Specification Outline & Instruction for the 21030C00 Converter

Specification Outline & Instruction for the 21030C00 Converter
REVISIONS
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DESCRIPTION
001 3939 PRODUCTION RELEASE
BY
10/15/03 GF
002 4597 REMOVE 21030E00 REFERENCES
7/15/05 BF
003 4650 ADD 6 & 4 PIN MATING CONN PN’S
10/12/05 BF
Specification Outline
21030C00 DC-DC CONVERTER
UNLESS OTHERWISE SPECIFIED
DIMENSIONS ARE IN INCHES [MM]
TOLERANCES ARE: .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
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
DZD
TITLE
DATE
6/28/05
MODEL NO: 21030C00
CONVERTER,30A
SPECIFICATION OUTLINE
PROJECT ENGR
ENGR MANAGER
SALES/MRKTG
SIZE
CAGE CODE NO.
A
55156
DRAWING NO.
REV
21030C00
SCALE: NONE FILE: 21030C00-003
SHEET
1
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General Description
The Sure Power family of converters are designed to provide 24V to 12V power conversion for heavyduty applications.
The 21030C00 provides a fixed output to power 12V loads directly where a 12V battery is not available.
An optional switched output is also available which corresponds to an IGNITION input signal. The two
outputs are then summed for maximum output capability.
This product is designed to withstand the severe electrical environment of the heavy-duty trucks and off
highway equipment:
Features
•
•
•
•
•
•
Under and Over Voltage Protection
Reverse Voltage Protection
Voltage Transient Protection
Over load and Short Circuit Protection
Thermal Overload Shutdown
Sealed from Environmental Element
Part Number / Ordering Information
Sure Power Part Number
Output Current
Converter
21030C00
30 Amps
Converter w/ switched output
TITLE
MODEL NO: 21030C00
CONVERTER,30A
SPECIFICATION OUTLINE
SIZE
CAGE CODE NO.
A
55156
DRAWING NO.
REV
21030C00
SCALE: NONE FILE: 21030C00-003
SHEET
2
003
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9
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Theory of Operation
The 21030C00 converter utilizes paralleled buck converters to step down the input voltage in order to
achieve the appropriate output voltage.
VOLTAGE
INPUT
TERMINAL
DIFFERENTIAL
AMPLIFIERS,
ERROR
AMPLIFIER,
AND OTHER
CONTROL AND
PROTECTION
CIRCUITS
INPUT
INPUT
BUCK
CONVERTER
BUCK
CONVERTER
OUTPUT
OUTPUT
GND
GND
OUTPUT
VOLTAGE
TERMINAL
GROUND
TERMINAL
Block Diagram
Description of Features
Included are a number of protection and added features.
PROTECTION FEATURES:
Reversal of the input polarity is protected with MOSFET devices in series with the input.
Reversal of the output polarity is protected with MOSFET devices in series with the ground 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. The converters all have
over-voltage protection. The switched output has under-voltage protection and will turn all loads off
during an under-voltage condition. The un-switched output does not have an under-voltage shutdown
and will operate down to lower voltages to keep power applied to loads during starting conditions.
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 heat sink temperature provides thermal protection.
Detection of extreme temperature shuts the unit off. When the heat sink
cools approximately 15°C the unit will automatically turn back on.
Loss of ground protection ensures no damage occurs to the unit.
TITLE
MODEL NO: 21030C00
CONVERTER,30A
SPECIFICATION OUTLINE
SIZE
CAGE CODE NO.
A
55156
DRAWING NO.
REV
21030C00
SCALE: NONE FILE: 21030C00-003
SHEET
3
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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
80V
Note 1
Reverse Polarity
-36V
Note 2
Output Current
30A
Note 3
100°C
Note 4
Operating Temperature Range
-40°C - +85°C
Note 3
Storage Temperature Range
-55°C- 105°C
Heat Sink Temperature
Notes:
1.
This is maximum voltage applied between VBAT 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.
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 should be provided.
TITLE
MODEL NO: 21030C00
CONVERTER,30A
SPECIFICATION OUTLINE
SIZE
CAGE CODE NO.
A
55156
DRAWING NO.
REV
21030C00
SCALE: NONE FILE: 21030C00-003
SHEET
4
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ELECTRICAL CHARACTERISTICS
Unless otherwise stated, conditions apply to full temperature range and full input voltage range.
Characteristic
Min
Input Under Voltage
Turn ON
Typ
20
Input Under Voltage
Hysteresis
Input Over Voltage
Turn OFF
Input Over Voltage
Hysteresis
Max
20.5
Unit
21
V
0.5
32
34
V
0.4
Output Voltage
13
Input current
Current Limit
30
Over-Temp Limit
Over-Temp
Hysteresis
Below this input voltage the unit will set
the output to half the input to protect
itself. The unit will shut down at
Vin=13V
V
33
Quiescent Current
Notes:
V
10
15
mA
13.5
14
V
21
A
32
A
105
°C
15
°C
Current draw from the INPUTwith no
load attached to OUTPUT. VIN = 24V
Maximum input current
The trip point for over-temp shutdown
Current vs Temperature
35
Current (A)
30
25
20
15
10
5
0
-40
-15
10
35
60
85
110
Temperature (C)
TITLE
MODEL NO: 21030C00
CONVERTER,30A
SPECIFICATION OUTLINE
SIZE
CAGE CODE NO.
