TEN 40-WI Series Application Note DC/DC Converter 9 to 36Vdc or 18 to 75Vdc Input 3.3 to 15Vdc Single Outputs and ±12 to ±15Vdc Dual Output, 40W Features • Single output current up to 10A • Dual output current up to ±1.667A • 40 watts maximum output power • 4:1 ultra wide input voltage range of 9-36 and 18-75VDC • Six-sided continuous shield • Case grounding • High efficiency up to 88% • Low profile: 50.8°50.8°10.2 mm (2.00°2.00°0.40 inch) • Fixed switching frequency • RoHS directive compliant • Input to output isolation: 1500Vdc,min • Over-temperature protection • Input under-voltage protection • Output over-voltage protection • Over-current protection, auto-recovery • Output short circuit protection, auto-recovery E188913 • Remote ON/OFF • Output Voltage adjustment Complete TEN 40-WI datasheet can be downloaded at: http://www.tracopower.com/products/ten40wi.pdf Options • Heat sinks available for extended operation Applications • Distributed power architectures • Workstations • Computer equipment • Communications equipment General Description The TEN 40WI series offer 40 watts of output power from a 50.8°50.8°10.2 mm (2.00 x 2.00 x 0.4 inch) package. This product has a 4:1 ultra wide input voltage of 9 – 36Vdc and 18 – 75Vdc with an I/O isolation test voltage of 1500Vdc, indefinite short-circuit protection and over- temperature protection, as well as six sided shielding. All models are particularly suited to telecommunications, industrial, mobile telecom and test equipment applications. Table of Contents Absolute Maximum Rating Output Specification Input Specification General Specification Characteristic Curves Test Configurations EMC Considerations Input Source Impedance Output Over Current Protection Output Over Voltage Protection Thermal Consideration Created by Traco Electronic AG Arp. P2 P2 & P3 P3 P4 P5 - P28 P29 P30 & P31 P32 P32 P32 P32 Heat Sink Consideration Remote ON/OFF Control Mechanical Data Recommended Pad Layout Output Voltage Adjustment Remote Sense Application Circuit Soldering and Reflow Consideration Packaging Information Part Number Structure Safety and Installation Instruction MTBF and Reliability www.tracopower.com th P33 P33 P34 P34 P35 P36 P36 P37 P37 P38 P38 Date: December 16 , 2008 / Rev.: 1.2 / Page 1 / 38 Application Note 40W, Single and Dual Output Absolute Maximum Rating Parameter Input Voltage Continuous Input Voltage Transient (100ms) Input Voltage Variation (complies with EST300 132 part 4.4) Operating Ambient Temperature (with derating) Operating Case Temperature Storage Temperature Input to Output Isolation ( Functional Insulation ) Model TEN 40-24xxWI TEN 40-48xxWI TEN 40-24xxWI TEN 40-48xxWI Min All All All All All -40 -55 1500 Max 36 75 50 100 Unit 5 V/ms 105 105 125 °C °C °C Vdc Vdc Vdc Output Specification Parameter Output Voltage (Vin = Vin nom; Full Load; TA = 25°C) Voltage Adjustability Output Regulation Line (Vin min to Vin max at Full Load) Load (Min. to 100% of Full Load) Load (Min. to 100% of Full Load) Cross Regulation Asymmetrical Load 25% / 100% of Full Load Output Ripple & Noise Peak-to-Peak (20MHz bandwidth) Temperature Coefficient Output Voltage Overshoot (Vin min to Vin max; Full Load; TA = 25°C) Dynamic Load Response (Vin nom; TA = 25°C) Load step change from 75% to 100% or 100 to 75% of Full Load Peak Deviation Setting Time (VOUT＜10% peak deviation) Output Current Model TEN 40-xx10WI TEN 40-xx11WI TEN 40-xx12WI TEN 40-xx13WI TEN 40-xx22WI TEN 40-xx23WI All Min 3.267 4.95 11.88 14.85 ±11.88 ±14.85 -10 All Single Output Dual Output -0.2 -0.5 -1.0 +0.2 +0.5 +1.0 Dual output -5.0 +5.0 -0.02 50 50 75 75 120 150 +0.02 TEN 40-xx10WI TEN 40-xx11WI TEN 40-xx12WI TEN 40-xx13WI TEN 40-xx22WI TEN 40-xx23WI All All 0 All All 250 250 TEN 40-xx10WI TEN 40-xx11WI TEN 40-xx12WI TEN 40-xx13WI TEN 40-xx22WI TEN 40-xx23WI Output Over Voltage Protection (Single output models only) TEN 40-xx10WI (Zener diode clamp) TEN 40-xx11WI TEN 40-xx12WI TEN 40-xx13WI