(R) (R) INNOVATION and EXCELLENCE Triple Output A-Series, TWR Models High-Reliability, 2" x 1" 8-11 Watt, DC/DC Converters A-SERIES Features The smallest, full-featured triples Low cost! Highly reliable! Proven SMT-on-pcb construction Qual tested; HALT tested; EMC tested Output voltages: +5V/12V or +5V/15V Four input voltage ranges: Small packages, 2" x 1" x 0.375" -40 to +100C operating temperature Fully isolated, 1500Vdc guaranteed Guaranteed efficiencies to 82% Designed to meet UL1950 and EN60950 Modifications and customs for OEM's 4.7-7V, 9-18V, 18-36V or 36-72V Among the three families of triple-output DC/DC converters in DATEL's new A-Series, the 8-11W, 2" x 1" devices stand out as the industry's smallest full-featured triples. Housed in miniature 2" x 1" x 0.375", 5-side shielded, metal packages with electrically non-conductive coatings, these power converters offer nonlatching output current limiting, input overvoltage shutdown (except D5A models), input reverse-polarity protection, and output overvoltage clamping to protect both the power converters and their loads. As members of DATEL's new A-Series, the 8-11W triples feature both low cost and outstanding long-term reliability. Their design combines straightforward circuit topologies, the newest components, proven SMT-on-pcb construction methods, and highly repeatable automatic-assembly techniques. Their superior durability is substantiated by a rigorous in-house qualification program that includes HALT (Highly Accelerated Life Testing). Each of these fully line and load-regulated switching DC/DC converters has a +5V primary output (with output current as high as 1A) and either 12V or 15V auxiliary outputs (with currents as high as 210mA). These devices were designed to power small analog/digital partitions in equipment employing distributed-power architectures with bus voltages between 4.7 and 72 Volts. Applications include computer/networking, telecom/datacom equipment, industrial instrumentation and automatic test equipment. +VIN +5V -VIN -12V (-15V) +12V (+15V) PWM CONTROLLER COMMON OPTO ISOLATION ERROR AMPLIFIER Figure 1. Simplified Schematic DATEL, Inc., Mansfield, MA 02048 (USA) * Tel: (508)339-3000, (800)233-2765 Fax: (508)339-6356 * Email: sales@datel.com * Internet: www.datel.com A Series 8 - 1 1 W, T R I P L E OUTPUT Output Model IOUT (mA) TWR-5/1000-12/125-D5A TWR-5/1000-12/210-D12A TWR-5/1000-12/210-D24A TWR-5/1000-12/210-D48A TWR-5/800-15/150-D5A TWR-5/1000-15/200-D12A TWR-5/1000-15/200-D24A TWR-5/1000-15/200-D48A CONVERTERS Performance Specifications and Ordering Guide VOUT (Volts) DC/DC Input R/N (mVp-p) Typ. Max. Regulation (Max.) Load Line +5 1000 75 100 1.0% 2.0% 12 125 100 150 5.0% 5.0% +5 1000 75 100 1.0% 2.0% 12 210 100 150 5.0% 5.0% +5 1000 75 100 1.0% 2.0% 12 210 100 150 5.0% 5.0% +5 1000 75 100 1.0% 2.0% 12 210 100 150 5.0% 5.0% +5 800 75 100 1.0% 2.0% 15 150 125 175 5.0% 5.0% +5 1000 75 100 1.0% 2.0% 15 200 125 175 5.0% 5.0% +5 1000 75 100 1.0% 2.0% 15 200 125 175 5.0% 5.0% +5 1000 75 100 1.0% 2.0% 15 200 125 175 5.0% 5.0% Typical @ TA = +25C under nominal line voltage and full-load conditions unless otherwise noted. 20MHz bandwidth. 12/15V outputs are specified with 10F, 25V output capacitors. Efficiency Min. Typ. Package (Case, Pinout) VIN Nom. (Volts) Range (Volts) IIN (mA) 5 4.7-7 100/2324 74% 76% C3, P5 12 9-18 50/1087 80.5% 82% C3, P5 24 18-36 50/534 82% 84% C3, P5 48 36-72 50/267 82% 84% C3, P5 5 4.7-7 100/2441 74% 76% C3, P5 12 9-18 50/1187 79% 82% C3, P5 24 18-36 50/572 82% 84% C3, P5 48 36-72 50/286 82% 84% C3, P5 5V output, 10% to 100% load. 12/15V outputs, balanced loads, 20% to 100% load . Nominal line voltage, no-load/full-load conditions. M E C H A N I C A L S P E C I F I C AT I O N S PART NUMBER STRUCTURE T WR - 5 / 1000 - 15 / 200 - D12 A Output Configuration: T = Triple 2.00 (50.80) A-Series High Reliability METAL CASE 0.375 (9.53) Wide Range Input Input Voltage Range: D5 = 4.7-7 Volts (5V nominal) D12 = 9-18 Volts (12V nominal) D24 =18-36 Volts (24V nominal) D48 =36-72 Volts (48V nominal) Nominal Primary Output Voltage (+5 Volts) Maximum Primary Output Current in mA Nominal Auxiliary Output Voltages (12 or 15 Volts) Case C3 INSULATED BASE 0.040 0.002 DIA. (1.016 0.051) 0.20 MIN (5.08) 0.10 (2.54) 1.800 (45.72) 0.200 (5.08) Maximum Auxiliary Output Currents in mA from each output T E M P E R AT U R E D E R AT I N G 4 1 5 2 6 0.300 (7.62) 0.600 (15.24) 0.800 (20.32) 1.00 (25.40) 7 20 19 BOTTOM VIEW TWR-5/1000-12/125-D5A TWR-5/1000-12/210-D12A TWR-5/1000-12/210-D24A TWR-5/1000-12/210-D48A TWR-5/800-15/150-D5A TWR-5/1000-15/200-D12A TWR-5/1000-15/200-D24A TWR-5/1000-15/200-D48A 18 17 16 Output Power (Watts) 15 14 13 A B B B C D D D 0.10 (2.54) I/O Connections 12 11 D 10 B 9 Pin 1 2 3 4 5 6 7 C 8 A 7 6 5 4 3 2 1 0 -40 0 40 45 50 55 60 65 70 75 80 85 90 95 100 Ambient Temperature (C) 2 Function P5 +Input -Input No Pin +12V/15V Out -12V/15V Out Common +5V Out Notes: For "D5A/ D12A/D24A" models, the case is connected to pin 2 (-VIN). For "D48A" models, the case is connected to pin 1 (+VIN). 