UWR Series Single Output, High Reliability, 2" x 2", 14-20 Watt, DC/DC Converters Typical units FEATURES PRODUCT OVERVIEW Low cost! Highly reliable! Proven SMT-on-pcb construction Designed to meet UL/ EN60950, BASIC insulation (D48A models) mark available (48VIN models) Output voltages: 3.3/5/5.2/12/15 Volts Ultra-wide input voltage ranges:4.7-7.5V, 9-36V or 18-75V Small packages, 2" x 2" x 0.45" Industry-standard pinouts Fully isolated, 1500Vdc guaranteed Guaranteed efficiencies to 84% –40 to +100°C operating temperature Modifications and customs for OEM’s DATEL's new A-Series switching DC/DC converters are designed to meet the demanding longterm-reliability and low-cost requirements of modern telecom, datacom, computer/networking and industrial-electronics applications. These highly-efficient, rugged devices combine straightforward circuit topologies, new components, proven SMT-on-pcb construction methods, and highly repeatable automatic-assembly techniques. The flexibility of the designs and their assembly methods readily permit minor modifications to optimize performance for specific applications. The single-output, 14-20 Watt Models of the A-Series deliver both high power densities and impressive MTBF’s. Packaged in standard, 2" x 2" x 0.45", shielded metal cases with non-conductive coatings, these fully isolated (1500Vdc minimum) DC/DC’s offer excellent line/load regulation, full I/O protection, thermal shutdown, and industry-standard pinouts. Output voltages include 3.3, 5, 5.2, 12 or 15 Volts. Input voltage ranges are DATEL's traditional ultra-wide 9-36V and 18-75V, as well as 4.7-7.5V. Each device provides remote on/off control and VOUT trim capability. All A-Series UWR models are fully EMI characterized and designed to meet UL1950, CSA 950 and IEC 950 safety. A-Series DC/DC’s are extremely reliable, easy-to-use, cost-effective power converters. Use them to improve the reliability of existing equipment or to develop new systems that exceed design objectives. +VOUT (6) +VIN (1) COMMON (7) –VIN (2) ON/OFF CONTROL (4) PWM CONTROLLER OPTO ISOLATION Figure 1. Simplified Schematic REFERENCE & ERROR AMP +VOUT TRIM (8) Typical topology is shown. For full details go to www.murata-ps.com/rohs www.murata-ps.com Technical enquiries email: [email protected], tel: +1 508 339 3000 MDC_UWR14-20 Series.B02 Page 1 of 6 UWR Series Single Output, High Reliability, 2" x 2", 14-20 Watt, DC/DC Converters ~ Performance Specifications and Ordering Guide Output Input VOUT (Volts) IOUT (mA) R/N (mVp-p) Typ. Max. Regulation (Max.) Line Load UWR-3.3/4250-D5A 3.3 4250 50 100 ±1.0% ±1.0% UWR-3.3/4850-D12A 3.3 4850 50 75 ±0.5% UWR-3.3/4850-D48A Root Model Efficiency Package (Case, Pinout) Range (Volts) IIN (mA) Min. Typ. 5 4.7-7.5 80/3720 76% 77% C4, P6 ±1.0% 24 9-36 35/852 77% 79% C4, P6 VIN Nom. (Volts) 3.3 4850 50 100 ±1.0% ±1.0% 48 18-75 15/419 79% 80% C4, P6 UWR-5/3000-D5A 5 3000 50 100 ±1.0% ±1.0% 5 4.7-7.5 80/3800 78% 79% C4, P6 UWR-5/4000-D12A 5 4000 50 100 ±0.3% ±0.5% 24 9-36 15/1020 81% 82% C4, P6 UWR-5/4000-D48A 5 4000 50 100 ±0.3% ±0.5% 48 18-75 15/496 82% 84% C4, P6 UWR-5/4000-D48E 5 4000 50 100 ±0.3% ±0.5% 48 36-72 15/484 84% 86% C4, P6 UWR-5.2/3000-D5A 5.2 3000 50 100 ±1.0% ±1.0% 5 4.7-7.5 80/3900 79% 80% C4, P6 UWR-12/1250-D5A 12 1250 75 120 ±1.0% ±1.0% 5 4.7-7.5 80/3660 80% 82% C4, P6 UWR-12/1650-D12A 12 1650 50 100 ±0.3% ±0.5% 24 9-36 15/1000 79.5% 82.5% C4, P6 UWR-12/1650-D48A 12 1650 75 100 ±0.3% ±0.5% 48 18-75 15/491 84% 85% C4, P6 UWR-15/1000-D5A 15 1000 75 150 ±1.0% ±1.0% 5 4.7-7.5 80/3660 80% 82% C4, P6 UWR-15/1300-D12A 15 1300 50 100 ±0.3% ±0.5% 24 9-36 20/967 84% 85% C4, P6 UWR-15/1300-D48A 15 1300 75 100 ±0.3% ±0.5% 48 18-75 10/484 84% 86% C4, P6 ~ Typical at TA = +25°C under nominal line voltage and full-load conditions unless otherwise noted. Ripple/Noise (R/N) measured over a 20MHz bandwidth. 