Power Mate Technology Data Sheet May 2003 PDL 02 Series of Power Modules: Dc/Dc Converter 4.5 to 9Vdc, 9 to 18 Vdc, 18 to 36Vdc, 36 to 75 Vdc Input, 3.3 to 15Vdc Single Output, 2Watt Features ■ Low profile: 0.86 x 0.36 x 0.44 inches (21.8 × 9.2 × 11.2 mm) ■ 2:1 wide input voltage range: 4.5 to 9Vdc, 9 to 18 Vdc, 18 to 36Vdc, 36 to 75 Vdc ■ 3.3V, 5V, 9V, 12V, 15Vdc output ■ Input to output isolation: 1000Vdc, min ■ Remote on/off control The PDL02 Series Power Modules use Advanced and deliver high quality, compact, dc/dc converter at ■ No external input and output capacitor an economical prices. ■ UL 1950 pending needed ■ ISO 9001 certified manufacturing facilities Applications: ■ Communications equipment ■ Industrial equipment ■ mobile telecom equipment ■ test equipment General Description The PDL02 series offer 2 watts of output power from a 21.8 x 9.2 x 11.1 mm package without de-rating to 85ºC and without external input/output capacitor. The PDL02 series with 2:1 wide input voltage of 4.5-9, 9-18, 18-36 and 36-75VDC and features 1000VDC of isolation, short-circuit protection. The safety meets to EN60950 and UL60950. Simplified Schematic 1/21 Power Mate Technology Data Sheet May 2003 FDC 10 Series of Power Modules: Dc/Dc Converter 9 to 75 Vdc Input, 3.3 to 15Vdc Single Output, 10W Table of contents Absolute Maximum Rating Electrical Specification Feature Description Thermal consideration Solder, Clearing, and Drying Considerations Characteristic Curve Test Configurations EMC Consideration Mechanical Data Part number structure Safety and Installation Instruction MTBF and Reliability 2/21 Power Mate Technology Data Sheet May 2003 Absolute Maximum Ratings Stress in excess of the absolute maximum ratings can cause permanent damage to the device. Parameter Device Symbol Min Max Unit 15 05Sxx 36 Input Voltage continuous 12Sxx Transient(100ms) 24Sxx 50 48Sxx 100 Vin 0 Vdc Operating temperature range All Ta -40 85 ℃ Storage Temperature All Tstg -55 105 ℃ I/O Isolation Voltage All — 1000 — Vdc Isolation capacitance All 300 pF Electrical Specification Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Table 1: Input Specifications The input filter for PDL02 is used capacitor type. Parameter Device Symbol Min Typ Max 4.5 5 9 9 12 18 24Sxx 18 24 36 48Sxx 36 48 75 05Sxx Operating input range Input Voltage variation (Complies with ETS300 132 part 4.4) Maximum Input current (NOTE 1) Input reflected-ripple current (NOTE 2) 12Sxx Vin All dV/dt See Note Iin, max All Iin — V/ms — A 400 mAp-p Note: 1. Maximum Input Current Iin = (Vo * Io)/(η*Vin, min) Maximum Input Current xxS33 xxS05 xxS09 xxS12 xxS15 4.5~9 0.58 0.69 0.64 0.65 0.63 9~18 0.27 0.30 0.29 0.29 0.29 18~36 0.13 0.15 0.14 0.14 0.14 36~75 0.07 0.08 0.07 0.07 0.07 2. There is an external capacitor connected on the input side. 3/21 Unit A Vdc 5 — input voltage range Unit Power Mate Technology Data Sheet May 2003 Table 2: Output Specifications Parameter Device Symbol Min Typ Max Unit xxS33 xxS05 xxS09 xxS12 xxS15 Vout 3.234 4.9 8.82 11.76 14.7 3.3 5 9 12 15 3.366 5.10 9.18 12.24 15.30 Output Volt Accuracy Vdc All — 0.5% 0.5%Vout Output Regulation Line, HH-LL Load, FL- 1/4 FL Output Ripple & Noise Volt Peak-to-peak 20MHz BW (Measured with a 104pF/50V MLCC) xxS33 xxS05 xxS09 