XC-Series - Calex Mfg. Co. Inc. - Datasheet.Directory

25 to 30 Watt XC Triple 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

13/2001

ANTI-PHASE

DUAL PWM

CONTROLLER

DIFFERENTIAL

MODE

INPUT

FILTER

SHIELDED

ISOLATION TRANSFORMERS

THERMAL SHUTDOWN

SINGLE SECTION

ISOLATION BARRIER

DUAL SECTION

SHIELDED, LOW THERMAL GRADIENT COPPER CASE

48T MODELS

ONLY

12T AND 24T

MODELS

+ INPUT

- INPUT

ON/OFF

+ 5

+ 5 CMN

+ 5 TRIM

+ 12/15

± CMN

- 12/15

Features

!Single and Dual Output Sections Isolated

from each Other and Independently Regulated

!Overall Output Accuracy up to 10:1 Better than

Competitive Products

!Standby Current Less than 0.5 mA for Low Power

Pulsed Battery Operation

!Fully Filtered and Specified; Very Low Noise Inputs

and Outputs

!PCB Mounting with Optional Heat Sink and Chassis

Mounting Kit

!Industrial Operating Temperature Range Standard,

-40 to 85°C

!Five Year Warranty

Description

The 25-30 Watt Triple Series opens up new application areas

in high efficiency DC/DC conversion. The unique dual control

loop output design allows for independent regulation of both

the single and dual outputs. This increases the total output

accuracy by up to 10:1 over competitive designs. The design

also eliminates cross regulation from the +5 section to the

dual outputs. The 25-30 Watt Triple Series runs at 80-85%

efficiency.

25-30 Watt Triple Series Block Diagram

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CX21.5T210.010.0221±,5005±,0052

CX51.5T210.010.0251±,5004±,0052

CX21.5T420.810.6321±,5526±,0003

CX51.5T420.810.6351±,5005±,0003

CX21.5T840.630.2721±,5526±,0003

CX51.5T840.630.2751±,5005±,0003

25 to 30 Watt XC Triple 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

23/2001

(5) The dual section load regulation is defined as the voltage

change in either output as the loads on both outputs are changed

from minimum load to maximum load at the same time.

(6) Cross regulation is defined as the change in one output when the

other output is changed from minimum to maximum load.

(7) Short term stability is specified after a 30 minute warmup at full

load, constant line, load and ambient conditions.

(8) Transient response is defined as the time for the output to settle

from a 25 to 75 % step load change to a 1% error band (rise time

of step = 2µ Sec).

(9) Dynamic response is defined as the peak overshoot during a

transient as defined in note 8 above.

(10) The input ripple rejection is specified for DC to 120 Hz ripple with

a modulation amplitude of 1% of Vin.

NOTES

*All parameters measured at Tc = 25°C, 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.

(2) Noise is measured per CALEX Application Notes found in the

CALEX Power Conversion Design Guide and Catalog.

Measurement bandwidth is 0 - 20 MHz. See the applications

section of this note for more information.

(3) Determine the correct fuse size by calculating the maximum DC

current drain at low line input, maximum load and then adding 20

to 25% to get the desired fuse size. A slow blow type fuse is

recommended.

(4) Minimum load is required for proper regulation only. No module

damage is sustained if run less than minimum load. Regulation

of the dual output degrades with substantial load unbalance.

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25 to 30 Watt XC Triple 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

33/2001

Heat Sink Option

The 25-30 Watt Triple can be ordered with a “-I” configuration

which provides a case with 3 by M3 inserts located on the top

surface of the case for attaching a heat sink. When an “-HS”

is ordered CALEX will ship the converter with a heat sink

attached. The CALEX HS heat sink was specially developed

for this model and can reduce the case temperature rise to

below 3.3°C per watt with natural convection and less with

moving air. One heat sink is needed for each 25-30 Watt

Triple ordered.

Customer installed heat sinks may also be used. It is

recommended that only liquid heat sink compound be used on

the heat sink interface. Avoid the so called “Dry” pad heat sink

materials. In our experience these materials are actually

worse than using no compound at all.