10% to 100% load. Nominal line voltage, no-load/full-load conditions. See Technical Notes for an explanation of trading off input voltage ranges for higher full-power operating temperature. These are not complete part numbers. Please see the Part Number Structure. Part Number Structure Mechanical Specifications U WR - 5 / 4000 - D12 A - C 2.00 (50.80) RoHS-6 hazardous substance compliant* A-Series High Reliability Output Configuration: U = Unipolar Wide Range Input Case C4 Input Voltage Range: D5 = 4.7-7.5 Volts (5V nominal) D12 = 9-36 Volts (24V nominal) D48 = 18-75/36-72 Volts (48V nominal) Nominal Output Voltage: 3.3, 5, 12 or 15 Volts Maximum Output Current in mA METAL CASE 0.45 (11.43) INSULATED BASE 0.040 ±0.002 DIA. (1.016 ±0.051) 0.20 MIN (5.08) 1.800 (45.72) 0.10 (2.54) * Contact Murata Power Solutions (Datel) for availability. Temperature Derating 5 0.200 (5.08) 20 6 G BB 18 1 2 16 D Output Power (Watts) E C 0.400 (10.16) BB, G D, E, F 7 3 1.200 (30.48) 3 EQ. SP. @ 0.400 (10.16) 2.00 (50.80) 4 F 14 8 A 12 AA UWR-3.3/4250-D5A UWR-3.3/4850-D12A UWR-3.3/4850-D48A UWR-5/3000-D5A UWR-5/4000-D12A UWR-5/4000-D48A UWR-5/4000-D48E UWR-5.2/3000-D5A UWR-12/1250-D5A UWR-12/1650-D12A UWR-12/1650-D48A UWR-15/1000-D5A UWR-15/1300-D12A UWR-15/1300-D48A 10 8 6 4 2 0.100 (2.54) B F A A E C B G D E C B E C B BOTTOM VIEW I/O Connections 0 –40 0 40 45 50 0.40 (10.16) 55 60 65 70 75 80 85 90 95 100 Ambient Temperature (°C) 1. UWR-3.3/4850-D48A (18-75V input, curve A) and UWR-3.3/4850-D12A (9-36V input, curve A) will derate curve AA if used over the limited input ranges of 20-60V or 10-30V, respectively. 2. "D48A" models (18-75V input ranges) that derate along curve B will derate along curve BB if used over the more limited input range of 24-60V. www.murata-ps.com Pin 1 2 3 4 5 6 7 8 Function P6 +Input –Input Pin not installed On/Off Control Pin not installed +Output Common Trim Notes: For "D5A" and "D12A" models, the case is connected to pin 2 (–VIN). For "D48A" and "D48E" models, the case is connected to pin 1 (+VIN). Dimensions are in inches (mm shown for ref. only). Third Angle Projection Tolerances (unless otherwise specified): .XX ± 0.02 (0.5) .XXX ± 0.010 (0.25) Angles ± 2˚ Components are shown for reference only. Technical enquiries email: [email protected], tel: +1 508 339 3000 MDC_UWR14-20 Series.B02 Page 2 of 6 UWR Series Single Output, High Reliability, 2" x 2", 14-20 Watt, DC/DC Converters Performance/Functional Specifications Typical @ TA = +25°C under nominal line voltage and full-load conditions, unless noted. ~ Input Absolute Maximum Ratings Input Voltage Range: D5A Models D12A Models D48A/D48E Models 4.7-7.5 Volts (5V nominal) 9-36 Volts (24V nominal) 18-75/36-72 Volts (48V nominal) Input Current See Ordering Guide Input Filter Type Pi (C-type for D5A models) Overvoltage Shutdown: D5A Models D12A Models D48A and /D48E Models 10 Volts 40 Volts 80 Volts Reverse-Polarity Protection Yes (Instantaneous, 10A maximum) Output Overvoltage Protection: 3.3V Outputs 5V/5.2V