximum Preheat Temperature 115 C Maximum Pot Temperature 270 C Maximum Solder Dwell Time 7 seconds Wave Solder Guideline For Sn/Pb based solders Maximum Preheat Temperature 105 C Maximum Pot Temperature 250 C Maximum Solder Dwell Time 6 seconds Fig. 6: Test setup for measuring output voltage ripple, startup and step load transient waveforms. 24S24.42FXW 24S48.21FXW 24S28.36FXW 24S53.19FXW Ref. Des. Manufacturing p/n 24S12.84FXW L1 N/A 6 ft. cable, AWG 4 100nH 100nH CIN MAL214699108E3 (Vishay) 2 x 470 F / 72m (650m) 2 x 470 F / 72m (650m) 2 x 470 F / 76m (650m) C1 GRM32ER72A475KA12L 10 F / 1210 / X7R / 100v 10 F / 1210/X7R/100V 10 F / 1210 / X7R / 100V PCR1E471MCL1GS 3 X 470 F/ 25V / 15 m (30 m) N/A N/A PCR1J101MCL1GS (Nichicon) N/A 3 x 100 F / 63V / 24 m (48 m) N/A PCR1K680MCL1GS (Nichicon) N/A N/A 3 x 68 F / 80V / 28 m (56 m) UPS2A221MPD (Nichicon) N/A 220 F / 100V / 100m 220 F / 100V / 100m MAL214699108E3 (Vishay) N/A 470 F / 72m (650m) N/A MAL214699606E3 (Vishay) 2 X 1500 F / 50m (450m) N/A N/A MAL214699608E3 (Vishay 2200 F / 50m (450m) N/A N/A C2 Table 1: Component values used in test setup from Figs. 5 and 6. Resistance in ( ) represents ESR value at -40C for specified capacitor. 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Page 13 of 24 Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS Characteristic Curves - Efficiency and Power Dissipation Fig. 7: 24S12.84FXW (ROHS) Efficiency Curve Fig. 8: 24S12.84FXW (ROHS) Power Dissipation Fig. 9: 24S24.42FXW (ROHS) Efficiency Curve Fig. 10: 24S24.42FXW (ROHS) Power Dissipation Fig. 11: 24S28.36FXW (ROHS) Efficiency Curve Fig. 12: 24S28.36FXW (ROHS) Power Dissipation 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Page 14 of 24 Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS Characteristic Curves - Efficiency and Power Dissipation (Cont'd) Fig. 13: 24S48.21FXW (ROHS) Efficiency Curve Fig. 14: 24S48.21FXW (ROHS) Power Dissipation Fig. 15: 24S53.19FXW (ROHS) Efficiency Curve Fig. 16: 24S53.19FXW (ROHS) Power Dissipation 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Page 15 of 24 Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS Characteristic Curves - Derating Curves Fig. 18: 24S12.84FXW (ROHS) Derating Curve Fig. 17: 24S12.84FXW (ROHS) Derating Curve Output Current vs. Base Plate Temperature - 24S24.42FXW Output Power vs. Base Plate Temperature - 24S24.42FXW 1000 40 900 36 800 32 Output Current [W] 44 Output Power [W] 1100 700 600 500 400 300 28 24 20 16 12 8 200 4 100 0 0 25 30 35 40 45 50 55 60 65 70 75 80 Baseplate Temperature [C] Vin=9V 85 90 25 95 100 105 35 40 45 50 55 60 65 70 75 80 Baseplate Temperature [C] Vin=9V Vin=12V, 24V, 36V 85 90 95 100 105 Vin=12V, 24V, 36V Fig. 20: 24S24.42FXW (ROHS) Derating Curve Fig. 19: 24S24.42FXW (ROHS) Derating Curve Output Current vs. Base Plate Temperature - 24S28.36FXW Output Power vs. Base Plate Temperature - 24S28.36 XW 40 1100 36 1000 32 Output Current [W] 900 800 Output Power [W] 30 700 600 500 400 300 28 24 20 16 12 8 200 4 100 0 0 25 25 30 35 40 45 50 55 60 65 70 75 80 Baseplate Temperature [C] Vin=9V 85 90 35 40 45 50 55 60 65 70 75 80 Baseplate Temperature [C] Vin=9V Vin=12V, 24V, 36V Fig. 21: 24S28.36FXW (ROHS) Derating Curve 2401 Stanwell Drive, Concord Ca. 94520 30 95 100 105 Ph: 925-687-4411 Page 16 of 24 85 90 95 100 105 Vin=12V, 24V, 36V Fig. 22: 24S28.36FXW (ROHS) Derating Curve Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS Characteristic Curves - Derating Curves (Cont'd) Output Power vs. Base Plate Temperature - 24S48.21FXW Output