250 Watts to 1500 Watts
CA5MGXCX, CA5MKXCX, CA5MMXCX, CA5MNXCX
FEATURES
DESCRIPTION
• 97-98% Efficient
Core Technology’s CA5MXXCX series of
Autoranging Front-End Modules are members
of our Power Converter Building Blocks. The
CA5MXXCX carries the complete front end of
a Switching Power Supply housed in a
rugged industry standard (2.4” x 2.3” x 0.5”)
form factor. In addition, this module provides
a patent pending AC-OK/Fail Logic Output for
AC Line Monitoring. The CA5MXXCX is
utilized for offline AC to DC power conversion
systems requiring tracking of the AC mains to
insure proper strapping of the converter
voltage doubler circuit. The user is required
to provide AC Line Filtering and hold up
capacitance for their particular application.
The CA5MXXCX has an efficiency of 97%98% and can provide 250 to 1500 Watts of
Output Power. The CA5MXXCX can be used
with or without Core Technology’s line of
CT4XXXEX, CI3XXXEX and CI4XXXEX
Converter Modules.
• 250 to 1500 Watts
• 85 to 264 VAC, 47 to 63 Hz, Autoranging
• Small Form Factor 2.4” x 2.3” x 0.50”
• “AC OK” Signal Output
• UL & C-UL(CSA) Safety Approvals
(UL E186932 97NK16122)
• 100 °C Base Plate Operation
APPLICATIONS
• AC Front-Ends that Require Tracking
of the AC Line to Insure Correct
Strapping of the Voltage Doubler.
AUTORANGING MODULE
Front-End Modules
* UL is a registered trademark of the Underwriters Laboratories, Inc.
† CSA is a registered trademark of the Canadian Standards Association.
+† This product is intended for integration into end-use equipment. All the
required procedures for CE marking of end-use equipment
should be followed. (The CE mark is placed on selected products.)
CORE Technology, Inc.
33750 Lear Industrial Pkwy • Avon, Ohio 44011 • Ph (440) 937-9934 • Fax (440) 937-6638 • Website www.coretechnology.com
1
AUTORANGING MODULE
ABSOLUTE MAXIMUM RATINGS
ISOLATION SPECIFICATIONS
Parameter
Parameter
AC Line Input
270
Notes
VAC
Unit
Isolation Voltage
Input to Output
Input to baseplate
Output to baseplate
Input Current
CA5MNXCX
CA5MMXCX
CA5MKXCX
CA5MGXCX
12
10
8
4
Amps
Amps
Amps
Amps
Vout Switch-over
400
VDC
Max output before switchover into 240 VAC range
Max Output Current
Max Output Voltage
12.5
9.0
425
Amps
Amps
VDC
at 90-132 VAC Range
at 180-264 VAC Range
Internal Clamp
Base Plate
100
Celsius
For Military Version
None
2500
2500
Notes
Vrms
Vrms
GENERAL SPECIFICATIONS
Parameter
Operating Temperature
Industrial
Military
Unit
-25 to +85
-40 to +100
Thermal Resistance
0.08°C/W
±0.02°C/W
Notes
Celsius
Celsius
Base Plate Temperature
Base Plate Temperature
C/Watt
Base Plate to sink
(Grafoil) ® Interface
Stressing this product in excess of the Absolute Maximum Ratings can cause permanent
damage to the product. Extended exposure to Absolute Maximum Ratings can adversely
affect the operation and the reliability of the product. These are absolute maximum
ratings and operation of this device is not implied at these conditions or conditions beyond
the ratings given in the electrical specification of the data sheet.
