Application Note TEN 25WI Series TEN 25WI Series 25-30W, Ultra-Wide Input Range, Single & Dual Output DC/DC Converters Features ► Efficiency up to 89% ► 1500VDC Isolation ► MTBF > 450,000 Hours ► Complies with EN55022 Class A ► Six-Sided Shielding ► Remote On/Off Control ► Over Voltage Protection ► Over Temperature Protection ► Output Trim ► Soft Start ► UL60950-1 Safety Approval ► 3 Years Product Warranty Applications ► Distributed power architectures ► Workstations ► Computer equipment ► Communications equipment General Description TRACO’s TEN-25WI-Series power modules are low-profile dc-dc converters that operate over input voltage ranges of 10-40VDC and 18-75VDC which provide precisely regulated output voltages of 3.3V, 5V, 12V, 15V, ±12V and ±15VDC, specially addressing data communication equipments, mobile battery driven equipments, distributed power systems, telecommunication equipments, mixed analog/digital subsystems, process/machine control equipments, computer peripheral systems and industrial robot systems. Packing up to 30W of power into a 2x1.6x0.37inch package, with efficiencies as high as 89%, the TEN 25WI includes continuous short circuit protection, overvoltage protection, over temperature protection, output trim function, remote on/off, six-sided shielded case and EN55022 Class A conducted noise compliance minimize design-in time, cost and eliminate the need for external filtering. Table of contents Absolute Maximum Rating……………… Output Specification…………………… Input Specification……………………… General Specification…………………… Characteristic Curves…………………… Testing Configurations………………… EMC Considerations…………………… Input Source Impedance………………… Output Over Current Protection………… Output Over Voltage Protection………… http://www.tracopower.com P2 P2 P3 P4 P5 P29 P30 P32 P32 P32 Remote ON/OFF Control………………… Heat Sink Consideration………………… Mechanical Data…………………………… Recommended Pad Layout Single & Dual Packaging Information…………………… Soldering and Reflow Consideration…… Part Number Structure…………………… Safety and Installation Instruction……… MTBF and Reliability……………………… P33 P34 P35 P35 P36 P36 P37 P38 P38 Page 1 of 38 Application Note TEN 25WI Series Absolute Maximum Rating Parameter Model Min Max Unit 24VDC Input Models -0.7 50 VDC 48VDC Input Models -0.7 100 All -40 +50 -40 +85 Input Voltage Input Surge Voltage ( 1 sec. ) Operating Ambient Temperature Without Derating With Derating Operating Case Temperature All Storage Temperature All -50 ℃ +105 ℃ +125 ℃ Output Specification Parameter Output Voltage (Vin=Vin nom; Full Load; TA=25℃) Model Min Nominal Max TEN 25-xx10WI 3.267 3.3 3.333 TEN 25-xx11WI 4.95 5 5.05 TEN 25-xx12WI 11.88 12 12.12 TEN 25-xx13WI 14.85 15 15.15 TEN 25-xx22WI ±11.88 ±12 ±12.12 TEN 25-xx23WI ±14.85 ±15 ±15.15 ±0.2 ±0.5 ±0.3 ±1.0 55 80 ±0.01 ±0.02 %/℃ ±2%Vo ±4%Vo mV 150 300 μS Output Regulation Line (Vin min to Vin max at Full Load) Output Regulation Load (50% to 100% of Full Load) All Output Ripple & Noise Peak-to-Peak (5Hz to 20MHz bandwidth) Temperature Coefficient Unit VDC % % mV pk-pk Dynamic Load Response (Vin = Vin nom ; TA=25℃ Load step change form 25% Load Step Change All Peak Deviation Setting Time TEN 25-xx10WI 400 5500 TEN 25-xx11WI 350 5000 TEN 25-xx12WI 166 2500 TEN 25-xx13WI 133 2000 TEN 25-xx22WI ±83 ±1250 TEN 25-xx23WI ±65 ±1000 Output Over Current Protection All 120 180 Output Short Circuit Protection