FEATURES Efficiency up to 80% Industry standard form factor and pinout Body size: 25.95 x9.25 x12.45mm (1.02" x0.36" x0.49") Input: 5V, 12V, 24V, 48V (2:1) Output: 3.3, 5, 12, 15, 5, 12, 15V Output OCP, SCP Low ripple and noise 1500V isolation UL 94V-0 Package Material ISO 9001 and ISO14001 certified manufacturing facility Delphi DEW1000 Series DC/DC Power Modules: 24, 48Vin, 2W SIP The Delphi DEW1000, 24V and 48V 4:1 wide input, single or dual output, DIP form factor, isolated DC/DC converter is the latest offering from a world leader in power systems technology and manufacturing Delta Electronics, Inc. The DEW1000 series operate from 24V or 48V (4:1) and provides 3.3V, 5V, 12V, or 15V of single output or 5V, 12V, or 15V of dual output in an industrial standard, plastic case encapsulated SIP package. This series provides up to 2W of output power with 1500V isolation and a typical full-load efficiency up to 80%. With creative design technology and optimization of component placement, these converters possess outstanding electrical and thermal performance, as well as extremely high reliability under highly stressful operating conditions. DATASHEET DS_DEW1000_12032008 OPTIONS APPLICATIONS Industrial Transportation Process/ Automation Telecom Data Networking TECHNICAL SPECIFICATIONS TA = 25C, airflow rate = 0 LFM, nominal Vin, nominal Vout, resistive load unless otherwise noted. PARAMETER NOTES and CONDITIONS DEW1000 (Standard) Min. ABSOLUTE MAXIMUM RATINGS Input Voltage Transient Transient Internal Power Dissipation Operating Temperature Storage Temperature Humidity Lead Temperature in Assembly Input/Output Isolation Voltage INPUT CHARACTERISTICS Operating Input Voltage Turn-On Voltage Threshold Turn-Off Voltage Threshold Maximum Input Current No-Load Input Current Input Reflected Ripple Current Short Circuit Input Power Reverse Polarity Input Current OUTPUT CHARACTERISTICS Output Voltage Set Point Accuracy Output Voltage Balance Output Voltage Regulation Over Load Over Line Over Temperature Output Voltage Ripple and Noise Peak-to-Peak Peak-to-Peak, over line, load, temperature RMS Output Over Current/Power Protection Output Short Circuit Output Voltage Current Transient Step Change in Output Current Settling Time (within 1% Vout nominal) Maximum Output Capacitance EFFICIENCY 100% Load ISOLATION CHARACTERISTICS Isolation Voltage Isolation Voltage Test Isolation Resistance Isolation Capacitance FEATURE CHARACTERISTICS Switching Frequency ON/OFF Control Logic Low (module is on) Logic High (module is off) ON/OFF Current Standby Input current GENERAL SPECIFICATIONS MTBF Weight Case Material Flammability Input Fuse 24V input model, 1000ms 48V input model, 1000ms -0.7 -0.7 Ambient Case -40 -40 -55 Typ. Max. Units 50 100 2500 85 100 105 95 260 Vdc Vdc mW C C C % C Vdc 36 75 8.5 17 8 16 1.5 0.5 Vdc Vdc Vdc Vdc Vdc Vdc Vdc mA mA mA mA W A 1.0 1.0 2.0 2.0 % % 0.5 0.3 0.01 0.75 0.5 0.02 % % %/C 30 50 75 15 mV mV mV % 3 100 5 300 2200 1000 170 110 470 100 47 % uS F F F F F F F 500 Vdc Vdc M pF 1.5mm from case for 10 seconds 1500 24V model 48V model 24V model 48V model 24V model 48V model Please see Model List table on page 6 24V model 48V model 24V model 48V model All models All models 9 18 4.5 8.5 ----- 20 15 300 600 Dual output models Io=25% to 100% Vin= Vin,min to Vin,max Tc=-40C to 71C 5Hz to 20MHz bandwidth Full Load, 0.47F ceramic Full Load, 0.47F ceramic Full Load, 0.47F ceramic Auto restart Continuous 12, 24 24, 48 6 12 ----- 120 25% step change 3.3Vo 5Vo 12Vo 15Vo 5Vo, each output 12Vo, each output 15Vo, each output Please see Model List table on page 6 Input to output, 60 Seconds Flash Test for 1 seconds 500VDC 100KHz, 1V 1500 1650 1000 250 300 Von/off Von/off at Ion/off=1.0mA Logic High, Von/off=5V -0.7 2.9 1 MIL-HDBK-217F; Ta=25C, Ground Benign 1 6.5 kHz 0.6 15 1 3 V V mA mA M hours grams Non-conductive black plastic UL94V-0 