W25-48S5 & W25-48S5N DC/DC MODULES 1400 PROVIDENCE HIGHWAY • BUILDING 2 NORWOOD, MASSACHUSETTS 02062-5015 WWW.INTRONICS.COM Technical Specifications for W25-48S5 & W25-48S5N (48Vin, 5 Vout @ 5A) The W25 family of high efficiency, low power DC/DC converters offer power levels that exceed other bricks with similar footprints. They are targeted specifically at the telecommunication, industrial electronics, mobile telecommunication and distributed power markets. With a wide input voltage range of 36-75V they are available with output voltages of either 1.5, 1.8, 2.5, 3.3 or 5 Volts. All models feature an input filter, input undervoltage lockout, output overvoltage and overtemperature protection, output current limiting and short circuit protection. The fully enclosed, encapsulated construction with aluminum heat spreader design achieves very efficient heat transfer with no hot spots. The use of patented design concepts facilitate maximum power delivered with the highest efficiency up to 90%. The converters combine creative design concepts with highly derated power devices to achieve very high reliability, high performance and low cost solution to systems designers requiring maximum power in small footprints. 3.3Vo Model Shown Applications Features • • • • • • • Delivers up to 25W in 1.2” x 2.0” format • High power density up to 30W/inch3 • Synchronous rectification topology • No airflow or heat sink required • No minumum load required • Low profile of only 0.35 inch • High output current in small footprint • 1.5V, 1.8V, 2.5V, 3.3V or 5V models • Wide input operating range 36-75V • -40°C to +100°C ambient operation • Input undervoltage lockout • • • • • Telecommunications Output overvoltage protection Output current limit and short circuit protection • Data Communications On/Off pin • Wireless Communications Output adjustment +/-10% range • Networking Gear 1500V, 10MΩ input-to-output isolation Enclosed construction with heat spreader for • Servers, Switches and Data Storage low temperature rise • Semiconductor Test Equipment Enclosed six-sided metal shield for low EMI/RFI • Distributed Power Architecture UL 60950 recognized, TUV EN60950 and CSA C22.2 No. 60950-00 Certified (Approval Pending) Meets conducted limits of FCC Class B and CEI IEC61204-3 Class B with external filter MTBF of 850,000 hours @ 50°C (MIL-HDBK-217F) Outline Information and Summary Specifications Pin Connection Pin# Single Output 1 On/Off 2 Vin 3 Vin + 4 Vout + 5 Vout 6 Trim Tolerance Inches •XX ± 0.020 •XXX ± 0.010 Pin: ± 0.002 4 3 All dimensions are in inches [mm] All pins are dia. 0.040 [1.02] Pin material: Brass Pin finish: Gold plated Insulator pad around pins: Silicone rubber Case: Aluminum material with anodized finish Weight: 39.2 (1.4oz) 0.60 [15.24] 2 0.30 [7.62] 0.80 [20.32] 5 0.40 [10.16] 1.20 [30.48] 0.40 [10.16] 1 6 0.20 [5.08] 1.80 [45.72] 0.10 [2.54] 2.00 [50.80] 0.20 [5.08] Millimeters •X ± 0.5 •XX ± 0.25 ± 0.05 0.35 [8.89] SIDE VIEW Thermal derating for vertical orientation, Vin=54V The information and specifications contained in the specification are believed to be accurate and reliable at the time of publication. Specifications are subject to change without notice. Output Voltage (Volts) 5 Output Current at 40°C (Amps) Output Current at 60°C (Amps) Free Air 200 LFM 300 LFM Free Air 200 LFM 5.0 5.0 5.0 4.6 5.0 • Output Current at 80°C (Amps) 300 LFM 5.0 • Free Air 200 LFM 300 LFM 0.3 1.8 3.8 Intronics, Inc. 1400 Providence Highway, Building 2, Norwood, MA 02062-5015 Phone: 1-800-367-0004, 1-781-551-5500 Fax: 1-781-551-5555 Rev. A, Page 1 of 7 Electrical Specifications Ta=25°C, Vin=48V unless otherwise noted. PARAMETER Absolute maximum rating Input voltage Operating case temperature Storage temperature Humidity Input characteristics Operating input voltage range Turn on voltage threshold Turn off voltage threshold Transient withstand Maximum input current Off converter input current Output characteristics Output voltage set point Output voltage line regulation Output voltage load regulation Output voltage trim range Output voltage ripple and noise Output over power protection Over-voltage protection Over-temperature protection Temperature coefficient Capacitive Load Output dynamic characteristics Startup time Transient recovery time Transient peak deviation Efficiency (see efficiency curve) 100% load efficiency Isolation characteristics Isolation voltage (primary to secondary ) Isolation voltage (primary to case) Isolation voltage (secondary to case) Isolation resistance Isolation capacitance Feature Characteristics Switching frequency ON/OFF control (Positive logic) Converter On Converter Off ON/OFF control (Negative logic) Converter On Converter Off Output voltage trim range Calculated MTBF Weight NOTES MIN TYP 0 -40 -55 36 48 35 MAX UNIT 80 100 125 95 V °C °C % 75 V V V V A mA 34 100 0.85 36 Transient duration: 100ms 100% load , 36Vin 48Vin 5 36~75 Vin 10%-100%Load 20Mz bandwidth, 100% Load, 48Vin 100 6.2 50 120 V ±0.3 ±0.5 ±10 100 140 7.1 % % % mV(pk-pk) % V ±0.04 100,000 °C %/°C µF 100 800 2 ms µs %Vo 100 0 5% to 95% of the output voltage 25% load change 25% load change 50 48 Vin 88 % 1500 1000 1000 1000 VDC VDC VDC MΩ pF 275 7 1.2 KHz V V -1 3 1.2 7 V V -10 900,000 +10 % Hrs g(oz) 1minute 1minute 1minute 500VDC, Primary to secondary Primary to secondary W25-48S5 W25-48S5N Percentage of normal output Bellcore @ 50°C 10 225 3 -1 250 28(1.0) • • Intronics, Inc. 1400 Providence Highway, Building 2, Norwood, MA 02062-5015 Phone: 1-800-367-0004, 1-781-551-5500 Fax: 1-781-551-5555 Rev. A, Page 2 of 7 Output Trim (Pin 6) Basic Operation And Functions Permits the user to adjust the output voltage up or down to achieve the custom voltage or to make the output voltage margining. W25-48S5/W25-48S5N is a high efficiency, isolated DC/DC converter. Neither heat sink nor airflow is required when the unit operates at ambient temperature of 25°C. The unit has basic control, output adjustment and protection functions. The unit’s output voltage can be adjusted up10% or down 10% relative to the rated output voltage by adding an external resistor between pin 6 and one of the output pins (pin 4 and 5). Input (Pin 2, Pin 3) To increase the output voltage, a trim resistor should be connected between pin 6(Trim) and pin 5 (Vout-), as shown in Fig 2. Input power Vin(+) must be connected to Positive input pin 3; Input power Vin(-) must be connected to Negative input pin2. Output (Pin 4, Pin 6) To decrease the output voltage, a trim resistor should be connected between pin 6 (Trim) and pin 4 (Vout+), as shown in Fig 3. Output power Vout(+) must be connected to Positive output pin 4; Output power Vout(-) must be connected to Negative output pin6. The recommended trim resistor values can be found in the trim table (Table 1) and charts (Fig 4 and 5). ON/OFF (Pin 1) Permits the user to maintain unit On/Off, in order to properly sequence different power supplies and reduce power consumption during the standby condition. There are two ON/OFF control options: positive logic (W25-48S5) and negative logic (W25-48S5N). Both are referenced to Vin-. Pin 1 is the "Enable" pin, connecting a TTL compatible pin. A TTL control signal to this pin, according to the specification, turns the unit on or off. Fig 2. Configuration for increasing the output voltage The positive logic unit turns on when the pin is at logic high or open, and turns off at logic low. The negative logic unit turns on when the pin is at logic low, and turns off at logic high state. Typical ON/OFF connection is shown in Fig 1. Fig 3. Configuration for decreasing the output voltage Trim resistace (k) 120 Fig 1. Recommended ON/OFF circuit configuration Remote Sense The unit does NOT have remote sense pins. 100 80 60 40 20 0 1 2 3 4 5 6 7 8 9 10 Trim-up Vout change (%) Fig 4 Trim-up output vs. trim resistance • • Intronics, Inc. 1400 Providence Highway, Building 2, Norwood, MA 02062-5015 Phone: 1-800-367-0004, 1-781-551-5500 Fax: 1-781-551-5555 Rev. A, Page 3 of 7 Trim resistace (k) 140 Application Considerations 120 100 Input source Impedance 80 The unit has been designed to be stable with no external capacitor when used in a low inductance input and output circuit. 