All Output Current http://www.tracopower.com mA %FL Continuous Page 2 of 38 Application Note TEN 25WI Series Input Specification Parameter Operating Input Voltage Under Voltage Lockout Turn-on Threshold Under Voltage Lockout Turn-off Threshold Input reflected ripple current (0 to 500KHz, 4.7μH source impedance) Input Current (Maximum value at Vin= Vin nom;Full Load) Input Standby Current (Typical value at Vin = Vin nom; No Load) Remote ON/OFF Control (The On/Off pin voltage is referenced to-Vin) Positive logic On/Off pin High Voltage (Remote ON) On/Off pin Low Voltage (Remote OFF) Remote Off Stand by Input Current Control Pin Input Current (Remote ON) Control Pin Input Current (Remote OFF) Output Voltage Trim (% of nominal output voltage) http://www.tracopower.com Model 24V Input Models 48V Input Models 24V Input Models 48V Input Models 24V Input Models 48V Input Models 24V Input Models 48V Input Models TEN 25-2410WI TEN 25-2411WI TEN 25-2412WI TEN 25-2413WI TEN 25-2422WI TEN 25-2423WI TEN 25-4810WI TEN 25-4811WI TEN 25-4812WI TEN 25-4813WI TEN 25-4822WI TEN 25-4823WI TEN 25-2410WI TEN 25-2411WI TEN 25-2412WI TEN 25-2413WI TEN 25-2422WI TEN 25-2423WI TEN 25-4810WI TEN 25-4811WI TEN 25-4812WI TEN 25-4813WI TEN 25-4822WI TEN 25-4823WI All All Min 10 18 9.4 17 9 16 Nominal 24 48 9.7 17.5 9.3 16.5 50 25 922 1225 1404 1404 1404 1404 461 613 702 702 702 702 Max 40 75 10 18 9.5 17 Unit VDC VDC VDC mA pk-pk mA 20 mA 10 2.5 -1 ±9 2 100 1 5 5 -100 VDC VDC mA uA uA ±10 ±11 % Page 3 of 38 Application Note TEN 25WI Series General Specification Parameter Efficiency (Vin =Vin nom; Full Load; TA =25℃) Model Min Nominal TEN 25-2410WI 82 TEN 25-2411WI 85 TEN 25-2412WI 89 TEN 25-2413WI 89 TEN 25-2422WI 89 TEN 25-2423WI 89 TEN 25-4810WI 82 TEN 25-4811WI 85 TEN 25-4812WI 89 TEN 25-4813WI 89 TEN 25-4822WI 89 TEN 25-4823WI Isolation Voltage Max Unit % 89 1500 VDC 1000 MΩ Input to Output (for 60 seconds) Isolation Resistance All Isolation Capacitance Switching Frequency MTBF MIL-STD-217F, TC=25℃ http://www.tracopower.com 290 450,000 1200 1500 pF 330 360 KHz Hours Page 4 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-2410WI 85 90 80 Efficiency(%) Efficiency(%) 80 70 60 50 10V 40 24V 40V 30 20 40 60 80 100 % of Full Load 75 70 65 60 10 25 40 Input Voltage(V) Efficiency Versus Output Current Efficiency Versus Input Voltage Full Load Typical Output Ripple and Noise. Vin =Vin nom; Full Load; TA Transient Response to Dynamic Load Change from 100% to 75% of Full Load ; Vin =Vin nom ON/OFF Voltage Start-Up and Output Rise Characteristic Typical Input Start-Up and Output Rise Characteristic Vin =Vin nom ; Full Load http://www.tracopower.com Vin =Vin nom ; Full Load Page 5 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-2410WI(Continued) Conduction Emission of EN55022 Class A Vin =Vin nom ; Full Load Conduction Emission of EN55022 Class B Vin =Vin nom ; Full Load 100 100 400LFM 60 100LFM Natural convection 80 Natural convection Output Power (%) Output Power (%) 80 400LFM 200LFM 40 20 200LFM 60 100LFM 40 20 0 0 ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (without heatsink) http://www.tracopower.com ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (with heatsink) Page 6 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-2411WI 95 100 90 Efficiency(%) Efficiency(%) 90 80 70 60 10V 50 24V 40V 40 20 40 60 80 100 % of Full Load 85 80 