TECHNICAL DATASHEET Rev. E RA4805UW5 5W DC-DC Converter 18-75 Vdc Input 5 Vdc Output at 1.0 A DIP Package High Reliability COTS Converter Features: • Over 80% Efficient at Full Load • Wide Input Range • Fast Transient Response • Low Output Ripple • Fixed Switching Frequency • Output Over Current Protection • Output Short Circuit Protection • 1000 Vdc Isolation (888) 597-WALL • • • • • • • ISO9001 Compliant IPC-A-610 Compliant J-STD-001 Compliant Conformal Coat IAW IPC-CC-830, Type UR GEIA-STD-0005-2, Level 2B Tin Whisker Compliant 100% Burn In Manufactured in the United States www.wallindustries.com 1 of 10 WALL INDUSTRIES, INC. Technical Specifications Rev. E TECHNICAL DATASHEET RA4805UW5 Model No. RA4805UW5 Unless otherwise noted, all specifications are based over the entire rated ambient temperature as described in Graph 2. Min 273 Nom 307 Max 338 Unit kHz Low Line No Load With a 1 µF ceramic 100 mS Nominal Line 18 16.5 15.4 1.1 78 36 17.4 16.1 1.3 341 6.5 5 80 75 18.3 16.7 1.6 360 13 15 100 - Vdc Vdc Vdc Vdc mA mA mA Vdc % Voltage Set Point at 25 °C – see Temperature Drift for Set Point at other Temperatures 4.925 -1.5 5.000 5.075 +1.5 Vdc % Load Regulation (Graph 6) = Vo(Min. Load) - Vo(Full Load) Vin = Nominal Line Vo(Min. Load) - 0.1 0.5 % Line Regulation (Graph 7) = Vo( Low Line) - Vo(High Line) Io = 100% Load Vo(Low Line) - 0.05 0.2 % Temperature Drift (Graph 8) = Vo(25°C) - Vo(-40°C or + 85°C) Io = 50% Load Vo(25°C) - 0.006 0.02 % / °C Ripple (Photo 5) Spikes (Photo 5) Current Current Limit Over Voltage Limit With 1 µF ceramic & 20 MHz BW With 1 µF ceramic & 20 MHz BW 0 1.3 6.8 30 30 1.9 7.4 100 100 1.0 2.5 8.0 mVpk-pk mVpk-pk A A Vdc 0 64 200 13 0 - 100 300 20 0 - mV µs ms % mS 1000 1000 20 - 2350 3000 Vdc Vdc GΩ pF SPECIFICATION Switching Frequency INPUT (Vin) Operating Voltage Range UVLO Turn On at UVLO Turn Off at UVLO Hysterisis Maximum Input Current (Graph 3) No Load Input Current (Graph 5) Reflected Ripple Current (Photo 1) Input Surge Voltage EFFICIENCY (Graph 1) OUTPUT (Vo) DYNAMIC RESPONSE Load step ∆ V (Photo 6) Recovery Time (Photo 6) Turn On Delay (Photos 2 & 3) Turn On Overshoot (Photos 2 & 3) Hold Up Time (Photo 4) ISOLATION Input-Output Input/Output-Chassis Isolation Resistance Isolation Capacitance THERMAL Ambient Operating Temperature (Graph 2) Storage Temperature MTBF MECHANICAL Weight (888) 597-WALL Related condition Power Limited 25% to 75% Io, di/dt=0.15A/µS, Cout=1µF Recovery to within 1% Vout (nom), Cout=1µF From Vin (min) to Vout (90%), no external capacitance Full Load Resistive From Vin (min) to VULVO_Turn_Off 1 minute 1 minute Max. Ambient limited by Derating Curves (Graph 2) -40 -55 MIL-HDBK-217F Notice 2; Tamb=75°C 17 www.wallindustries.com Graph 2 25 125 369,0000 See Figure 1 19 21 °C °C hours g Page 2 of 10 WALL INDUSTRIES, INC. TECHNICAL DATASHEET Rev. E RA4805UW5 Figure 1: Mechanical Dimensions LABEL NAVSEA NUMBER .025 [0.64] STANDOFF 4X OPTIONAL SEE ODERING INFORMATION DC/DC CONVERTER DENOTES PIN-1 ESD 8226613 XXXX EXETER, NH 03833 USA XXXX DATE CODE SERIAL NUMBER .40 [10.2] .15 [3.8] MIN .700 [17.78] .900 [22.86] .100 [2.54] .175 [4.45] .000 [0.00] .60 [15.2] .00 [0.0] .10 [2.5] BAR CODE, CONTAINS: SERIAL NO, DATE CODE & BOM REVISION LEVEL 2 3 9 11 23 22 16 14 PIN Ø.02 [0.5] .80 [20.3] 1.25 [31.8] NOTES: Pin to Pin Tolerance: ± 0.01 (±0.3) Pin Diameter