DataSheet for the 12040E00 Equalizer

DataSheet for the 12040E00 Equalizer
REV
ECO
001
002
4265
5070
REVISIONS
DESCRIPTION
PRODUCTION RELEASE
REFORMAT TITLE BLOCK – REFINE LABEL DET ON LAST TWO PAGES
DATE
BY
10/18/04
3/6/08
BF
BF
Product Specification
120XXE00 EQUALIZER AND 120XXC00
CONVERTER, 12V TO 24V FAMILY
12040E00 Model Shown
UNLESS OTHERWISE SPECIFED
DIMENSIONS ARE IN INCHES [MM]
.XX ± .10 [X.X ± 2.5]
.XXX ± .030 [X.XX ± 0.76]
INTERPRET GEOMETRIC DIMENSIONS AND
TOLERANCING PER ASME Y14.5-1994
DRAWINGS IN THIS DOCUMENT ARE NOT TO SCALE
TOLERANCES ARE:
APPROVALS
DRAWN BY
DSR
TITLE
MODEL NO: 120XXX00
12V TO 24V DC TO DC
CONVERTER / EQUALIZER
SPECIFICATION OUTLINE
DATE
9/21/04
PROJECT ENG APPROVAL
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 written permission of
SURE POWER INC.
ENG MANAGER APPROVAL
SALES/MRKTG APPROVAL
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
120XXX00
FILE:
120XXX00-002
002
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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
Output Voltage Shift Pin (equalizers only)
Part Number / Ordering Information
Sure Power Part Number
Output Current
Equalizer / Converter
12040E00
12025E00
40 Amps
25 Amps
Equalizer
Equalizer
12040C00
12025C00
40 Amps
25 Amps
Converter
Converter
TITLE
MODEL NO: 120XXX00
12V TO 24V DC TO DC
CONVERTER / EQUALIZER
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
120XXX00
FILE:
120XXX00-002
002
SHEET
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Theory of Operation
The 120XXX Sure Power family of equalizers and converters are designed to step up the input
voltage in order to achieve the appropriate output voltage. To reduce quiescent current, the
converter / equalizer is enabled through an ignition terminal.
The equalizers monitor the input voltage at the terminals and provide an output that is twice the
input. On equalizers, an output voltage shift terminal is available to aid in optimizing charging
systems. This terminal also serves as an ignition pin. When power is applied to the voltage shift
terminal, the output voltage is increased. At 13.5V input, the output will increase 0.9V above the
normal 2*Vin value. The amount of increase is input voltage dependent. Please refer to graph for
other voltages.
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
OUTPUT
OUTPUT
OUTPUT
BOOST
CONVERTER
BOOST
CONVERTER
BOOST
CONVERTER
BOOST
CONVERTER
INPUT
GND
INPUT
GND
INPUT
INPUT
GND
GND
INPUT
VOLTAGE
TERMINAL
GROUND
TERMINAL
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.
TITLE
MODEL NO: 120XXX00
12V TO 24V DC TO DC
CONVERTER / EQUALIZER
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
120XXX00
FILE:
120XXX00-002
002
SHEET
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Description of Features (cont.)
Short circuit and current limiting protection is supplied by monitoring the output 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 heatsink temperature. Detection of extreme
temperature shuts the unit off. When the heatsink cools approximately 15°C 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
GND is connected to system +12V, Unit +12V is connected to system +24V, Unit +24V is
connected to GND, and Unit IGN is connected to system +24V.
STATUS INDICATOR:
An LED status indicator is provided to denote when the unit is producing current. As the batteries
become equalized the equalizer current will approach 0 amps, and the LED indicator will diminish
in intensity and eventually go dark. In converters, as the output current approaches zero the LED
will go dark.
