beta dyne 35W HIGH-VOLTAGE DC/DC CONVERTER Single, Dual, Dual Independent Outputs 120Vdc Out Key Features * * * * * * * * * * * * * Efficiency up to 91% 2:1 input voltage range Input under/overvoltage protection Input to output isolation Soft start Dual short circuit protection 500A off-state current Multiple converter synchronization Adjustable outputs 200kHz switching frequency Thermal protection Dual independent outputs Six-sided shielding 1 2 3 4 beta dyne 9 DC/DC CONVERTER 35D120/48 8 7 6 5 MADE IN USA Applications Functional Description This family of 35W DC/DC converters is specifically designed for telecommunications applications including xDSL remote power feed. These converters accept wide input voltage ranges with nominal inputs of 12, 24, 48 and 120Vdc. Outputs can be single or dual and can be set as two independent adjustable outputs of 120, 120, and 240Vdc. Additional features include total input to output isolation, short circuit and thermal protection, soft start, under/overvoltage protection, adjustable outputs, and efficiency up to 91%. Telecom Micro-mirror Drivers DSL Systems Remote Feed Systems Battery Power Systems High Voltage Power OPAMs Transducer Drivers P TRANSFORMER 4 5 +V IN + AUX (Vo2) 6 2 RECTIFIER & FILTER SYNC L 7 + MAIN (Vo1) 1 ON/OFF - 8 PWM - ERROR OPAM 9 V OUT ADJ 3 -V IN Typical Block Diagram Beta Dyne, Inc. * 110 Elm St, Unit 12 * Bridgewater, MA 02324 * Phone 508-697-1993 * Fax 508-697-2045 * www.beta-dyne.com 35W DC/DC CONVERTER DCDC35_DS_REV02.PDF SHEET 1 OF 7 Electrical Specifications Unless otherwise specified, all parameters are given under typical +25C with nominal input voltage and under full output load conditions. INPUT SPECIFICATIONS PARAMETER Input Voltage Range CONDITION / NOTE MIN TYP MAX UNIT See Model Selection Guide Input Startup Voltage, 12VIN 10.5 11 V dc Input Startup Voltage, 24VIN 17 18 V dc Input Startup Voltage, 48VIN 35 36 V dc Input Startup Voltage, 120VIN 74 75 V dc Input Overvoltage Protection, 12VIN 19 20 V Input Overvoltage Protection, 24VIN 37 38 V Input Overvoltage Protection, 48VIN 74 76 Input Overvoltage Protection, 120VIN 145 V V Pi () Input Filter Reverse Polarity External series-blocking diode Reflected Ripple IO = FL, CIN = 10F, See Model Selection Guide No Load Input Current See Model Selection Guide Input Surge Current (20S Spike) Short Circuit Current Limit 10 See Short Circuit Protection Off State Current A 150 % IIN 500 A Remote ON/OFF Control Supply ON Pin 1 Open (Open circuit voltage: 12V max.) Supply OFF 0 Logic Input Reference -Input for ON/OFF and SYNC Logic Compatibility for Reference TTL Open Collector or CMOS Open Drain 0.8 V dc Sync, High See External Synchronization, Figure 5 2 6 V Sync, Low See External Synchronization, Figure 5 0 0.8 V TYP MAX UNIT 1 2 %VPP of VOUT 0.5 1 % 3 5 % 1 2 % 1 2 % 3 5 OUTPUT SPECIFICATIONS PARAMETER CONDITION / NOTE Output Voltage Accuracy See Model Selection Guide Ripple & Noise (See App. Note DC-003) Outuput Current See Model Selection Guide MIN Line Regulation, Single and Dual Line Regulation, Dual Independent Outputs VO2 only (For VO1, see Single and Dual) Load Regulation, Single Load Regulation, Dual With balanced loads Dual Independent Outputs1 Outputs fully