60 40 20 However in many applications, the inductance with the distribution from the power source to the input of the unit can affect the stability of the unit. An external capacitor across the input will improve the stability of the unit. Also in many applications, the user has to use decoupling capacitors at the output load, to ensure the hold up time for the load. 0 1 2 3 4 5 6 7 8 9 10 Trim-down Vout change (%) Fig 5 Trim-down output vs. trim resistance Safety Requirements (SR) Table 1 Output voltage trim vs. trim resistor value Trim Voltage +10% +9% +8% +7% +6% +5% +4% +3% +2% +1% Trim Resistor 2.08k 3.38k 5.00k 7.10k 9.87k 14.22k 20.30k 31.20k 51.00k 109.70k Trim Voltage -10% -9% -8% -7% -6% -5% -4% -3% -2% -1% Trim Resistor 0.28k 1.77k 3.60k 5.97k 9.46k 14.17k 20.20k 32.96k 55.82k 127.6k The unit meets UL/CSA/TUV safety requirements per UL60950, TUV EN60950 and CSA C22.2 No.60950-00. Basic insulation is provided between input and output. Caution: The unit does NOT have a fuse inside. The safety agencies require an external normal-blow fuse to be used at the input side to achieve maximum safety. The recommended fuse rating is 2A/100V. If the input source is non-SELV (ELV or a hazardous voltage greater than 60 Vdc and less than or equal to 75 Vdc), for the unit output to be considered meeting the requirements of safety extra low voltage (SELV), all of the following must be met: • The input source is to be provided with reinforced insulation from any hazardous voltage, including the ac main. • The input pins of the unit are not operator accessible. • For the whole system, for safety agencies requirements, and for the combination of the unit input side (primary side) and the output side (secondary side), verify that under a single fault, hazardous voltages do not appear at the unit output side (secondary side). • Never ground either of the input pins of the unit without grounding one of the output pins. This may allow a non-SELV voltage to appear between the output pin and ground. Protection Features Input under voltage lockout (UVL) The input voltage must be at least 35V for the unit to turn on. Once the unit has been turned on, it will shut off when the input voltage drops below 34V. Output Over-Current Protection (OCP) The unit is protected against over current or short circuit on the output. When sensing an over current condition, the unit will enter constant current operation and reduce the output voltage. Upon short-circuit condition, the unit will shut down. After over-current or short circuit condition is removed, the unit will resume normal operation automatically. Output Over Voltage Protection (OVP) This unit will shut down and latch off if the output voltage exceeds the over protection point. The over-voltage-protection latch is reset only by another cycle of the input power. The OVP set point is between 4.1V~4.7V. Electromagnetic Compatibility (EMC) The unit’s conducted emission meets the requirement of EN55022 Class B Specifications, so no external input filter is needed unless a stricter conducted EMI/EMC limitation is required to satisfy or user has its own requirement on the input. Over Temperature Protection (OTP) This unit will shut down if the case temperature exceeds the over temperature set point. The unit will resume normal operation automatically when the case temperature drops down. The OVP set point is around 100°C. Fig 6 shows the measured conducted EMC. Six-sided metal shields for zero radiate emission. • • Intronics, Inc. 1400 Providence Highway, Building 2, Norwood, MA 02062-5015 Phone: 1-800-367-0004, 1-781-551-5500 Fax: 1-781-551-5555 Rev. A, Page 4 of 7 Start up The startup scenarios are explained in Fig 7 and 8. The measured waveforms showing the turn on transient are given in Fig 9 and 10, for both positive and negative logic control units. Efficiency Efficiency vs. load current curve at different inputs of 36V, 48V and 75V is given in Fig 11. The ambient temperature is 25°C. Efficiency with nominal input (48V) at different ambient temperatures (25°C, 40°C and 55°C) is also given in Fig 12. Dynamic Response The dynamic response of the unit at load step is shown in Fig 13. The output load current change from 50% to 75% and return to 50% at the slew of 0.1A/µs. The input is 48V and a filter of 10µF tantalum capacitor plus a 1µF ceramic capacitor is put parallel to the output. Fig 6. Conducted EMC (150KHz-30MHz) test result, the upper trace is the limit of EN55022 Class B specification Input Transient Withstand (ITW) Ripple and Noise The unit can withstand input transient voltage with 100V/100ms pulse and never be damaged. The output voltage waveform has been measured at full load condition, with 10µF tantalum capacitor plus 1µF Ceramic capacitor closely parallel to the unit’s output. Fig 14 shows the output ripple and noise waveform. Characterization General information Thermal De-rating This unit has many operational characterized aspects including thermal derating, efficiency, start up and