Specification Installation Instructions

Specification Installation Instructions
REVISIONS
DESCRIPTION
REV
ECO
001
002
003
004
5156 PRODUCTION RELEASE
5217 For 12 Volt system, Spec is corrected to 24V (not 36V)
5276 Addition of Pressure Wash Specification
5325 Remove altitude – Adjust emissions
DATE
BY
5/1/08
7/2/08
8/26/08
1/14/09
BF
JT
JT
BF
Product Specification
11050C00 50A
TRAILCHARGER
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
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.
TITLE
MODEL NO: 11050C00
50A TRAIL CHARGER
SPECIFICATION OUTLINE
DATE
JAR
2/5/2008
PROJECT ENG APPROVAL
ENG MANAGER APPROVAL
SALES/MRKTG APPROVAL
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
11050C00
FILE:
11050C00-004
004
SHEET
1
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10
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REVISIONS
- SEE SHEET 1 -
THEORY OF OPERATION
The 11050C00 is a specially designed DC/DC converter that is used to charge a battery
from a 12V source. The specific application is charging the battery that is mounted on
the trailer of a vehicle used to power a lift gate. The distance between the alternator of
the vehicle and the trailer-mounted battery makes it difficult to get adequate voltage to
the battery.
The 11050C00 has two modes of operation:
• Boost Mode: the output voltage is held at the recommended charge setpoint.
This mode occurs when the input voltage is less than the output voltage setpoint.
• Bypass Mode: the current is passed straight through the converter. This mode
occurs when the input voltage is greater than the output voltage. The output
voltage may be increased above recommended charge setpoint; thus it is
important to ensure the input voltage is regulated such that overcharging of the
battery will not occur. During this mode since unlimited input current would
normally be allowed to flow, the 11050C00 will enter a burst mode of operation
whereby the output will cycle on and off until the input voltage is returned to
nominal Boost Mode range.
The converter provides a temperature compensated output optimized for recharging
automotive batteries.
An LED indicator is provided as a simple means to determine operation. The LED glows
when the converter is running and is supplying current in Boost Mode.
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, input and output over/under-voltage, short circuit, and over-temperature without
damage to the unit.
TITLE
MODEL NO: 11050C00
50A TRAIL CHARGER
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
11050C00
FILE:
11050C00-004
004
SHEET
2
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REVISIONS
- SEE SHEET 1 -
Connection Assignments:
Terminal
Terminal 1
Name
+12V Output Voltage.
Terminal 2
+12V Input Voltage.
Terminal 3
Ground.
Terminal 4
Ignition.
1
2
Description
This Terminal provides
charging current for the
auxiliary battery. (M8 Stud)
This Terminal provides the
input voltage to the
converter. (M8 Stud)
This Terminal should be
connected to the system
ground. (M8 Stud)
This Terminal provides a
signal that turns the
converter on and off. (FastOn)
3
4
TITLE
MODEL NO: 11050C00
50A TRAIL CHARGER
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
11050C00
FILE:
11050C00-004
004
SHEET
3
OF
10
F04-019-007
REVISIONS
- SEE SHEET 1 -
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 – 19 Ft.
20 - 29 Ft.
30 – 39 Ft.
40 – 49 Ft.
50 – 59 Ft.
≥ 60 Ft.
10
8
6
4
4
2
ELECTRICAL SPECIFICATIONS
Maximum Ratings:
Maximum ratings establish the maximum electrical rating to which the unit may be subjected
without damage.
Characteristic
Parameter
Unit
Standoff Voltage
24
V
Time at Standoff
5
min
Reverse Polarity
-24
V
5
min
57
A
55
A
Time at Reverse
Polarity
Maximum Input Current
Maximum Output
Current
Notes:
This is maximum voltage applied between input
and GND that the unit will standoff without
causing damage to the unit.
This is the maximum reverse voltage that may be
applied between input and GND Terminals.
Tested at 85°C.
