A
30 Watt CS 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
+5 / +12 volt outputs for computer systems
Up to 4 amps of +12 volt current for motor spinup
Fully isolated design cuts ground loop problems
Ultra Wide 4:1 Input Voltage Range
Water washable shielded copper case
5 Year Warranty
Description
These dual output converters are designed for modern
computer systems with motorized data storage. The +5 / +12
volt outputs permit operation of standard +5 volt microprocessor
circuits while the +12 volt output allows driving of standard
hard disks or CD ROMs. To make system use easy the +12
volt output is rated for up to 4 amps of surge current to insure
quick startup of even the biggest drive motors.
The very wide input range (4:1) is ideal for battery or
unregulated input applications while the low noise
complements even the most sensitive analog circuitry.
The CS series has full input to output isolation to cut ground
loop problems. This helps to make your system bullet proof
from noisy input circuits such as those found in automotive
and industrial applications.
These converters are state of the art 220 kHz MOSFET
30 Watt CS Dual Series Block Diagram
based designs that provide outstanding regulation and
conversion efficiencies of up to 85%.
Remote ON/OFF and output voltage trim functions are also
included.
The converters are protected from output shorts to common
by a high speed pulse by pulse digital current limit circuit and
a self resetting thermal overload protection circuit.
As with all CALEX converters the 30 Watt CS Dual series
is covered by our 5 Year Warranty.
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A
30 Watt CS 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
NOTES
*
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.
(1)
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 10f, tantalum and 0.01F,
ceramic capacitor located 1 inch away from the converter. Input
ripple is measured into a 10H source impedance.
(2)
See our application note for picking the correct fuse size.
(3)
The converter may be safely operated at any load from zero to
the full rating. Dynamic response of the converter will degrade
if the converter is operated with less than 25% output load. See
"Applying the Output" for more information.
(4)
Load regulation is defined for loading/unloading one output
while the other output is kept at full load. Load range is 25 to
100%.
(5)
Cross regulation is defined for loading/unloading one output
while the other output is kept at full load. Load range is
25 to 100%.
(6)
Short term stability is specified after a 30 minute warmup
at full load, constant line and recording the drift over a 24
hour period.
(7)
Case is tied to the CMN output pin.
(8)
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 may reduce the expected operational
life. The data sheet specifications are not guaranteed over
the functional temperature range.
(9)
The case thermal impedance is specified as the case temperature
rise over ambient per package watt dissipated.
(10) Specifications subject to change without notice.
(11) 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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A
30 Watt CS 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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Mechanical tolerances unless otherwise noted:
X.XX dimensions: 0.020 inches
X.XXX dimensions: 0.005 inches
BOTTOM VIEW
SIDE VIEW
Applications Information
You truly get what you pay for in a CALEX converter, a
complete system oriented and specified DC/DC converter -
no surprises, no external noise filtering circuits needed, no
heatsinking problems, just "plug and play".
The 30 Watt CS Dual 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.
Keep reading, you'll find out why.
General Information
The CS Dual series is mindful of battery operation for industrial,
medical control and remote data collection applications. The
remote ON/OFF pin places the converter in a very low power
mode that draws typically less than 10 mA from the input
source.
Full overload protection is provided by independent pulse-
by-pulse current limiting and an over-temperature shutdown
circuit. These protection features assure you that our CS Dual
will provide you with zero failure rate operation.
Five sided shielding is standard along with specified
operation over the full industrial temperature range of -40 to
+85C case temperature.
Applying The Input
Figure 1 shows the recommended input connections for the
CS Dual DC/DC converter. A fuse is recommended to protect
the input circuit and should not be omitted. The fuse serves to
prevent unlimited current from flowing in the case of a
catastrophic system failure.
No external capacitance on the input is required for normal
operation, in fact it can degrade the converters performance.
Normal RF bypass capacitors in the 1000 pF to 0.01 F range
may be used without harm.
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A
30 Watt CS 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
Figure 1.
Standard connections for the CS Dual. The ON/OFF and TRIM pins
may be left floating if they are not used. The input protection fuse
should not be omitted. If desired, external transient protection
diodes can be used. See the text below for suggestions regarding
input and output capacitance.
Ultra Low Noise Input Circuit
The circuit shown in figure 2 can be used to reduce the input
noise to below 10 mA p-p over a 20 MHz bandwidth. It is
important to size inductor L1 appropriately for the maximum
expected load current plus any surge at the minimum input
voltage. Capacitor C1 should be the moderate ESR type
specified. The use of a very low ESR capacitor should be
avoided as this will make a high-Q filter when we really want
a low-Q, controlled cutoff filter.
Figure 2.
This circuit may be used to reduce the input reflected ripple to less
than 10 mA p-p. Capacitor C1 should be the moderate ESR type
shown to prevent input filter response peaking. Size the current
carrying capability of L1 for the maximum expected load and
minimum input operating voltage.
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 3. 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. 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.