xxS12 xxS15 Output Current ( At Io < Io, min, the modules may exceed output ripple specification) xxS33 xxS05 xxS09 xxS12 xxS15 -0.5% — -0.75% — — — — — 125 100 55 42 33 Io 0.75% 0.75%Vout 50 mVp-p 500 400 222 167 134 mA Table 3: General Specification Parameter Min Typ Efficiency Frequency Max Unit See Table II 100 650 kHz (Full load to minimum load) Isolation I/O 1000 Vdc Weight 4.8g (0.95 oz) Humidity 10%~95% RH Non-condensing Vibration 10~55Hz, 2G, 3minitues period, 30minitues along X,Y and Z Table II Efficiency Parameter Efficiency ( nominal input voltage and full load) Device Typical(%) Device Typical(%) 05S33 05S05 05S09 05S12 05S15 12S33 12S05 12S09 12S12 12S15 65 66 71 71 73 70 75 79 80 80 24S33 24S05 24S09 24S12 24S15 48S33 48S05 48S09 48S12 24S15 71 76 80 80 81 70 73 78 79 79 4/21 Power Mate Technology Data Sheet May 2003 Feature Description Output over current protection When excessive output currents occur in the system, circuit protection is required on all power supplies. Normally, overload current is maintained at approximately 115~175% percent of rated current for PDL02. We used the fold back current limiting method in PDL02 over current protection. Fold back current protection reduces the load current when the over current fault occurs. The figure below shows the typical curve. Because of the current fold back, the worst power dissipation is at point s. The drawback is that it provides less current at start up, hence the output rises slower, or the power supply may not start up at all if the load current during start up is larger than the fold back current. Vout Rated Iout Vout,real < 0.98* Vout ● Fold back point S (Iout, max, Pi,max) Iocp ● Pi (Input Power) Remote On/Off Control Only one type of remote on/off control is available for PDL02. The module will turn on during the ctrl pin left open or high impedance between ctrl pin and Vi(-) pin. The module will turn off when the control pin applied current 3~6mA. To reach this purpose, we recommended the circuit applied is as below. DC-DC ON +Input 1KΩ 4mA current Source DC-DC OFF +Input ctrl 4mA current Source -Input 1KΩ ctrl -Input When the module is off, the normal input current is about 1mA max. Short Circuitry Protection Continuous and auto-recovery mode. During short circuit, converter still shut down. The average current during this condition will be very low and the device can be safety in this condition. 5/21 Power Mate Technology Data Sheet May 2003 Thermal Consideration The range of operating temperature for PDL02 is from -40℃ to 85℃ without de-rating. However, sufficient cooling should be provided to help ensure reliable operation of the unit. The followings are some typical de-rating curve for PDL02. PDL02-24S05 PDL02-05S33 120 120 Outpu t Po w er(% ) Output Power(%) 100 20LFM 80 200LFM 60 400LFM 40 590LFM 20 0 100 20LFM 80 200LFM 400LFM 60 590LFM 40 20 0 -40 -25 0 50 70 75 80 85 90 95 100 -40 -25 0 Ambient Temperature 50 70 75 80 85 90 95 100 Ambient Temperature PDL02-48S12 Output Power(%) 120 100 20LFM 80 200LFM 60 400LFM 40 590LFM 20 Ambient Temperature 100 95 90 85 80 75 70 0 50 -25 -40 0 Soldering, Clearing and Drying Considerations soldering Flow soldering : 260±10℃ less than 15 seconds Soldering iron : 370±10℃ less than 5 seconds Note: The pin of this module is coated with Tin. To assure the solder-ability, modules should be kept in their original shipping containers to provide adequate protection. Also, the storage environment shall be well controlled to protect the oxidation. 