24V model, 350mA slow blown type 48V model, 135mA slow blown type 2 ELECTRICAL CHARACTERISTICS CURVES Figure 1: Efficiency vs. Input Voltage (Single Output) Figure 2: Efficiency vs. Input Voltage (Dual Output) Figure 3: Efficiency vs. Output Load (Single Output) Figure 4: Efficiency vs. Output Load (Dual Output) 3 Design & Feature Considerations Test Configurations Input Reflected-Ripple Current Test Setup To Oscilloscope + + Battery +Vin Lin Cin +Out DC / DC Converter Current Probe -Vin The DEW1000 circuit block diagrams are shown in Figures 5 and 6. +Vin Load +Vo LC Filter -Out -Vo Input reflected-ripple current is measured with a inductor Lin (4.7uH) and Cin (220uF, ESR < 1.0 at 100 KHz) to simulate source impedance. Capacitor Cin is to offset possible battery impedance. Current ripple is measured at the input terminals of the module and measurement bandwidth is 0-500 KHz. PFM -Vin Isolation Ref.Amp Figure 5: Block diagram of DEW1000 single output modules. Peak-to-Peak Output Noise Measurement Scope measurement should be made by using a BNC socket, measurement bandwidth is 0-20 MHz. Position the load between 50 mm and 75 mm from the DC/DC Converter. A Cout of 0.47uF ceramic capacitor is placed between the terminals shown below. +Vin +Out Single Output DC / DC Converter -Out +Vin +Out Dual Output DC / DC Converter Com. -Vin -Out +Vo LC Filter Com -Vo PFM -Vin Isolation Ref.Amp Copper Strip Cout -Vin +Vin Scope Resistive Load Figure 6: Block diagram of DEW1000 dual output modules. Input Source Impedance Copper Strip Cout Scope Cout Scope Resistive Load The power module should be connected to a low acimpedance input source. Highly inductive source impedances can affect the stability of the power module. + DC Power Source - +Vin + +Out DC / DC Converter Load Cin -Vin -Out In applications where power is supplied over long lines and output loading is high, it may be necessary to use a capacitor at the input to ensure startup. Capacitor mounted close to the input of the power module helps ensure stability of the unit, it is recommended to use a good quality low Equivalent Series Resistance (ESR < 1.0 at 100 KHz) capacitor of a 1.5uF for the 24V and 48V devices. 4 Design & Feature Considerations Overcurrent Protection Maximum Capacitive Load The DEW1000 series has limitation of maximum connected capacitance at the output. The power module may be operated in current limiting mode during start-up, affecting the ramp-up and the startup time. The maximum allowed capacitive load is listed in table on page 2. To provide protection in a fault (output overload) condition, the unit is equipped with internal current limiting circuitry and can endure current limiting for an unlimited duration. At the point of current-limit inception, the unit shifts from voltage control to current control. The unit operates normally once the output current is brought back into its specified range. Output Ripple Reduction Soldering and Cleaning Considerations A good quality low ESR capacitor placed as close as practicable across the load will give the best ripple and noise performance. Post solder cleaning is usually the final board assembly process before the board or system undergoes electrical testing. Inadequate cleaning and/or drying may lower the reliability of a power module and severely affect the finished circuit board assembly test. Adequate cleaning and/or drying is especially important for un-encapsulated and/or open frame type power modules. For assistance on appropriate soldering and cleaning procedures, please contact Delta's technical support team. To reduce output ripple, it is recommended to use 3.3uF capacitors at the output. + +Vin Single Output DC / DC Converter DC Power Source - -Vin + +Vin Notes: Cout Load -Out +Out Dual Output DC / DC Com. Converter DC Power Source - +Out -Vin -Out Cout Load 1. These power converters require a minimum output load to maintain specified regulation (please see page 6 for the suggested minimum load). Operation under no-load conditions will not damage these modules; however, they may not meet all specifications listed above. 