Applying The Output
Figure 1 shows typical output connections for the CS Dual. In
most applications no external output capacitance will be
necessary. Only your normal 1 to 10 F and 0.001 to 0.1 F
bypass capacitors sprinkled around your circuit as needed
locally are required. Do not add extra output capacitance and
cost to your circuit "Just Because".
If you feel you must add external output capacitance, 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 Output
Impedance For Optimum Decoupling" for more information.
Instead use the ultra low noise output circuit in figure 5.
Output Power Allocation
To be as flexible as possible for your specific application the
CS dual incorporates a primary side power limit scheme to
limit the maximum power delivered to your load. The power
limit circuitry is a pulse by pulse digital limit that causes the
output voltages to droop gradually if an over power condition
exists. This gradual droop prevents the load lockup phenomena
associated with foldback current limit schemes.
The power limit is dependent on two factors. The first is the
input voltage to the converter. At low input voltages the power
limit will go down. This is a non-linear function of input voltage,
it is akin to a drop out phenomena. The second factor is case
temperature. As the case temperature goes up the maximum
power limit goes down. This is a linear function of case
temperature. The typical temperature coefficient is -0.4%
per C.
It is recommended that your system design be checked at
the lowest input voltage and highest case temperature for
your needs before committing to production. You should
leave a design tolerance of at least 4% to be sure that any CS
Dual converter will operate in your system.
The CS dual may be used continuously with the following
loads,
Maximum Continuous Load:
+5 volts @ 3 amps
+12 volts at 1.3 amps
Figure 3.
The simplified schematic of the CS Dual series ON/OFF pin. The
input impedance is approximately 6 k ohms. By leaving this pin
floating the converter will be in the ON state. When the pin is pulled
below 1.0 volts (with respect to the -Input pin) the converter is placed
in the power down or OFF state. See our application note on the
remote ON/OFF function for more information.
L1 = 50H
C1 = 10F / 100V, 0.25 - 1 ohm ESR
C2 = 10F / 100V, 0.25 - 1 ohm ESR
A
30 Watt CS 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
Non Standard Output Voltages
The CS Duals will typically trim much lower than the -10%
specified. This allows the CSs to be trimmed lower than
specified for RF or other special applications.
The 5 and 12 volt outputs track each other so the trim operates
on both outputs simultaneously. The typical trim range for the
CS dual is,
5 volt output ..................... 3.3 to 5.7 volts
12 volt output ................... 8.2 to 14.2 volts
Ultra Low Noise Output Circuit
The circuit shown in figure 5 can be used to reduce the output
noise to below 10 mV p-p over a 20 MHz bandwidth. Size the
inductors appropriately for the maximum expected steady
state and surge load current.
Operation With Very Light Loads
The dynamic response of the CS Dual will degrade when the
unit is operated with less than about 25% of full rated power.
The 5 volt output may go below 4.75 volts if only the 5 volt
output is loaded. The solution is to load the +12 volt output
from 10 to 200 mA as needed. The exact 12 volt loading
depends on the 5 volt output loading and to a lesser extent the
input voltage.
The maximum surge current allowed on the outputs are,
Maximum Surge Load:
+5 volts @ 6 amps
+12 volts at 4 amps
However the maximum power from all loads combined is
limited to typically 50 watts maximum. This surge must not
exceed a 10 second, 50 watt surge out of every minute and the
case temperature must not exceed the maximum operational
specification.
How this maximum power limit may be applied is best
described by some examples:
Example 1:
If your load will use the +5 volts at 3 amps and the +12 volts
at 1.3 amps continuously (31 watts) the CS still has typically
19 watts left for startup surges. This means that the +12 volt
output may supply up to an additional 1.6 amps at startup, for
a total startup current of 1.3 + 1.6 = 2.9 amps (or about 35
watts).
Example 2:
If your load will use the +5 volts at 1 amp and the +12 volts at
1 amp continuously (17 watts) the CS still has typically 33
watts left for startup surges. This means that the +12 volt
output may supply up to an additional 2.7 amps at startup, for
a total startup current of 1.0 + 2.7 = 3.7 amps (or about 44
watts).
Example 3:
If your load will use the +5 volts at 2 amps and the +12 volts
at 0.5 amps continuously (16 watts) the CS still has typically
34 watts left for startup surges. This means that the +12 volt
output may supply up to an additional 2.8 amps at startup, for
a total startup current of 0.5 + 2.8 = 3.3 amps (or about 40
watts).
Example 4:
If your load will use the +5 volts at 2 amps and the +12 volts
at 1.0 amps continuously (22 watts) the CS still has typically
28 watts left for startup surges. This means that the +5 volt
output may supply up to an additional 5.6 amps at startup. The
+ 5 volt output is limited to a maximum of 6 amps however so
the maximum surge power available from the +5 volt output is
30 watts maximum.
Output Trimming
The trim pin may be used to adjust the outputs from the
nominal factory setting. The trim may be used to adjust for
system wiring voltage drops. Figure 4 shows the proper
connections to use the trim pin. If output trimming is not
desired the trim pin may be safely left floating.