loaded, See Figure 3 Temperature Coefficient @ FL 0.02 Transient Response Time 50% FL to FL to 50% FL Short Circuit Protection By input current limiting Output Adjust Range See App. Note DC-010 200 5 % %/C 250 S 10 % MAX UNIT GENERAL SPECIFICATIONS PARAMETER Efficiency CONDITION / NOTE MIN TYP See Model Selection Guide Isolation Voltage (1 min.), Input to Output 1500 V dc Isolation Voltage (1 min.), Output to Output 500 V dc Isolation Resistance 109 2700 pF Isolation Capacitance Switching Frequency 200 kHz Turn-on Delay See Figure 7 7 10 mS Soft Start Time See Figure 7 7 15 mS Beta Dyne, Inc. * 110 Elm St, Unit 12 * Bridgewater, MA 02324 * Phone 508-697-1993 * Fax 508-697-2045 * www.beta-dyne.com 35W DC/DC CONVERTER DCDC35_DS_REV02.PDF SHEET 2 OF 7 ENVIRONMENTAL SPECIFICATIONS PARAMETER CONDITION / NOTE Operating Temperature Range (Ambient)2 MIN Industrial, See Figure 4 TYP -40 Storage Temperature Range -55 Thermal Resistance C per watt internally dissipated UNIT +71 C +125 C 5 C/WDISS 110 C 4 Maximum Operating Case Temperature Derating MAX See Figure 4 Cooling Free-air convection EMI/RFI Six-sided continuous shielded metal case MTBF per MIL-HNBK-217F (Ground benign, +25C) Humidity Up to 95% non-condensing Thermal Shutdown Case Temperature 1.1x106 110 Thermal Hysterisis 2 5 MIN TYP hours 115 C C PHYSICAL CHARACTERISTICS PARAMETER CONDITION / NOTE Case Size 2x2x0.5in. (50.8x50.8x12.7mm) Case Material Blue coated metal Weight 2.43oz. (69g) Shielding Connection, 24VIN -VIN (Pin 3) Shielding Connection, 48VIN, 120VIN +VIN (Pin 4) MAX UNIT Model Selection Guide MODEL NUMBER INPUT Voltage (Vdc) OUTPUT Current (mA) N o L o ad Full Load3 10.5-18 50 3515 18-36 30 1676 Nominal R an g e 35S120/12 12 35S120/24 24 4 Reflected Ripple (mAPP) 50 Voltage (Vdc) (with C1=100F) 100 Current (mA) Efficiency Full Load (%) 120 292 83 120 292 87 35S120/48 48 36-72 20 820 100 120 292 89 35S120/120 120 75-140 15 320 100 120 292 91 35D120/12 12 10.5-18 50 3515 120 146 83 50 (with C1=100F) 35D120/24 24 18-36 30 1676 100 120 146 87 35D120/48 48 36-72 20 820 100 120 146 89 35D120/120 120 75-140 15 320 100 120 146 91 1 A dual independent output converter is generated from the single output converter by floating VO2 (see Figure 3). A 10% minimum load is required. 2 Contact factory for -55 to +85C operating temperature range. 3 The maximum input current at any given input range measured at minimum input voltage is given as 1.6*INOMINAL. Nominal input current is the typical value measured at the input of the converter under full-load room temperature and nominal input voltage (12, 24, 48, and 120Vdc). 4 Measured with 10F capacitor at the input power pins. ORDERING GUIDE 35 Power Number of Outputs (S = Single, D = Dual) __/__ Input Voltage Output Voltage Beta Dyne, Inc. * 110 Elm St, Unit 12 * Bridgewater, MA 02324 * Phone 508-697-1993 * Fax 508-697-2045 * www.beta-dyne.com 35W DC/DC CONVERTER DCDC35_DS_REV02.PDF SHEET 3 OF 7 5V ON OFF 2K 0V PS2701 1 +Vo2 ON/OFF -Vo2 500nS 2 35S120/48 35S120/120 SYNC 5 + 2.2-4.7F 200V 6 +RL - +Vo1 7 F>200kHz F1 3 - 48/120Vin 4 + Vin 48Vin 120Vin -Vin -Vo1 8 C1 10-100F +Vin VoADJ F1 2A SLOW BLOW 1A SLOW BLOW 9 2M ** ** ** 2200pF TO .01F 2000V 2200pF 2200pF ** OPTIONAL PARTS CASE