DataSheet for the 21100E00 Equalizer

DataSheet for the 21100E00 Equalizer
REV
ECO
001
5332
002
003
REVISIONS
DESCRIPTION
PRODUCTION RELEASE
ADD 21100C00 MODEL NUMBER – CLARIFY EQUALIZER’S OUTPUT
5489 VOLTAGE DURING NO-LOAD – CHG ‘SALES/MRKTG APPROVAL’ BLOCK
TO ‘PROD MANAGER APPROVAL’ BLOCK
CHANGED UNIT WEIGHT TO MAX – ADDED .531±.030 [13.49±0.76] DIM –
5666 CORRECTED 12V & 24V POSITION ON UNIT DIMENSION DRAWING –
ADDED TERMINAL COATING NOTE
DATE
BY
11/26/08
JT
10/15/09
JT
6/2/10
BF
Product Specification
21XXXE00 EQUALIZER AND
21XXXC00 CONVERTER FAMILY
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:
DRAWN BY
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.
APPROVALS
DATE
MGEORGE
08/28/08
TITLE
MODEL NO: 21XXXC00/E00
CONVERTER AND EQUALIZER
FAMILY
SPECIFICATION OUTLINE
PROJECT ENG APPROVAL
ENG MANAGER APPROVAL
PROD MANAGER APPROVAL
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
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Overview
In dual battery (24V systems) it is often desirable to have 12V power available. Often this 12V power
is available by tapping the battery stack at the junction of the lower and upper battery. Tapping the
battery stack will result in unequal current draw from the lower and upper battery. Unequal current
draw from the batteries will result in a state of charge unbalance. The lower battery will be
discharged more than the upper battery. Eventually this will lead to damage and reduced life from the
batteries.
The battery equalizer provides an effective method for ensuring that the two batteries maintain
voltage balance by providing all of the 12V current. The battery is only called upon to supply transient
currents that exceed the output capability of the equalizer. The equalizer thus maximizes the life of
the batteries in dual battery systems.
Converters provide fixed outputs to power 12V loads directly where a 12V battery is not available.
Features
•
•
•
•
•
•
•
Under and Over Voltage Protection
Reverse Voltage Protection
Voltage Transient Protection
Over load and Short Circuit Protection
Thermal Overload Shutdown
Equalization Status Indicator
Protected from the Elements
Part Number / Ordering Information
Table 1
Sure Power Part Number
Output Current
Equalizer / Converter
21100E00
21080E00
21060E00
100 Amps
80 Amps
60 Amps
Equalizer
Equalizer
Equalizer
21100C00
21080C00
21060C00
100 Amps
80 Amps
60 Amps
Converter
Converter
Converter
TITLE
MODEL NO: 21XXXC00/E00
CONVERTER AND EQUALIZER
FAMILY
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
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Theory of Operation
The family of equalizers and converters utilize paralleled buck converters to step down the input
voltage in order to achieve the appropriate output voltage.
The equalizers monitor the input voltage at the terminals and provide an output that is one-half of the
input. Converters provide a fixed output independent of the input voltage at the terminals.
Isolation is provided between chassis and input / output / ground terminals.
Internal construction consists of both SMT and thru-hole components.
VOLTAGE
INPUT
TERMINAL
DIFFERENTIAL
AMPLIFIERS,
ERROR
AMPLIFIER,
AND OTHER
CONTROL AND
PROTECTION
CIRCUITS
INPUT
INPUT
INPUT
INPUT
BUCK
CONVERTER
BUCK
CONVERTER
BUCK
CONVERTER
BUCK
CONVERTER
OUTPUT
GND
OUTPUT
GND
OUTPUT
OUTPUT
GND
GND
OUTPUT
VOLTAGE
TERMINAL
GROUND
TERMINAL
Block Diagram
Figure 1
TITLE
MODEL NO: 21XXXC00/E00
CONVERTER AND EQUALIZER
FAMILY
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
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Description of Features
Included are a number of protection and other features.
PROTECTION FEATURES:
Reversal of the input polarity is protected with MOSFETs in series with the input. Reversal of the
output polarity is protected with MOSFETs in series with the ground connection. The protection
feature will automatically reset when the correct polarity is applied.
