Data Sheet - 11020C01 Converter
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PRODUCTION RELEASE
BY
9/23/01 BF
Product Specification
11020C01 DC-DC CONVERTER
TRAIL CHARGER
UNLESS OTHERWISE SPECIFIED
DIMENSIONS ARE IN INCHES [MM]
TOLERANCES ARE: .XX ± .10 [X.X ± 2.5 ]
]
.XXX ±
[X.XX ±
INTERPRET GEOMETRIC DIMENSIONS AND
TOLERANCING PER ASME Y14.5-1994
DRAWINGS IN THIS DOCUMENT ARE NOT TO SCALE
APPROVALS
PROPRIETARY
THIS DRAWING IS THE PROPERTY OF SURE POWER INC. and shall not be
copied, reproduced, lent, or disposed of, nor used for any purpose other than
that for which it is specifically provided without the written permission of
SURE POWER INC.
DRAWN
JAR
TITLE
MODEL NO: 11020C01
TRAIL CHARGER
SPECIFICATION OUTLINE
DATE
05MAR09
PROJECT ENGR
ENGR MANAGER
SALES/MRKTG
SIZE
CAGE CODE NO.
A
55156
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THEORY OF OPERATION
The 11020C01 is a specially designed DC/DC converter that is used to charge a battery from a
12V source. An example is a battery that is mounted on the trailer of a vehicle. The distance
between the alternator of the vehicle and the trailer-mounted battery makes it difficult to get
adequate charging voltage to the battery. The 11020C01 has a microprocessor on-board to
measure the input voltage, output voltage and current, boost voltage, temperature sensors. An
Intelligent Power Switch on the output is used to provide consistent, robust protection and control
of the output current.
The 11020C01 has two modes of operation:
•
•
Boost Mode: This mode is enabled when input voltage is nominal (e.g.. Vin ≤ (Vout + 0.6
Vdc)). When the converter is operating in this mode, the output voltage is temperature
compensated, see graph 1.
Bypass Mode: This mode is enabled when the input voltage is greater than the output
voltage. In this mode, the converter will enter a “burst” operation whereby the output will
burst on and off when the pass through current exceeds 20ADC.
The microprocessor measures the temperature of the converter and provides a temperature
compensated output, optimized for recharging AGM batteries. This is most effective when the
charger and battery are at the same temperature (mounted in near proximity).
Monitoring the internal temperature provides thermal protection. When the microprocessor
detects extreme temperatures, action is taken to protect the unit, including shutdown of output.
The converter is designed to withstand the severe electrical environment of heavy-duty trucks
and off highway equipment. The converter can withstand load dump, reverse battery, short
circuit, and over-temperature conditions without sustaining damage.
The unit is adequately sealed to meet the performance standards called out in SAE J1455
Section 4 specification relative to Humidity, Salt Spray, Splash and Dust bombardment (See table
4, p. 5 of this document).
TITLE
MODEL NO: 11020C01
TRAIL CHARGER
SPECIFICATION OUTLINE
SIZE
CAGE CODE NO.
A
55156
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DRAWING NO.
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FUNCTIONAL DESCRIPTION
Connections to the unit are made via a 4-pin Deutsch connector. The terminals are as follows:
Conn – Pin
Name
Notes:
J1-1
J1-2
J1-3
Vin
Vout
Ground
Provides the input voltage to the converter.
Output to the battery to be charged. Keep wiring as short as possible.
System ground. Must be common to both input and output.
J1-4
Ignition
Enables the converter when Ignition is on.
40A FUSE
12V IN
IGN
1
2
4
3
12V OUT
GND
4 PIN MATING CONNECTOR
(DEUTSCH)
HOUSING:
DTP06-4S
SOCKET:
1062-12-0166
LOCK:
WP4S
TITLE
MODEL NO: 11020C01
TRAIL CHARGER
SPECIFICATION OUTLINE
SIZE
CAGE CODE NO.