75 70 10 24 40 Input Voltage(V) Efficiency Versus Output Current Efficiency Versus Input Voltage Full Load Typical Output Ripple and Noise. Vin =Vin nom; Full Load; Transient Response to Dynamic Load Change from 100% to 75% of Full Load ; Vin =Vin nom ON/OFF Voltage Start-Up and Output Rise Characteristic Typical Input Start-Up and Output Rise Characteristic Vin =Vin nom ; Full Load http://www.tracopower.com Vin =Vin nom ; Full Load Page 7 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-2411WI(Continued) Conduction Emission of EN55022 Class A Vin =Vin nom ; Full Load Conduction Emission of EN55022 Class B Vin =Vin nom ; Full Load 100 100 400LFM 60 100LFM Natural convection 80 Natural convection Output Power (%) Output Power (%) 80 400LFM 200LFM 40 20 200LFM 60 100LFM 40 20 0 0 ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (without heatsink) http://www.tracopower.com ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (with heatsink) Page 8 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-2412WI 95 100 90 Efficiency(%) Efficiency(%) 90 80 70 60 10V 50 24V 40V 40 20 40 60 80 100 % of Full Load 85 80 75 70 10 24 40 Input Voltage(V) Efficiency Versus Output Current Efficiency Versus Input Voltage Full Load Typical Output Ripple and Noise. Vin =Vin nom; Full Load; TA Transient Response to Dynamic Load Change from 100% to 75% of Full Load ; Vin =Vin nom ON/OFF Voltage Start-Up and Output Rise Characteristic Typical Input Start-Up and Output Rise Characteristic Vin =Vin nom ; Full Load http://www.tracopower.com Vin =Vin nom ; Full Load Page 9 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-2412WI(Continued) Conduction Emission of EN55022 Class A Vin =Vin nom ; Full Load Conduction Emission of EN55022 Class B Vin =Vin nom ; Full Load 100 100 400LFM 60 100LFM Natural convection 80 Natural convection Output Power (%) Output Power (%) 80 400LFM 200LFM 40 20 200LFM 60 100LFM 40 20 0 0 ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (without heatsink) http://www.tracopower.com ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (with heatsink) Page 10 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-2413WI 95 100 90 Efficiency(%) Efficiency(%) 90 80 70 60 10V 50 24V 40V 40 20 40 60 80 100 % of Full Load 85 80 75 70 10 24 40 Input Voltage(V) Efficiency Versus Output Current Efficiency Versus Input Voltage Full Load Typical Output Ripple and Noise. Vin =Vin nom; Full Load; TA Transient Response to Dynamic Load Change from 100% to 75% of Full Load ; Vin =Vin nom ON/OFF Voltage Start-Up and Output Rise Characteristic Typical Input Start-Up and Output Rise Characteristic Vin =Vin nom ; Full Load http://www.tracopower.com Vin =Vin nom ; Full Load Page 11 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-2413WI(Continued) Conduction Emission of EN55022 Class A Vin =Vin nom ; Full Load Conduction Emission of EN55022 Class B Vin =Vin nom ; Full Load 100 100 400LFM 60 100LFM Natural convection 80 Natural convection Output Power (%) Output Power (%) 80 400LFM 200LFM 40 20 200LFM 60 100LFM 40 20 0 0 ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (without heatsink) http://www.tracopower.com ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (with heatsink) Page 12 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-2422WI 95 100 90 Efficiency(%) Efficiency(%) 90 80 70 60 10V 50 24V 40V 40 20 40 60 80 100 % of Full Load 85 80 75 70 10 24 40 Input Voltage(V) Efficiency Versus Output Current Efficiency Versus Input Voltage Full Load Typical Output Ripple and Noise. Vin =Vin nom; Full Load; TA Transient Response to Dynamic Load Change from 100% to 75% of Full Load ; Vin =Vin nom ON/OFF Voltage Start-Up and Output Rise Characteristic Typical Input Start-Up and Output Rise Characteristic Vin =Vin nom ; Full Load http://www.tracopower.com Vin =Vin nom ; Full Load Page 13 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-2422WI(Continued) Conduction Emission of EN55022 Class A Vin =Vin nom ; Full Load Conduction Emission of EN55022 Class B Vin =Vin nom ; Full Load 100 100 400LFM 60 100LFM Natural convection 80 Natural convection Output Power (%) Output Power (%) 80 400LFM 200LFM 40 20 200LFM 60 100LFM 40 20 0 0 ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (without heatsink) http://www.tracopower.com ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (with heatsink) Page 14 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-2423WI 95 100 90 Efficiency(%) Efficiency(%) 90 80 70 60 10V 50 24V 40V 40 20 40 60 80 100 % of Full Load 85 80 75 70 10 24 40 Input Voltage(V) Efficiency Versus Output Current Efficiency Versus Input Voltage Full Load Typical Output Ripple and Noise. Vin =Vin nom; Full Load; TA Transient Response to Dynamic Load Change from 100% to 75% of Full Load ; Vin =Vin nom ON/OFF Voltage Start-Up and Output Rise Characteristic Typical Input Start-Up and Output Rise Characteristic Vin =Vin nom ; Full Load http://www.tracopower.com Vin =Vin nom ; Full Load Page 15 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-2423WI(Continued) Conduction Emission of EN55022 Class A Vin =Vin nom ; Full Load Conduction Emission of EN55022 Class B Vin =Vin nom ; Full Load 100 100 400LFM Natural convection 60 100LFM 400LFM Natural convection 80 Output Power (%) Output Power (%) 80 200LFM 40 20 200LFM 60 100LFM 40 20 0 0 ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (without heatsink) http://www.tracopower.com ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (with heatsink) Page 16 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-4810WI 85 90 80 Efficiency(%) Efficiency(%) 80 70 60 50 18V 40 48V 75V 30 20 40 60 80 100 % of Full Load 75 70 65 60 18 48 75 Input Voltage(V) Efficiency Versus Output Current Efficiency Versus Input Voltage Full Load Typical Output Ripple and Noise. Vin =Vin nom; Full Load; TA Transient Response to Dynamic Load Change from 100% to 75% of Full Load ; Vin =Vin nom ON/OFF Voltage Start-Up and Output Rise Characteristic Typical Input Start-Up and Output Rise Characteristic Vin =Vin nom ; Full Load http://www.tracopower.com Vin =Vin nom ; Full Load Page 17 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-4810WI(Continued) Conduction Emission of EN55022 Class A Vin =Vin nom ; Full Load Conduction Emission of EN55022 Class B Vin =Vin nom ; Full Load 100 100 400LFM 60 100LFM Natural convection 80 Natural convection Output Power (%) Output Power (%) 80 400LFM 200LFM 40 20 200LFM 60 100LFM 40 20 0 0 ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (without heatsink) http://www.tracopower.com ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (with heatsink) Page 18 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-4811WI 95 100 90 Efficiency(%) Efficiency(%) 90 80 70 60 18V 50 