Tolerance: ±0.005 (±0.13) Unless otherwise specified all dimensions are in inches [XX] are in millimeters. Applied Tolerances: Angles ±1°, .XX = ±0.02 [0.5] .XXX = ± 0.010 [0.25] Do not scale drawing. Interpret dimension and tolerance per ASME Y14.5M – 1994 Third Angle Projection Pin Material: Brass alloy “360, 1/2 Hard" per ASTM B16-85, chemical composition; 61.5%Cu, 35.4%Zn, 3.1%Pb. Pin Finish: 10u Gold over Nickel. Meets the solder ability requirements of MIL-STD-202, Method 208. PCB Cleaning: Devices shall be capable of exposure to the following PCB assembly cleaning processes: Aquanox XJN+ an aqueous cleaner chemistry made by Kyzen Corp. This solution operates at a concentration of 25% XJN and 75% deionized water sprayed onto the device at 25-40 PSI. This cleaning process includes the following steps: a. Pre-wash and wash at 150°F. Dwell time 3-4 minutes. b. Isolation water rinse at 140°F c. Deionized water rinse at 140°F d. Final deionized water rinse e. Blower dry f. 1 hour CCA bake at 125 Deg F prior to CCA conformal coat. 10. Unit is not hermetically sealed 11. Pin Table: Pin # Description Pin Ø 2 -Vin 0.020 (0.51) 3 -Vin 0.020 (0.51) 9 NC 0.020 (0.51) 11 NC 0.020 (0.51) 14 +Vout 0.020 (0.51) 16 -Vout 0.020 (0.51) 22 +Vin 0.020 (0.51) 23 +Vin 0.020 (0.51) 1. 2. 3. 4. 5. 6. 7. 8. 9. (888) 597-WALL www.wallindustries.com Page 3 of 10 WALL INDUSTRIES, INC. Rev. E TECHNICAL DATASHEET RA4805UW5 DESIGN CONSIDERATIONS Under Voltage Lock Out (UVLO) The converter output is disabled until the input voltage exceeds the UVLO turn-on limit. The converter will remain ON until the input voltage falls below the UVLO turn-off limit. Over Current Protection The converter is protected from short circuit and over current conditions. Upon sensing an over current, the output will begin to drop (or ‘foldback’) limiting the output power. Further increasing the output current will cause the converter to shut off and then restart (or ‘hiccup’) until the over current condition is removed. Shorting the output will cause the converter to immediately enter the ‘hiccup’mode. Over Temperature Protection The converter is NOT protected from over temperature conditions. Exceeding the rated case temperature of 100°C may cause permanent damage to the unit. Input Filter No additional input capacitor is needed for the power supply to operate. However, to reduce input ripple and high frequency noise, it is highly recommended that a minimum 1 µF/100 V ceramic capacitor be added across the input pins. Output Filter No additional output capacitor is needed for the power supply to operate. However, to reduce high frequency noise, a 1µF/10V ceramic capacitor is recommended. Fusing For applications that are required to meet UL and/or CSA safety regulations, the input to the converter shall be current limited or supplied through a 2 A fuse. This unit is designed to meet these regulations, but is not certified. Final Electrical Test See Appendix I for description of Final Electrical Test. All units tested 100% at 25°C. Qualification Testing 40 samples, No Failures Allowed, 40/0 (Devices shall be exposed to PCB cleaning process prior to testing) Subgroup 1 - 1000 hour life test per MIL-STD-883, Method 1015: 1. 