Trimming the output up reduces the output current
proportionally to keep the maximum power constant. Output
current is not increased over the listed maximum when
trimming the output voltage down.
Down trim can actually reduce the minimum input voltage
in some circuits. Full up trim may not be achievable at
minimum input voltage and full rated load. The maximum
current available does not increase from the listed maximum
under low trim conditions.
L1 = 20H
C1 = 1000F / 25V, ALUMINUM
C2 = 47F / 25V, TANTALUM
Figure 4.
The output can be trimmed by either a trimpot or fixed resistors. If
fixed resistors are used their values may range from 0 to infinite
ohms. The trimpot should be typically 20 k ohms.
Figure 5.
For very low noise applications this circuit will reduce the output
noise to less than 10 mV p-p over a 0-20 MHz bandwidth. Be sure
to size the inductor appropriately for the maximum expected load
current.
A
30 Watt CS 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
Grounding
The input and output sections are fully floating from each
other. They may be operated fully floating or with a common
ground. If the input and output sections are connected either
directly at the converter or at some remote location from the
converter it is suggested that a 3.3 to 10 F, 0.5 to 5 ohm ESR
capacitor bypass be used directly at the converter output pins.
This capacitor prevents any common mode switching currents
from showing up at the converters output as normal mode
output noise. See "Applying the Output" for more information.
Another "Trick" that can be used when operating with a
common ground is to use a 10 to 100 H choke between the
grounds. This gives you a solid low frequency ground
connection, but looks like a high impedance to the switching
current effects and prevents them from flowing in the
connection. This will have the effect of preventing the common
mode currents from showing up as normal mode components
in your input or output circuits.
Be sure that the inductor has a self resonant frequency of
greater than 200 kHz and that the Q of the inductor is quite low.
If necessary to keep the inductor Q under control, parallel it
with a 200 to 1 k ohm resistor.
Case Grounding
The copper case serves not only as a heat sink but also as a
EMI shield. The 0.25 inch thick case provides >30 dB of
absorption loss to both electric and magnetic fields at 220
kHz, while at the same time providing 20 to 40 % better heat
sinking over competitive thin steel, aluminum or plastic designs.
The case shield is tied to the output CMN pin. This
connection is shown on the block diagram. The case is
floating from the input sections. The input is coupled to the
outputs only by the low 500 pF of isolation capacitance. This
low I/O capacitance insures that any AC common mode noise
on the inputs is not coupled to your output circuits.
Compare this isolation to the more usual 1000 - 2000 pF
found on competitive designs and you will see that CALEX
provides the very best DC and AC isolation available. After all,
you are buying an isolated DC/DC to cut ground loops. Don't
let the isolation capacitance add them back in.
Temperature Derating
The CS Dual series can operate up to 85C case temperature
without derating. Case temperature may be roughly calculated
from ambient by knowing that the CS Dual case temperature
rise is approximately 4.4C per package watt dissipated.
For example: If a CS converter is outputting 25 Watts, at
what ambient could it expect to run with no moving air and no
extra heatsinking?
Efficiency is approximately 80%, this leads to an input
power of 31 Watts. The case temperature rise would be 6
watts 4.4 = 26C. This number is subtracted from the
maximum case temperature of 85C to get: 59C.
This example calculation is for a CS Dual without any extra
heat sinking or appreciable air flow. Both of these factors can
greatly effect the maximum ambient temperature (see below).
Exact efficiency depends on input line and load conditions,
check the efficiency curves for exact information. Repetitive
surge loads can also increase the average case dissipation.
This is a rough approximation to 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.
Heat Sinking
The CS Dual can be ordered in a "-I" configuration which
provides a case with 3 X M3 inserts located on the top surface
of the case for attaching a heat sink or mounting the converter
on it's back using the inserts provided. The mounting surface
should be flat to within 0.01 inches to prevent warping the CS
Dual's case.
The CALEX HS-1 heat sink was specially developed for
this model and can reduce the case temperature rise to
typically below 3.3C per watt with natural convection and less
with moving air. It also increases the heat removing efficiency
of any cooling air flow.
When the CS Dual is ordered with the -HS option CALEX
will ship the converter with inserts and a heatsink attached.
For the exact size of the heatsink see the package outline
drawing.
Customer installed heat sinks may also be used. It is
recommended that either liquid heatsink compound or nothing
be used on the heatsink interface. Stay away from the so
called "Dry" pad heat sink materials, in our experience these
materials are actually worse than no compound at all. Test
them thoroughly before committing to production.
Additional heatsinking will lower internal temperatures and
increase the expected operational life.
Mounting Kit
The MS9 chassis mounting kit allows for direct wire connection
to the CS Dual series pins. The mounting kit includes two
barrier strips for wire attachment. The MS9 may be conveniently
attached to a chassis by use of the 4 - 0.156 inch diameter
mounting holes provided at each corner.
Although the MS9 comes with solderless sockets, for
improved reliability in severe temperature or vibration
environments it is recommended that the CS Dual be soldered
to the mounting kit.
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