A
15 Watt TC Dual Series 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
1
3/2001, eco# 041007-1
Features
Wide input voltage range
Efficiencies of 82% typical
1544 VDC isolation
Small 2.02" x 1.62" case
Overvoltage and overtemperature protection
Five Year Warranty
Description
These 48 Volt, dual output converters are designed to provide
a wide range of power solutions. Their extra wide input range
of 20 to 72 VDC covers both the common American and
European telecom standards plus 24 Volt industrial control
applications.
For flexibility, the output voltage can be adjusted with a trim
pin to compensate for voltage drops or to achieve non-
standard voltages. A remote ON/OFF function maximizes
battery life.
The TC Dual Series continues the CALEX tradition of
reliable design by including transient overvoltage suppressor
diode protection. Overcurrent and overtemperature protection
circuits are also standard. All CALEX products are backed by
a Five Year Warranty.
15 Watt TC Dual Series Block Diagram
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UL Recognition only applies up to 60 VDC
A
15 Watt TC Dual Series 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
2
3/2001, eco# 041007-1
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NOTES
*
All Parameters measured at 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.
(1)
Noise is measured per CALEX Application Notes. Measurement
bandwidth is 0-20 MHz.
(2)
An input capacitor must be used for proper operation of the
converter. See the Application Note on sizing the input capacitor.
(3)
See the typical application note. Also refer to CALEX Application
Notes on fuse sizing.
(4)
Load regulation for the outputs is specified as the voltage
change when both outputs are changed from maximum to
minimum at the same time.
(5)
Cross regulation is defined as the change in one output when the
other output is changed from full load to 25% of full load. The
converter can be run at no load on either or both outputs with no
damage.
(6)
Short term stability is specified after a 60 minute warmup at full
load, constant line and recording the drift over a 24 hour period.
(7)
The transient response is specified as the time required to settle
from a 50 to 75 % step load change (rise time of step = 2 s) to
a 1% error band.
(8)
Dynamic response is the peak overshoot during a transient as
defined in note 7 above.
(9)
The input ripple rejection is specified for DC to 120 Hz ripple with
a modulation amplitude of 1% of Vin.
(10) For module protection only, see also note 3.
(11) The logic ON/OFF pin is Open Collector TTL, CMOS, and relay
compatible. The input to this pin is referenced to Pin 2, -Input
and is protected to +100 VDC.
(12) Case is tied to Pin 1, + input.
(13) The case thermal impedance is specified as the case temperature
rise over ambient per package watt dissipated.
(14) Specifications subject to change without notice.
(15) 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.
*
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UL Recognition only applies up to 60 VDC
A
15 Watt TC Dual Series 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
3
3/2001, eco# 041007-1
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BOTTOM VIEW
S I D E
VIEW
Mechanical tolerances unless otherwise noted:
X.XX dimensions: 0.010 inches
X.XXX dimensions: 0.005 inches
Figure 1.
Typical Application
Sizing The Input Capacitor
For maximum reliability the 15 Watt TC Dual Series DC/DC
converter 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 and shortening of the capacitors and hence your
system's 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:
1) Expected ambient temperature and your temperature
derating guidelines.
2) Your ripple current derating guidelines.
3) The maximum load expected on the converter.
4) The minimum input voltage expected on the converter.
5) The statistical probability that your system will spend
a significant amount of time at any worst case extreme.
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 the capacitor
can do 1A RMS and 100 VDC you would not use the part over
15 Watt TC Dual Typical Application
An input capacitor is required for proper operation (see Figure
1). 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
prevents unlimited current from flowing in the case of a
catastrophic system failure.
AN INPUT CAPACITOR IS REQUIRED FOR PROPER
OPERATION. SEE NOTE TEXT.
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Note: On nominal 48Vin models UL recognition only applies up to 60 VDC
A
15 Watt TC Dual Series 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
4
3/2001, eco# 041007-1
maximum) because these usually have the highest ripple
current capability per unit volume.