48V 75V 40 20 40 60 80 100 % of Full Load 85 80 75 70 18 48 75 Input Voltage(V) Efficiency Versus Output Current Efficiency Versus Input Voltage Full Load Typical Output Ripple and Noise. Vin =Vin nom; Full Load; TA Transient Response to Dynamic Load Change from 100% to 75% of Full Load ; Vin =Vin nom ON/OFF Voltage Start-Up and Output Rise Characteristic Typical Input Start-Up and Output Rise Characteristic Vin =Vin nom ; Full Load http://www.tracopower.com Vin =Vin nom ; Full Load Page 19 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-4811WI(Continued) Conduction Emission of EN55022 Class A Vin =Vin nom ; Full Load Conduction Emission of EN55022 Class B Vin =Vin nom ; Full Load 100 100 400LFM 60 100LFM Natural convection 80 Natural convection Output Power (%) Output Power (%) 80 400LFM 200LFM 40 20 200LFM 60 100LFM 40 20 0 0 ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (without heatsink) http://www.tracopower.com ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (with heatsink) Page 20 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-4812WI 95 100 90 Efficiency(%) Efficiency(%) 90 80 70 60 18V 50 48V 75V 40 20 40 60 80 100 % of Full Load 85 80 75 70 18 48 75 Input Voltage(V) Efficiency Versus Output Current Efficiency Versus Input Voltage Full Load Typical Output Ripple and Noise. Vin =Vin nom; Full Load; TA Transient Response to Dynamic Load Change from 100% to 75% of Full Load ; Vin =Vin nom ON/OFF Voltage Start-Up and Output Rise Characteristic Typical Input Start-Up and Output Rise Characteristic Vin =Vin nom ; Full Load http://www.tracopower.com Vin =Vin nom ; Full Load Page 21 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-4812WI(Continued) Conduction Emission of EN55022 Class A Vin =Vin nom ; Full Load Conduction Emission of EN55022 Class B Vin =Vin nom ; Full Load 100 100 400LFM 80 Natural convection 60 100LFM Output Power (%) Output Power (%) 80 400LFM Natural convection 200LFM 40 20 200LFM 60 100LFM 40 20 0 0 ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (without heatsink) http://www.tracopower.com ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (with heatsink) Page 22 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-4813WI 95 100 90 Efficiency(%) Efficiency(%) 90 80 70 60 18V 50 48V 75V 40 20 40 60 80 100 % of Full Load 85 80 75 70 18 48 75 Input Voltage(V) Efficiency Versus Output Current Efficiency Versus Input Voltage Full Load Typical Output Ripple and Noise. Vin =Vin nom; Full Load; TA Transient Response to Dynamic Load Change from 100% to 75% of Full Load ; Vin =Vin nom ON/OFF Voltage Start-Up and Output Rise Characteristic Typical Input Start-Up and Output Rise Characteristic Vin =Vin nom ; Full Load http://www.tracopower.com Vin =Vin nom ; Full Load Page 23 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-4813WI(Continued) Conduction Emission of EN55022 Class A Vin =Vin nom ; Full Load Conduction Emission of EN55022 Class B Vin =Vin nom ; Full Load 100 100 400LFM 60 100LFM Natural convection 80 Natural convection Output Power (%) Output Power (%) 80 400LFM 200LFM 40 20 200LFM 60 100LFM 40 20 0 0 ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (without heatsink) http://www.tracopower.com ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (with heatsink) Page 24 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-4822WI 95 100 90 80 Efficiency(%) Efficiency(%) 