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. When the correct
voltage is applied to the input the unit will automatically turn back on.
Short circuit and current limiting protection is supplied by monitoring the output current. Detection of
a short circuit or overload limits the output current to 1.2 to 1.4 times the maximum steady state
output rating. Upon removal of this condition the output voltage will return to its normal state.
Monitoring the internal temperature provides thermal protection. Detection of excess temperature
shuts the unit off. As the heat sink cools, the unit will automatically reset.
Loss of ground protection ensures no damage occurs to the unit if ground is inadvertently lost.
STATUS INDICATOR:
An LED status indicator is provided to denote when the unit is producing current. In
equalizers, as the batteries become equalized the LED indicator will diminish in intensity and
eventually go dark. In converters, when the output current approaches zero, the LED will go
dark.
TITLE
MODEL NO: 21XXXC00/E00
CONVERTER AND EQUALIZER
FAMILY
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
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ELECTRICAL SPECIFICATIONS
Table 2 ABSOLUTE MAXIMUM RATINGS:
Maximum ratings establish the maximum electrical rating to which the unit may be subjected without damage.
Parameter
Typical
Notes:
Standoff Voltage
36V
Note 1
Reverse Polarity
-26V
Note 2
Model 21060E00, 21060C00
60A
Note 3
Model 21080E00, 21080C00
80A
Note 3
Model 21100E00, 21100C00
100A
Note 3
Heat Sink Temperature
100°C
Note 4
Over-temperature Shutdown
110°C
Over-temperature hysteresis
12°C
Output Current
Ambient Operating
Temperature Range
-40°C
+85°C
Storage Temperature Range
-55°C
+105°C
Unit will shutdown if internal temperature
exceeds this value.
Amount temperature of unit must drop before it
will automatically turn back on.
Note 3
Note 1: Standoff Voltage
This is maximum voltage applied between +24V and GND that the unit will standoff without causing damage to the unit.
Note 2: Reverse Polarity
This is the maximum reverse voltage that may be applied between the 24V terminal and the GND terminal, or between +12V
terminal and the GND terminal.
Note 3: Output Current
Units can be operated up to +85°C at a reduced output current. Refer to “Output Current Derating Guideline.”
Note 4: Heat Sink Temperature
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. Under all conditions the heatsink temperature must be maintained below this required
value.
TITLE
MODEL NO: 21XXXC00/E00
CONVERTER AND EQUALIZER
FAMILY
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
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Output Current Derating Guideline
120
21100E00 & 21100C00
100
21080E00 & 21080C00
80
Output Current
60
(Amps)
21060E00 & 21060C00
40
20
0
40
50
60
70
Ambient Temperature (deg C)
80
90
Figure 2
Table 1 INPUT 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
Turn OFF
Input Over Voltage
Turn OFF
Input Over Voltage
Hysteresis
MIN
TYP
MAX
Unit
14.9
15.9
16.9
V
10.1
10.8
11.5
V
32
33
34
V
0.5
Quiescent Current1,2
18
Isolation rating
50
Notes:
Voltage on INPUT that causes the
equalizer to turn off.
V
25
mA
V
Current draw from the INPUT with no
load attached to OUTPUT. Input
voltage is 24V, 25ºC ambient
Input/output/GND to chassis
Note 1: Quiescent Current may slightly increase at elevated temperatures.
Note 2: With no load on the output, the output voltage will drift up slightly due to leakage currents.
TITLE
MODEL NO: 21XXXC00/E00
CONVERTER AND EQUALIZER
FAMILY
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
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Table 2 OUTPUT ELECTRICAL CHARACTERISTICS
Unless otherwise stated, conditions apply to full temperature range and full input voltage range.
Characteristic
Output Voltage
(Equalizers)
2
MIN
TYP
MAX
Unit
V24/2
–1%
V24/2
V24/2
+1%
V
21100E00, 21080E00, 21060E00
14
V
For Models 21080C00, 21060C00
When Input Voltage is greater than 22V.
(For Input Voltage less than 22V,
Output Voltage Equals ½ Input Voltage)
60
A
See derating curves for extended
ambient operating temperatures.
74
A
Constant Current
80
A
See derating curves for extended
ambient operating temperatures.