Current vs. Base Plate Temperature - 24S48.21FXW 1000 20 900 18 800 16 Output Current [W] 22 Output Power [W] 1100 700 600 500 400 300 14 12 10 8 6 200 4 100 2 0 0 25 30 35 40 45 50 55 60 65 70 75 80 Baseplate Temperature [C] Vin=9V 85 90 95 100 105 25 35 40 45 50 55 60 65 70 75 80 Baseplate Temperature [C] Vin=9V Vin=12V, 24V, 36V 20.0 1000 18.0 900 16.0 Output Current [W] 700 600 500 400 300 95 100 105 Vin=12V, 24V, 36V 14.0 12.0 10.0 8.0 6.0 200 4.0 100 2.0 0 90 Output Current vs. Base Plate Temperature - 24S53.19FXW Output Power vs. Base Plate Temperature - 24S53.19FXW 1100 800 85 Fig. 24: 24S48.21FXW (ROHS) Derating Curve Fig. 23: 24S48.21FXW (ROHS) Derating Curve Output Power [W] 30 0.0 25 30 35 40 45 50 55 60 65 70 75 80 Baseplate Temperature [C] Vin=9V 85 90 95 100 105 25 30 35 40 50 55 60 65 70 75 80 Baseplate Temperature [C] Vin=9V Vin=12V, 24V, 36V Fig. 25: 24S53.19FXW (ROHS) Derating Curve 2401 Stanwell Drive, Concord Ca. 94520 45 Ph: 925-687-4411 Page 17 of 24 85 90 95 100 105 Vin=12V, 24V, 36V Fig. 26: 24S53.19FXW (ROHS) Derating Curve Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS Characteristic Waveforms - 24S12.84FXW Fig. 27: Turn-on by ON/OFF transient (with Vin applied) at full rated load current (resistive) at Vin = 14V. Top trace (C1): ON/OFF signal (5 V/div.). Bottom trace (C4): Output voltage (5 V/div.). Time: 10 ms/div. Fig. 28: Turn-on by Vin transient (ON/OFF high) at full rated load current (resistive) at Vin = 44V. Top trace (C2): Input voltage Vin (5 V/div.). Bottom trace (C4): Output voltage (5 V/div.). Time: 100 ms/div. Fig. 29: Output voltage response to load current step change 70% - 100%70% (58.5A-84A-58.8A) with di/dt =0.5A/s at Vin = 14V . Top trace (C4): Output voltage (200 mV/div.). Bottom trace (C3): Load current (50A/div.). Time: 1ms/div. Fig. 30: Output voltage response to load current step change 50% - 100%50% (42A-84A-42A) with di/dt =1A/s at Vin = 14 V. Top trace (C4): Output voltage (500 mV/div.). Bottom trace (C3): Load current (50A/div.). Time: 1ms/div. Fig. 31: Output voltage ripple (100 mV/div.) at full rated load current into a resistive load at Vin = 14 V. Time: 2 s/div. Fig. 32 Input reflected ripple current, ic (500mA/mV), measured at input terminals at full rated load current at Vin = 24 V. Refer to Fig. 2 for test setup. Time: 2 s/div. RMS input ripple current is 7.3*0.5A = 3.65Arms. . 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Page 18 of 24 Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS Characteristic Waveforms - 24S24.42FXW Fig. 33: Turn-on by ON/OFF transient (with Vin applied) at full rated load current (resistive) at Vin = 24V. Top trace (C1): ON/OFF signal (5 V/div.). Bottom trace (C4): Output voltage (10 V/div.). Time: 5 ms/div. Fig. 34: Turn-on by Vin transient (ON/OFF high) at full rated load current (resistive) at Vin = 24V. Top trace (C2): Input voltage Vin (10 V/div.). Bottom trace (C4): Output voltage (10 V/div.). Time: 100 ms/div. Fig. 35: Output voltage response to load current step change 50% - 75%50% (21A-31.5A-21A) with di/dt =1A/s at Vin = 24V . Top trace (C4): Output voltage (200 mV/div.). Bottom trace (C3): Load current (20A/div.). Co = 470F/70m. Time: 1ms/div. Fig. 36: Output voltage response to load current step change 50% - 100%50% (21A-42A-21A) with di/dt =1A/s at Vin = 24 V. Top trace (C4): Output voltage (500 mV/div.). Bottom trace (C3): Load current (20A/div.). Co = 2 x 470 F/70m. Time: 1ms/div. Fig. 37: Output voltage ripple (100 mV/div.) at full rated load current into a resistive load at Vin = 24 V. Co = 2 x 470 F/70m. Time: 2 s/div. Fig. 38: Input reflected ripple current, ic (500mA/mV), measured at input terminals at full rated load current at Vin = 24 V. Refer to Fig. 2 for test setup. Time: 2 s/div. RMS input ripple current is 7.3*0.5A = 3.65Arms. 