Outputs 12V Outputs 15V Outputs On/Off (Sync.) Control (Pin 4) TTL high = off, low (or open) = on Output Current Input Voltage: "D5A" Models "D12A" Models "D48A" and "D48E" Models Input Reverse-Polarity Protection 11 Volts 44 Volts 88 Volts Current must be <10A. Brief duration only. Fusing recommended. No protection 6.8 Volts, limited duration 15 Volts, limited duration 18 Volts, limited duration Current limited. Max. current and short-circuit duration are model dependent Output VOUT Accuracy (50% load) ±1%, maximum Storage Temperature –40 to +105°C Temperature Coefficient ±0.02% per °C Lead Temperature See soldering guidelines Ripple/Noise (20MHz BW) See Ordering Guide Line/Load Regulation See Ordering Guide Efficiency See Ordering Guide Isolation Voltage 1500Vdc guaranteed Isolation Capacitance 550pF Current Limiting Auto-recovery Overvoltage Protection Zener/transorb clamp, magnetic feedback Dynamic Characteristics Transient Response (50% load step) 200μsec max. to ±1.5% of final value Switching Frequency 165kHz (±15kHz) Environmental Operating Temperature (Ambient): Without Derating With Derating –40 to +40/50/55/65°C (Model dependent) to +100°C (See Derating Curves) Storage Temperature -40 to +105°C Flammability UL94V-0 Physical Dimensions 2" x 2" x 0.45" (51 x 51 x 11.4mm) Shielding 5-sided Case Connection: D5A, D12A Models D48A, D48E Models Pin 2 (–VIN) Pin 1 (+VIN) Case Material Corrosion resistant steel with non-conductive, epoxy-based, black enamel finish and plastic baseplate Pin Material RoHS: Gold-plated copper alloy Non-RoHS: Tin over copper alloy Weight 2.7 ounces (76.5 grams) ~ These converters require a minimum 10% loading 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 and perhaps added internally upon request. Contact DATEL Applications Engineering for details. Applying a voltage to the Control pin when no input power is applied to the converter can cause permanent damage to the converter. "D48A" models have BASIC, all other models have Functional insulation. Devices can be screened or modified for higher guaranteed isolation voltages. Contact DATEL Applications Engineering for details. Except for 3.3V outputs which have no protection. www.murata-ps.com These are stress ratings. Exposure of devices in excess 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. TECHNICAL NOTES Floating Outputs Since these are isolated DC/DC converters, their outputs are "floating." Users may ground either the Common (pin 7) for normal usage or the positive side (+Output, pin 6) to effectively reverse the output polarity. Filtering and Noise Reduction All A-Series UWR 14-20 Watt DC/DC Converters achieve their rated ripple and noise specifications without the use of external input/output capacitors. In critical applications, input/output 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. 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. To Reduce Input Ripple D5A Models D12A Models D48A Models 47μF, 16V 20μF, 50V 20-50μF, 100V To Reduce Output Ripple 3.3V Outputs 5V/5.2V Outputs 12/15V Outputs 100μF, 6V, Low ESR 47μF, 10V, Low ESR 22μF, 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. Technical enquiries email: [email protected], tel: +1 508 339 3000 MDC_UWR14-20 Series.B02 Page 3 of 6 UWR Series Single Output, High Reliability, 2" x 2", 14-20 Watt, DC/DC Converters Input Fusing Certain applications and/or safety agencies may require the installation of fuses at the