A
55156
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SHEET
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LED indications:
The STATUS LED will indicate several different conditions of the Trail Charger. This is
accomplished by the use of a Bi-Color LED that will indicate with either a solid color or a blinking
color at three different blink rates, see table below:
RATE
Slow
Medium
High
TIMING
1 second on, 1 second off
500ms on, 500 ms off
250ms on, 250ms off
Definition of indications is found in the following table:
INDICATION
LED off
RED, blink,
high-rate
STATUS
Module off, ignition or input voltage not
present.
FAULT, any on the fault list,
which follows this table.
Fault
Condition
Input Command
Shutdown
Reduce
—
—
—
Any Fault
condition
—
—
A RED LED blinking at a high rate indicates one of the following fault conditions exist:
•
Input over-voltage limit.
•
Input under-voltage limit.
•
Output over-voltage limit.
•
Output over-current limit.
•
Output FET’s over thermal limits.
A fast blinking RED from any fault indication has a higher priority than all other indications if the
ignition is on.
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MODEL NO: 11020C01
TRAIL CHARGER
SPECIFICATION OUTLINE
SIZE
CAGE CODE NO.
A
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ENVIRONMENTAL SPECIFICATIONS
Characteristic
Operational Temperature
Range
Maximum Heatsink
Temperature
Humidity
Salt Spray
Parameter
Unit
Notes:
-40 to +85
°C
As tested in Tenney T10RC-1.5 thermal chamber.
100
°C
Heatsink temperature must be kept below this
value to prevent activation of over-temperature
protection circuit.
0 to 100
%RH
48
Hrs
Tested per SAE J1455, Section 4.2.3
Tested per SAE J1455 Section 4.3
Splash
per SAE J1455 Section 4.4, Splash only.
Dust
per SAE J1455 Section 4.7.
Altitude
12000
Ft
per SAE J1455 Section 4.9 and Appendix A,
Category 2.
Vibration
Handling Shock
per SAE J1455 Section 4.8.
Will show
damage
per SAE J1455 Section 4.10
ELECTRICAL SPECIFICATIONS
MAXIMUM RATINGS:
Maximum ratings establish the maximum electrical rating to which the unit may be subjected without
damage.
Characteristic
Parameter
Unit
Notes:
Standoff Voltage
24
V
Time at Standoff
5
min
Reverse Polarity
-24
V
This is the maximum reverse voltage that may be
applied between input and GND pins.
Time at Reverse Polarity
5
min
Tested at 85°C. Per SAE J1455, Section 4.11.1
Maximum Input Current
27
A
When operating in boost mode
Maximum Output Current
23
A
Maximum output current when in boost mode. Above
60°C ambient temperature the maximum output
current must be derated.
Maximum Output Current
(Bypass mode)
25
A
Maximum RMS output current when Vin>Vout.
(bursting output)
This is maximum voltage applied between input and
GND that the unit will standoff without causing
damage to the unit.
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MODEL NO: 11020C01
TRAIL CHARGER
SPECIFICATION OUTLINE
SIZE
CAGE CODE NO.
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Maximum Iout Vs. Vin
24
Iout (Amps DC)
22
20
18
16
14
12
9
10
11
12
13
14
15
Vin (Volts DC)
Load Regulation
15
Output Voltage (Volts DC)
14.8
14.6
14.4
14.2
14
13.8
13.6
13.4
13.2
13
0
5
10
15
20
Load Current (Am ps DC)
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MODEL NO: 11020C01
TRAIL CHARGER
SPECIFICATION OUTLINE
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ELECTRICAL CHARACTERISTICS
Unless otherwise stated, conditions apply to full temperature range and full input voltage range.
Characteristic
Input Under-Voltage
Turn Off
Input Under-Voltage
Recovery
Input Over-Voltage
Turn off
Input Over-Voltage
Recovery
Input
Quiescent Current
MIN
TYP
MAX
Unit
Notes:
7.8
8.0
8.2
V
Input voltages below this level will cause the
output to turn off.
10.3
10.5
10.7
V
Input voltages below this level will cause the
output to turn off.
16.7
17.0
17.3
V
Input voltages above this level will cause the
output to turn off.