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Page 19 of 24 Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS Characteristic Waveforms - 24S28.36FXW Fig. 39: Turn-on by ON/OFF transient (Vin applied) at full rated load current (resistive) at Vin = 24V. Top trace (C1): ON/OFF signal (5 V/div.). Bottom trace (C4): Output voltage (10 V/div.). Time: 5 ms/div. Fig. 40: Turn-on by Vin (ON/OFF high) transient at full rated load current (resistive) at Vin = 24V. Top trace (C2): Input voltage Vin (10 V/div.). Bottom trace (C4): Output voltage (10 V/div.). Time: 100 ms/div. Fig. 41: Output voltage response to load current step change 50% - 75%50% (18A-27A-18A) with di/dt =1A/s at Vin = 24V . Top trace (C4): Output voltage (200 mV/div.). Bottom trace (C3): Load current (10A/div.). Co = 470F/70m. Time: 1ms/div. Fig. 42: Output voltage response to load current step change 50% - 100%50% (18A-36A-18A) with di/dt =1A/s at Vin = 24V . Top trace (C4): Output voltage (500 mV/div.). Bottom trace (C3): Load current (10A/div.). Co = 470 F/70m. Time: 1ms/div. Fig. 43: Output voltage ripple (100 mV/div.) at full rated load current into a resistive load at Vin = 24 V. Co = 470 F/70m. Time: 2 s/div. Fig. 44: Input reflected ripple current, ic (500 mA/div.), measured at input terminals at full rated load current at Vin = 24 V. Refer to Fig. 2 for test setup. Time: 2 s/div. RMS input ripple current is 4.968*0.5A = 2.48Arms. 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Page 20 of 24 Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS Characteristic Waveforms - 24S48.21FXW Fig. 45: Turn-on by ON/OFF transient (Vin applied) at full rated load current (resistive) at Vin = 24V. Top trace (C1): ON/OFF signal (5 V/div.). Bottom trace (C4): Output voltage (10 V/div.). Time: 10 ms/div. Fig. 46: Turn-on by Vin (ON/OFF high) transient at full rated load current (resistive) at Vin = 24V. Top trace (C2): Input voltage Vin (10 V/div.). Bottom trace (C4): Output voltage (10 V/div.). Time: 100 ms/div. Fig. 47: Output voltage response to load current step change 50% - 75%50% (10.5A-15.75A-10.5A) with di/dt =1A/s at Vin = 24V . Top trace (C4): Output voltage (200 mV/div.). Bottom trace (C3): Load current (10A/div.).. Time: 1ms/div. Fig. 48: Output voltage response to load current step change 50% - 100%50% (10.5A-21A-10.5A) with di/dt =1A/s at Vin = 24V . Top trace (C4): Output voltage (500 mV/div.). Bottom trace (C3): Load current (10A/div.). Time: 1ms/div. Fig. 49: Output voltage ripple (100 mV/div.) at full rated load current into a resistive load at Vin = 24 V. Time: 2 s/div. Fig. 50: Input reflected ripple current, ic (500 mA/div.), measured at input terminals at full rated load current at Vin = 24 V. Refer to Fig. 2 for test setup. Time: 2 s/div. RMS input ripple current is 7.3*0.5A = 3.65Arms.. 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Page 21 of 24 Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS Characteristic Waveforms - 24S53.19FXW Fig. 51: Turn-on by ON/OFF transient (Vin applied) at full rated load current (resistive) at Vin = 24V. Top trace (C1): ON/OFF signal (5 V/div.). Bottom trace (C4): Output voltage (10 V/div.). Time: 10 ms/div. Fig. 53: Output voltage response to load current step change 50% - 75%50% (9.5A-14.25A-9.5A) with di/dt =1A/s at Vin = 24V . Top trace (C4): Output voltage (200 mV/div.). Bottom trace (C3): Load current (10A/div.).. Time: 1ms/div. Fig. 55: Output voltage ripple (100 mV/div.) at full rated load current into a resistive load at Vin = 24 V. Time: 2 s/div. 