TITLE
MODEL NO: 11050C00
50A TRAIL CHARGER
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
11050C00
FILE:
11050C00-004
004
SHEET
4
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10
F04-019-007
REVISIONS
- SEE SHEET 1 -
Environmental Specifications:
Characteristic
Parameter
Unit
-40 to +85
ºC
As tested in Tenney T10RC-1.5 thermal chamber.
100
ºC
Heatsink temperature must be kept below this
value to prevent activation of over-temperature
protection circuit.
-55 to +105
ºC
105
ºC
Humidity
0 to 100
%RH
Salt Fog
48
Hrs
Operational Temperature
Range
Maximum Heatsink
Temperature
Storage Temperature
Range
Over-Temp Limit
Notes:
Approximate heatsink temperature that activates
the over-temperature protection circuit.
Tested per SAE J1455, Section 4.2.3
Tested per SAE J1455 Section 4.3
Splash
per SAE J1455 Section 4.4, Splash only.
Pressure Wash
Per SAE J1455 Section 4.5
1000PSI @ 1GPM from a distance of 10CM
Dust
per SAE J1455 Section 4.7.
Altitude
12000
per SAE J1455 Section 4.8.
per SAE J1455 Section 4.9 and Appendix A,
Category 2.
Vibration
Handling Shock
ft
Will show
damage
per SAE J1455 Section 4.10
TITLE
MODEL NO: 11050C00
50A TRAIL CHARGER
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
11050C00
FILE:
11050C00-004
004
SHEET
5
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10
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REVISIONS
- SEE SHEET 1 -
Electrical Characteristics:
Unless otherwise stated, conditions apply to full temperature range and full input voltage
range.
Characteristic
MIN
TYP
MAX
Unit
Notes:
9
-
16
V
Full input voltage range for normal operation.
Note that the input voltage must exceed the
undervoltage recovery point (10.5Vdc) to turn on
initially.
7.0
7.5
8.0
V
An input voltage below this level will turn off the
trailcharger.
10.0
10.4
10.7
V
An input voltage above this level will turn the
trailcharger back on after an undervoltage event.
16.2
16.5
16.8
V
An input voltage above this level will turn off the
trailcharger.
16.0
16.2
16.6
V
An input voltage below this level will turn the
trailcharger back on after an overvoltage event.
17.4
18
18.6
V
Quiescent Current
1.5
2
mA
Output Quiescent
1.5
2
mA
Operating Input
Voltage Range
Under-Voltage
Turn Off
Under-Voltage
Recovery
Input Over Voltage
Turn Off
Input Over Voltage
Recovery
Output Over Voltage
Turn Off
Efficiency
90%
Output Voltage
14.2
V
A
Input Current Limit
50
55
Load Regulation
2
3.5
7
mV/A
An output voltage above this level will turn off the
trailcharger.
(At –40°C output should be 16.5Vdc.)
Measured @ 12.6V. Current draw from the input
with no load attached to the output, and ignition
off.
Measured @ 12.6Vdc. Current draw from the
output with no load, and ignition turned off.
Over entire input voltage range at rated output
current.
Regulation point of output voltage. The output of
the trailcharger is temperature compensated.
See Temperature Compensation Graph on page 7
Traicharger is input current limited on a cycle by
cycle basis. 10% Margin by design.
Output voltage drop per Amp of current draw on
output terminal.
TITLE
MODEL NO: 11050C00
50A TRAIL CHARGER
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
11050C00
FILE:
11050C00-004
004
SHEET
6
OF
10
F04-019-007
REVISIONS
- SEE SHEET 1 -
Temperature Compensation:
The output voltage will vary over temperature to give a higher charging potential at cold
temperatures.
Output Voltage (Vdc)
Temperature Compensation (Typical)
17.5
17
16.5
16
15.5
15
14.5
14
13.5
13
-40
-20
0
20
40
60
80
100
Temperature (Deg. C)
Current Limit:
The maximum output current available while maintaining the output voltage at the regulation
point.