90 70 60 50 18V 40 48V 75V 30 20 40 60 80 100 % of Full Load 85 80 75 70 18 48 75 Input Voltage(V) Efficiency Versus Output Current Efficiency Versus Input Voltage Full Load Typical Output Ripple and Noise. Vin =Vin nom; Full Load; TA Transient Response to Dynamic Load Change from 100% to 75% of Full Load ; Vin =Vin nom ON/OFF Voltage Start-Up and Output Rise Characteristic Typical Input Start-Up and Output Rise Characteristic Vin =Vin nom ; Full Load http://www.tracopower.com Vin =Vin nom ; Full Load Page 25 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-4822WI(Continued) Conduction Emission of EN55022 Class A Vin =Vin nom ; Full Load Conduction Emission of EN55022 Class B Vin =Vin nom ; Full Load 100 100 400LFM Natural convection 60 100LFM 400LFM Natural convection 80 Output Power (%) Output Power (%) 80 200LFM 40 20 200LFM 60 100LFM 40 20 0 0 ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (without heatsink) http://www.tracopower.com ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (with heatsink) Page 26 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-4823WI 95 100 90 Efficiency(%) Efficiency(%) 90 80 70 60 18V 50 48V 75V 40 20 40 60 80 100 % of Full Load 85 80 75 70 18 48 75 Input Voltage(V) Efficiency Versus Output Current Efficiency Versus Input Voltage Full Load Typical Output Ripple and Noise. Vin =Vin nom; Full Load; TA Transient Response to Dynamic Load Change from 100% to 75% of Full Load ; Vin =Vin nom ON/OFF Voltage Start-Up and Output Rise Characteristic Typical Input Start-Up and Output Rise Characteristic Vin =Vin nom ; Full Load http://www.tracopower.com Vin =Vin nom ; Full Load Page 27 of 38 Application Note TEN 25WI Series Characteristic Curves All test conditions are at 25℃ The figures are identical for TEN 25-4823WI(Continued) Conduction Emission of EN55022 Class A Vin =Vin nom ; Full Load Conduction Emission of EN55022 Class B Vin =Vin nom ; Full Load 100 100 400LFM 60 100LFM Natural convection 80 Natural convection Output Power (%) Output Power (%) 80 400LFM 200LFM 40 20 200LFM 60 100LFM 40 20 0 0 ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (without heatsink) http://www.tracopower.com ~ -40 50 60 70 80 90 100 110 Ambient Temperature ] Derating Output Current Versus Ambient Temperature and Airflow Vin =Vin nom (with heatsink) Page 28 of 38 Application Note TEN 25WI Series Testing Configurations Input reflected-ripple current measurement test up Component Value Reference L 4.7µH ----- C 220µF (ESR<1.0Ω at 100KHz) Aluminum Electrolytic Capacitor Peak-to-peak output ripple & noise measurement test up This noise pickup is eliminated as shown in Figure by using a scope probe with an external ground band or ring and pressing this band directly against the output common terminal of the power converter while the tip contacts the voltage output terminal. This makes the shortest possible connection across the output terminals. Output voltage and efficiency measurement test up CONTACT AND DISTRIBUTION LOSSES CONTACT AND DISTRIBUTION LOSSES +Vin üüü V V -Vin http://www.tracopower.com +Vo Load -Vo Page 29 of 38 Application Note TEN 25WI Series EMC considerations C2 L1 + INPUT T1 C2 +Output +Vout Vout +Vin L1 + INPUT T1 +Output +Vout Vout +Vin Load Load C1 COM C1 Load -Vin - INPUT -Vout -Output -Vin - INPUT C3 -Vout -Output C3 Single Output Dual Output Recommended circuit to