inputs of power conversion components. For DATEL A-Series UWR 14-20 Watt DC/DC Converters, you should use slow-blow type fuses with values no greater than the following: VIN Range D5A D12A D48A/D48E Fuse Value 6A 4A 2A +OUTPUT 1 +INPUT TRIM On/Off Control 6 2 8 20k7 5-10 TURNS LOAD –INPUT The On/Off Control pin (pin 4) may be used for remote on/off operation. A TTL logic high (+2 to +5 Volts, 250μA max.) applied to pin 4 disables the converter. A TTL logic low (0 to +0.8 Volts, 70μA max.), or no connection, enables the converter. Control voltages should be referenced to pin 2 (–Input). Applying a voltage to the Control pin when no input power is applied to the converter can cause permanent damage to the converter. COMMON 7 Figure 2a. Trim Connections Using a Trimpot Output Trimming VOUT may be trimmed ±5% via a single external trimpot or fixed resistor. The trimpot should be connected as shown in Figure 2a with its wiper connected to pin 8 (Trim). A trimpot can be used to determine the value of a single fixed resistor which should be connected as shown in Figure 2b. Connect the resistor between pin 8 (Trim) and pin 6 (+Output) to trim "down" the output voltage. Connect the resistor between pins 8 and 7 (Common) to trim "up" the output voltage. Fixed resistors should be metalfilm types with absolute TCR’s less than 100ppm/°C to ensure stability. +OUTPUT 1 Trim Down +INPUT TRIM 2 6 8 –INPUT LOAD Trim Up COMMON 7 Custom Capabilities 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. More importantly . . . we’ll do it on time and within budget! 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. 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. Figure 2b. Trim Connections Using Fixed Resistors Soldering Guidelines Murata Power Solutions recommends the specifications below when installing these converters. These specifications vary depending on the solder type. Exceeding these specifications may cause damage to the product. Be cautious when there is high atmospheric humidity. We strongly recommend a mild pre-bake (100° C. for 30 minutes). Your production environment may differ; therefore please thoroughly review these guidelines with your process engineers. Wave Solder Operations for through-hole mounted products (THMT) For Sn/Ag/Cu based solders: Maximum Preheat Temperature 115° C. Maximum Pot Temperature 270° C. Maximum Solder Dwell Time 7 seconds For Sn/Pb based solders: Maximum Preheat Temperature www.murata-ps.com 105° C. Maximum Pot Temperature 250° C. Maximum Solder Dwell Time 6 seconds Technical enquiries email: [email protected], tel: +1 508 339 3000 MDC_UWR14-20 Series.B02 Page 4 of 6 UWR Series Single Output, High Reliability, 2" x 2", 14-20 Watt, DC/DC Converters Typical Performance Curves (TA = +25°C) EMI RADIATED EMISSIONS The performance curves below were derived from actual test data for a single model number (UWR-5/4000-D12A). Since all devices in the 14-20W UWR A-Series have the same circuit topology, the performance curves are representative of all devices. EFFICIENCY Efficiency vs. Output Current and Input Voltage If you’re designing with EMC in mind, please note that all of DATEL’s UWR 14-20 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. Radiated emissions plots to FCC and CISPR 22 for model UWR-5/4000-D12A appear below. 