2. These DC/DC converters should be externally fused at the front end for protection. Remote On/Off The DEW1000 has negative remote on/off logic. Negative logic remote on/off turns the module on during a logic low voltage on the remote on/off pin, and off during a logic high. Remote on/off can be controlled by an external switch between the on/off terminal and the -Vin terminal. The switch can be an open collector or equivalent. ON/OFF Vo(-) Vi(-) Vi(+) Vo(+) 5 THERMAL CONSIDERATIONS Thermal management is an important part of the system design. To ensure proper, reliable operation, sufficient cooling of the power module is needed over the entire temperature range of the module. Convection cooling is usually the dominant mode of heat transfer. Hence, the choice of equipment to characterize the thermal performance of the power module is a wind tunnel. Thermal Testing Setup Delta's DC/DC power modules are characterized in heated vertical wind tunnels that simulate the thermal environments encountered in most electronics equipment. This type of equipment commonly uses vertically mounted circuit cards in cabinet racks in which the power modules are mounted. THERMAL CURVES DEW1000series Output Current vs. Ambient Temperature and Air Velocity (Either Orientation) 120% Output Power (%) 100% 80% Natural Convection 60% 40% 20% 0% 25 35 45 55 65 75 85 Ambient Temperature () Figure 8: Derating Curves The following figure shows the wind tunnel characterization setup. The power module is mounted on a test PWB and is vertically positioned within the wind tunnel. The space between the facing PWB and PWB is constantly kept at 25.4mm (1''). Figure 7: Wind tunnel test setup Thermal Derating Heat can be removed by increasing airflow over the module. To enhance system reliability, the power module should always be operated below the maximum operating temperature. If the temperature exceeds the maximum module temperature, reliability of the unit may be affected. 6 MODEL LIST INPUT OUTPUT Full Load Efficiency MODEL NAME Vdc (V) Max (mA) Vdc (V) Max (mA) Min (mA) % DEW1021 97 3.3 500 125 71 DEW1022 110 5 400 100 76 DEW1023 106 12 167 42 79 DEW1024 105 15 134 33 80 24 (9 ~ 36) 114 5 200 50 73 DEW1026 108 12 83 21 77 DEW1027 106 DEW1031 49 15 3.3 67 500 17 125 70 DEW1032 58 5 400 100 72 DEW1033 54 12 167 42 78 54 15 134 33 78 60 5 200 50 70 DEW1036 55 12 83 21 76 DEW1037 55 15 67 17 76 DEW1025 DEW1034 DEW1035 48 (18 ~ 75) 79 7 3.2 [0.13] 12.45 [0.49] MECHANICAL DRAWING 2.54 [0.10] 2.03 [0.08] 7.62 [0.30] 9.25 [0.36] 2.54[0.100]X8=20.32 [0.80] 25.95 [1.02] 2 3 7 6 8 9 2.75 [0.11] 1 0.3 [0.01] SIDE VIEW BOTTOM VIEW Pin 1 2 3 6 7 8 9 Single Output -Vin +Vin On/off +Vout NC NC -Vout Dual Output -Vin +Vin On/off +Vout Common NC -Vout 0.5 [0.02] CONTACT: www.delta.com.tw/dcdc USA: Europe: Asia & the rest of world: Telephone: East Coast: (888) 335 8201 West Coast: (888) 335 8208 Fax: (978) 656 3964 Email: DCDC@delta-corp.com Phone: +41 31 998 53 11 Fax: +41 31 998 53 53 Email: DCDC@delta-es.com Telephone: +886 3 4526107 ext 6220~6224 Fax: +886 3 4513485 Email: DCDC@delta.com.tw WARRANTY Delta offers a two (2) year limited warranty. Complete warranty information is listed on our web site or is available upon request from Delta. Information furnished by Delta is believed to be accurate and reliable. However, no responsibility is assumed by Delta for its use, nor for any infringements of patents or other rights of third parties, which may result from its use. No license is granted by implication or otherwise under any patent or patent rights of Delta. Delta reserves the right to revise these specifications at any time, without notice. 8