®
®
A SUBSIDIARY OF C&D TECHNOLOGIES
Mixed Voltage, BCP Models
Dual Output
5V and 3.3V, "Half-Brick"
75 Watt, DC/DC Converters
Features
■
■
■
■
■
■
■
Independent 5V and 3.3V outputs
Each output fully regulated
No minimum load requirements
Up to 15 Amps per output
75 Watts total output power
Standard "half-brick" package
UL1950, EN60950 and VDE safety
approvals (BASIC insulation)
Fully isolated, 1500Vdc guaranteed
18-36V or 36-75V input ranges
mark available (75V-input models)
Input under and overvoltage shutdown
Continuous short-circuit protection
Thermal shutdown
■
■
■
■
■
■
As your new, mixed-logic (5V and 3.3V) design evolves and your current require-
ments change, your new DC/DC converter will not. DATEL’s BCP-5/15-3.3/15-D24
(18-36V input) and BCP-5/15-3.3/15-D48 (36-75V input) are fully isolated DC/DC
converters providing both 5V and 3.3V outputs. Housed in standard "half-brick"
packages (2.3" x 2.4" x 0.525"), the BCP’s can support any combination of 5V and
3.3V loading up to a combined total of 15 Amps. Both outputs are fully isolated
(1500Vdc) and independently line (±0.2%) and load (±0.5% and ±0.6%) regulated.
Both BCP models feature input pi filters, input undervoltage and overvoltage shut-
down, input reverse-polarity protection, output overvoltage protection, current limiting,
and thermal shutdown. Each has an on/off control function, and the two output volt-
ages can be trimmed independently.
BCP Model DC/DC’s deliver low noise (50mVp-p), high efficiency (87%) and are
fully specified for –40 to +100°C operation. Utilization of metal baseplate technology
with threaded inserts permits easy heat-sink attachment and/or pcb mounting. These
devices meet IEC950, UL1950, EN60950 and VDE safety standards, including
BASIC insulation requirements. CB reports are available on request. "D48" models
are CE marked (meet the requirements of LVD).
+INPUT
(4)
+5V OUTPUT
(7)
SWITCH
CONTROL
5V RETURN (6)
+3.3V OUTPUT
(10)
–INPUT
(1)
3.3V RETURN
(9)
MAG AMP
CONTROLLER
ON/OFF
CONTROL
(3)
PWM
CONTROLLER
UV & OV
COMPARATORS
REFERENCE &
ERROR AMP
3.3V TRIM
(8)
OPTO
ISOLATION
REFERENCE &
ERROR AMP
5V TRIM
(5)
Figure 1. Simplified Schematic
DATEL, Inc., Mansfield, MA 02048 (USA) · Tel: (508)339-3000, (800)233-2765 Fax: (508)339-6356 · Email: sales@datel.com · Internet: www.datel.com
XCP Series
7 5 W, D UA L O U T P U T, M I X E D - VO LTAG E D C / D C C O N V E R T E R S
Performance Specifications and Ordering Guide
V
OUT
(Volts)
5
3.3
5
3.3
➀
Input
Regulation (Max.)
Line
±0.2%
±0.2%
±0.2%
±0.2%
Model
BCP-5/15-3.3/15-D24
BCP-5/15-3.3/15-D48
I
OUT
➄
(Amps)
15
15
15
15
Output
R/N (mVp-p)
Typ.
50
50
50
50
Max.
100
100
100
100
Load
➂
±0.5%
±0.6%
±0.5%
±0.6%
➂
➃
➄
➅
V
IN
Nom.
(Volts)
24
48
Range
(Volts)
18-36
36-75
I
IN
➃
(mA)
215/3720
125/1860
Efficiency
Min.
84%
84%
➅
Typ.
Package
(Case,
Pinout)
C19, P29
C19, P29
87.2%
88%
➀
Typical at T
A
= +25°C under nominal line voltage and balanced "full-load" (5V @7.5A, 3.3V @ 7.5A)
conditions unless otherwise noted.
➁
Ripple/Noise (R/N) measured over a 20MHz bandwidth. All models are specified with 22µF, low-ESR,
input capacitor and 10µF tantalum in parallel with 1µF ceramic output capacitors.
PA R T N U M B E R S T R U C T U R E
No load to 100% load, other output at no-load.