Mechanical tolerances unless otherwise noted:

X.XX dimensions: ±0.020 inches

X.XXX dimensions: ±0.005 inches

Seal around terminals is not hermetic. Do not immerse units in any

liquid.

BOTTOM VIEW SIDE VIEW

(11) For module protection only, see also note 3.

(12) The ON/OFF pin is Open Collector TTL, CMOS, and relay

compatible. The input to this pin is referenced to the -input.

(13) The functional temperature range is intended to give an additional

data point for use in evaluating this power supply. At the low

functional temperature the power supply will function with no

side effects, however, sustained operation at the high functional

temperature will reduce expected operational life. The data

sheet specifications are not guaranteed over the functional

temperature range.

(14) Specifications subject to change without notice.

Chassis Mounting Kit - MS12

The MS12 chassis mounting kit allows for direct wire connection

to the 25-30 Watt Triple Series. The mounting kit includes two

barrier strips for wire attachment, an input fuse and an output

trim pot for trimming the +5 volt output. Provisions are also

made for additional output bypassing and grounding.

If the MS12 is ordered at the same time as a 25-30 Watt

Triple the mounting kit will be shipped with the correct fuse

size.

The MS12 may be conveniently attached to a chassis by

using the 4 - 0.156 inch diameter mounting holes provided at

each corner.

Although the MS12 comes with solderless sockets for the

25-30 Watt Triple, it is recommended that the converter be

soldered to the mounting kit for improved reliability under

severe environmental or vibration conditions.

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25 to 30 Watt XC Triple 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

43/2001

TRIM DOWN

TRIM UP

+ 5 LOAD

10K TRIMPOT

+ 5

+ 5 TRIM

+ 5 CMN

+ INPUT

- INPUT

ON/OFF

+ 5 LOAD

+ 5 TRIM

+ LOAD

- LOAD

+ 5

+ 5 CMN

+ 5 TRIM

+ 12/15

± CMN

- 12/15

ON/OFF

- INPUT

+ INPUT

FUSE

Application Information

The dual control loops are locked together in time by a

proprietary “Anti-Phase Dual PWM Controller” subassembly.

The synchronization reduces beat frequency problems that

occur when two switching supplies run at slightly different

frequencies. The “Anti-Phase” operation also evens out the

current pulses on the input bulk capacitor allowing for

conservative derating and hence longer life.

The dual loop design allows both the single and dual

outputs to be fully isolated from each other. This helps the

system design by allowing the common analog and digital

ground point to be elsewhere in the system. The dual outputs

can also be used as single ended 24 or 30 volt outputs.

The 25-30 Watt Triple Series is also mindful of battery

operation for industrial/medical control and remote data

collection. The remote ON/OFF control pin places the converter

in a very low power mode that draws only 0.5 mA maximum

from the input source. This is at least a 10:1 improvement over

industry standard specifications of 5 to 30 mA standby current

drain.

These converters achieve an output noise of 30 mV peak

to peak typical and are fully specified and tested to a maximum

specification of 65 mV peak to peak over a wide bandwidth of

0-20 MHz. Input filtering reduces reflected ripple noise and is

similarly low and also fully specified for typical and maximum

values (exact value depends on input voltage range).

All inputs and outputs are protected from transient

overvoltage conditions by 500 watt transient overvoltage

suppressors. Full overload protection is provided by

independent pulse-by-pulse current limiting and

overtemperature shutdown. These protection features assure

you that our 25-30 Watt Triple will provide zero failure rate

operation.

Six-sided shielding is standard along with specified

operation over the full industrial temperature range of -40° to

+85°C.

The 25-30 Watt Triple Series, like all CALEX converters,

carries the full 5 year CALEX no hassle warranty. We can offer

a five year warranty where others can’t because with CALEX

it’s rarely needed.

General Operation

Figure 1 shows the recommended connections for the 25-30

Watt Triple DC/DC converter. A fuse is recommended to

protect the input circuit and 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.

Figure 1.

Standard connections for the 25-30 Watt Triple. The ON/OFF and

Trim pins can be left floating if they are not used. The input fuse

should not be omitted.