FIGURE 1. Typical connection diagram of High-Voltage 35W Single DC/DC Converter 5V ON OFF 2K 0V PS2701 1 +Vo2 ON/OFF -Vo2 500nS 2 SYNC 35W SERIES +Vo1 5 2.2-4.7F 200V 6 7 2.2-4.7F 200V F>200kHz 3 12/24Vin C1 10-100F F1 Vin 12Vin 24Vin 4 -Vin -Vo1 +Vin VoADJ F1 5A SLOW BLOW 3A SLOW BLOW +RL -RL 8 9 2M ** ** ** 2200pF TO .01F 2000V 2200pF 2200pF ** OPTIONAL PARTS CASE FIGURE 2. Typical connection diagram of High-Voltage 35W Dual DC/DC Converter 5V ON OFF 2K 0V PS2701 1 +Vo2 5 + ON/OFF 2.2-4.7F 200V 500nS 2 -Vo2 +Vo1 SYNC RL 6 7 + 35W SERIES 2.2-4.7F 200V F>200kHz 3 -Vin -Vo1 8 RL Vo1 2M 12/24Vin C1 10-100F F1 Vin 12Vin 24Vin Vo2 F1 5A SLOW BLOW 3A SLOW BLOW 4 +Vin VoADJ 9 ** ** ** 2200pF 2200pF TO .01F 2000V 2200pF ** OPTIONAL PARTS CASE FIGURE 3. Typical connection diagram of High-Voltage 35W Dual Independent Output DC/DC Converter Beta Dyne, Inc. * 110 Elm St, Unit 12 * Bridgewater, MA 02324 * Phone 508-697-1993 * Fax 508-697-2045 * www.beta-dyne.com 35W DC/DC CONVERTER DCDC35_DS_REV02.PDF SHEET 4 OF 7 FREE AIR PO FORCED AIR APPROX. 100LFM 40 35 30 25 20 15 10 9 8 5 Po W = 1.4 T C Po W = .875 T C 0 50 60 70 80 90 100 110 C FIGURE 4. Worst case derating EXTERNAL TRIMMING OF OUTPUT VOLTAGES (SINGLE AND DUAL ONLY) To trim the output voltage DOWN, connect a 5% 1/4W 1.5M resistor (DO NOT GO BELOW 1M) between the +V01 (Pin 7) output and trim pin of the converter. To trim the output voltage UP, connect a 5% 1/4W resistor between the -V01 (Pin 8) output and trim pins of the converter. For UP/DOWN trimming capability, connect a 2M potentiometer between the + and - output pins, with the wiper arm connected to the trim pin. The trim resistors/potentiometer can be connected at the con- verter output pins or the load. However, if connected at the load, the resistance of the runs becomes part of the feedback network which improves load regulation. If the load is some distance from the converter, the use of #20 gauge wire is recommended to avoid excessive voltage drop due to the resistance of the circuit paths. See our application notes: DC-001: Testing Transient Response in DC/DC Converters DC-004: Thermal Consideration for DC/DC Converters EXTERNAL SYNCHRONIZATION A TTL signal applied at the SYNC pin of the converter will synchronize the switching frequency of the converter to that of the TTL input signal. The external (TTL) frequency must be equal or higher than the converter's frequency. At the positive-going edge of the applied pulse, the internal power-switching transistor turns off and the PWM discharges its timing capacitor. At the negativegoing edge, the PWM resumes normal operation. The minimum positive pulse width of the TTL signal must be 300nS minimum and its frequency between 190kHz and 220kHz. NOTE: Higher frequencies will reduce the efficiency of the converter and wide TTL pulses will force the PWM to follow the external TTL width modulation, which may effect regulation. A high TTL signal at the SYNC pin of the converter will turn the converter off. An internal pull-down resistor will keep this pin low when it is not used. A pulse differentiator (see Figure 6) can be used to shape a square wave sync signal as shown in Figure 5. DIMENSIONS 0.50 [12.70] MAX. CASE HEADER PIN ASSIGNMENT