Nominal line voltage, no-load/5V at full-load condition.
Current from either output at maximum value, or both outputs to a combined total of 15 A.
5V at full-load condition.
BCP
-
5
/
15
-
3.3
/
15
-
D24 N
LX
Dual Output/
Standard Half-Brick Package
V
1
Nominal Output Voltage:
5 Volts
I
1
Maximum Output Current:
15A
V
2
Nominal Output Voltage:
3.3 Volts
I
2
Maximum Output Current:
15A
M E C H A N I C A L S P E C I F I C AT I O N S
Optional Functions
Blank
Optional Functions:
See also last page
On/Off Control function (positive polarity) on pin 3
On/Off Control function (negative polarity) on pin 3
Pin length: 0.110 in. (2.79mm) ±0.010
Pin length: 0.145 in. (3.68mm) ±0.010
N
L1
L2
Input Voltage Range:
D24
= 18-36 Volts (24V nominal)
D48
= 36-75 Volts (48V nominal)
Refer to last page for additional options
Optional Heat Sink
(Part Number HS-CPLP2)
3.50
(88.90)
2.000
(50.80)
0.75
(19.05)
0.20
(5.08)
2.30
(58.42)
METAL BASEPLATE
0.545 (13.84) MAX.
0.525 (13.34) TYP.
Case C19
PLASTIC SHELL
0.20 MIN
(5.08)
0.040 ±0.002 DIA.
(1.016 ±0.051)
1.900
(48.26)
2.30
(58.42)
1.900
(48.26)
0.20
(5.08)
1
10
9
2
2.000
1.400
(50.80)
(35.56)
8
0.140 THRU AND COUNTERSINK
90˚ TO 0.26 (4 PLACES)
2.40
1.600
1.300
(40.64)
(60.96)
1.000
(33.02)
(25.40)
1.000
(25.40)
0.400
(10.16)
3
7
6
0.600
(15.24)
0.16
(4.06)
2.48
(62.99)
0.47
(11.94)
4
(4) THREADED INSERTS
#M3 THD THRU
5
0.300
(7.62)
0.30
(7.62)
0.200
(5.08)
BOTTOM VIEW
0.20
(5.08)
MATERIAL: BLACK ANODIZED ALUMINUM
Optional Heat Sink
(Part Number HS-CP)
2.30
(58.42)
DIMENSIONS ARE IN INCHES (MM)
0.50 (12.70) TYP.
051 (12.95) MAX.
0.20
(5.08)
0.10
(2.54)
1.900
(48.26)
I/O Connections
Pin Function P29
Pin
1
–Input
6
2 Case (Baseplate)
7
3
On/Off Control
8
4
+Input
9
5
5V Trim
10
Function P29
5V Return
+5V Output
3.3V Trim
3.3V Return
+3.3V Output
2.000
(50.80)
2.40
(60.96)
TOP VIEW
0.147 DIA. (3.734)
(4 PLACES)
0.20
(5.08)
MATERIAL: BLACK ANODIZED ALUMINUM
4 MOUNTING SCREWS AND 0.009 (0.229)
THICK THERMAL PAD INCLUDED
2
7 5 W, D UA L O U T P U T, M I X E D - VO LTAG E D C / D C C O N V E R T E R S
BCP Models
Performance/Functional Specifications
Typical @ T
A
= +25°C under nominal line voltage, balanced "full-load" conditions, unless noted.