8 - 1 1 W, T R I P L E OUTPUT DC/DC TWR Models CONVERTERS Performance/Functional Specifications Typical @ TA = +25C under nominal line voltage and full-load conditions, unless noted. Absolute Maximum Ratings Input Input Voltage Ranges: "D5A" Models "D12A" Models "D24A" Models "D48A" Models 4.7-7 Volts (5V nominal) 9-18 Volts (12V nominal) 18-36 Volts (24V nominal) 36-72 Volts (48V nominal) Input Voltage: "D5A" Models "D12A" Models "D24A" Models "D48A" Models Input Current See Ordering Guide Input Reverse-Polarity Protection Input Filter Type Pi Reverse-Polarity Protection Yes (Instantaneous, 6A maximum) Current must be <6A. Brief duration only. Fusing recommended. Output Overvoltage Protection +5V Output 12V Outputs 15V Outputs Output VOUT Accuracy (50% loads): +5V Output 12V or 15V Outputs 10 Volts 22 Volts 44 Volts 80 Volts 6.8 Volts, limited duration 13 Volts, limited duration 16 Volts, limited duration 0.5% 3% Output Current Current limited. Max. current and short-circuit duration model dependent. Temperature Coefficient 0.02% per C Storage Temperature -40 to +105C Ripple/Noise (20MHz BW) See Ordering Guide Lead Temperature (soldering, 10 sec.) +300C Line/Load Regulation See Ordering Guide These are stress ratings. Exposure of devices to any of these conditions may adversely affect long-term reliability. Proper operation under conditions other than those listed in the Performance/Functional Specifications Table is not implied. Efficiency See Ordering Guide Isolation Voltage 1500Vdc, minimum Isolation Capacitance 300pF Current Limiting Auto-recovery Overvoltage Protection Zener/transorb clamps, magnetic feedback TECHNICAL NOTES Dynamic Characteristics Transient Response (50% load step) 200sec max. to 2% of final value Filtering and Noise Reduction Switching Frequency 175kHz All A-Series TWR 8-11 Watt DC/DC Converters achieve their rated ripple and noise specifications without the use of external input/output capacitors. In critical applications, input/output ripple and noise may be further reduced by installing electrolytic capacitors across the input terminals and/or low-ESR tantalum or electrolytic capacitors across the output terminals. Output capacitors should be connected between their respective output pin (pin 4, 5 or 7) and Common (pin 6) as shown in Figure 2. The caps should be located as close to the power converters as possible. Typical values are listed below. In many applications, using values greater than those listed will yield better results. Environmental Operating Temperature (Ambient): Without Derating With Derating Storage Temperature -40 to +60/70C (Model dependent) to +100C (See Derating Curve) -40 to +105C Physical Dimensions 2" x 1" x 0.375" (51 x 25 x 9.5mm) Shielding 5-sided Case Connection Pin 2 (-VIN) Case Material Corrosion resistant steel with non-conductive, epoxy-based, black enamel finish and plastic baseplate Pin Material Brass, solder coated Weight 1.3 ounces (37 grams) These power converters require a minimum 10% loading on their primary output and a minimum 20% loading on their auxiliary outputs to maintain specified regulation. Operation under no-load conditions will not damage these devices; however they may not meet all listed specifications. Application-specific internal input/output filtering can be recommended or perhaps added internally upon request. Contact DATEL Applications Engineering for details. Devices can be screened or modified for higher guaranteed isolation voltages. Contact DATEL Applications Engineering for details. On "D48A" models, the case is connected to pin 1 (+VIN). To Reduce Input Ripple "D5A" Models "D12A" Models "D24A" Models "D48A" Models 47F, 10V 20F, 25V 20F, 50V 10F, 100V To Reduce Output Ripple +5V Output 12/15V Outputs 47F, 10V, Low ESR 22F, 20V, Low ESR In critical, space-sensitive applications, DATEL may be able to tailor the internal input/output filtering of these units to meet your specific requirements. Contact our Applications Engineering Group for additional details. 