“Grafoil” is a registered Trade Mark of Union Carbide Corporation
ELECTRICAL SPECIFICATIONS
FEATURE SPECIFICATIONS
Parameter
Parameter
AC Line Input
Input Frequency
Unit
Notes
85-132
180-264
VAC
VAC
Auto Switching
47-63
Hz
Output Power
CA5MNXCX
CA5MNXCX
1000
1500
Watts
Watts
at 90-132 VAC Range
at 180-264 VAC Range
Output Power
CA5MMXCX
CA5MMXCX
750
1000
Watts
Watts
at 90-132 VAC Range
at 180-264 VAC Range
Output Power
CA5MKXCX
CA5MKXCX
500
750
Watts
Watts
at 90-132 VAC Range
at 180-264 VAC Range
Output Power
CA5MGXCX
CA5MGXCX
250
500
Watts
Watts
at 90-132 VAC Range
at 180-264 VAC Range
Efficiency
No Load Dissipation
MTBF
2
Unit
Better than 97%
Better than 98%
at full load & 120 VAC
at full load & 240 VAC
<4.0
Watts
Across entire Vin range
961631
HRS
Per MIL-HDBK-217E @40°C
Storage Temperature
-50 to +120
Celsius
Unit
Notes
AC-Fail logic Assertion point
83
VAC
±2.5% @120VAC Range
AC-Fail logic Assertion point
170
VAC
±2.5 % @240VAC Range
AC-Fail logic Delay Time
12
m Sec
Time from AC Fail to logic
output assertion.
FUSING CONSIDERATIONS
In order to maintain maximum flexibility and to allow this product
to be utilized in a wide variety of applications, internal fusing is not
provided. For protection of this product and the system in which it
will exist, fusing must always be provided. Fusing must be
determined in accordance with the proper safety requirements for
a particular application. Refer to a fuse manufacturer for further
information.
SAFETY CONSIDERATIONS
In order to insure agency approval of the application in which this
power module is utilized, the unit must be used in compliance with
the creepage (spacing and separation) requirements of UL-1950,
CSA22.2-950 and EN60950.
CORE Technology, Inc.
33750 Lear Industrial Pkwy • Avon, Ohio 44011 • Ph (440) 937-9934 • Fax (440) 937-6638 • Website www.coretechnology.com
AC - Fail Logic Output - The CA5MXXCX Series of Modules come with a FET
Drain Output providing a logic low signal when AC is normal and an open drain
signal when the output line falls below 83VAC.
Autoranging - The CA5MXXCX’s primary function is tracking the AC line to
automatically provide correct strapping of the Voltage doubling circuit providing a
power supply with an input voltage range of 90VAC to 132VAC and 180VAC to
264VAC. This product is properly utilized in power supplies which require both 90132VAC and 180-264VAC Line Voltage Input.
TYPICAL APPLICATION
AC IN
F1
5
6
CHASSIS
4
CF514EX
CHASSIS
3
LINE (N)
CAP
AC(N)
2
LOAD (N)
F2
AC(L)
25KΩ
CA5MXXCX
7
L2
HOLD UP CAPACITORS
5
+VOUT
4
ACF+
3
ACF-
LOAD (L) 1
LINE (L)
L1
-VOUT
C1
+
+VOUT 10
9
OG+
OG-
EN-
VOUT+
8
7
VOUT-
6
VIN-
4
10V
-VOUT
5
DISTRIBUTED POWER
MODULE
AUTORANGING
FRONT-END
MODULE
FILTER
MODULE
EN+
C2 3
PRIMARY
VCC
D1
VIN+
2
CT4XXXEX
25KΩ
2
1
1
SECONDARY VCC
ACFAIL+
OPTO
THERMAL CURVES
OUTPUT POWER P(W) vs AMBIENT TEMPERATURE
AUTORANGING AC Front End Module
FIGURE 1
1000 FREE
AIR
800
• •
400
LFM
• •
•
240V ONLY
800 LFM
• •
•
120V/240V
OPERATION
600
200
10
FIGURE 3
20
30
40
50
60
70
Ambient Temperature (Deg. C)
80
90
100
1/2” HEAT SINK
•
1400
200
LFM
• •
400
LFM
•
• •
1000
•
•
800
• • ••
600
800 LFM
120V/240V OPERATION
400
FREE
AIR
10
20
30
•
•
40
50
60
Ambient Temperature (Deg. C)
70
80
••
•
120V/240V