➀
Input
Input Voltage Range:
D24 Models
D48 Models
Overvoltage Shutdown:
➁
D24 Models
D48 Models
Start-Up Threshold:
➁
D24 Models
D48 Models
Undervoltage Shutdown:
➁
D24 Models
D48 Models
Input Current:
Normal Operating Conditions
Minimum Input Voltage:
D24 Models
D48 Models
Standby Mode:
Off, OV, UV, Thermal Shutdown
Input Reflected Ripple Current:
Source Impedance <0.1Ω
22µF Low-ESR Capacitor
Input Filter Type
Reverse-Polarity Protection:
➁
D24 Models
D48 Models
On/Off Control:
(Pin 3)
➁ ➂ ➄
D24 & D48 Models
D24N & D48N" Models
18-36 Volts (24V nominal)
36-75 Volts (48V nominal)
37.5-40.5 Volts (39V typical)
78.8-87.0 Volts (83V typical)
15.5-18 Volts (16.5V typical)
33.5-36 Volts (34.4V typical)
14-16 Volts (15.3V typical)
30.5-33.5 Volts (31.8V typical)
See Ordering Guide
5.02 Amps maximum
2.51 Amps maximum
17mA typical
Dynamic Characteristics
Dynamic Load Response:
5V (50-100% load step to 1% V
OUT
)
3.3V (50-100% load step to 1% V
OUT
)
Start-Up Time:
➁
V
IN
to V
OUT
On/Off to V
OUT
Switching Frequency
MTBF
D24 Models
D48 Models
Operating Temperature
(Ambient):
θ
Case to Ambient, No Heatsink
Without Derating
With Derating
Case Temperature:
Maximum Allowable
For Thermal Shutdown
➁
Storage Temperature
450µsec maximum
450µsec maximum
30msec maximum
20msec maximum
350kHz (±35kHz)
Environmental
Bellcore, ground fixed, controlled
1.49M hours (case @ 50°C)
1.72M hours (case @ 50°C)
6.8°C/Watt
–40 to +45°C (with heat sink)
To +100°C (See Derating Curves)
+100°C
+100°C minimum, +110°C maximum
–40 to +120°C
Physical
53mArms, 150mAp-p maximum
Pi (0.47pF - 4.7µH - 3µF)
1 minute duration, 6A maximum
1 minute duration, 4A maximum
On = open or 2.0 - +V
IN
, I
IN
= 50µA max.
Off = 0-0.6V, I
IN
= 1mA max.
On = 0-0.6V, I
IN
= 1mA max.
Off = open or 2.0 - +V
IN
, I
IN
= 50µA max.
Dimensions
Case
(Baseplate) Connection
➁
Case/Pin Material
Weight
2.3" x 2.4" x 0.525" (58.4 x 61 x 13.3mm)
Pin 2
Diallyl phthalate, UL94V-0 rated, aluminum
baseplate; solder-tinned brass pins
4.2 ounces (118 grams)
Primary to Secondary Insulation Level
Basic
➀
Models are specified at "full load" (5V & 3.3V @ 7.5A), with an external 22µF, low-ESR,
input capacitor and 10µF tantalum in parallel with 1µF ceramic output capacitors.
➁
See Technical Notes for details.
➂
Devices may be ordered with opposite polarity (pin 3 open = off). See Part Number
Suffixes and Technical Notes for additional information.
➃
Output noise may be further reduced with the installation of additional external output
capacitors. See Technical Notes.
➄
These signals must be referenced to the input return pin (–V
IN
).
➅
Demonstrated MTBF available on request.
Output
V
OUT
Accuracy
5V Output
3.3V Output
Minimum Loading Per Specification
Ripple/Noise
(20MHz BW)
➁ ➃
Line/Load Regulation
Efficiency
Trim Range
➁
Isolation Voltage:
Input-to-Output
Input-to-Case
Output-to-Case
Isolation Capacitance
Isolation resistance
Current Limit Inception:
➁
5V @ 98% V
OUT
(3.3V no-load)
3.3V @ 98% V
OUT
(5V no-load)
Short Circuit Current:
➁
Temperature Coefficient
Overvoltage Protection:
➁
5V Output
3.3V Output
±2% maximum
±2% maximum
No load
See Ordering Guide
See Ordering Guide
See Ordering Guide and Efficiency Curves
±10% independent
1500Vdc minimum
1000Vdc minimum
1000Vdc minimum
470pF
100MΩ
16-20 Amps
16-20 Amps
Constant current 25A, indefinite
±0.02% per °C
Magnetic feedback, latching
6.8 volts
4.5Volts
Absolute Maximum Ratings
Input Voltage:
Continuous:
D24 Models
D48 Models
Transient (100msec): D24 Models
D48 Models
40.5 Volts
87 Volts
50 Volts
100 Volts
Input Current must be limited. 1 minute
duration. Fusing recommended.
6 Amps
4 Amps
3.8 Volts, latching
6.2 Volts, latching
Current limited. Devices can withstand
an indefinite output short circuit.
–40 to +120°C
+300°C
Input Reverse-Polarity Protection
➁
D24 Models
D48 Models
Output Overvoltage Protection
➁
3.3V Outputs
5V Outputs
Output Current
➁
Storage Temperature
Lead Temperature
(Soldering, 10 sec.)