Created by Traco Electronic AG Arp. Typ 3.3 5 12 15 ±12 ±15 www.tracopower.com Max 3.333 5.05 12.12 15.15 ±12.12 ±15.15 +10 3 3.9 6.2 15 18 th Vdc % % % mV pk-pk %/°C % Vout mV µS 10000 8000 3333 2666 ±1667 ±1333 0 0 50 50 ±65 ±50 Unit mA Vdc Date: December 16 , 2008 / Rev.: 1.2 / Page 2 / 38 Application Note 40W, Single and Dual Output Output Specification (continue) Parameter Output Over Current Protection Output Short Circuit Protection Model All All Min Typ Max Unit 150 % FL. Hiccup, automatics recovery Input Specification Parameter Operating Input Voltage Input Current (Maximum value at Vin = Vin nom; Full Load) Input Standby Current (Typical value at Vin = Vin nom; No Load) Under Voltage Lockout Turn-on Threshold Under Voltage Lockout Turn-off Threshold Input Reflected Ripple Current (5 to 20MHz, 12µH Source Impedance) Start Up Time (Vin nom and Constant Resistive Load) Power Up Remote ON/OFF Remote ON/OFF Control (The ON/OFF pin voltage is referenced to -VIN) Positive Logic DC-DC ON (Open) DC-DC OFF (Short) Remote Off Input Current Input Current of Remote Control Pin Created by Traco Electronic AG Arp. Model TEN 40-24xxWI TEN 40-48xxWI TEN 40-2410WI TEN 40-2411WI TEN 40-2412WI TEN 40-2413WI TEN 40-2422WI TEN 40-2423WI TEN 40-4810WI TEN 40-4811WI TEN 40-4812WI TEN 40-4813WI TEN 40-4822WI TEN 40-4823WI TEN 40-2410WI TEN 40-2411WI TEN 40-2412WI TEN 40-2413WI TEN 40-2422WI TEN 40-2423WI TEN 40-4810WI TEN 40-4811WI TEN 40-4812WI TEN 40-4813WI TEN 40-4822WI TEN 40-4823WI TEN 40-24xxWI TEN 40-48xxWI TEN 40-24xxWI TEN 40-48xxWI Min 9 18 Typ 24 48 Max 36 75 1677 2008 2008 2008 2032 2032 838 992 1004 1004 1016 1016 80 100 50 50 60 60 50 60 30 30 30 30 Vdc mA mA 9 18 All Unit Vdc 8 16 Vdc 20 mA pk-pk 20 20 All mS Vdc All TEN 40-24xxWI TEN 40-48xxWI All www.tracopower.com 12 1.2 3 0 10 5 -0.5 mA 0.5 th mA Date: December 16 , 2008 / Rev.: 1.2 / Page 3 / 38 Application Note 40W, Single and Dual Output General Specification Parameter Efficiency (Vin = Vin nom ; Full Load; TA = 25°C) Isolation Voltage (Functional Insulation) Input to Output Input to Case, Output to Case Isolation Resistance Isolation Capacitance Switching Frequency Weight MTBF Bellcore TR-NWT-000332, TC = 40°C MIL-STD-217F Over Temperature Protection Created by Traco Electronic AG Arp. Model TEN 40-2410WI TEN 40-2411WI TEN 40-2412WI TEN 40-2413WI TEN 40-2422WI TEN 40-2423WI TEN 40-4810WI TEN 40-4811WI TEN 40-4812WI TEN 40-4813WI TEN 40-4822WI TEN 40-4823WI Min All 1500 1500 10 All All All All All All www.tracopower.com Typ 86 87 87 87 86 86 86 88 87 87 86 86 Max Unit % Vdc 2500 300 60 1’105’000 151’100 110 th GΩ pF KHz g hours °C Date: December 16 , 2008 / Rev.: 1.2 / Page 4 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-2410WI Efficiency Versus Output Current Typical Output Ripple and Noise. Vin = Vin nom, Full Load Efficiency Versus Input Voltage. Full Load Derating Output Current Versus Ambient Temperature and Airflow Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com Transient Response to Dynamic Load Change from 100% to 75% to 100% of Full Load ; Vin = Vin nom Typical Input Start-Up and Output Rise Characteristic Vin = Vin nom, Full Load th Date: December 16 , 2008 / Rev.: 1.2 / Page 5 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-2410WI (Continued) Conduction Emission of EN55022 Class A Vin = Vin nom, Full Load Using ON/OFF Voltage Start-Up and Vout Rise Characteristic Vin = Vin nom, Full Load Conduction Emission of EN55022 Class B Vin = Vin nom, Full Load Power Dissipation Versus Output Current Derating Output Current Versus Ambient Temperature with Heat-Sink and Airflow, Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 6 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-2411WI Efficiency Versus Output Current Typical Output Ripple and Noise. Vin = Vin nom, Full Load Efficiency Versus Input Voltage. Full Load Derating Output Current Versus Ambient Temperature and Airflow Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com