The ON/OFF and +5 trim pins may be left floating if they are

not used. No external capacitance on either the input or

outputs is required for normal use which can, in fact, degrade

the converter’s operation. See our application note

“Understanding Power Supply Output Impedance for Optimum

Decoupling” for more information. The usual 0.1 to 0.01µF

bypasses may be used around your PCB as required for local

bypassing without harm. Extremely low ESR capacitors ( <0.2

ohms) should not be used at the input. This will cause peaking

of the input filters’ transfer function and actually degrade the

filters’ performance.

Single Output

The single output is independently regulated and isolated

from the dual outputs and can be operated independently or

with a common ground with the dual output.

The +5 TRIM pin may be used to adjust the +5 volt output

by up to ±5 % from the nominal factory setting of +5.000 volts.

The trim may be used to adjust for system wiring voltage drops

or to adjust the +5 output up to 5.2 volts for ECL applications.

Since the 5 volt output is completely isolated from the dual

section the output can be grounded to generate -5.2 volts or

+5.2 volts. Figure 2 shows the proper connections for the trim

pin.

Figure 2.

The 5 volt output can be trimmed by using either a trimpot or fixed

resistors. If fixed resistors are used their values may range from

zero to infinite ohms the trimpot should be 10K ohms nominal.

25 to 30 Watt XC Triple 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

53/2001

+ 12/15

± CMN

- 12/15

+ LOAD

- LOAD

24 or 30V

LOAD

+ INPUT

ON/OFF

- INPUT

100K

15V

100 W

REMOTE

+ 5 VOLT

LOAD

+ 5

+ 5 TRIM

+ 5 CMN

R1 R3

IC1

Figure 3.

This simple circuit allows for remote sensing with the 5 volt output.

The circuit can correct for up to 0.25 volts of total drop in the power

leads. At 3 amps of output this is approximately 0.08 ohms of line

resistance. A trimpot may be added to R5 to allow for exact

adjustment of the 5 volt output.

Figure 3 shows how to implement remote sense with the

trim pin and a TL431 adjustable voltage reference. This circuit

allows automatic correction of the output voltage up to 0.25

volts total.

Dual Output

The dual output is independently regulated and isolated from

the single output and can be operated separately or with a

common ground with the single output. The dual outputs can

also be connected for single-ended load applications of either

24 or 30 volts as shown in Figure 4. This configuration allows

for full output current operation up to the full 25 or 30 watt

rating.

Figure 4.

The dual output may be used either as a dual polarity or single-

ended source. If the output is used as a single-ended source, pin 4

should be left unconnected.

Grounding

The +5 and ± dual sections are floating independently from

each other. They may be operated this way or with a common

ground.

If the single and dual sections are connected either directly

at the converter or at some remote location it is suggested that

1 µF, 35 volt Tantalum capacitor bypasses be used directly at

the converter output pins. These capacitors prevent any

common mode switching currents from showing up on the

converter’s outputs as normal mode output noise.

Do not use the lowest ESR, biggest value capacitor that

you can find! This can only lead to reduced system performance

or oscillation.

See our application note “Understanding Power Supply

Output Impedance for Optimum Decoupling” in the CALEX

Power Conversion Design Guide and Catalog for more

information.

Figure 5.

The simplified schematic of the ON/OFF pin shows a 100K resistor

connected between the +Input and the ON/OFF pin. The maximum

open circuit voltage is clamped by the 15 volt zener diode. The 100

ohm resistor prevents large ground currents from flowing out the

ON/OFF pin instead of the -Input pin during power up transients.

Case Grounding

The case serves not only as a heat sink but also as an EMI

shield. The case/header shield is tied to the +Input pin for the

48T models. The 12T and 24T models have the case tied to

the -Input pin. These connections are shown on the 25-30

Watt Triple block diagram.

For all models the case is floating from the output sections.

Remote ON/OFF Pin Operation

The remote ON/OFF pin may be left floating if this function is

not used. The equivalent input circuit for the ON/OFF pin is

shown in Figure 5. The best way to drive this pin is with an

open collector/drain or relay contact. See our application note

titled “Understanding the Remote ON/OFF Function” for more

information about using the remote ON/OFF pin.