These are stress ratings. Exposure of devices to any of these conditions may adversely
affect long-term reliability. Proper operation under conditions other than those listed in the
Performance/Functional Specifications Table is not implied, nor recommended.
3
XCP Series
7 5 W, D UA L O U T P U T, M I X E D - VO LTAG E D C / D C C O N V E R T E R S
TECHNICAL NOTES
5V & 3.3V Outputs/Returns
The BCP Series outputs (pins 7 & 10) and returns (pins 6 & 9) are isolated
from the +V
IN
and –V
IN
inputs (pins 4 & 1) via a transformer and opto-coupled
transistors.
The +5V Return (pin 6) and +3.3V Return (pin 9) are connected internal
to the DC/DC converter. Though the returns are common within the DC/DC
converter, the regulating control loop for each output is sensed directly at its
respective output and return pins. In order to maintain optimum regulation if
ground plane is not used, it is critical that PC board layouts also return each
output to its corresponding return pin.
Filtering and Noise Reduction
All BCP DC/DC Converters achieve their rated ripple and noise specifications
using the external input and output capacitors specified in the Performance/
Functional Specifications table. In critical applications, input/output noise may
be further reduced by installing additional external I/O caps. Input capacitors
should be selected for bulk capacitance, low ESR and high rms-ripple-current
ratings. Output capacitors should be selected for low ESR and appropriate
frequency response. All caps should have appropriate voltage ratings and be
mounted as close to the converters as possible.
The most effective combination of external I/O capacitors will be a function of
your particular load and layout conditions. Our Applications Engineers will be
pleased to recommend potential solutions and can discuss the possibility of
our modifying a device’s internal filtering to meet your specific requirements.
Contact our Applications Engineering Group for additional details.
Input Fusing
Certain applications and/or safety agencies may require the installation of
fuses at the inputs of power conversion components. Fuses should also be
used if the possibility of sustained, non-current-limited, input-voltage polarity
reversals exists. For DATEL BCP DC/DC Converters, you should use slow-
blow type fuses with values no greater than the following.
V
IN
Range
"D24" Models
"D48" Models
Fuse Value
6 Amps
4 Amps
Input voltages exceeding the input overvoltage shutdown specification listed
in the Performance/Functional Specifications will cause the device to shut-
down. A built-in hysteresis (2V typical for "D24" models, 4V typical for
"D48" models) will not allow the converter to restart until the input voltage
is sufficiently reduced.
Start-Up Time
The V
IN
to V
OUT
start-up time is the interval between the time at which
a ramping input voltage crosses the turn-on threshold point and the fully-
loaded output voltage enters and remains within its specified accuracy band.
Actual measured times will vary with input source impedance, external input
capacitance, and the slew rate and final value of the input voltage as it
appears to the converter.
The On/Off to V
OUT
start-up time assumes the converter has its nominal input
voltage applied but is turned off via the On/Off Control. The specification
defines the interval between the time at which the converter is turned on
and the fully loaded output voltage enters and remains within its specified
accuracy band.
On/Off Control
(Standard feature)
The On/Off Control (pin 3) may be used for remote on/off operation. As shown
in Figure 1A, the control pin is referenced to the –Input (pin 1) and will be
pulled to a high state internally. The standard BCP converter (no suffix) is
designed so that it is enabled when the control pin is left open and disabled
when the control pin is pulled low (to less than +0.6V relative to –Input).
Dynamic control of the on/off function is best accomplished with a mechanical
relay or an open-collector/open-drain drive circuit (optically isolated if
appropriate). The drive circuit should be able to sink approximately 1mA for
logic low.
The on/off control function is designed such that the converter can be dis-
abled (pin 3 pulled low for no-suffix models) while input power is ramping up
and then "released" once the input has stabilized.
For BCP converters configured with the negative-polarity option on the On/Off
Control pin ("N" suffix added to part number), operation is opposite to that
described above. The converter is disabled when the On/Off Control pin is left
open and enabled when pulled low.
3.3V
Fuses should be installed in the +Input line.
Input Overvoltage/Undervoltage Shutdown and Start-Up Threshold
Under normal start-up conditions, devices will not begin to regulate until
the ramping-up input voltage exceeds the Start-Up Threshold Voltage (35V
for "D48" models). Once operating, devices will not turn off until the input
voltage drops below the Undervoltage Shutdown limit (32V for "D48" models).
