1100 - 2100 WATT MBH SERIES DC/DC CONVERTERS Features Delivers up to 2100 Watts Efficiency up to 97% Groundbreaking low profile compact 9.0"L x 6.5"W x 1.25"H package Only 3.3 lbs No minimum load required Fixed frequency operation at 400 kHz Fully protected (OTP, OCP, OVP, UVLO) Auto Recovery Input reverse polarity protection High Reliability Made in USA 5 Year Warranty Model Description The Calex 2100 Watt MBH DC/DC Converter series are high efficiency non-isolated dc/dc switched-mode single output converters specifically designed for both military and commercial mobile applications. This series is packaged in an unprecedented low profile 9.0"L x 6.5"W x 1.25"H mechanically enclosed package weighing only 3.3lbs making the unit ideal for harsh shock and vibration environments. The MBH series integrates high efficiency dc/dc converters with input transient and reverse polarity protection circuitry. The DC/DC Converters are designed with a wide operational temperature range and are well suited for a high temperature environment. The MBH Series DC/DC converter's high efficiency and high power density are accomplished through the use of high-efficiency synchronous rectification technology, advanced electronic circuitry, packaging and thermal design resulting in highly reliable product. The MBH series operates at a fixed switching frequency and follows conservative component de-rating guidelines. The converter is designed and manufactured in the USA and is backed by Calex's 5 year warranty. 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Input Range VDC Vout VDC Iout ADC Min Max 13S28.40MBH 10 16 28 40 13S28.60MBH 10 16 28 60 13S28.75MBH 10 16 28 75 1. Designed to meet MIL-STD-810G for functional shock and vibration. The unit must be properly secured to the interface medium (PCB/Chassis) by use of the mounting holes of the unit. Fax: 925-687-3333 www.calex.com Email: sales @calex.com 6/10/15, eco 160224-3, 180206-1 1100 - 2100 WATT MBH SERIES DC/DC CONVERTERS ON/OFF FUNCTION: There are two connectors J900 and J901 that are used to implement the ON/OFF function. Connector J900 has three contacts: BAT+, ON/OFF and BAT-. BAT+ is connected to the voltage after the input reverse protections circuit: without input power present there is a diode between +12Vin DC (Terminal T1) and BAT+. BAT- is internally connected to GND (Terminal T2). It is provided if two wire connections is used for ON/OFF. Connector J901 has three pins: GND (pin1), ON/OFF (pin 2) and PULL-UP (pin 3). PULL-UP pin is connected via a 7.5K resistor to BAT+. There are several ways to enable and disable the converter via connectors J900 and J901. Connector J901 with no jumper: To enable converter voltage needs to be applied across ON/OFF pin and BAT- pin of J900 connector, or ON/OFF pin is connected to BAT+ pin. To disable converter the ON/OFF pin is connected to BAT- pin of J900 or left open. Connector J901 with jumper: Jumper between pin 1 and pin 2 - converter is disabled and ON/OFF pin is shorted to GND. DO NOT use J900! Jumper between pin 2 and pin 3 - converter is enabled when J900 is not used, i.e ON/OFF pin of J900 is left open or connected to BAT+ pin. Converter is disabled when the ON/OFF pin is connected to BAT- pin on J900. Figure 2. Input terminals and ON/OFF connector J900 Figure 3. Output Terminals 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales @calex.com 6/10/15, eco 160224-3, 180206-1 1100 - 2100 WATT MBH SERIES DC/DC CONVERTERS 13S28.40MBH Specifications Conditions: TA=25C, VIN = 12VDC, unless otherwise noted; not required to operate below 10V. Input Parameter Conditions Min Typ Max Units Absolute Maximum Ratings Input Voltage Non-Operating VDC Protected from reverse polarity on the input