97
A
Constant Current
100
A
See derating curves for extended
ambient operating temperatures.
120
A
Constant Current
Output Voltage
(Converters)
13
Load Range
0
Model 21060C00, 21060E00
Current limit3
Model 21060C00, 21060E00
Load Range
Model 21080C00, 21080E00
Current limit3
Model 21080C00, 21080E00
Load Range
Model 21100E00, 21100C00
Current limit3
Model 21100E00, 21100C00
Loop Stability (BW)
64
13.5
69
0
87
92
0
110
115
2
kHz
Notes:
Line, Load, temperature
Note 2: Output Voltage
To maintain battery balance, the equalizer monitors the input voltage and provides an output voltage that is one-half of the
input voltage. The input voltage is the voltage that exists between the 24V Terminal and the GND Terminal. The input
voltage is called V24, for simplicity. Table 1 lists the input operating voltage range. The output voltage is the voltage
between the 12V Terminal and the GND Terminal. The output voltage is called V12 for simplicity. For example, if the input
voltage (V24) is 24.0 volts, the output voltage (V12) would be 12.0 volts.
Note 3: Current Limit Protection
The equalizer automatically limits the output current. It monitors the output current and limits it to a preset value (Current
Limit). As the output load is increased beyond Current Limit the output voltage will drop and the current will only slightly
increase. The Table above gives the typical characteristics of the current limit circuit. When the over-load or short circuit is
removed the output voltage will automatically return to normal.
TITLE
MODEL NO: 21XXXC00/E00
CONVERTER AND EQUALIZER
FAMILY
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
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Table 3 Electromagnetic Compatibility Specifications
Characteristic
Typical
Notes:
28V + 122
Ref. SAE J1455 Rev Aug94, Table 4b. As tested with EM
Test LD200. Applied to +24V terminal.
Inductive Load Switching
±600 V
Ref. SAE J1455 Rev Aug94, Table 4b. As tested with EM
Test MPG200.
Mutual Coupling
±300 V
Ref. SAE J1455 Rev Aug94, Table 4b. As tested with EM
Test MPG200.
ESD – Handling
±8kV, Direct
±15kV, Air
Per SAE J1113-13 Rev Nov2004
ESD – In Vehicle
±8kV, Direct
±15kV, Air
SAE J 1113-13
Class C, Region 2
Conducted Immunity
0 - 100 mA
Load Dump
Radiated Immunity
Conducted Emmissions
40 - 150 V/m
Per SAE J1113-4 Rev Aug2004
Bulk Current Injection
Appendix A, Class C
SAE J1113-21 Rev Oct2005
Absorber-Lined Chamber
Appendix C, Group 2
Class 2
Per J1113-41 Rev May2000
Radiated Emmissions
Immunity and Emissions
Class 2
Per UN Regulation ECE R 10.02 for E mark.
TITLE
MODEL NO: 21XXXC00/E00
CONVERTER AND EQUALIZER
FAMILY
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
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Table 4 ENVIRONMENTAL SPECIFICATIONS
Parameter
Thermal Shock
Thermal Cycle
Humidity
Splash
Pressure Wash
Dust Bombardment
Salt Spray
Altitude
Mechanical Vibration
Operational Shock
Handling Shock
Level
Conditions / Notes
+85ºC to -40ºC
2hr soak per temp
36 Cycles
per . SAE J1455 Rev Aug94
Sec 4.1.3.
+85ºC, -40ºC
9 Cycles, 2 hr exposure
0 – 98 %RH
per SAE J1455 Rev Aug94, Section
4.2.3
DOT4 brake fluid, 20W40
synthetic motor oil, unleaded
gas, engine degreaser, and
carburetor cleaner.
per SAE J1455 Rev Aug94 Section 4.4,
Splash only
1400 kPa
per SAE J1455 Rev Aug94 Section 4.5
3
0.88 g/m
per SAE J1455 Rev Aug94 Section 4.7
96 Hrs
per SAE J1455 Rev Aug94 Section 4.3
12000 ft
per SAE J1455 Rev Aug94 Section 4.8
0.0635G2/Hz, 5 to 100Hz
3dB per Octave roll-off to
500Hz
30g, 11ms, Sawtooth
Will Show Damage
Random Vibration, 3 axes, 3 hr/axis.