comply EN55022 Class B Limits (TEN 25-24xxWI) Single Output Dual Output Recommended PCB Layout with Input Filter (TEN 25-24xxWI) http://www.tracopower.com Page 30 of 38 Application Note TEN 25WI Series C4 L1 T1 +INPUT C4 +Output +Vout +Vin L1 T1 +INPUT +Output +Vout +Vin Load C1 C2 C3 C1 Load C2 C3 COM Load -Vin -INPUT - Vout -Output -Vin -INPUT C5 -Vout -Output C5 Single Output Dual Output Recommended circuit to comply EN55022 Class B Limits (TEN 25-48xxWI) Single Output Dual Output Recommended PCB Layout with Input Filter (TEN 25-48xxWI) http://www.tracopower.com Page 31 of 38 Application Note TEN 25WI Series To: comply with EN55022 CLASS B following components are needed: Model TEN 25-24xxWI TEN 25-48xxWI Component C1 C2,C3 L1 T1 C1 C2,C3 C4 C5 L1 T1 Value 3.3µF/50V 1210 X7R 470pF/2KV 1808 X7R 2.2µH SCD0705T/3.7A 460µH Common choke, core:T10X2.5X5 H5B2/HPN155 <-> 0.44X16T 4.7µF/100V 2220 X7R 10µF/100V 2220 X7S 470pF/2KV 1808 X7R 1000pF/2KV 1808 X7R 4.7µH SCD0705T/3.5A 1.07mH Common choke, core:T10X2.5X5 H5B2/HPN155 <-> 0.34X20T Input Source Impedance The power module should be connected to a low ac-impedance input source. Highly inductive source impedances can affect the stability of the power module. 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 power module helps ensure stability of the unit, it is recommended to use a good quality low Equivalent Series Resistance (ESR < 1.0Ω at 100 KHz) capacitor of a 33µF for the 24V input devices and a 10µF for the 48V devices. Output Over Current Protection 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 Over Voltage Protection The output overvoltage clamp consists of control circuitry, which is independent of the primary regulation loop, that monitors the voltage on the output terminals. The control loop of the clamp has a higher voltage set point than the primary loop. This provides a redundant voltage control that reduces the risk of output overvoltage. The OVP level can be found in the output data http://www.tracopower.com Page 32 of 38 Application Note TEN 25WI Series Remote ON/OFF Control With no suffix, the positive logic remote ON/OFF control circuit is included. Turns the module ON during logic High on the ON/Off pin and turns OFF during logic Low. The ON/OFF input signal (Von/off) that referenced to GND. If not using the remote on/off feature, please open circuit between on/off pin and -Vin pin to turn the module on. Remote ON/OFF implementation +Vin POWER MODULE lo ON/OFF OPTOISOLATOR + Von/off -Vin Isolated-Closure Remote ON/OFF +Vin POWER MODULE Vcc TTL lo + SYSTEM ON/OFF CONTROL ON/OFF Von/off -Vin Level Control Using TTL Output http://www.tracopower.com Page 33 of 38 Application Note TEN 25WI Series Heat Sink Consideration Equip heat-sink for lower temperature and higher reliability of the module. 23.0[0.91] Suffix-H 17.2[0.68]Max 55.32[2.18]Max Heat-sink Thermal pad Clamp Converter All dimensions in mm (inches) http://www.tracopower.com Page 34 of 38 Application Note TEN 25WI Series Mechanical Dimensions 10.16 [0.40] 8 7 1.1 [0.04] Bottom View 1 2 4 5.08 [0.20] 3.6 [0.14] Pin Connections Pin Single Output Dual Output 1 +Vin +Vin 2 -Vin -Vin 4 Remote On/Off 5 No Pin +Vout 6 +Vout Common 7 -Vout -Vout 8 Trim 1.0 [ 0.04] 6 45.72 [1.80] 5 5.08 [0.20] 10.16 [0.40] 50.8 [2.00] 10.16 [0.40] 10.16 [0.40] 7.6 [0.30] 6.0 [0.24] 40.6 [1.60] 10.2 [0.40] 1. All dimensions