A
55156
DRAWING NO.
REV
21030C00
SCALE: NONE FILE: 21030C00-003
SHEET
5
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ELECTROMAGNETIC COMPATIBILITY:
Transient Immunity
Tests
Load Dump
Inductive Switching Kick
Mutual Inductance
Level
28 + 122et/(0.4)
28 ± 600et/(0.001)
28 ± 300et/(0.00015)
Electrostatic Discharge
Immunity
Level
ESD – Handling
±15 kV
ESD – In Vehicle
±8 kV direct
±15 kV air
Radiated Immunity Test
Level
Absorber Lined Chamber
20MHz to 1GHz
Stripline Test Method
10kHz to 200MHz
100V/m
Emissions Test
100V/m
Level
Radiated
Class 2
Conducted
Class 2
Notes:
IAW with SAE J1455 Rev 8/94 Section 4.11.2.2,
Table 4a. Pulse applied to Vbat and ignition
terminal.
IAW with SAE J1455 Rev 8/94 Section 4.11.2.2,
Table 4a. Pulse applied to all I/O.
IAW with SAE J1455 Rev 8/94 Section 4.11.2.2,
Table 4a. Pulse applied to all I/O.
Notes:
IAW with SAE J1455 Rev 8/94 Section
4.11.2.2.5.1
IAW with SAE J1113-13 Rev 2/95. Class C
Notes:
SAEJ1113/21. Units also pass ISO13766
SAEJ1113/23. Units also pass ISO13766
Notes:
SAEJ1113/41. Units also pass ISO13766
SAEJ1113/41. Units also pass ISO13766
TITLE
MODEL NO: 21030C00
CONVERTER,30A
SPECIFICATION OUTLINE
SIZE
CAGE CODE NO.
A
55156
DRAWING NO.
REV
21030C00
SCALE: NONE FILE: 21030C00-003
SHEET
6
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ENVIRONMENTAL SPECIFICATIONS
Parameter
Level
Thermal Shock
per SAE J1455 Section 4.1 Rev 8/94.
Thermal Cycle
Humidity
0 – 100 %RH
Splash
Pressure Wash
Dust Bombardment
Salt Spray
Altitude
0.88 g/m3
96 Hrs
12000 ft
Mechanical Vibration
Handling Shock
Conditions / Notes
Will Show Damage
per SAE J1455, Section 4.2.3 Rev 8/94.
See Note 1
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
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 Rev 8/94
and Appendix A, Category 2
See Note 1
per SAE J1455 Section 4.10 Rev 8/94.
Note 1: Specifications not validated at this revision, SAE 1455 represents design intent.
TITLE
MODEL NO: 21030C00
CONVERTER,30A
SPECIFICATION OUTLINE
SIZE
CAGE CODE NO.
A
55156
DRAWING NO.
REV
21030C00
SCALE: NONE FILE: 21030C00-003
SHEET
7
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FUNCTIONAL DESCRIPTION:
UNIT CONNECTIONS:
24V INPUT
6 PIN MATING CONNECTOR
(DEUTSCH)
HOUSING:
DT06-6S
SOCKET:0462-209-16141
LOCK:
W6S
4 PIN MATING CONNECTOR
(DEUTSCH)
HOUSING:
DTP06-4S
SOCKET:1062-12-0166
GND LOCK:
WP4S
IGNITION
2
4
12V
UNSWITCHED
4
12V SWITCHED
12V
OUTPUT
UNSWITCHED
Deutsch 4 Pin Connector
24V INPUT: Pin 1
This terminal is connected to the +24V side of the battery stack.
GND: Pin 2
This is the terminal for grounding the unit. All internal operating currents are returned to this
terminal.
12V SWITCHED OUTPUT: Pin 3
This is the Switched Output. It can be connected to the desired 12V switched loads.
12V UNSWITCHED: Pin 4
This is the unswitched output. This pin will normally be wired in parallel with Pin 4 of the 6-pin
connector.
Deutsch 6 Pin Connector
12V UNSWITCHED: Pin 4
The Memory terminal is connected to the 12V un-switched loads. If this pin is not wired in
parallel with PIN 4 of the 4-pin connector, it should be fused with a 20A rated fuse
IGN ITION: Pin 2
This is the ignition input terminal. Connecting this to an ignition
signal will enable the switched output loads.
TITLE
MODEL NO: 21030C00
CONVERTER,30A
SPECIFICATION OUTLINE
SIZE
CAGE CODE NO.
A
55156
DRAWING NO.
REV
21030C00
SCALE: NONE FILE: 21030C00-003
SHEET
8
003
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UNIT DIMENSIONS
4X .280±.005
[7.11±0.13]
7.125±.030
[181.00±.76]
2X 4.000±.010
[101.60±0.25]
4X 1.563±.050
[39.71±1.27]
.240±.010
[6.10±0.25]
5.144±.045
[130.67±1.14]
1
2
3
4
1 2 3
6 5 4
(5.62)
([142.9])
TITLE
MODEL NO: 21030C00
CONVERTER,30A
SPECIFICATION OUTLINE
SIZE
CAGE CODE NO.
A
55156
DRAWING NO.
REV
21030C00
SCALE: NONE FILE: 21030C00-003
SHEET
9
003
OF
9
F04-019-006
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