3 axes, both directions.
per SAE J1455 Rev Aug94 Section 4.10
TITLE
MODEL NO: 21XXXC00/E00
CONVERTER AND EQUALIZER
FAMILY
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
21XXXC00-E00
FILE: 211XXXC00-E00-003
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Efficiency and Power Dissipation Curves
21100X00 Typical Efficiency and
Power Dissipation vs Output Current
V24=24V, V12=12V
21080X00 Typical Efficiency and
Power Dissipation vs Output Current
V24=24V, V12=12V
120
96
94
107
94
92
93
90
80
88
67
86
53
84
40
21100C00, 21100E00 Power Dissipation
80
78
5
15
25
35
45
55
65
Output Current (Amps)
75
85
80
21080E00 & 21080C00
Efficiency
92
Efficiency (%)
Power Dissipation (W)
90
70
90
60
88
50
86
40
21080E00 & 21080C00
Power Dissipation
84
30
27
82
20
13
80
10
0
78
0
5
95
15
25
35
45
55
Output Current (Amps)
Figure 3
65
75
Figure 4
21060X00 Typical Efficiency and
Power Dissipation vs Output Current
V24=24V, V12=12V
96
70
94
62
21060E00 & 21060C00
Efficiency
92
54
90
47
88
39
86
31
21060E00 & 21060C00 Power
Dissipation
84
23
82
16
80
8
78
Power Dissipation (W)
82
Efficiency (%)
Efficiency (%)
21100C00, 21100E00 Efficiency
Power Dissipation (W)
96
0
5
10
15
20
25
30
35
40
45
50
55
60
Output Current (Amps)
Figure 5
TITLE
MODEL NO: 21XXXC00/E00
CONVERTER AND EQUALIZER
FAMILY
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
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FILE: 211XXXC00-E00-003
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CONNECTION DIAGRAMS:
Recommended Equalizer Connection
*
+
Bat.1
-
24V
*
12V
+
Bat.2
-
STARTER
MOTOR
ALTERNATOR
GND
LOAD
Figure 6
Typical Converter Connection
Figure 7
Note *: Fuses
See Sure Power document 180098E for appropriate fuse ratings
Unit Connections
24V:
GND:
12V:
This terminal is connected to the +24V
side of the battery stack
This is the terminal for grounding the
unit. All internal operating currents are
returned to this terminal
This terminal is connected to the +12V
terminal of the battery stack for
equalizers.
In converter applications the OUTPUT
terminal is connected to the loads.
TITLE
MODEL NO: 21XXXC00/E00
CONVERTER AND EQUALIZER
FAMILY
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
21XXXC00-E00
FILE: 211XXXC00-E00-003
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MECHANICAL SPECIFICATIONS
Unit power connections are made through three M8 threaded studs. A plastic cover is provided to
protect these studs from damage.
Finish: Cast Aluminum
Terminals: 0.050 C11000 ETP 1045 steel, Bright Tin Plate per ASTM-B545, Class A over,
Nickel Plate per ASTM-B689, Type 1
Hardware Included:
Nuts – 3X, M8 Hex, Tin Plated Steel
Lock Washers – 3X, M8, Tin Plated Steel
Maximum Torque: 110 in-lbs
Apply a coating of corrosion inhibitor material (E.g., dielectric grease, insulating paint,
etc.), as per manufacturers application instructions, to Battery Equalizer terminals to help
eliminate corrosion and protect the metal surfaces.
21100E00, 21100C00, 21080E00, 21080C00, 21060E00, and 21060C00
Mounting Slots: 6X, Accepts M6 or ¼” Hardware (not included)
Weight: 5.15 kg max (11.35 lbs max)
TITLE
MODEL NO: 21XXXC00/E00
CONVERTER AND EQUALIZER
FAMILY
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
21XXXC00-E00
FILE: 211XXXC00-E00-003
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Unit Dimensions – 21100E00, 21100C00, 21080E00, 21060E00,
21080C00, and 21060C00
Figure 8
TITLE
MODEL NO: 21XXXC00/E00
CONVERTER AND EQUALIZER
FAMILY
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
21XXXC00-E00
FILE: 211XXXC00-E00-003
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