3 A Series 8 - 1 1 W, T R I P L E OUTPUT DC/DC CONVERTERS E M I R A D I AT E D E M I S S I O N S +12/15V If you're designing with EMC in mind, please note that all of DATEL's TWR 8-11 Watt A-Series DC/DC Converters have been characterized for radiated and conducted emissions in our new EMI/EMC laboratory. Testing is conducted in an EMCO 5305 GTEM test cell utilizing EMCO automated EMC test software. Radiated emissions are tested to the limits of FCC Part 15, Class B and CISPR 22 (EN 55022), Class B. Correlation to other specifications can be supplied upon request. Radiated emissions plots to FCC and CISPR 22 for model TWR-5/1000-12/125-D5A appear below. Published EMC test reports are available for each model number. Contact DATEL's Applications Engineering Department for more details. 4 + COUT 1 +INPUT 7 +5V + COUT + CIN 6 2 COMMON -INPUT + 5 COUT -12/15V Figure 2. Using External Capacitors to Reduce Input/Output Ripple/Noise TWR-5/1000-12/125-D5A Radiated Emissions FCC Part 15 Class B, 3 Meters Converter Output = +5Vdc @ 950mA and 12Vdc @ 114mA 80 70 Input Fusing Radiated Emissions (dBV/M) 60 Certain applications and/or safety agencies may require the installation of fuses at the inputs of power conversion components. For DATEL A-Series TWR 8-11 Watt DC/DC Converters, you should use slow-blow type fuses with values no greater than 3A. FCC Class B Limit 50 40 30 20 10 0 Radiated Emissions C U S TO M C A PA B I L I T I E S -10 -20 DATEL's world-class design, development and manufacturing team stands ready to work with you to deliver the exact power converter you need for your demanding, large volume, OEM applications. And ... we'll do it on time and within budget! 1000 100 Frequency (MHz) TWR-5/1000-12/125-D5A Radiated Emissions EN 55022 Class B, 10 Meters Converter Output = +5Vdc @ 950mA and 12Vdc @ 114mA Our experienced applications and design staffs; quick-turn prototype capability; highly automated, SMT assembly facilities; and in-line SPC quality-control techniques combine to give us the unique ability to design and deliver any quantity of power converters to the highest standards of quality and reliability. 80 70 60 Radiated Emissions (dBV/M) We have compiled a large library of DC/DC designs that are currently used in a variety of telecom, medical, computer, railway, aerospace and industrial applications. We may already have the converter you need. Contact us. Our goal is to provide you the highest-quality, most cost-effective power converters available. 50 EN 55022 Class B Limit 40 30 20 10 0 Radiated Emissions -10 -20 1000 100 Frequency (MHz) 4 8 - 1 1 W, T R I P L E OUTPUT DC/DC TWR Models CONVERTERS Quality and Reliability technology" is determined. The A-Series are the first DC/DC Converters to emerge from DATEL's new, company-wide approach to designing and manufacturing the most reliable power converters available. The five-pronged program draws our Quality Assurance function into all aspects of new-product design, development, characterization, qualification and manufacturing. DATEL has invested in a Qualmark OVS-1 HALT tester capable of applying voltage and temperature extremes as well as 6-axis, linear and rotational, random vibration. A typical HALT profile (shown above) consists of thermal cycling (-55 to +125C, 30C/minute) and simultaneous, gradually increasing, random longitudinal and rotational vibration up to 20G's with load cycling and applied-voltage extremes added as desired. Many devices in DATEL's new ASeries could not be made to fail prior to reaching either the limits of the HALT chamber or some previously known physical limit of the device. We also use the HALT chamber and its ability to rapidly cool devices to verify their "coldstart" capabilities. Design for Reliability Design for Reliability is woven throughout our multi-phased, new-productdevelopment process. Design-for-reliability practices are fully documented and begin early in the new-product development cycle with the following goals: 1. To work from an approved components/vendors list ensuring the use of reliable components and the rigorous qualification of new components. 2. To design with safety margins by adhering to a strict set of derating guidelines and performing theoretical worst-case analyses. 