6/21 Power Mate Technology Data Sheet May 2003 Characteristic Curve Efficiency a. Efficiency with load change under different line condition at room temperature PDL02-05S33 EFF(%) 80.00 70.00 60.00 50.00 40.00 30.00 4.5Vin 5Vin 9Vin 125 150 200 250 300 350 400 450 500 Load(mA) EFF(%) PDL02-24S05 85.00 80.00 75.00 70.00 65.00 60.00 55.00 50.00 45.00 40.00 18Vin 24Vin 36Vin 100 120 160 200 240 280 320 360 400 Load(mA) PDL02-48S12 90.00 EFF(%) 80.00 36Vin 70.00 48Vin 60.00 75Vin 50.00 40.00 42 50.1 66.8 83.5 100.2 116.9 133.6 150.3 Load(mA) 7/21 167 Power Mate Technology Data Sheet May 2003 b. Efficiency with line change under different load condition at room temperature PDL02-05S33 Efficiency (%) 80.00 60.00 125mA 250mA 500mA 40.00 20.00 0.00 4.5V 5V 5.5V 6V 6.5V 7V 7.5V 8V 8.5V 9V 125mA 55.58 53.23 51.11 48.88 46.67 44.67 42.70 40.98 39.22 37.63 250mA 65.72 65.05 63.84 63.64 62.60 61.22 59.92 58.58 57.31 55.72 500mA 64.74 66.28 67.21 67.65 67.93 67.95 67.72 67.76 67.23 66.75 Input Voltage PDL02-24S05 Efficiency (%) 100.00 80.00 100mA 60.00 200mA 40.00 400mA 20.00 0.00 18V 20V 22V 24V 26V 28V 30V 32V 34V 36V 100mA 70.16 68.16 66.13 63.98 62.11 59.97 58.17 56.28 54.34 53.31 200mA 77.73 76.85 76.05 75.27 75.18 73.14 72.01 70.73 69.74 69.18 400mA 78.03 78.34 78.09 78.31 78.04 77.90 77.60 77.29 76.93 76.49 Input Voltage PDL02-48S12 Efficiency(%) 100.00 80.00 42mA 60.00 83.5mA 40.00 167mA 20.00 0.00 36V 40V 44V 48V 52V 57V 61V 65V 70V 75V 42mA 73.39 71.31 69.15 67.04 65.24 62.46 60.21 58.50 55.56 53.00 83.5mA 80.84 80.28 79.66 78.48 77.40 76.20 74.71 73.45 71.94 70.02 167mA 80.76 81.35 82.43 80.81 81.71 81.48 81.31 80.60 80.25 80.55 Input Voltage 8/21 Power Mate Technology Data Sheet May 2003 c. Efficiency with line change under different ambient temperature at full load PLD02-05S33 Efficiency (%) 68 LOW NOMINAL HIGH 66 64 62 -40℃ 25℃ 70℃ LOW NOMINAL 64.57 65.84 64.72 66.28 64.37 65.93 HIGH 65.24 66.5 66.89 Ambient Temperature PDL02-24S05 Efficiency (%) 80 LOW NOMINAL HIGH 75 70 65 -40℃ 25℃ 70℃ LOW NOMINAL 76.53 77.03 77.93 78.31 76.96 77.78 HIGH 70.06 76.44 76.02 Ambient Tempaerature PDL02-48S12 Efficiency (%) 84 82 80 LOW NOMINAL HIGH 78 76 74 LOW NOMINAL HIGH -40℃ 25℃ 70℃ 81.7 80.69 78.59 82 81.74 80.27 79.12 79.46 77.55 Ambient Temperature 9/21 Power Mate Technology Data Sheet May 2003 Power Dissipation Curve Pd(W) PDL02-05S33 4.5Vin 1.000 0.900 0.800 0.700 0.600 0.500 0.400 0.300 0.200 0.100 0.000 5Vin 9Vin 125 150 200 250 300 350 400 450 500 Iout(mA) Power Dissipation Vs Output Current for 3.3V Pd(W) PDL02-24S05 0.700 0.600 0.500 0.400 0.300 0.200 0.100 0.000 18Vin 24Vin 36Vin 100 120 160 200 240 280 320 360 400 Iout(mA) Power Dissipation Vs Output Current for 5V PDL02-48S12 Pd(W) 0.600 0.500 0.400 0.300 0.200 36Vin 0.100 0.000 75Vin 48Vin 42 50.1 66.8 83.5 100.2 116.9 133.6 150.3 167 Iout(mA) Power Dissipation Vs Output Current for 12V 10/21 Power Mate Technology Data Sheet May 2003 Output ripple & noise PDL02-05S33 Low Line, Full Load Output Ripple & Noise = 9.6mV