Output Current (Adc)
Maximum Output Current Vs.
Input Voltage (maintaining regulation, typical)
50.00
45.00
40.00
35.00
30.00
25.00
20.00
15.00
10.00
5.00
0.00
+85°C
-40°C
+25°C
8
10
12
14
16
18
Input Voltage (Vdc)
TITLE
MODEL NO: 11050C00
50A TRAIL CHARGER
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
11050C00
FILE:
11050C00-004
004
SHEET
7
OF
10
F04-019-007
REVISIONS
- SEE SHEET 1 -
Electromagnetic Compatibility:
Immunity Test
Level
Notes:
Immunity to Radiated
Electromagnetic Fields - Bulk
Current Injection Method
Class B,
Region 2,
60mA
SAE J1113-4
Immunity to Electromagnetic
Fields, 30 MHz to 18 GHz,
Absorber-Lined Chamber
Class B,
Region 2,
L3,
60V/m
SAE J1113-21
Transient Immunity Test
Level
Test Pulse 1
Inductive Load Switching
Test Pulse 2a
Mutual Coupling
Test Pulse 5
Load Dump
14 ± 600et/(0.001)
IAW with SAE J1455 Rev 8/94 Section 4.11.2.2,
Table 4a. Pulse applied to all I/O.
14 ± 300et/(0.00015)
IAW with SAE J1455 Rev 8/94 Section 4.11.2.2,
Table 4a. Pulse applied to all I/O.
Electrostatic Discharge
Immunity
Level
ESD, In Vehicle
ESD, Package and Handling
Emissions Limit Test
14 + 86et/(0.4)
±8kV direct
±15kV air
±8kV direct
±15kV air
Level
Notes:
IAW with SAE J1455 Rev 8/94 Section 4.11.2.2,
Table 4a. Pulse applied to Vbat and ignition.
Notes:
Ref. SAE J1113/13. All connections and exposed parts.
Ref. SAE J1113/13.
Notes:
Conducted Emissions
Class 2
SAE J1113-41, Section 6.0
Radiated Emissions
Class 1
SAE J1113-41, Section 8.0
TITLE
MODEL NO: 11050C00
50A TRAIL CHARGER
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
11050C00
FILE:
11050C00-004
004
SHEET
8
OF
10
F04-019-007
REVISIONS
- SEE SHEET 1 -
Wiring Diagram:
BUSSMAN MRBF-075.
75A, 32V DC rated fuse
or equivalent, required
on both Input and Output
terminals.
1
2
3
4
NOTE: Input wiring must adhere to
“Installation Wire Size” table found
on page 4 of this specification.
Vehicle chassis wiring
+
Keep wiring short
on output side.
Ignition
Switch
+
12Volt
Main
Battery
12Volt
Battery to
be charged
-
-
TITLE
MODEL NO: 11050C00
50A TRAIL CHARGER
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
11050C00
FILE:
11050C00-004
004
SHEET
9
OF
10
F04-019-007
REVISIONS
- SEE SHEET 1 -
Unit Dimensions:
(.255 [6.48])
(8.000 [203.20])
(4X FULL R)
(4X .28)
([7.1])
(4.000 [101.60])
(7.125 [180.98])
(8.254 [209.66])
(1.563 [39.69])
(.597 [15.18])
(1.750)
([44.45])
(2.500 [63.50])
(3.500 [88.90])
(8.500 [215.90])
(7.362 [187.01])
(3.168 [80.47])
Mounting Recommendation:
For best environmental performance, it is recommended to mount the unit vertically just
as illustrated in the dimensional drawing above, terminals facing downwards.
TITLE
MODEL NO: 11050C00
50A TRAIL CHARGER
SPECIFICATION OUTLINE
SIZE
A
SCALE:
CAGE CODE NO. DRAWING NO.
55156
NONE
REV
11050C00
FILE:
11050C00-004
004
SHEET
10
OF
10
F04-019-007
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