Transient Response to Dynamic Load Change from 100% to 75% to 100% of Full Load ; Vin = Vin nom Typical Input Start-Up and Output Rise Characteristic Vin = Vin nom, Full Load th Date: December 16 , 2008 / Rev.: 1.2 / Page 7 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-2411WI (Continued) Conduction Emission of EN55022 Class A Vin = Vin nom, Full Load Using ON/OFF Voltage Start-Up and Vout Rise Characteristic Vin = Vin nom, Full Load Conduction Emission of EN55022 Class B Vin = Vin nom, Full Load Power Dissipation Versus Output Current Derating Output Current Versus Ambient Temperature with Heat-Sink and Airflow, Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 8 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-2412WI Efficiency Versus Output Current Typical Output Ripple and Noise. Vin = Vin nom, Full Load Efficiency Versus Input Voltage. Full Load Derating Output Current Versus Ambient Temperature and Airflow Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com Transient Response to Dynamic Load Change from 100% to 75% to 100% of Full Load ; Vin = Vin nom Typical Input Start-Up and Output Rise Characteristic Vin = Vin nom, Full Load th Date: December 16 , 2008 / Rev.: 1.2 / Page 9 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-2412WI (Continued) Conduction Emission of EN55022 Class A Vin = Vin nom, Full Load Using ON/OFF Voltage Start-Up and Vout Rise Characteristic Vin = Vin nom, Full Load Conduction Emission of EN55022 Class B Vin = Vin nom, Full Load Power Dissipation Versus Output Current Derating Output Current Versus Ambient Temperature with Heat-Sink and Airflow, Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 10 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-2413WI Efficiency Versus Output Current Typical Output Ripple and Noise. Vin = Vin nom, Full Load Efficiency Versus Input Voltage. Full Load Derating Output Current Versus Ambient Temperature and Airflow Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com Transient Response to Dynamic Load Change from 100% to 75% to 100% of Full Load ; Vin = Vin nom Typical Input Start-Up and Output Rise Characteristic Vin = Vin nom, Full Load th Date: December 16 , 2008 / Rev.: 1.2 / Page 11 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-2413WI (Continued) Conduction Emission of EN55022 Class A Vin = Vin nom, Full Load Using ON/OFF Voltage Start-Up and Vout Rise Characteristic Vin = Vin nom, Full Load Conduction Emission of EN55022 Class B Vin = Vin nom, Full Load Power Dissipation Versus Output Current Derating Output Current Versus Ambient Temperature with Heat-Sink and Airflow, Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 12 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-2422WI Efficiency Versus Output Current Typical Output Ripple and Noise. Vin = Vin nom, Full Load Efficiency Versus Input Voltage. Full Load Derating Output Current Versus Ambient Temperature and Airflow Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com Transient Response to Dynamic Load Change from 100% to 75% to 100% of Full Load ; Vin = Vin nom Typical Input Start-Up and Output Rise Characteristic Vin = Vin nom, Full Load th Date: December 16 , 2008 / Rev.: 1.2 / Page 13 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-2422WI (Continued) Conduction Emission of EN55022 Class A Vin = Vin nom, Full Load Using ON/OFF Voltage Start-Up and Vout Rise Characteristic Vin = Vin nom, Full Load Conduction Emission of EN55022 Class B Vin = Vin nom, Full Load Power Dissipation Versus Output Current Derating Output Current Versus Ambient Temperature with Heat-Sink and Airflow , Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 14 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-2423WI Efficiency Versus Output Current Typical Output Ripple and Noise. Vin = Vin nom, Full Load Efficiency Versus Input Voltage. Full Load Derating Output Current Versus Ambient Temperature and