Specification Outline & Instruction for the 12010C00 Converter

Specification Outline & Instruction for the 12010C00 Converter
001 4178
002 4583
PRODUCTION RELEASE
ADD PIN DETAIL TO PAGE 8
8/5/04 BF
7/15/05 BF
Product Specification
12010E00 EQUALIZER AND 12010C00
CONVERTER, 12V TO 24V FAMILY
.10
.030
2.5
.76
MODEL NO: 12010X00
EQUALIZER/CONVERTER,
12 TO 24V FAMILY
SPECIFICATION OUTLINE
INTERPRET GEOMETRIC DIMENSIONS AND
TOLERANCING PER ASME Y14.5-1994
DRAWINGS IN THIS DOCUMENT ARE NOT TO SCALE
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
DSR
21JUNE04
PRJCT ENGR
ENGR MNGR
SALES/MRKTG
12010X00
A
NONE
12010X00-002
002
1
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General Description
This Sure Power product is designed to provide 12V to 24V power conversion for heavy-duty
applications.
The equalizers provide equalization for dual battery systems where the charging system is 12V.
Features
•
•
•
•
•
•
•
•
Under and Over Voltage Protection
Reverse Voltage Protection
Voltage Transient Protection
Over load and Short Circuit Protection
Thermal Overload Shutdown
Equalization Status Indicator
Sealed from the Elements
Ignition Turn On
Theory of Operation
The 12010X00 Sure Power equalizers and converters are designed to step up the input voltage in
order to achieve the appropriate output voltage.
The equalizer monitors the input voltage at the terminals and provides an output that is twice the
input.
The converters provide a fixed output to power 24V loads directly from a 12V source.
Block Diagram
OUTPUT
VOLTAGE
TERMINAL
DIFFERENTIAL
AMPLIFIERS,
ERROR
AMPLIFIER,
AND OTHER
CONTROL AND
PROTECTION
CIRCUITS
OUTPUT
BOOST
CONVERTER
INPUT
GND
INPUT
VOLTAGE
TERMINAL
GROUND
TERMINAL
MODEL NO: 12010X00
EQUALIZER/CONVERTER,
12 TO 24V FAMILY
SPECIFICATION OUTLINE
12010X00
A
NONE
12010X00-002
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Description of Features
Included are a number of protection and added features.
PROTECTION FEATURES:
Reversal of the input polarity is protected with MOSFETs in series with the ground.
Reversal of the output polarity is protected with MOSFETs in series with the output connection.
A Metal Oxide Varistor circuit is used to protect the input from load dump and inductive transients.
Input under-voltage and over-voltage conditions cause the unit to safely turn off.
Short circuit and current limiting protection is supplied by monitoring the input current. Detection
of a short circuit or overload turns the output off. The unit then cycles the output on every 1.5
seconds to determine if the short circuit has been removed. Upon removal of this condition the
output voltage will return to its normal state.
Thermal protection is provided by monitoring the unit temperature. Detection of extreme
temperature shuts the unit off. When the heatsink cools, the unit will automatically turn back on.
Loss of ground protection ensures no damage occurs to the unit.
Unit is protected against all miswiring conditions with the exception of the condition where: Unit
ground is connected to system Load, unit +12V is connected to system +12V, Unit +24V is
connected to system Ground and unit ignition is connected to system +12V.
STATUS INDICATOR:
An LED status indicator is provided to denote when the unit is producing current. As the batteries
become equalized and the charger current approaches 0 amps, the LED indicator will diminish in
intensity and eventually go dark.
MODEL NO: 12010X00
EQUALIZER/CONVERTER,
12 TO 24V FAMILY
SPECIFICATION OUTLINE
12010X00
A
NONE
12010X00-002
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ELECTRICAL SPECIFICATIONS
ABSOLUTE MAXIMUM RATINGS:
Maximum ratings establish the maximum electrical rating to which the unit may be subjected without damage.
Parameter
Value
Notes:
Standoff Voltage
36V
Note 1
Reverse Polarity
-26V
Note 2
Output Current
10A
Note 5
100°C
Note 4
Operating Temperature Range
-40°C to +85°C
Note 3
Storage Temperature Range
-55°C to 105°C
Heat Sink Temperature
Notes:
1.
This is maximum voltage applied between INPUT and GND that the unit
will standoff without causing damage to the unit.
2.
This is the maximum reverse voltage that may be applied between
INPUT and GND, or between OUTPUT and GND.
3.
Unit tested at full current at 85°C within a Tenney T10RC thermal
chamber.
4.
The unit generates a significant amount of heat. When determining a
mounting location it is important to account for this heat. Adequate
ventilation must be provided.
5.
Due to boost topology for a converter, the output current is dependent
on input voltage. Below 12.0V input voltage, the output current cannot
be sustained. Please refer to graph. Equalizers are able to sustain 10
amps throughout the entire operating range.
MODEL NO: 12010X00
EQUALIZER/CONVERTER,
12 TO 24V FAMILY
SPECIFICATION OUTLINE
12010X00
A
NONE
12010X00-002
4
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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 ON
Input Under Voltage
Hysteresis
Input Over Voltage
Turn OFF
(Equalizers)
Input Over Voltage
Turn OFF
(Converters)
Input Over Voltage
Hysteresis
Quiescent Current
IGN off
Quiescent Current
IGN on
Output Voltage
(Equalizers)
Output Voltage
(Converters)
MIN
TYP
MAX
Unit
8
9.5
10
V
0.5
Notes:
V
16
16.5
17
V
Voltage on INPUT that causes the equalizer
to turn off.