Normal Line, Full Load Output Ripple & Noise = 10.0mV High Line, Full Load Output Ripple & Noise = 7.2mV PDL02-24S05 Low Line, Full Load Output Ripple & Noise = 32.4mV Normal Line, Full Load Output Ripple & Noise = 21.2mV High Line, Full Load Output Ripple & Noise = 16.4mV PDL02-48S12 Low Line, Full Load Output Ripple & Noise = 21.6mV Normal Line, Full Load Output Ripple & Noise = 20.4mV 11/21 High Line, Full Load Output Ripple & Noise = 18.4mV Power Mate Technology Data Sheet May 2003 Transient Peak and Response PDL02-05S33 Low Line, Full Load Normal Line, Full Load High Line, Full Load Transient Peak = 85mV Transient Peak =82mV Transient Peak =78mV ？ Transient Response = 420uS Transient Response = 400uS Transient Response = 420uS PDL02-24S05 Low Line, Full Load Normal Line, Full Load Transient Peak = 101mV Transient Peak = 87mV Transient Response = 212uS Transient Response = 248uS 12/21 High Line, Full Load Transient Peak = 79mV Transient Response = 216uS Power Mate Technology Data Sheet May 2003 PDL02-48S12 Low Line, Full Load Transient Peak = 116mV Transient Response = 328uS Normal Line, Full Load Transient Peak = 100 mV Transient Response = 328mS 13/21 High Line, Full Load Transient Peak = 91mV Transient Response = 336uS Power Mate Technology Data Sheet May 2003 Inrush current PDL02-05S33 Low Line, Full Load Inrush current = (27/10)* 2A = 5.4A Low Line, Full Load Duration: 26uS Normal Line, Full Load Inrush current = (27.8/10)* 2A = 5.56A Normal Line, Full Load Duration: 26.6uS Normal Line, Full Load Inrush current = (25.8/10)* 2A = 5.16A High Line, Full Load Duration: 29.2 uS PDL02-24S05 Low Line, Full Load Inrush current = (24.6/10)* 2A = 4.92A Low Line, Full Load Duration: 280 uS Normal Line, Full Load Inrush current = (18.8/10)* 2A =3.76A Normal Line, Full Load Duration: 260uS 14/21 High Line, Full Load Inrush current = (12.4/10)* 2A = 2.48A High Line, Full Load Duration: 340 uS Power Mate Technology Data Sheet May 2003 PDL02-48S12 Low Line, Full Load Inrush current = (27/10)* 2A = 5.4A Low Line, Full Load Duration: 580uS Normal Line, Full Load Inrush current = (22.8/10)* 2A = 4.56A Normal Line, Full Load Duration: 540uS 15/21 High Line, Full Load Inrush current = (15.8/10)* 2A = 3.16A High Line, Full Load Duration: 460 uS Power Mate Technology Data Sheet May 2003 Input ripple current PDL02-05S33 Low Line, Full Load Input ripple current = (23.0/10)* 200mA = 460mA Normal Line, Full Load Input ripple current = (18.2/10)* 200mA = 364mA High Line, Full Load Input ripple current = (7.8/10)* 200mA = 156mA PDL02-24S05 Low Line, Full Load Input ripple current = (57/10)* 50mA = 285mA Normal Line, Full Load Input ripple current = (32.6/10)* 50mA = 163mA High Line, Full Load Input ripple current = (20.2/10)* 50mA = 101mA PDL02-48S12 Low Line, Full Load Input ripple current = (29.6/10)* 50mA = 148mA Normal Line, Full Load Input ripple current = (19.6/10)* 50mA = 98mA 16/21 High Line, Full Load Inrush current = (12.4/10)* 50mA = 62mA Power Mate Technology Data Sheet May 2003 Delay time and Raise time PDL02-05S33 Normal Line, Full Load Raise time = 200 uS Normal Line, Full Load Delay time = 312uS PDL02-24S05 Normal Line, Full Load Raise time = 264 uS Normal Line, Full Load Delay time = 320 uS PDL02-48S12 Normal Line, Full