Pin O0.040 [1.02] (9PL) Function 0.10 [2.54] MIN SI NGLE DIMENSION ARE IN INCH(mm) TOLERANCE: .XX .02(.508) .XXX .01(.254) 5 2.00 [50.80] 1.100 [27.94] 4 +Vin +Vo2 3 -Vin -Vo2 2 SYNC +Vo1 1 ON/OFF -Vo1 Vadj BOTTOM VIEW 0.900 [22.86] 0.700 [17.78] 0.500 [12.70] 6 7 8 9 ON/OFF ON/OFF 2 SYNC SYNC 3 -VIN -VIN 4 +VIN +VIN 5 +VO2 (CONNECT TO PIN 7) +VO2 6 -VO2 (CONNECT TO PIN 8) -VO2 7 +VO1 (CONNECT TO PIN 5) +VO1 8 -VO1 (CONNECT TO PIN 6) 9 VOUT ADJ 1.200 [30.48] 1.000 [25.40] 0.800 [20.32] 0.600 [15.24] 0.400 [10.16] DUAL 1 -VO1 VOUT ADJ 0.100 [2.54] 1.800 [45.72] 2.00 [50.80] Beta Dyne, Inc. * 110 Elm St, Unit 12 * Bridgewater, MA 02324 * Phone 508-697-1993 * Fax 508-697-2045 * www.beta-dyne.com 35W DC/DC CONVERTER DCDC35_DS_REV02.PDF SHEET 5 OF 7 ! 2.2V minimum ! ! 0.8V Voltage at Pin 2 ! 5V Typical TTL level ! ! 0.8V Voltage at Pin 2 700nS ! ! 500nS 3) CH1 5V 500nS 4) CH2 5V 500nS ! ! 1) CH1 2V 500nS 2) CH2 2V 500nS FIGURE 5. Waveforms of sync signal shaping SYNC SIGNAL SHAPING As described in External Synchronization, the PWM of the 35W converter requires a TTL signal of 0.8 to 2Vdc minimum amplitude and minimum duration of 300nS. When such a signal is not available (through one shot multivibrator or other pulse-shaping circuits) a C-R differentiator, such as the one in Figure 6, can be used to shape a square wave TTL signal. As is shown by the oscillogram in Figure 5, the positive edge of the sync pulse must be 2V minimum and the decaying exponential must reach the low 0.8Vdc in 300nS minimum from the positive edge. The parallel diode with the resistor is a small signal switching diode or a Schottky signal diode with 0.3 to 0.5V forward drop, it is used to clamp the voltage at pin 2@-0.5Vdc. 220pF PIN#2 2K 1N4148 5S FIGURE 6. Suggested pulse-shaping circuit Beta Dyne, Inc. * 110 Elm St, Unit 12 * Bridgewater, MA 02324 * Phone 508-697-1993 * Fax 508-697-2045 * www.beta-dyne.com 35W DC/DC CONVERTER DCDC35_DS_REV02.PDF SHEET 6 OF 7 ON/OFF (Pin 1) ! ! Turn on delay Soft start ! ! VOUT 1) CH1 20V 5mS 2) CH2 100V 5mS FIGURE 7. Turn on delay with soft start SHORT CIRCUIT PROTECTION The 35W high-voltage series of converters have a dual short circuit protection feature. At the input side of the converter, two short circuit current comparators are used to monitor the input current of the converter. They are biased at different voltage levels; the lower threshold (LTH) comparator provides the power limiting function of the converter. Under normal operating conditions, the LTH comparator limits the output power of the converter when the maximum output power is exceeded. When a hard short is applied across the output of the converter and the input current exceeds the set threshold of the second comparator, the converter goes into shutdown mode, the overcurrent latch is set and the converter is turned off. The converter will turn on again when its input voltage is recycled (OFFON) or if the ON/OFF pin is used to turn the converter on and off. The time required for the ON/OFF pin to be held low is between 100mS and 800mS. Beta Dyne, Inc. * 110 Elm St, Unit 12 * Bridgewater, MA 02324 * Phone 508-697-1993 * Fax 508-697-2045 * www.beta-dyne.com 35W DC/DC CONVERTER DCDC35_DS_REV02.PDF SHEET 7 OF 7