TITLE
MODEL NO: 120XXX00
12V TO 24V DC TO DC
CONVERTER / EQUALIZER
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
120XXX00
FILE:
120XXX00-002
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
Standoff Voltage
Reverse Polarity
Output Current
Model 12040X00
Model 12025X00
Heat Sink Temperature
Operating Temperature Range
Storage Temperature Range
Value
Notes:
36V
-26V
Note 1
Note 2
40A
25A
100°C
-40°C - +85°C
-55°C - +105°C
Note 4
Note 3
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.
Units can be operated up to 85°C at a reduced output current. Reference “Output Current vs Ambient
Temperature Chart”.
4.
The unit generates a significant amount of heat (as shown in the ELECTRICAL CHARACTERISTICS
section). When determining a mounting location it is important to account for this heat. Adequate
ventilation must be provided.
TITLE
MODEL NO: 120XXX00
12V TO 24V DC TO DC
CONVERTER / EQUALIZER
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
120XXX00
FILE:
120XXX00-002
002
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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)
Output Offset Voltage
Current Limit
Over-Temp Limit
Over-Temp Hysteresis
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 converter to turn off
0.4
V
1
55
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
40
0.9
42
105
15
V
A
°C
°C
Equalizers only. With Vin = 13.5V; refer to graph for other
voltages
The trip point for over-temp shutdown
ELECTROMAGNETIC COMPATIBILITY:
Transient Immunity Tests
Load Dump
Inductive Switching Kick
Mutual Inductance
Electrostatic Discharge
Immunity
In Vehicle ESD
Package and Handling ESD
Emissions Testing
Radiated; 30MFz – 1 GHz
Level
14 + 86et/(0.4)
14 ± 600et/(0.001)
14 ± 300et/(0.000015)
Level
±8 kV direct
±15 kV air
±8 kV direct
±15 kV air
Level
Per spec
Notes:
IAW with SAE J1455 Rev 8/94 Section 4.11.2.2, Table 4a.
IAW with SAE J1455 Rev 8/94 Section 4.11.2.2, Table 4a.
IAW with SAE J1455 Rev 8/94 Section 4.11.2.2, Table 4a.
Notes:
Ref. SAE J1113/13 Rev 2/95, Class C utilizing a 330pF /
2000ohm discharge network.
IAW with SAE J1455 Rev 8/94 Section 4.11.2.2.5.1 / SAE
J551/15 Rev 5/95 utilizing a 150pF/150ohm discharge network
Notes:
Certified to UN Regulation ECE R 10.02
Also reference ISO 13766, EN 13309
TITLE
MODEL NO: 120XXX00
12V TO 24V DC TO DC
CONVERTER / EQUALIZER
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
120XXX00
FILE:
120XXX00-002
002
SHEET
6
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REVISIONS
- SEE SHEET 1 -
ELECTRICAL CHARACTERISTICS (cont.)
12025X00 Typical Efficiency and Power
Dissipation vs. Output Current with Vin at 14V
12040X00 Typical Efficiency and Power
Dissipation vs Output Current with Vin at 14V
81
105
12025C00 Efficiency
94
90
12025E00 Efficiency
54
88
45
12025C00
Power Dissipation
86
84
36
27
12025E00
Power Dissipation
82
78
5
10
15
75
90
60
72
45
54
12040C00
Power Dissipation
30
36
18
80
0
Efficiency(%)
90
20
108
12040E00 Efficiency
63
Power Dissipation (W)
92
Efficiency (%)
126
12040C00 Efficiency
72
Power Dissipation(W)
96
12040E00
Power Dissipation
9
15
0
0
25
18
0
0
5
10
15
Output Current (amp)
20
25
30
35
40
Output Current(A)
12025E00 Typical Offset Voltage vs. Input Voltage
12040E00 Typical Offset Voltage vs. Input Voltage
33
1.20
36
1.05
33
0.90
28
0.75
Vout w/ offset
25
0.60
Vout normal
23
0.45
20
0.30
18
15
9
10
11
12
13
14
15
16
1.02
Vout w/ offset - Vout
30
Outputt Voltage(V)
30
Differential Voltage (v)
Output Voltage (v)
Vout w/ offset - Vout
1.19
0.85
27
0.68
Vout w/ offset
24
0.51
Vout Normal
21
0.34
0.15
18
0.17
0.00
15
Differential Voltage(V)
35
0.00
9
10
11
12
Input Voltage (v)
13
14
15
16
Input Voltage(V)
TITLE
MODEL NO: 120XXX00
12V TO 24V DC TO DC
CONVERTER / EQUALIZER
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
120XXX00
FILE:
120XXX00-002
002
SHEET
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REVISIONS
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ELECTRICAL CHARACTERISTICS (cont.)