When the ON/OFF pin is pulled low with respect to the -

Input, the converter is placed in a low power drain state. This

low power state typically draws less than 200 mA from the

input source. When the ON/OFF pin is released the converter

powers up in typically 35 mSec. The ON/OFF pin turns the

converter off while keeping the input bulk capacitor fully

charged. This prevents the large inrush current spike that

occurs when the +Input pin is opened and closed.

Temperature Derating / Mounting Options

The XC Triple Series can operate up to 85°C case temperature

without derating. Case temperature may be roughly calculated

from ambient by knowing that the XC Triples’ case temperature

rise is 4.4°C per package watt dissipated. For example, if the

converter was functioning at an output of 30 Watts, at what

ambient could it expect to run with no moving air and no

additional heatsinks?

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25 to 30 Watt XC Triple 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

63/2001

Efficiency is approximately 85%, this leads to an input

power of 35 watts. The case temperature rise would be 5 watts

x 4.4 = 22°C. This number is subtracted from the maximum

case temperature of 85°C to get 63°C.

This is a rough approximation of the maximum ambient

temperature. Because of the difficulty of defining ambient

temperature and the possibility that the loads’ dissipation may

actually increase the local ambient temperature significantly,

these calculations should be verified by actual measurement

before committing to a production design.

Typical Performance (Tc=25°C, Vin=Nom VDC, Rated Load).

0 102030405060708090100

LOAD (%)

EFFICIENCY (%)

12 VOLT EFFICIENCY Vs. LOAD

LINE = 10VDC

LINE = 12VDC

LINE = 20VDC

0 2 4 6 8 101214161820

LINE INPUT (VOLTS)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

INPUT CURRENT (AMPS)

12 VOLT INPUT CURRENT Vs. LINE INPUT VOLTAGE

100% LOAD

50% LOAD

10 12 14 16 18 20

LINE INPUT(VOLTS)

EFFICIENCY(%)

12 VOLT EFFICIENCY Vs. LINE INPUT VOLTAGE

100% FULL LOAD

50% FULL LOAD

0 4 8 12162024283236

LINE INPUT (VOLTS)

0.0

0.5

1.0

1.5

2.0

2.5

INPUT CURRENT (AMPS)

24 VOLT INPUT CURRENT Vs. LINE INPUT VOLTAGE

100% LOAD

50% LOAD

0 102030405060708090100

LOAD (%)

EFFICIENCY (%)

24 VOLT EFFICIENCY Vs. LOAD

LINE = 18VDC

LINE = 24VDC

LINE = 36VDC

18 20 22 24 26 28 30 32 34 36

LINE INPUT(VOLTS)

EFFICIENCY(%)

24 VOLT EFFICIENCY Vs. LINE INPUT VOLTAGE

100% FULL LOAD

50% FULL LOAD

0 1020304050607080

LINE INPUT (VOLTS)

0.00

0.25

0.50

0.75

1.00

1.25

INPUT CURRENT (AMPS)

48 VOLT INPUT CURRENT Vs. LINE INPUT VOLTAGE

100% LOAD

50% LOAD

0 102030405060708090100

LOAD (%)

EFFICIENCY (%)

48 VOLT EFFICIENCY Vs. LOAD

LINE = 36VDC

LINE = 48VDC

LINE = 72VDC

35 40 45 50 55 60 65 70 75

LINE INPUT(VOLTS)

EFFICIENCY(%)

48 VOLT EFFICIENCY Vs. LINE INPUT VOLTAGE

100% FULL LOAD

50% FULL LOAD

0 50 100 150 200 250 300 350 400 450 500

OUTPUT LOAD (%)

100

110

NORMALIZED OUTPUT (%)

OUTPUT VOLTAGE Vs. OUTPUT LOAD

5V OUTPUT +/- DUAL OUTPUT

10 100 1000 10000 100000 1000000

FREQUENCY (Hz)

.01

OUTPUT IMPEDANCE (OHMS)

OUTPUT IMPEDANCE Vs. FREQUENCY

5V OUTPUT

DUAL OUTPUT

-40 -25 -10 5 20 35 50 65 80 95 110

AMBIENT TEMPERATURE (Deg C)

100

110

OUTPUT POWER (%)

DERATING

INFINITE HEAT SINK

NO HEAT SINK

SAFE OPERATING AREA