10 samples, No Failures Allowed, 10/0 2. Final Electrical Test performed at maximum ambient and full load per Graph 2 with no external air 3. Final Electrical Test performed at 168, 250, 500 and 1000 hours Subgroup 2 - Accelerated Non-Operating Humidity and Thermal/Mechanical Fatigue: 1. 10 samples, No Failures Allowed, 10/0 2. 500 hrs at 85°C at 85% Relative Humidity, Unbiased 3. 200 temperature cycles (T/C), -46°C to +85°C @ 5°C/minute minimum, 45 minute dwell 4. Final Electrical Test at 25°C 5. 500 hrs at 85°C at 85% Relative Humidity, Unbiased 6. 200 temperature cycles (T/C), -46°C to +85°C @ 5°C/minute minimum, 45 minute dwell 7. Final Electrical Test at 25°C Subgroup 3 - Snap Start from Low Operating Temp: 1. 10 samples, No Failures Allowed, 10/0 2. Cold soak at -40°C until device reaches thermal equilibrium 3. Power up under full load with worse case input transient waveform applied (as specified on datasheet) 4. Total cycles: 500 (definition of 1 cycle: -40°C soak, power up, re-soak -40°C) 5. Final Electrical Test at 25°C Subgroup 4 - Non-Operating Vibration and Shock: 1. 10 samples, No Failures Allowed, 10/0 2. Non-operating Mechanical Shock: Method 2002, MIL-STD-883, Condition B, 1500g, 0.5 ms pulse 3. Non-operating Random Vibration: Method 2026, MIL-STD-883, Condition K, 44.8 grms 4. Final Electrical Test at 25°C (888) 597-WALL www.wallindustries.com Page 4 of 10 WALL INDUSTRIES, INC. TECHNICAL DATASHEET Rev. E RA4805UW5 Graph 1: Efficiency vs. Output Current 85% 80% 75% 70% Effiency (%) 65% 60% Vin=18V Vin=36V Vin=48V Vin=60V Vin=75V 55% 50% 45% 40% 35% 30% 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 Io (A) Graph 2: Max. Ambient vs. Output Current 1.1 1.0 0.9 0.8 Io (A) 0.7 0.6 100 LFM External Air No Air (Vin=18-50 Vdc No Air (Vin=51-75 Vdc) 0.5 0.4 0.3 0.2 0.1 0.0 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 Ambient (°C) (888) 597-WALL www.wallindustries.com Page 5 of 10 WALL INDUSTRIES, INC. Rev. E Graph 3: Input Current vs. Input Voltage TECHNICAL DATASHEET RA4805UW5 Graph 4: Power Dissipation vs. Input Voltage 1.6 0.35 Io=0.1A Io=0.2A Io=0.4A Io=0.6A Io=0.8A Io=1.0A 0.30 1.2 Pdissipation (W) 0.25 1.4 Iin (A) 0.20 0.15 1.0 0.8 0.6 0.10 0.4 0.05 Io=0.1A Io=0.2A Io=0.4A Io=0.6A Io=0.8A Io=1.0A 0.2 0.00 0.0 18 33 47 Vin(V) 62 7 18 33 47 62 Vin(V) 12 1.2 10 1.0 8 0.8 6 0.6 Input Current Power Dissipation 4 0.4 2 0.2 0 Pdissipation (W) Iin (mA) Graph 5: No Load Input Current and Power Dissipation vs. Input Voltage 0.0 18 33 47 62 76 Vin(V) (888) 597-WALL www.wallindustries.com Page 6 of 10 76 WALL INDUSTRIES, INC. Rev. E Graph 6: Load Regulation RA4805UW5 Graph 7: Line Regulation 0.15% 0.15% Vin=18V Vin=36V Vin=48V Vin=60V Vin=75V 0.10% 0.10% 0.05% 0.05% Regulation (%) Regulation (%) TECHNICAL DATASHEET 0.00% 0.00% -0.05% -0.05% -0.10% -0.10% -0.15% Io=0.0A Io=0.2A Io=0.4A Io=0.6A Io=0.8A Io=1.0A -0.15% 0.0 0.2 0.4 0.6 0.8 1.0 18 33 47 62 Vin (V) Io (A) Graph 8: Output Temperature Drift 1.0% 0.8% 0.5% Vout (%) 0.3% 0.0% -0.3% -0.5% -0.8% -1.0% -40 -20 0 20 40 60 80 100 Case Temperature (°C) (888) 597-WALL www.wallindustries.com Page 7 of 10 76 WALL INDUSTRIES, INC. Rev. E TECHNICAL DATASHEET RA4805UW5 Photo 1: Input Ripple Voltage and Current Vin=36 V, Iout = 1.0 A With a 1 µF Ceramic across the Input Photo 2: Turn On at 1 A Load, Vin = 36 Vdc Cout = 2200 µF Aluminum Electrolytic Photo 3: Normal Turn On at No Load, Vin = 36 Vdc Photo 4: Turn Off at 36 V Photo 5: Output Ripple and Noise (20 MHz BW) Vin=36 V, Iout = 1.0 A With a 1 µF Ceramic across the Output Photo 6: Transient Response – 0.15A/µs Vin = 36 Vdc, Iout = 0.25 to 0.75 A (25% to 75%) With a 1 µF Ceramic across the Output (888) 597-WALL www.wallindustries.com Page 8 of 10 WALL INDUSTRIES, INC. Rev. E TECHNICAL DATASHEET RA4805UW5 PART ORDERING: RA4805UW5 RA4805UW5/ES (with Electrical Screening) RA4805UW5/SO (with Standoffs) RA4805UW5/ES/SO (with Electrical Screening and Standoffs) Electrical Screening Option: 1. 