OPERATION
400
LFM
600 LFM
•
FIGURE 4
20
30
100
80
1” HEAT SINK
400
200
LFM
LFM
•
•
90
100
• ••
150
LFM
1200 240V ONLY
•
800 LFM
•
•
• ••
800
600
600 LFM
120V/240V OPERATION
FREE
AIR
200
90
40
50
60
70
Ambient Temperature (Deg. C)
•
1000
•• ••
OUTPUT POWER P(W) vs AMBIENT TEMPERATURE
AUTORANGING AC Front End Module
400
200
240V ONLY
•
•
1400
240V ONLY
800 LFM
•
600
10
600 LFM
••
•
LFM
1600
150
LFM
1200
• •
200
200
OUTPUT POWER P(W) vs AMBIENT TEMPERATURE
AUTORANGING AC Front End Module
1600
800
1/4” HEAT SINK
150
LFM
1200 FREE
AIR
1000
400
• • ••
•
•
1400
600 LFM
400
Output Power (Watts)
1600
• •
Output Power (Watts)
•
1200
•
Output Power (Watts)
200
LFM
1400
Output Power (Watts)
NO HEAT SINK
150
LFM
1600
OUTPUT POWER P(W) vs AMBIENT TEMPERATURE
AUTORANGING AC Front End Module
FIGURE 2
AUTORANGING MODULE
FEATURE DESCRIPTIONS
10
20
30
•
40
50
60
70
Ambient Temperature (Deg. C)
•
80
90
100
FORCED AIR CONVECTION COOLING
These figures can be utilized to determine if a heat sink and forced air
convection cooling will be required in your particular application. Figures 1
through 4 show typical output power vs ambient temperature with various heat
sink and air flow conditions. By utilizing these curves, the required cooling can
be determined.
EXAMPLE: For your particular application you have determined that you will
require an input power of 750 watts with a 120VAC input. Selecting the
CA5MM1CLXX, will provide you with the 750 watts. This unit is 97% efficient at
120VAC, therefore, the power dissipation from the module will be approximately
22.5 watts. By viewing Figure 3, it can be determined that in a 60 °C environment,
forced air cooling of 200LFM with a 1/2” heat sink will be required.
CORE Technology, Inc.
33750 Lear Industrial Pkwy • Avon, Ohio 44011 • Ph (440) 937-9934 • Fax (440) 937-6638 • Website www.coretechnology.com
3
0.20 RAD
4.40 THREADED THROUGH
2.30
PIN DIA. 0.080 (X5)
1.90
CASE OUTLINE
AUTORANGING MODULE
1.20
0.70
OUTPUT
INPUT
AC-IN 120/240
VDC 220-400
AMPS
5
1.55
4
3
1.10
1.00
2
0.65
1
0.35
6
7
PIN DIA. 0.030 (X2)
WATTS
MADE IN USA
PATENTS PENDING
0.00
2.40
0.00
0.00
0.00
2.00
AUTORANGING MODULE
PCB PIN LAYOUT
TOP VIEW
BOTTOM VIEW
SIDE VIEW
0.50
0.46
Connector
Pin Assignment
0.00
TOLERANCES: - 0.000”
+0.030”
1
-Vout
2
CAP
3
ACF-
4
ACF+
5
+ Vout
6
AC(L)
7
AC(N)
Ordering Information
Part Numbering Scheme for
CA5MXXCX Autoranging Front End Modules
C
TYPE
IN VOLTS
OUT-VOLTS
POWER LEVEL
@90-132VAC
TEMPERATURE
RANGE
PACKAGE
SIZE
HEAT SINK TYPE
C
A = Autoranging
Module
5 = 90-264VDC
M = 200-400V
G = 250 Watts
K = 500 Watts
M = 750 Watts
N = 1000 Watts
**
2 = -25C to +85C
3 = -40C to +100C
C = 1/2 Full Size
Blank = No Sink
L02 = 0.25” Longitudinal
L05 = 0.50” Longitudinal
L10 = 1.0” Longitudinal
T02 = 0.25” Transverse
T05 = 0.50” Transverse
T10 =1.0” Transverse
C
A
5
M
** See electrical specifications on page 2 for 180VAC - 264VAC power level
N
2
C
L05
EXAMPLE - To order an Autoranging Front End Module with an output of
1000 watts, -25C to +85C operating temperature range, and 1/2” longitudinal
heat sink would require the part number above.
4
CORE Technology, Inc.
33750 Lear Industrial Pkwy • Avon, Ohio 44011 • Ph (440) 937-9934 • Fax (440) 937-6638 • Website www.coretechnology.com