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Page 22 of 24 Fig. 52: Turn-on by Vin (ON/OFF high) transient at full rated load current (resistive) at Vin = 24V. Top trace (C2): Input voltage Vin (10 V/div.). Bottom trace (C4): Output voltage (10 V/div.). Time: 100 ms/div. Fig. 54: Output voltage response to load current step change 50% - 100%50% (9.5A-19A-9.5A) with di/dt =1A/s at Vin = 24V . Top trace (C4): Output voltage (500 mV/div.). Bottom trace (C3): Load current (10A/div.). Time: 1ms/div. Fig. 56: Input reflected ripple current, ic (500 mA/div.), measured at input terminals at full rated load current at Vin = 24 V. Refer to Fig. 2 for test setup. Time: 2 s/div. RMS input ripple current is 4.968*0.5A = 2.48Arms. Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS EMC Consideration The filter circuit schematic for suggested input filter configuration as tested to meet the conducted emission limits of MILSTD-461F CE102 Base Curve is shown in Fig. 57. The plots of conducted EMI spectrum measured using 5uH LISNs are shown in Fig. 58. Note: Customer is ultimately responsible for the proper selection, component rating and verification of the suggested parts based on the end application. Comp. Des. Description C1, C2, C12, C14 470F/50V/70m Electrolytic Capacitor (Vishay MAL214699108E3 or equivalent) C3, C4, C5, C6 4.7nF/1210/X7R/1500V Ceramic Capacitor C7, C8, C9, C10, C11, C13 10F/1210/X7R/50V Ceramic Capacitor L1 CM choke, 130uH, Leakage = 0.6uH (4T on toroid 22.1mm x 13.7 mm x 7.92 mm) Fig. 57: Typical input EMI filter circuit to attenuate conducted emissions per MILSTD-461F CE102 Base Curve. a) b) Without input filter from Fig. 47 (C9 = 2 x 470F/50V/70m) With input filter from Fig. 47. Fig. 58: Input conducted emissions measurement (Typ.) of 24S24.42FXW. 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Page 23 of 24 Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2 1000 WATT FXW SERIES DC/DC CONVERTERS Mechanical Specification Input/ Output Connections Pin Label Function 1 +ON/OFF TTL input with internal pull up, referenced to -ON/OFF pin, used to turn converter on and off 2 -ON/OFF Negative input of Remote ON/OFF 3 -INPUT Negative Input Voltage 3A -INPUT Negative Input Voltage 4 +INPUT Positive Input Voltage 4A +INPUT 5 +OUT Positive Output Voltage 6 +OUT Positive Output Voltage 8 -OUT Negative Output Voltage 9 -OUT Negative Output Voltage SENSE- Negative Remote Sense 11 SENSE+ Positive Remote Sense Unless otherwise specified: All dimensions are in inches [millimeter] Tolerances: x.xx in. 0.02 in. [x.x mm 0.5mm] x.xxx in. 0.010 in. [x.xx mm 0.25mm] Torque fasteners into threaded mounting inserts at 10 in.lbs. or less. Greater torque may result in damage to unit and void the warranty. Positive Input Voltage 10 NOTES: TRIM Used to trim output voltage +10/-40% 12 Note: 1) Pinout as well as pin number and pin diameter are inconsistent between manufacturers of the full brick converters. Make sure to follow the pin function, not the pin number as well as spec for pin diameter when laying out your board. 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Page 24 of 24 Fax: 925-687-3333 www.calex.com Email: sales@calex.com ECO 171214-1, (1/16/18), 180206-2