Airflow Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com Transient Response to Dynamic Load Change from 100% to 75% to 100% of Full Load ; Vin = Vin nom Typical Input Start-Up and Output Rise Characteristic Vin = Vin nom, Full Load th Date: December 16 , 2008 / Rev.: 1.2 / Page 15 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-2423WI (Continued) Conduction Emission of EN55022 Class A Vin = Vin nom, Full Load Using ON/OFF Voltage Start-Up and Vout Rise Characteristic Vin = Vin nom, Full Load Conduction Emission of EN55022 Class B Vin = Vin nom, Full Load Power Dissipation Versus Output Current Derating Output Current Versus Ambient Temperature with Heat-Sink and Airflow , Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 16 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-4810WI Efficiency Versus Output Current Typical Output Ripple and Noise. Vin = Vin nom, Full Load Efficiency Versus Input Voltage. Full Load Derating Output Current Versus Ambient Temperature and Airflow Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com Transient Response to Dynamic Load Change from 100% to 75% to 100% of Full Load ; Vin = Vin nom Typical Input Start-Up and Output Rise Characteristic Vin = Vin nom, Full Load th Date: December 16 , 2008 / Rev.: 1.2 / Page 17 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-4810WI (Continued) Conduction Emission of EN55022 Class A Vin = Vin nom, Full Load Using ON/OFF Voltage Start-Up and Vout Rise Characteristic Vin = Vin nom, Full Load Conduction Emission of EN55022 Class B Vin = Vin nom, Full Load Power Dissipation Versus Output Current Derating Output Current Versus Ambient Temperature with Heat-Sink and Airflow, Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 18 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-4811WI Efficiency Versus Output Current Typical Output Ripple and Noise. Vin = Vin nom, Full Load Efficiency Versus Input Voltage. Full Load Derating Output Current Versus Ambient Temperature and Airflow Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com Transient Response to Dynamic Load Change from 100% to 75% to 100% of Full Load ; Vin = Vin nom Typical Input Start-Up and Output Rise Characteristic Vin = Vin nom, Full Load th Date: December 16 , 2008 / Rev.: 1.2 / Page 19 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-4811WI (Continued) Conduction Emission of EN55022 Class A Vin = Vin nom, Full Load Using ON/OFF Voltage Start-Up and Vout Rise Characteristic Vin = Vin nom, Full Load Conduction Emission of EN55022 Class B Vin = Vin nom, Full Load Power Dissipation Versus Output Current Derating Output Current Versus Ambient Temperature with Heat-Sink and Airflow, Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 20 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-4812WI Efficiency Versus Output Current Typical Output Ripple and Noise. Vin = Vin nom, Full Load Efficiency Versus Input Voltage. Full Load Derating Output Current Versus Ambient Temperature and Airflow Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com Transient Response to Dynamic Load Change from 100% to 75% to 100% of Full Load ; Vin = Vin nom Typical Input Start-Up and Output Rise Characteristic Vin = Vin nom, Full Load th Date: December 16 , 2008 / Rev.: 1.2 / Page 21 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-4812WI (Continued) Conduction Emission of EN55022 Class A Vin = Vin nom, Full Load Using ON/OFF Voltage Start-Up and Vout Rise Characteristic Vin = Vin nom, Full Load Conduction Emission of EN55022 Class B Vin = Vin nom, Full Load Power Dissipation Versus Output Current Derating Output Current Versus Ambient Temperature with Heat-Sink and Airflow, Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 22 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-4813WI Efficiency Versus Output Current Typical Output Ripple and Noise. Vin = Vin nom, Full Load Efficiency Versus Input Voltage. Full Load Derating Output Current