terminals Operating Voltage at ON/OFF input pin -20 30 VDC 10 16 VDC 0 30 VDC 13.2 16 VDC 118 Input Characteristics Operating Input Voltage Range 10 Maximum Input Current PO = 1100W @ 10VDC in 115 Start-up Voltage VIN 9.5 Shut Down Voltage VIN 9.0 Input Stand-by Current VIN = 12V, converter disabled 1.25 3 mA Input No load Current VIN = 12V, converter enabled 1.25 1.5 A Min Typ Max Units 28.0 28.5 30.0 VDC 80 120 mV Output Parameter Conditions A VDC VDC Output Characteristics Output Voltage Set Point VIN = 12V, IO = 30.5A Output Regulation Over Line and Load Total Output Voltage Range Over sample, line, load, temperature & life 27.6 29.3 VDC Output Voltage Ripple and Noise Peak to Peak RMS 20MHz Bandwidth, 10 F tantalum + 1 F ceramic Full Load Resistive Full Load Resistive 300 60 500 100 mVP-P mVRMS Output DC Current Limit Inception Non-Latching 44 Output DC Current Limit Shutdown Output Voltage at which converter shuts down 22 VDC Peak Short-Circuit Current Non-Latching, Startup into 10m 75 ADC Peak Short-Circuit Pulse Duration Non-Latching, Startup into Short 16 ms RMS Short-Circuit Current Non-Latching, Startup into Short TBD ARMS Load Change 20A - 36A - 20A VS=12V, Di/Dt=0.1 a/s, 6ft. input cable AWG 1/0, 6 ft load cable 1.9 VDC Load Change 20A - 36A - 20A VS=12V, Di/Dt=0.1 a/s, 20ft. input cable AWG 1/0, 6 ft load cable 2.3 VDC Load Change 20A - 36A - 20A VS=13.2V, Di/Dt=0.1 a/s, 6ft. input cable AWG 1/0, 6 ft load cable 2 VDC Setting Time * See Note 2 below for definition of Vs * See Note 4 for further cable length considerations and dynamic response To within 1% Vout nom 500 1000 s Output Over-Voltage Protection Non-Latching 34.8 37 VDC Operating Output Current Range 0 48 40 A 56 A Dynamic Response 32.7 Efficiency 100% Load 50% Load 96 96.55 % % Note 1: Input and output voltages are measured at input and output terminals of the converter Note 2: Vs - voltage at external power supply used for testing. V IN < Vs due to voltage drop in input cable. Note 3: All protections are non-latching. Once protection (OVP, OCP, input UVLO) are tripped converter enters into auto restart mode with 500 ms off time. Note 4: Consult the factory for input cable length and Dynamic Response requirements that differ from the conditions specified above. Some vehicle applications for DC/DC converters may require cable lengths of up to 30 feet. In such cases the voltage drop caused b y cable resistance (steady state) and cable inductance during transients must be accounted for to ensure stable operation of the DC/DC converter. In such cases where additional external capacitance is required for stable operation, it is recommended to add the external capacitance to the load side of the converter, as this is where most of the transients occur. 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales @calex.com 6/10/15, eco 160224-3, 180206-1 1100 - 2100 WATT MBH SERIES DC/DC CONVERTERS 13S28.60MBH Specifications Conditions: Ta=25C, Vin = 12VDC, unless otherwise noted; not required to operate below 10V. Input Parameter Conditions Min Typ Max Units Absolute Maximum Ratings Input Voltage Non-Operating VDC Protected from reverse polarity on the input terminals Operating Voltage at ON/OFF input pin -20 30 VDC 10 16 VDC 0 30 VDC 13.2 16 VDC 180 Input Characteristics Operating Input Voltage Range 10 Maximum Input Current PO = 1700W @ 10VDC in 176 Start-up Voltage VIN 9.5 Shut Down Voltage VIN 9.0 Input Stand-by Current VIN = 12V, converter disabled 1.25 3 mA Input No load Current VIN = 12V, converter enabled 1.25 1.5 A Min Typ Max Units 28.0 28.5 30.0 VDC 80 120 mV Output Parameter Conditions A VDC VDC Output Characteristics Output Voltage Set Point VIN = 12V, IO = 30.5A Output Regulation Over Line and Load