3. To locate potential design weaknesses early in the product-development cycle by using extensive HALT (Highly Accelerated Life Testing). 4. To prove that early design improvements are effective by employing a thorough FRACA (Failure Reporting Analysis and Corrective Action) system. Qualification For each new product, electrical performance is verified via a comprehensive characterization process and long-term reliability is confirmed via a rigorous qualification procedure. The qual procedure includes such strenuous tests as thermal shock and 500 hour life. Qual testing is summarized below. Qualification Testing HALT Testing The goal of the accelerated-stress techniques used by DATEL is to force device maturity, in a short period of time, by exposing devices to excessive levels of "every stimulus of potential value." We use HALT (Highly Accelerated Life Testing) repeatedly during the design and early manufacturing phases to detect potential electrical and mechanical design weaknesses that could result in possible future field failures. During HALT, prototype and pre-production DC/DC converters are subjected to progressively higher stress levels induced by thermal cycling, rate of temperature change, vibration, power cycling, product-specific stresses (such as dc voltage variation) and combined environments. The stresses are not meant to simulate field environments but to expose any weaknesses in a product's electro/mechanical design and/or assembly processes. The goal of HALT is to make products fail so that device weaknesses can be analyzed and strengthened as appropriate. Applied stresses are continually stepped up until products eventually fail. After corrective actions and/or design changes, stresses are stepped up again and the cycle is repeated until the "fundamental limit of the 0 0 -40 20 30 40 50 60 70 80 90 Test Time (minutes) (R) (R) INNOVATION and EXCELLENCE 10 cycles, -55 to +125C Temperature/Humidity +85C, 85% humidity, 48 hours Lead Integrity DATEL in-house procedure Life Test +70C, 500 hours* Marking Permanency DATEL in-house procedure End Point Electrical Tests Per product specification DATEL employs an outstanding corrective-action system to immediately address any detected shortcomings in either products or processes. Whenever our assembly, quality or engineering personnel spot a product/process problem, or if a product is returned with a potential defect, we immediately perform a detailed failure analysis and, if necessary, undertake corrective actions. Over time, this system has helped refine our assembly operation to yield one of the lowest product defect rates in the industry. -20 10 Max. rated temp., 1,000 hours Thermal Shock Rapid Response to Problems Random Vibration (G's) Temperature (C) 60 20 High Temperature Storage A combination of statistical sampling and 100% inspection techniques keeps our assembly line under constant control. Parameters such as solder-paste thickness, component placement, cleanliness, etc. are statistically sampled, charted and fine tuned as necessary. Visual inspections are performed by trained operators after pick-and-place, soldering and cleaning operations. Units are 100% electrically tested prior to potting. All devices are temperature cycled, burned-in, hi-pot tested and final-electrical tested prior to external visual examination, packing and shipping. 40 20 DATEL in-house procedure In-Line Process Controls and Screening Typical HALT Profile 40 Method/Comments HALT * Interim electrical test at 200 hours. 100 80 Qualification Test ISO 9001 R E G I S T E R E D DATEL, Inc. 11 Cabot Boulevard, Mansfield, MA 02048-1151 Tel: (508) 339-3000 (800) 233-2765 Fax: (508) 339-6356 Internet: www.datel.com Email: sales@datel.com Data Sheet Fax Back: (508) 261-2857 DS0324 10/98 DATEL (UK) LTD. Tadley, England Tel: (01256)-880444 DATEL S.A.R.L. Montigny Le Bretonneux, France Tel: 01-34-60-01-01 DATEL GmbH Munchen, Germany Tel: 89-544334-0 DATEL KK Tokyo, Japan Tel: 3-3779-1031, Osaka Tel: 6-354-2025 DATEL makes no representation that the use of its products in the circuits described herein, or the use of other technical information contained herein, will not infringe upon existing or future patent rights. The descriptions contained herein do not imply the granting of licenses to make, use, or sell equipment constructed in accordance therewith. Specifications are subject to change without notice. The DATEL logo is a registered DATEL, Inc. trademark. 5