87 84 Efficiency (%) 81 UWR-5/4000-D12A Radiated Emissions FCC Part 15 Class B, 3 Meters Converter Output = 5Vdc @ 3.6A 78 V IN = 12V 75 80 V IN = 24V 72 70 V IN = 36V 69 66 63 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 5V Output Current (Amps) LINE REGULATION Output Voltage vs. Input Voltage and Output Current Radiated Emissions (dBμV/M) 60 FCC Class B Limit 50 40 30 20 10 0 5.015 Radiated Emissions –10 I OU T = 1A 5.010 –20 1000 100 VOUT (Volts) 5.005 Frequency (MHz) UWR-5/4000-D12A Radiated Emissions EN 55022 Class B, 10 Meters Converter Output = +5Vdc @ 3.6A 5.000 I OU T = 2A 4.995 80 4.990 70 4.985 I OU T = 4A 4.975 9 12 15 18 21 24 27 30 33 36 VIN (Volts) LOAD REGULATION Output Voltage vs. Output Current and Input Voltage 5.015 Radiated Emissions (dBμV/M) 60 4.980 50 EN 55022 Class B Limit 40 30 20 10 0 V IN = 12V Radiated Emissions –10 5.010 –20 VOUT (Volts) 5.005 1000 100 Frequency (MHz) 5.000 4.995 4.990 V IN = 36V Quality and Reliability V IN = 24V 4.985 4.980 4.975 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 5V Output Current (Amps) www.murata-ps.com 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. Technical enquiries email: [email protected], tel: +1 508 339 3000 MDC_UWR14-20 Series.B02 Page 5 of 6 UWR Series Single Output, High Reliability, 2" x 2", 14-20 Watt, DC/DC Converters 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. 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 technology" is determined. Typical HALT Profile 100 80 40 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 +125°C, 30°C/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 A-Series 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 "cold-start" capabilities. 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 Qualification Test Method/Comments HALT DATEL in-house procedure High Temperature Storage Max. rated temp., 1,000 hours Thermal Shock 10 cycles, –55 to +125°C Temperature/Humidity +85°C, 85% humidity, 48 hours Lead Integrity DATEL in-house procedure Life Test +70°C, 500 hours* Marking Permanency DATEL in-house procedure End Point Electrical Tests Per product specification * Interim electrical test at 200 hours. In-Line Process Controls and Screening 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 20 0 0 Random Vibration (G's) Temperature (°C) 60 –20 –40 10 20 30 40 50 60 70 80 90 Test Time (minutes) Rapid Response to Problems 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. USA: Murata Power Solutions, Inc. 11 Cabot Boulevard, Mansfield, MA 02048-1151 U.S.A. Tel: (508) 339-3000 (800) 233-2765 Fax: (508) 339-6356 www.murata-ps.com email: [email protected] ISO 9001 and 14001 REGISTERED 12/04/08 Murata Power Solutions, Inc. 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. © 2008 Murata Power Solutions, Inc. www.murata-ps.com Mansfield (MA), Tel: (508) 339-3000, email: [email protected] Canada: Toronto, Tel: (866) 740-1232, email: [email protected] UK: Milton Keynes, Tel: +44 (0)1908 615232, email: [email protected] France: Montigny Le Bretonneux, Tel: +33 (0)1 34 60 01 01, email: [email protected] Germany: München, Tel: +49 (0)89-544334-0, email: [email protected] Japan: Tokyo, Tel: 3-3779-1031, email: [email protected] Osaka, Tel: 6-6354-2025, email: [email protected] China: Shanghai, Tel: +86 215 027 3678, email: [email protected] Guangzhou, Tel: +86 208 221 8066, email: [email protected] Singapore: Parkway Centre, Tel: +65 6348 9096, email: [email protected] Technical enquiries email: [email protected], tel: +1 508 339 3000 MDC_UWR14-20 Series.B02 Page 6 of 6