2. 3. 4. 5. Internal Visual: IPC-A-610 Temperature cycling: MIL-STD-883, Method 1010, Condition B, -55 to +125°C, 10 cycles Burn-In: MIL-STD-883, Method 1015, 96 hours, Iout=1.0 A, Ambient as specified in Graph 2 for specified input voltage range and no external air Final Electrical: 100% at 25°C. See appedix I External Inspection: MIL-STD-883, Method 2009 Company Information: Wall Industries, Inc. has created custom and modified units for over 40 years. Our in-house research and development engineers will provide a solution that exceeds your performance requirements on-time and on budget. Our ISO9001-2000 certification is just one example of our commitment to producing a high quality, well documented product for our customers. Our past projects demonstrate our commitment to you, our customer. Wall Industries, Inc. has a reputation for working closely with its customers to ensure each solution meets or exceeds form, fit and function requirements. We will continue to provide ongoing support for your project above and beyond the design and production phases. Give us a call today to discuss your future projects. Contact Wall Industries for further information: Phone: Toll Free: Fax: E-mail: Web: Address: (888) 597-WALL (603)778-2300 (888)587-9255 (603)778-9797 [email protected] www.wallindustries.com 5 Watson Brook Rd. Exeter, NH 03833 www.wallindustries.com Page 9 of 10 WALL INDUSTRIES, INC. Rev. E TECHNICAL DATASHEET RA4805UW5 Appendix I RA4805UW5 ATE FINAL ELECTRICAL TEST DESCRIPTION Rev. – A 2/14/08 Sequence #1 - Set State • Set Vin = 48 Vdc • Set Iout = 1.0 A Sequence #2 - Output voltage accuracy • Under the previously set conditions, measure the output voltage. • V min = 4.925 Vdc • V max = 5.075 Vdc Sequence #3 - Efficiency • Under the previously set conditions, measure the efficiency. • Min E = 78% • Max E = 99% Sequence #4 - Set State • Set Vin = 20 Vdc • Set Iout = 125 mA Sequence #5 - Input Current • Under the previously set conditions, measure the Input Current • Max Iin = 60 mA Sequence #6 – Line Regulation • Set number of points to take measurements = 5 • Set low line voltage for Vin = 18 Vdc • Set high line voltage for Vin = 75 Vdc • Set I out = 1.0 A • Min acceptable value = 0% delta • Max acceptable value = 0.2% delta Sequence #7 – Load Regulation • Set number of points to take measurements = 6 • Set Vin = 48 Vdc • Set high current = 1.0 A • Set low current = 0 A • Min acceptable value = 0% • Max acceptable value = 0.5% \Sequence #6 – Current Limit Threshold • Set Vin = 48 Vdc • Set threshold = 98% Vout • Increase Iout in increments of 0.1 A • I out start at 1.0 A • Min acceptable value = 1.3 A • Max acceptable value = 2.5 A Sequence #7 – Ripple Amplitude • Set Vin = 48 Vdc • Set Iout = 1.0 A • Min acceptable measurement = 0 • Max acceptable measurement = 100 mVp-p (888) 597-WALL www.wallindustries.com Page 10 of 10