12040X00 Output Current vs. Ambient Temperature,
Vin = 14V
12025X00 Output Current vs. Ambient Temperature,
Vin = 14.0V
30
50
25
40
Current(A)
Current (A)
20
15
30
20
10
10
5
0
0
0
20
40
60
80
0
100
20
40
60
80
100
Temperature(deg C)
Temperature (deg C)
12040C00 Output Voltage vs. Output Current
as a Function of Input Voltage, Room Temp
12025C00 Output Voltage vs. Output Current
as a Function of Input Voltage, Room Temp
30
30
25
15V
25
15V
14V
Voltage (V)
Voltage (V)
14V
13V
12V
11V
20
10V
15
9V
13V
20
12V
11V
10V
15
10
9V
10
5
0
5
10
15
20
25
30
35
40
20
25
30
35
Current (A)
40
45
50
55
60
65
Current (A)
TITLE
MODEL NO: 120XXX00
12V TO 24V DC TO DC
CONVERTER / EQUALIZER
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
120XXX00
FILE:
120XXX00-002
002
SHEET
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REVISIONS
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ENVIRONMENTAL SPECIFICATIONS
Parameter
Thermal Shock
Thermal Cycle
Humidity
Splash
Pressure Wash
Dust Bombardment
Salt Spray
Altitude
Mechanical Vibration
Handling Shock
Value
Notes:
per SAE J1455 Section 4.1, Rev 8/94
0 – 100 %RH
per SAE J1455 Section 4.2.3, Rev 8/94
per SAE J1455 Section 4.4, Rev 8/94 Splash only See
Note 1
per SAE J1455 Section 4.5, Rev 8/94 See Note 1
0.88 g/m3
96 Hrs
12000 ft
per SAE J1455 Section 4.7, Rev 8/94 See Note 1
per SAE J1455 Section 4.3, Rev 8/94 See Note 1
per SAE J1455 Section 4.8, Rev 8/94 See Note 1
per SAE J1455 Section 4.9 and Appendix A, Category 2,
Rev 8/94 See Note 1
Will Show Damage
per SAE J1455 Section 4.10, Rev 8/94
Note 1: Specifications not validated at this revision, SAE J1455 represents design intent.
TITLE
MODEL NO: 120XXX00
12V TO 24V DC TO DC
CONVERTER / EQUALIZER
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
120XXX00
FILE:
120XXX00-002
002
SHEET
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REVISIONS
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CONNECTION DIAGRAMS
The unit has three connections and a choice of one or two signal connections. The aluminum
chassis is isolated and can be grounded or ungrounded.
UNIT CONNECTIONS:
+24V: This terminal is connected to the +24V side of the battery stack for equalizers. In
converter applications, the 24V OUTPUT is connected directly to 24V loads.
GND:
This is the terminal for grounding the unit. All internal operating currents are
returned to this terminal.
+12V: This terminal is connected to the +12V terminal of the battery stack.
This connection enables and disables the unit. When voltage is applied to the
ignition terminal, the unit turns on.