overshoot, output ripple & noise, dynamic response, over current protection curve and etc. For thermal de-rating test, the output current vs. the ambient temperature and the airflow rates has been measured, and the results are given in Fig 15. The ambient temperature varies between 50°C and 85°C with the airflow of 0, 100 and 200LFM (0, 0.5m/s and 1m/s). The following pages contain specific plots or waveforms associated with the unit. Additional comments for specific data are provided below. Others Other curve and waveforms presented include the output voltage vs. current curve (Fig 16) and the input current ripple waveform at full load condition (Fig 17) Test Conditions All data presented were taken with the unit soldered to a test board, which is a 0.060” thick printed circuit board. No heat sink was used during all measurements. No airflow was used except in the de-rating test. Start up Information Scenario #1: Initial Start up from power supply On/Off function enabled, the unit starts via input voltage Vin, see Fig 7. For the input line, a 1µF /100V ceramic capacitor has been used during all these tests. On the output side, a 10µF tantalum capacitor with Esr < 0.12Ω and 1µF ceramic capacitor has been used. The capacitors on both the input and output sides were close to the unit. Time Comments t0 On/Off pin is On: system front-end power is switched on, Vin to unit begins to rise. t1 Vin crosses Under Voltage Lockout protection circuit threshold: the unit enabled to be on t2 The unit begins to turn on ( unit turn-on delay). t3 Unit output voltage reaches 100% of normal voltage. For this example, the unit total start up time (t3- t1) is typically 200us. NOTE: It is important to make sure that the components on the unit do not exceed their rating. Scenario #2: Initial Start up using On/Off Pin With Vin previously powered, the unit starts via On/Off pin, see Fig 8. • • Intronics, Inc. 1400 Providence Highway, Building 2, Norwood, MA 02062-5015 Phone: 1-800-367-0004, 1-781-551-5500 Fax: 1-781-551-5555 Rev. A, Page 5 of 7 ON/OFF signal (1V/div) , Ch1: Output voltage (2V/div), Co=10µF tantalum capacitor + 1µF Ceramic capacitor, time scale: 200µs/div Time Comments t0 Vin at nominal value. t1 Arbitrary time when On/Off pin is enabled (Unit enabled) t2 End of unit turn-on delay t3 Unit Vout reaches 100% of nominal voltage. For this example, the unit total start up time (t3- t1) is typically 300us. Fig 10. Startup under negative logic control at Vin=48v, Iout =5A. Ch1: ON/OFF signal (5V/div) , Ch2: Output voltage (2V/div), Co=10µF tantalum capacitor + 1µF Ceramic capacitor, time scale: 200µs/div Efficiency Curves 90 Efficiency (%) Fig 7. Start up waveform 85 80 75 36V 70 75V 48V 65 1 2 3 4 5 Output current (A) Fig 11. Efficiency vs. output current at various Input voltage The ambient temperature is 25°C. Fig 8. Start up using On/Off pin Turn-On Transient Waveforms Efficiency (%) 90 85 80 75 25°C 70 55°C 40°C 65 1 2 3 4 5 Output current (A) Fig12. Efficiency at nominal input (48V) vs. load at different ambient temperatures of 25°C, 40°C, 55°C without air flow, the input voltage is 48V. Fig 9. Startup under positive logic control at Vin=48v, Iout =5A. Ch2: • • Intronics, Inc. 1400 Providence Highway, Building 2, Norwood, MA 02062-5015 Phone: 1-800-367-0004, 1-781-551-5500 Fax: 1-781-551-5555 Rev. A, Page 6 of 7 Dynamic Response Waveform Thermal De-Rating Curve Output current(A) 6 5 4 3 0LFM 2 100FM 1 200LF M 0 50 55 60 65 70 75 80 85 Ambient Temperature(°C) Fig 15. Maximum output current vs. temperature. Both the input and output voltages are nominal. Fig 13. Dynamic response of load step at Vin=48v, Ch1: output voltage change(100mv/div), Ch2: output current step of 50%-75%-50% (2A/div). Current slew rate:0.1A/µs, Co=10µF tantalum capacitor + 1µF Ceramic capacitor, time scale: 1ms/div Over Current Protection Curve Output Ripples and Noise Waveform Fig 16. Output voltage vs current showing current limit point and converter shut down point Input Current Ripple Waveform Fig 14. Output voltage Ripple & Noise at Vin=48v, Iout=5A Co=10µF tantalum capacitor + 1µF Ceramic cap, ch1: 20mV/div, time scale: 2µs/div. Fig 17. Input current ripple with full output load at 48V input (50mA/div), time scale: 1µs/div • • Intronics, Inc. 1400 Providence Highway, Building 2, Norwood, MA 02062-5015 Phone: 1-800-367-0004, 1-781-551-5500 Fax: 1-781-551-5555 Rev. A, Page 7 of 7