Be careful to compare apples to apples. Some
manufacturers specify their capacitors at 85 C and others
specify at 105C. The manufacturers give temperature derating
guidelines, so all capacitors should be normalized to your
maximum ambient (plus 5 to account for self heating) before
making a selection. Since the 15 Watt TC Dual 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.
One note: The temperature derating multipliers are set up
on the basis of the same life as would be expected 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 1A RMS current at 105C and 2A RMS at 50C will
have the same life if used at either point, while the same
capacitor used at 1A RMS and 50C will have a longer life.
Suggested Capacitor Sources
Suitable capacitors can be found from the following sources:
United Chemi-Con SXE, RXC, RZ and RZA Series
Suggested Part:
SXE100VB221M12.5X35LL
220 F, 100V, 105C Rated
ESR = 0.087 ohms,
Allowable Ripple = 1.04 A
Nichicon
PR and PF
Suggested Part:
UPR100102MPHRH
1000F, 100V, 105C Rated
ESR = 0.047 ohms,
Allowable Ripple = 1.32 A
Panasonic
HFE Series
Suggested Part:
ECEA2AFE221L
220F, 100V, 105C Rated
ESR = 0.089 ohms,
Allowable Ripple = 1.04 A
The suggested capacitors will work worst case for any line
and load condition. They may be oversized for your application,
however. See the discussion above on capacitor sizing.
Remote ON/OFF Circuit Operation
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 pullup resistor inside the
unit to +9 Volts DC.
Other applications of the ON/OFF function can be found in
the CALEX Application Note: "Understanding the Remote
ON/OFF Function."
700 mA RMS and 70 VDC. Surge voltage rating should also
be evaluated against any expected voltage surges when
selecting a capacitor working voltage.
Factors 3 and 4 determine the worst case ripple current.
The reflected ripple current increases with output load and it
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
nearly 2.7:1 under what would be required for operation at 20
VDC with full load (see the "Input Ripple" curve).
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. However, you
can make educated assumptions about your system's usage.
It might not be strategically or economically sound to design
a system to survive in a worst case environment if you know
that no systems are likely to be in such an environment long
term.
Example Of Capacitor Sizing
Given the following conditions select the minimum size
capacitor needed to give reliable performance:
Converter .............................................. 48D12.625TC
Minimum Input Voltage ......................... 40 VDC
Maximum Input Voltage ........................ 52 VDC
Maximum Load ..................................... 470 mA
Maximum Ambient Temperature .......... 40 C
Your Capacitor Voltage
Derating Guideline ..... 70% of Maximum Specification
Your Capacitor Current
Derating Guideline ..... 70% of Maximum Specification
Solution
Looking at the 15 Watt TC Dual Series "Reflected Ripple vs.
Line Input" curve at 40 VDC input and 470 mA output (75% of
rated load) the reflected input ripple can be read as 590 mA
RMS. From the derating guidelines the capacitor's rated
voltage and ripple current can be found.
Capacitor voltage rating is calculated as:
V =
x Maximum Expected Input
V = (1/0.7) x 52 VDC = 74 Volts or greater
The next larger standard value is 80 VDC.
Capacitor ripple current rating is calculated as:
I =
x Reflected Ripple
I = (1/0.7) x 590 mA = 843 mA RMS or greater at 45C (40
C ambient + 5C for self heating).
A capacitor selection can now be made. Look only at
controlled low ESR types (where the ESR is specified as a
1
Voltage Derating Factor
1
Current Derating Factor
A
15 Watt TC Dual Series 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
3/2001, eco# 041007-1
Figure 2.
Output Trim Methods
Proper Application Of The Trim Pin
The trim pin is used to adjust the output voltage slightly to
compensate for voltage drops in the system's wiring. Figure
2 shows the proper application of the trim pin. Either a 10 K
trimpot or a fixed resistor may be used.