in mm (inches) Tolerance: X.X±0.25 (X.XX±0.01”) X.XX±0.13 (X.XXX±0.005”) 2. Pin diameter <->1.0 ±0.05 (0.04±0.002) Weight:48g Recommended Pad Layout for Single & Dual Output Converter 8 10.16 [0.40] 6 7 Top View 4 7.62 [0.30] 2 10.16 [0.40] 7X 2.5 0.1(PAD)[7X 0.098 0.04] 7X 1.3 +0.1(HOLE)[7X 0.05 +0.01] 10.16 [0.40] -0 -0 5 50.8 [2.00] 10.16 [0.40] 45.72 [1.80] 2.54 [0.10] 5.08 [0.20] 1 5.08 [0.20] 40.6 [1.60] http://www.tracopower.com Page 35 of 38 Application Note TEN 25WI Series Packaging Information Soldering and Reflow Considerations Lead free wave solder profile for TEN 25WI Series T1+T2 2nd WAVW 1st WAVW Preheat zone TIME(SEC) Zone Preheat zone Reference Parameter Rise temp. speed：3℃/sec max. Preheat temp.：100~130℃ Actual Peak temp.：250~260℃ heating Peak time(T1+T2)：4~6 sec Reference Solder: Sn-Ag-Cu：Sn-Cu：Sn-Ag Hand Welding: Soldering iron：Power 60W Welding Time: 2~4 sec Temp.: 380~400℃ http://www.tracopower.com Page 36 of 38 Application Note TEN 25WI Series Part Number Structure TEN 25-2413WI Max. Output Power 25W Input Voltage 24: 24V 48: 48V Model Number Input Range (VDC) TEN 25-2410WI 10-40 TEN 25-2411WI 10-40 TEN 25-2412WI 10-40 TEN 25-2413WI 10-40 TEN 25-2422WI 10-40 TEN 25-2423WI 10-40 TEN 25-4810WI 18-75 TEN 25-4811WI 18-75 TEN 25-4812WI 18-75 TEN 25-4813WI 18-75 TEN 25-4822WI 18-75 TEN 25-4823WI 18-75 Output Mode 1: Single 2: Dual (±) Output Voltage (VDC) 3.3 5 12 15 ±12 ±15 3.3 5 12 15 ±12 ±15 Output Voltage 0: 3.3V 1: 5V 2: 12V 3: 15V Max. Output Current (mA) 5500 5000 2500 2000 ±1250 ±1000 5500 5000 2500 2000 ±1250 ±1000 Feature WI: Wide Input Input Current at Full Load(1) (mA) Efficiency(2) (%) 922 82 1225 85 1404 89 1404 89 1404 89 1404 89 461 82 613 85 702 89 702 89 702 89 702 89 Note 1. Maximum value at nominal input voltage and full load of standard type. Note 2. Typical value at nominal input voltage and full load. http://www.tracopower.com Page 37 of 38 Application Note TEN 25WI Series Safety and Installation Instruction Fusing Consideration Caution: This power module is not internally fused. An input line fuse must always be used. This encapsulated power module can be used in a wide variety of applications, ranging from simple stand-alone operation to an integrated part of sophisticated power architecture. To maximum flexibility, internal fusing is not included; however, to achieve maximum safety and system protection, always use an input line fuse. The safety agencies require a slow-blow fuse in 24Vin, 48Vin with maximum rating of 5000mA, 3000mA. Based on the information provided in this data sheet on Inrush energy and maximum dc input current; the same type of fuse with lower rating can be used. Refer to the fuse manufacturer’s data for further information. MTBF and Reliability The MTBF of TEN 25WI series of DC/DC converters has been calculated using MIL-HDBK 217F NOTICE2, Operating Temperature 25℃, Ground Benign. Model MTBF TEN 25-2410WI 550,812 TEN 25-2411WI 518,995 TEN 25-2412WI 513,663 TEN 25-2413WI 555,278 TEN 25-2422WI 592,031 TEN 25-2423WI 578,235 TEN 25-4810WI 522,111 TEN 25-4811WI 505,791 TEN 25-4812WI 537,606 TEN 25-4813WI 562,430 TEN 25-4822WI 577,367 TEN 25-4823WI 581,328 Unit Hours Specifications can be changed without notice Rev. 05/12 Jenatschstrasse 1 · CH-8002 Zurich · Switzerland Tel. +41 43 311 45 11 · Fax +41 43 311 45 45 · [email protected] · www.tracopower.com Page 38 of 38