Load Raise time = 424 uS Normal Line, Full Load Delay time = 528 uS 17/21 Power Mate Technology Data Sheet May 2003 Testing Configurations Input reflected-ripple current Measurement Test up To Oscilloscope ● Current Probe ● ● ● 12uH Vi(+) DC/DC Converter Battery ● . ● Vi(-) 1. Use CHEMICON LXZ series for 05 and 12 Vin 2. Use CHEMICON KMF series for 24 and 48 Vin Peak-to-peak output ripple & noise Measurement Test up 0.1uF 50V Multilayer capacitor Resistive Load Output Voltage and Efficiency Measurement Test up Note: All measurements are taken at the module terminals. Vo × Io,max η= × 100% Vi, nominal × Ii 18/21 Power Mate Technology Data Sheet May 2003 Mechanical Data Dimensions are in inches and (millimeters) PIN PITCH TOLERANCE ±0.02(0.5) General Tolerances: x.xx in. ± 0.02 in. (x.xx mm ± 0.5mm) x.xxx in. ± 0.015 in. (x.xxx mm ± 0.4mm) Bottom View 0.36 (9.20) 0.13 (3.20) BOTTOM VIEW 0.08 (2.01)±0.5 .0.01 (0.32) Rectangular pin Front View PIN CONNECTION 0.86(21.80) FRONT VIEW 0.44 (11.10) 0.02 (0.50) 0.16 (4.10)±0.5 1 2 3 5 6 7 8 0.02 (0.50)±0.05 0.10(2.54) 0.70(17.78) Part number structure PDL 02-05 S 33 Total Output power 2 Watt Input Voltage Range 05: 4.5~9V 12: 9~18V 24: 18~36V 48: 36~75V Single Output 19/21 Output Voltage 33: 3.3V 05: 5V 09: 9V 12: 12V 15: 15V PIN DEFINE 1 2 3 5 6 7 8 - INPUT + INPUT CTRL NC + OUTPUT - OUTPUT NC Power Mate Technology Data Sheet May 2003 Safety and Installation Instruction Isolation consideration The PDL02 series features 1k Voltage DC isolated from input to output. The input to 9 output resistance is greater than 10 megohms. Nevertheless, if the system using the power module needs to receive safety agency approval, certain rules must be followed in the design of the system using the model. In particular, all of the creepage and clearance requirements of the end-use safety requirement must be observed. These documents include UL-1950, EN60950 and CSA 22.2-960, although specific applications may have other or additional requirements. EMC characteristics The PDL02 series cannot meet the EN55022 class A if there is no filter at input. The following external circuit will be recommended to satisfy the EN55022 class A & B. L +Vin C Input + Vout DC-DC Output Converter -Vin - Vout Where the type of L and C are listed as follows. Input Voltage L C 5V, 12V 10uH 100uF 24V, 48V 120uH 10uF 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 a 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 with maximum rating of 2 A. 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. Minimum Load 25% (of full load) minimum load required. The 25% minimum load requirement is in order to meet all performance specifications. Operating under no load condition will not damage these devices, however they may not meet 20/21 Power Mate Technology Data Sheet May 2003 all listed specification. MTBF and Reliability The MTBF of PDL02 series of DC/DC converters has been calculated using 1. MIL-HDBK-217F under the following conditions: Nominal Input Voltage Io = Io, max Ta = 25℃ 6 The resulting figure for MTBF is 2.911× 10 hours. 2. Bell-core TR-NWT-000332 Case I: 50% stress, Operating Temperature at 40 ℃ (Ground fixed and controlled environment) 6 The resulting figure for MTBF is 5.107× 10 hours. 21/21