Subsequent re-start will not occur until the input is brought back up to the
Start-Up Threshold. This built-in hysteresis prevents any unstable on/off
situations from occurring at a single voltage.
4
+INPUT
21k
4
+INPUT
100k
3
ON/OFF
CONTROL
3
ON/OFF
CONTROL
1
1
–INPUT
–INPUT
Figure 1A. No Suffix
Figure 1B. "N" Suffix
4
7 5 W, D UA L O U T P U T, M I X E D - VO LTAG E D C / D C C O N V E R T E R S
BCP Models
Output Overvoltage Protection
Each voltage output of the BCP Series converter is independently monitored
via an auxiliary winding in the output inductor. If the output voltage
should rise to a level which could be damaging to the load circuitry (see
Performance/Functional Specifications for limits), the overvoltage circuitry will
power down the PWM controller and latch off the DC/DC converter. The
device must now be restarted by powering cycling V
IN
.
Current Limiting
When output current demands exceed the maximum output current rating by
107% to 133%, the DC/DC converter will go into a current limiting mode.
In this condition the output voltage decreases proportionately as the output
current increases, thereby maintaining a somewhat constant power dissipa-
tion—referred to as Power Limiting (see Figure 2). As the load approaches a
short circuit, the output current will continue to increase until it reaches the
rated Short Circuit Current limit.
BCP-5/15-3.3/15-D24, D48 Current Limiting Characteristics
(Nominal V
IN
)
6.00
Input Reverse-Polarity Protection
Upon applying a reverse-polarity voltage to the DC/DC converter, an internal
diode will be forward biased and draw excessive current from the power
source. Therefore, it is required that the input current be limited be either an
appropriately rated input fuse or a current limited power source.
Heat Sinks for BCP Series
DATEL offers two standard heat sinks that can be mounted to the half-brick
package to extend the converter's operating temperature range. Along with
the standard 2.3" x 2.4" x 0.5" (HS-CP) heat sink, DATEL has designed
a low-profile heat sink for height-restricted applications. This new heat sink
(HS-CPLP2) is designed with radiant fins that extend 0.51" beyond either
side of the 2.4" dimension of the BCP package. The convenience of this
design is that the finned extensions protrude only 0.31" below the top surface
of the DC/DC converter, allowing components with a profile height less than
0.215" to be mounted on the pc board below the heat sink. Therefore, while
the surface area of the low-profile heat sink measures 2.3" x 3.5", pcb real
estate is unaffected.
For optimum thermal performance in a natural convection application, the
low-profile heat sink should be mounted with the fins vertically oriented. Both
models are shipped with 0.009" sellf-adhesive thermal pad and mounting
screws.
6
5.00
Output Voltage V
OUT
(Volts)
5V Output
4.00
3.00
2.00
˚
C
WATT
THERMAL RESISTANCE
5
4
3.3V Output
1.00
HS-CPLP2
3
2
1
0
0
100
200
300
400
500
600
700
AIR VELOCITY (FT./MIN.)
0
24
25
15.2
15.7
16.2
16.7
17.2
17.8
18.3
18.8
19.3
19.8
20.3
20.9
21.9
22.4
Output Current, I
OUT
(Amps)
Figure 2. Current Limiting Characteristics
Short Circuit Condition
As described under "Current Limiting," when the BCP Series DC/DC con-
verter output is subjected to a short circuit condition, the output current will
remain at the Short Circuit Current limit. In this state there is negligible power
dissipated in the load. Therefore, most of the input power is dissipated within
the converter, causing the internal temperature to increase. If this condition
persists, Thermal Shutdown will activate and shutdown the DC/DC converter.
When the internal temperature is sufficiently decreased, the converter will
self-start.
Thermal Shutdown
The BCP Series is equipped with Thermal Shutdown circuitry. If the internal
temperature of the DC/DC converter rises above the designed operating
temperature, a precision temperature sensor will power down the unit. When
the internal temperature decreases below the threshold of the temperature
sensor the unit will self-start.
22.6
23.5
26
HS-CP
HS-CP and HS-CPLP2 Heat Sink Performance Vs. Air Flow
(@ 10.5 Watts Power Dissipation)
5
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