15
15.5
16
V
Voltage on INPUT that causes the equalizer
to turn off.
0.4
V
1
20
mA
Current draw from the INPUT with IGN off.
VIN = 12V
mA
Current draw from the INPUT with no load
attached to OUTPUT. VIN = 14V
VIN*2
–1%
VIN*2
VIN*2
+1%
V
23.5
24.0
24.5
V
At 12.6V input voltage. Output current
derates with lower input voltage – refer to
graph.
10
11
A
At 12.6V input voltage
Over-Temp Limit
105
°C
The trip point for over-temp shutdown
Over-Temp Hysteresis
15
°C
Current Limit
Load Dump
100V
Inductive Load Switching
±300V
Mutual Coupling
±600V
ESD – Handling
ESD – In Vehicle
EMI Emmissions Radiated
(30MHz to 1GHz)
±8kV, Direct
±15kV, Air
±8kV, Direct
±15kV, Air
Per Spec
Ref. SAE J1455, Table 4b. As tested with
EM Test LD200
Ref. SAE J1455, Table 4b.
Ref. SAE J1455, Section 4.11.2.2.5.1
Ref. SAE J1113-13, Class C
Certified to UN Regulation ECE R 10.02
(Also Reference ISO 13766 and EN 13309)
MODEL NO: 12010X00
EQUALIZER/CONVERTER,
12 TO 24V FAMILY
SPECIFICATION OUTLINE
12010X00
A
NONE
12010X00-002
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ELECTRICAL CHARACTERISTICS (cont.)
12010X00 Typical Efficiency and Power
Dissipation vs. Output Current with Vin at 14V
30
96
94
12010C00 Efficiency
25
92
20
88
12010C00
Power Dissipation
86
15
12010E00
Power Dissipation
84
Watts
Efficiency (%)
12010E00 Efficiency
90
10
82
5
80
0
78
0
2
4
6
8
10
12
Output Current (amp)
12010C00 Current Limit vs. Input Voltage
16
Output Current (Amp)
14
12
10
8
6
4
2
0
8
9
10
11
12
13
14
15
16
Input Voltage (V)
Current Limit vs. Input Voltage
MODEL NO: 12010X00
EQUALIZER/CONVERTER,
12 TO 24V FAMILY
SPECIFICATION OUTLINE
12010X00
A
NONE
12010X00-002
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ENVIRONMENTAL SPECIFICATIONS
Parameter
Level
Conditions / Notes
Thermal Shock
per SAE J1455 Section 4.1
Thermal Cycle
Humidity
0 – 100 %RH
per SAE J1455 Section 4.4, Splash only
See Note 1
Splash
Pressure Wash
Dust Bombardment
Salt Spray
Altitude
per SAE J1455 Section 4.5, See Note 1
3
0.88 g/m
per SAE J1455 Section 4.7, See Note 1
96 Hrs
per SAE J1455 Section 4.3, See Note 1
12000 ft
per SAE J1455 Section 4.8. See Note 1
per SAE J1455 Section 4.9 and
Appendix A, Category 2, See Note 1
Mechanical Vibration
Handling Shock
per SAE J1455, Section 4.2.3
Will Show Damage
per SAE J1455 Section 4.10,
Note 1: Specifications not validated at this revision, SAE J1455 represents design intent.
MODEL NO: 12010X00
EQUALIZER/CONVERTER,
12 TO 24V FAMILY
SPECIFICATION OUTLINE
12010X00
A
NONE
12010X00-002
7
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CONNECTION DIAGRAM:
The unit has five power connections and
one signal connection. All terminations are
made via a Deutsch 6-pin sealed connector.
The aluminum chassis is isolated and can
be grounded or ungrounded.
IGN
FUSE
+12V
UNIT CONNECTIONS:
1
2
3
GND
+24V: Pin 4
This terminal is connected to the
+24V side of the top battery stack
for equalizers.
6
5
4
+24V
In converter applications, the +24V
OUTPUT is connected directly to
24V loads.
GND: Pin 3 and 6
These terminals are for grounding
the unit. All internal operating
currents are returned to this
terminal. Both should be wired for
proper operation.
+12V: PIN 1 and 5
These terminals are connected to
the +12V terminal of the battery
stack. Both should be wired and
appropriately fused for proper
operation.
IGN: Pin 2
This connection enables and
disables the unit. When voltage is
applied to the ignition terminal, the
unit turns on.
MODEL NO: 12010X00
EQUALIZER/CONVERTER,
12 TO 24V FAMILY
SPECIFICATION OUTLINE
12010X00
A
NONE
12010X00-002
8
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002
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MECHANICAL SPECIFICATIONS
The unit utilizes a 6 pin sealed Deutsch connector (DT Series).
Finish: Black Anodized Aluminum (0.5mils min)
Mounting Slots: 4X, Accepts M6 or ¼” Hardware (not included)
Weight: 3.51 Lb
Unit Dimensions
4X FULL RAD.
1.03
[26.2]
4X .280
[7.11]
6.060
[153.92]
4.000
[101.60]
.240
[6.10]
(5.14 [130.7])
(5.62 [142.8])
(2.35 [59.6])
MODEL NO: 12010X00
EQUALIZER/CONVERTER,
12 TO 24V FAMILY
SPECIFICATION OUTLINE
12010X00
A
NONE
12010X00-002
9
F04-019-005
002
9
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