15.5
15.8
16.1
V
Input voltages below this level will cause the
output to turn on.
-
1.5
2
mA
Output
Quiescent Current
-
1.5
2
mA
Efficiency
-
90
-
%
Output Voltage
-
14.2
-
V
-
20
-
A
Maximum current when in boost mode. See
“Maximum Iout Vs Vin” graph on Pg. 6
-
23
-
A
See “Maximum Iout Vs Vin” graph on Pg. 6
Output Current Limit
Boost Mode
Output Current Limit
Bypass Mode
Current draw from the input with no load
attached to the output(J1-2), and ignition off.
Measured with the Input voltage at 12.6Vdc.
Current draw from the output (J1-2) with
ignition off. Measured with the output voltage
at 12.6Vdc.
Over entire input voltage range at rated
output current.
The output voltage is temperature
compensated. See “Temperature
Compensation”graph on Pg. 8.
TITLE
MODEL NO: 11020C01
TRAIL CHARGER
SPECIFICATION OUTLINE
SIZE
CAGE CODE NO.
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Temperature Compensation
(The output is temperature compensated to provide a higher
voltage level at lower temperatures as recommended by AGM battery manufacturers.)
Temperature Compensation
17.5
17
Output Voltage (Vdc)
16.5
16
15.5
15
14.5
14
13.5
13
-40
-20
0
20
40
60
80
100
Temperature (Deg. C)
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MODEL NO: 11020C01
TRAIL CHARGER
SPECIFICATION OUTLINE
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Installation Wire Size:
(Proper installation requires a minimum run length of wire
on the input terminal. Use no less than 10Ft of 10AWG wire. Use standard wiring
practice for other connections).
Input Wire Length
Wire Gauge
10 – 20 Ft.
20 - 29 Ft.
30 – 39 Ft.
40 – 49 Ft.
50 – 59 Ft.
≥60 Ft.
14
12
10
8
8
6
ELECTROMAGNETIC COMPATIBILITY
Radiated Immunity Test
Level
Notes:
Immunity to Electromagnetic
Fields, 30 MHz to 18 GHz,
Absorber-Lined Chamber
60V/m
SAE J1113-21, Class B, Region 2, L3
Immunity to Radiated
Electromagnetic Fields—Bulk
Current Injection (BCI) Method
60mA
SAE J1113-4, Class B, Region 2
Emissions Limit Test
Level
Notes:
Radiated Emissions
Class 2
SAE J1113-41
Conducted Emissions
Class 2
SAE J1113-41
TITLE
MODEL NO: 11020C01
TRAIL CHARGER
SPECIFICATION OUTLINE
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ELECTROMAGNETIC COMPATIBILITY (continued)
Transient Immunity Tests
Level
Notes:
14 + 86et/(0.4)
SAE J1455, Section 4.11.2.2.1, Table 4a
Inductive Switching
14 ± 600et/(0.001)
SAE J1455, Section 4.11.2.2.2, Table 4a
Mutual Inductance
14 ± 300et/(0.00015)
SAE J1455, Section 4.11.2.2.3, Table 4a
Load Dump
Electrostatic Discharge
Immunity
Level
Notes:
ESD, In Vehicle
±8kV direct
±15kV air
SAE J1113-13, Section 4, Class C, Region 2
ESD, Package and Handling
±8kV direct
±15kV air,
SAE J1113-13, Section 5
TITLE
MODEL NO: 11020C01
TRAIL CHARGER
SPECIFICATION OUTLINE
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WIRING DIAGRAM
TITLE
MODEL NO: 11020C01
TRAIL CHARGER
SPECIFICATION OUTLINE
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UNIT DIMENSIONS
1.563
[39.69]
7.125
4.000 [180.98]
[101.60]
4X .280
[7.11]
4X FULL R
5.15
[130.7]
2.35
[59.6]
.240
[6.10]
5.63
[142.9]
TITLE
MODEL NO: 11020C01
TRAIL CHARGER
SPECIFICATION OUTLINE
SIZE
CAGE CODE NO.
A
55156
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