Total Output Voltage Range Over sample, line, load, temperature & life 27.6 29.3 VDC Output Voltage Ripple and Noise Peak to Peak RMS 20MHz Bandwidth, 10 F tantalum + 1 F ceramic Full Load Resistive Full Load Resistive 300 60 500 100 mVP-P mVRMS 60 A Output DC Current Limit Inception Non-Latching 66 Output DC Current Limit Shutdown Output Voltage at which converter shuts down 22 VDC Peak Short-Circuit Current Non-Latching, Startup into 10m 112 ADC Peak Short-Circuit Pulse Duration Non-Latching, Startup into Short 16 ms RMS Short-Circuit Current Non-Latching, Startup into Short TBD ARMS Operating Output Current Range 0 72 84 A Dynamic Response Load Change 30A - 54A - 30A VS=12V, Di/Dt=0.1 a/s, 6ft. input cable AWG 1/0, 6 ft load cable 1.9 VDC Load Change 30A - 54A - 30A VS=12V, Di/Dt=0.1 a/s, 20ft. input cable AWG 1/0, 6 ft load cable 2.3 VDC Load Change 30A - 54A - 30A VS=13.2V, Di/Dt=0.1 a/s, 6ft. input cable AWG 1/0, 6 ft load cable 2 VDC * See Note 2 below for definition of Vs * See Note 4 for further cable length considerations and dynamic response Setting Time To within 1% Vout nom Output Over-Voltage Protection Non-Latching 32.7 Efficiency 100% Load 50% Load 500 1000 s 34.8 37 VDC 96.5 97.0 % % Note 1: Input and output voltages are measured at input and output terminals of the converter Note 2: Vs - voltage at external power supply used for testing. V IN < VS due to voltage drop in input cable. Note 3: All protections are non-latching. Once protection (OVP, OCP, input UVLO) are tripped converter enters into auto restart mode with 500 ms off time. Note 4: Consult the factory for input cable length and Dynamic Response requirements that differ from the conditions specified above. Some vehicle applications for DC/DC converters may require cable lengths of up to 30 feet. In such cases the voltage drop caused b y cable resistance (steady state) and cable inductance during transients must be accounted for to ensure stable operation of the DC/DC converter. In such cases where additional external capacitance is required for stable operation, it is recommended to add the external capacitance to the load side of the converter, as this is where most of the transients occur. 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales @calex.com 6/10/15, eco 160224-3, 180206-1 1100 - 2100 WATT MBH SERIES DC/DC CONVERTERS 13S28.75MBH Specifications Conditions: Ta=25C, Vin = 12VDC, unless otherwise noted; not required to operate below 10V. Input Parameter Conditions Min Typ Max Units Absolute Maximum Ratings Input Voltage Non-Operating VDC Protected from reverse polarity on the input terminals -20 30 VDC 10 16 VDC 0 30 VDC Operating Voltage at ON/OFF input pin Input Characteristics Operating Input Voltage Range 13.2 16 VDC Maximum Input Current PO = 2100W @ 10VDC in 10 223 227 A Start-up Voltage VIN 9.5 VDC Shut Down Voltage VIN 9.0 VDC Input Stand-by Current VIN = 12V, converter disabled 1.25 3 mA Input No load Current VIN = 12V, converter enabled 1.25 1.5 A Output Parameter Conditions Min Typ Max Units 28.0 28.5 30.0 VDC 80 120 mV Output Characteristics Output Voltage Set Point VIN = 12V, IO = 30.5A Output Regulation Over Line and Load Total Output Voltage Range Over sample, line, load, temperature & life 27.6 29.3 VDC Output Voltage Ripple and Noise Peak to Peak RMS 20MHz Bandwidth, 10 F tantalum + 1 F ceramic Full Load Resistive Full Load Resistive 300 60 500 100 mVP-P mVRMS 75 A Output DC Current Limit Inception Non-Latching 83 105 A Output DC Current Limit Shutdown Output Voltage at which converter shuts down 22 VDC Peak Short-Circuit Current Non-Latching, Startup into 10m 140 ADC Operating Output Current Range 0 90 Peak Short-Circuit Pulse Duration Non-Latching, Startup into Short 