The TC series can be adjusted easily for other non-
standard output voltages. To get 8 or 9 Volts for RF applications
a 12 Volt output converter can be used.
The output power must be limited to 15 Watts when
trimming the output up (the output current must be reduced to
keep a constant power output). When trimming the output
down, the output current must be kept at or below the
maximum current listed for that model.
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 out the temperature of the entire system and prevent
temperature gradients.
The 15 Watt TC Dual Series has a thermal impedance of
10 C per package watt dissipated. In normal operation the 15
Watt TC Dual Series can be expected to run at 81 % efficiency
at 48 VDC and full load. This means that the 15 Watt TC Dual
Series is dissipating nearly 3.5 Watts internally at full load.
This translates to a package temperature rise of 35C (10C/
Watt x 3.5 Watts dissipated). The maximum rated case
temperature for the 15 Watt TC Series is 100C. This means
that in the absence of other heat sources (including the load
that the TC is powering) and with at least 3 inches of clearance
the 15 Watt TC Dual Series could be expected to operate at
an ambient of 65C.
Additional heat sinking or cooling air flow can extend the
ambient temperature of operation significantly.
In the event of system cooling blockage or failure, the
thermal shut-off of the 15 Watt TC Dual Series will prevent any
catastrophic power converter failure. When the ambient
temperature cools below the thermal limit temperature the
unit will restart.
A
15 Watt TC Dual Series 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
6
3/2001, eco# 041007-1
Typical Performance (Tc=25C, Vin=Nom VDC, Rated Load).
20
24
28
32
36
40
44
48
52
56
60
64
68
72
LINE INPUT (VOLTS)
75
80
85
90
EFFICIENCY (%)
EFFICIENCY Vs. LINE INPUT (12V OUTPUT)
100% FULL LOAD
50% FULL LOAD
10
100
1000
10000
100000
1000000
FREQUENCY (Hz)
.01
.1
1
10
OUTPUT IMPEDANCE (OHMS)
OUTPUT IMPEDANCE Vs. FREQUENCY
20
24
28
32
36
40
44
48
52
56
60
64
68
72
LINE INPUT (VOLTS)
0.0
0.2
0.4
0.6
0.8
1.0
REFLECTED RMS RIPPLE (AMPS)
INPUT RIPPLE Vs. LINE INPUT (12V OUTPUT)
100% FULL LOAD
50% FULL LOAD
75% FULL LOAD
-40 -30 -20 -10
0
10
20
30
40
50
60
70
80
90
100
CASE TEMPERATURE (Deg C)
-0.35
-0.30
-0.25
-0.20
-0.15
-0.10
-0.05
-0.00
0.05
NORMALIZED OUTPUT (%)
OUTPUT VOLTAGE Vs. CASE TEMPERATURE
0
8
16
24
32
40
48
56
64
72
LINE INPUT (VOLTS)
0.0
0.3
0.6
0.9
1.2
INPUT CURRENT (AMPS)
INPUT CURRENT Vs. LINE INPUT (12V OUTPUT)
100% FULL LOAD
50% FULL LOAD
0
50
100
150
200
250
300
350
400
OUTPUT LOAD (%)
0
20
40
60
80
100
120
OUTPUT VOLTAGE (%)
OUTPUT VOLTAGE Vs. OUTPUT LOAD (12V OUTPUT)
0
10
20
30
40
50
60
70
80
90
100
LOAD (%)
60
70
80
90
EFFICIENCY (%)
EFFICIENCY Vs. LOAD (12V OUTPUT)
LINE =
20VDC
LINE =
48VDC
LINE=
72VDC
-40 -30 -20 -10
0
10
20
30
40
50
60
70
80
90 100 110
AMBIENT TEMPERATURE (Deg C)
0
20
40
60
80
100
120
OUTPUT POWER (%)
DERATING
INFINITE HEAT SINK
NO HEAT SINK
SAFE OPERATING AREA
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