B+
12V
Alternator
24V
12V
GND
B+
FUSE
+
-
+
B
BATTERY
24V
12V
GND
FUSE
+
-
-
+
B
BATTERY
24V
Loads
Typical Converter Connection
24V
FROM 12V
IGN SOURCE
FUSE
A
BATTERY
12V
Loads
12V
Alternator
FROM 12V
IGN SOURCE
FUSE
24V
Loads
Typical Equalizer Connection with “OFFSET” Source
IGN
OFFSET
Typical Equalizer Connection with “IGN” Source
This connection also enables and disables the unit.
Applying the unit power to this connection increases the
output voltage between 0.6 to 1.4V – input voltage
dependent, refer to graph.
24V
Loads
-
GND
12V
Alternator
B+
FROM 12V
IGN SOURCE
FUSE
-
A
BATTERY
12V
IGN
OFFSET
OFFSET (Equalizers ONLY):
IGN
OFFSET
IGN:
+
A
BATTERY
12V
Loads
12V
Loads
TITLE
MODEL NO: 120XXX00
12V TO 24V DC TO DC
CONVERTER / EQUALIZER
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
120XXX00
FILE:
120XXX00-002
002
SHEET
10
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REVISIONS
- SEE SHEET 1 -
MECHANICAL SPECIFICATIONS
The unit utilizes three channel shaped bus bars for making power connections. Each bus bar is
equipped with an M8 hex head bolt. The bolt head is captured within the channel and the channel
prevents rotation of the head when tightening the nut. The control connections are made via ¼”
male tabs.
Finish: Black Anodized Aluminum
Terminals: 0.050 thick C11000 ETP Copper, Bright Tin Plate
Hardware Included:
Bolts – 3X, M8x20mm Hex Head, Tin Plated Steel
Nuts – 3X, M8 Hex, Tin Plated Steel
Lock Washers – 3X, M8, Tin Plated Steel
Maximum Torque: 110 in-lbs
Mounting Slots: 6X - (12040X00) 4X - (12025X00), Accepts M6 or ¼” Hardware (not included)
Weight: 13.5lbs / 6.12kg – 12040X00, 9lbs / 4.1kg – 12025X00
Unit Dimensions – 12040X00 (12040E00 pictured)
(6X .280 [7.11])
(.250)
([6.35])
STATUS LED
(2.500 [63.50])
(1.750 [44.45])
(8.500 [215.90])
(8.000 [203.20])
(1.750 [44.45])
IGNITION
OFFSET
(4.000 [101.60])
(1.250)
([31.75])
(4.000 [101.60])
(10.500 [266.70])
(11.075 [281.31])
(11.575 [294.01])
3X M8X20 1.25P TIN
PLATED HEX HEAD BOLT
(3.168)
([80.47])
(1.495)
([37.97])
(.965)
([24.51])
Note: Offset terminal only visible on equalizers. Product labels will dictate converter or equalizer and will coincide with the
model number.
TITLE
MODEL NO: 120XXX00
12V TO 24V DC TO DC
CONVERTER / EQUALIZER
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
120XXX00
FILE:
120XXX00-002
002
SHEET
11
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REVISIONS
- SEE SHEET 1 -
MECHANICAL SPECIFICATIONS (cont.)
Unit Dimensions – 12025X00 (12025E00 pictured)
(4X .280 [7.11])
(.250)
([6.35])
STATUS LED
(2.500 [63.50])
(1.750 [44.45])
(8.500 [215.90])
(8.000 [203.20])
(1.750 [44.45])
IGNITION
OFFSET
(4.000 [101.60])
(1.563 [39.69])
(7.125 [180.98])
(7.700 [195.58])
(8.200 [208.28])
3X M8X20 1.25P TIN
PLATED HEX HEAD BOLT
(3.168)
([80.47])
(1.495)
([37.97])
(.965)
([24.51])
Note: Offset terminal only visible on equalizers. Product labels will dictate converter or equalizer and will coincide with the
model number.
TITLE
MODEL NO: 120XXX00
12V TO 24V DC TO DC
CONVERTER / EQUALIZER
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
120XXX00
FILE:
120XXX00-002
002
SHEET
12
OF
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F04-019-007
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