16 ms RMS Short-Circuit Current Non-Latching, Startup into Short 15 Arms Dynamic Response Load Change 37.5A - 67.5A - 37.5A VS=12V, Di/Dt=0.1 a/s, 6ft. input cable AWG 1/0, 6 ft load cable 1.9 VDC Load Change 37.5A - 67.5A - 37.5A VS=12V, Di/Dt=0.1 a/s, 20ft. input cable AWG 1/0, 6 ft load cable 2.3 VDC Load Change 37.5A - 67.5A - 37.5A VS=13.2V, Di/Dt=0.1 a/s, 6ft. input cable AWG 1/0, 6 ft load cable 2 VDC * See Note 2 below for definition of Vs * See Note 4 for further cable length considerations and dynamic response Setting Time To within 1% Vout nom Output Over-Voltage Protection Non-Latching 32.7 Efficiency 100% Load 50% Load 500 1000 s 34.8 37 VDC 96.0 96.8 % % Note 1: Input and output voltages are measured at input and output terminals of the converter Note 2: Vs - voltage at external power supply used for testing. V IN < VS due to voltage drop in input cable. Note 3: All protections are non-latching. Once protection (OVP, OCP, input UVLO) are tripped converter enters into auto restart mode with 500 ms off time. Note 4: Consult the factory for input cable length and Dynamic Response requirements that differ from the conditions specified above. Some vehicle applications for DC/DC converters may require cable lengths of up to 30 feet. In such cases the voltage drop caused b y cable resistance (steady state) and cable inductance during transients must be accounted for to ensure stable operation of the DC/DC converter. In such cases where additional external capacitance is required for stable operation, it is recommended to add the external capacitance to the load side of the converter, as this is where most of the transients occur. 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales @calex.com 6/10/15, eco 160224-3, 180206-1 1100 - 2100 WATT MBH SERIES DC/DC CONVERTERS General Specifications Parameter Conditions Min Switching Frequency ON/OFF Control Converter ON Converter OFF Typ Max 400 Voltage at ON/OFF pin Voltage at ON/OFF pin Units KHz 8 0 12 16 1.8 VDC VDC Turn-on Time From ON/OFF Control Time from ON/OFF going high to Vo=90%Vout(NOM), Full Load (Resistive mode) 500 530 560 ms By Input Voltage (ON/OFF=Vin) Time from Vin reaching UVLO threshold to Vo=90% Vout (NOM), Full Load (Resistive mode) 500 530 560 ms Output Voltage Rise Time Time from 10% to 90% Vout (NOM) Over Temperature Shutdown - OTP Base Plate Temperature Non-Latching OTP Restart Hysteresis Measured on the PCB Auto Restart Period 12 ms 100 C 10 C 500 ms Operating Surge Protection 100ms transient with 1msec rise time 30 Operating Temperature At the top thermal interface Base Plate temperature -40 95 C Non-operating Temperature Ambient Storage Temperature -55 100 C Connection Stud Torque Shock and Vibration TBD VDC in lbs Designed to meet MIL-STD-810G for functional shock and vibration. Note 1: Input and output voltages are measured at input and output terminals of the converter Note 2: Vs - voltage at external power supply used for testing. V in < Vs due to voltage drop in input cable. Note 3: All protections are non-latching. Once protection (OVP, OCP, input UVLO) are tripped converter enters into auto restart mode with 500 ms off time. Curve for 13S28.75MBH 2401 Stanwell Drive, Concord Ca. 94520 Curve for 13S28.75MBH Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales @calex.com 6/10/15, eco 160224-3, 180206-1 1100 - 2100 WATT MBH SERIES DC/DC CONVERTERS Case Mechanicals: Dimensions L x W x H: 9.0" x 6.5" x 1.25". Tolerance 0.025" Unit Weight: 3.3 lbs 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales @calex.com 6/10/15, eco 160224-3, 180206-1 1100 - 2100 WATT MBH SERIES DC/DC CONVERTERS 2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales @calex.com 6/10/15, eco 160224-3, 180206-1