Versus Ambient Temperature and Airflow Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com Transient Response to Dynamic Load Change from 100% to 75% to 100% of Full Load ; Vin = Vin nom Typical Input Start-Up and Output Rise Characteristic Vin = Vin nom, Full Load th Date: December 16 , 2008 / Rev.: 1.2 / Page 23 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-4813WI (Continued) Conduction Emission of EN55022 Class A Vin = Vin nom, Full Load Using ON/OFF Voltage Start-Up and Vout Rise Characteristic Vin = Vin nom, Full Load Conduction Emission of EN55022 Class B Vin = Vin nom, Full Load Power Dissipation Versus Output Current Derating Output Current Versus Ambient Temperature with Heat-Sink and Airflow, Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 24 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-4822WI Efficiency Versus Output Current Typical Output Ripple and Noise. Vin = Vin nom, Full Load Efficiency Versus Input Voltage. Full Load Derating Output Current Versus Ambient Temperature and Airflow Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com Transient Response to Dynamic Load Change from 100% to 75% to 100% of Full Load ; Vin = Vin nom Typical Input Start-Up and Output Rise Characteristic Vin = Vin nom, Full Load th Date: December 16 , 2008 / Rev.: 1.2 / Page 25 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-4822WI (Continued) Conduction Emission of EN55022 Class A Vin = Vin nom, Full Load Using ON/OFF Voltage Start-Up and Vout Rise Characteristic Vin = Vin nom, Full Load Conduction Emission of EN55022 Class B Vin = Vin nom, Full Load Power Dissipation Versus Output Current Derating Output Current Versus Ambient Temperature with Heat-Sink and Airflow , Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 26 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-4823WI Efficiency Versus Output Current Typical Output Ripple and Noise. Vin = Vin nom, Full Load Efficiency Versus Input Voltage. Full Load Derating Output Current Versus Ambient Temperature and Airflow Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com Transient Response to Dynamic Load Change from 100% to 75% to 100% of Full Load ; Vin = Vin nom Typical Input Start-Up and Output Rise Characteristic Vin = Vin nom, Full Load th Date: December 16 , 2008 / Rev.: 1.2 / Page 27 / 38 Application Note 40W, Single and Dual Output Characteristic Curves All test conditions are at 25°C. The figures are identical for TEN 40-4823WI (Continued) Conduction Emission of EN55022 Class A Vin = Vin nom, Full Load Using ON/OFF Voltage Start-Up and Vout Rise Characteristic Vin = Vin nom, Full Load Conduction Emission of EN55022 Class B Vin = Vin nom, Full Load Power Dissipation Versus Output Current Derating Output Current Versus Ambient Temperature with Heat-Sink and Airflow , Vin = Vin nom Created by Traco Electronic AG Arp. www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 28 / 38 Application Note 40W, Single and Dual Output Test Configurations Input reflected-ripple current measurement test up Component L C Value 12µH 47µF Voltage ---100V Reference ---Aluminum Electrolytic Capacitor Peak-to-peak output ripple & noise measurement test up Single output Dual Output Output voltage and efficiency measurement test up Single Output Dual Output V × Io × 100 % Efficiency = o Vin × I in Created by Traco Electronic AG Arp. Note: All measurements are taken at the module terminals. www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 29 / 38 Application Note 40W, Single and Dual Output EMC Considerations Suggested Schematic to comply with Conducted Noise according to EN55022 Class A Recommended Layout with Input Filter Following components are needed to comply with EN55022 Class A conducted noise: TEN 40-24xxWI Component Value Voltage Reference C1, C2 ------C3, C4 1000pF 2KV 1206 MLCC TEN 40-48xxWI Component C1, C2 C3, C4 Created by Traco Electronic AG Arp. Value 2.2uF 1000pF Voltage 100V 2KV www.tracopower.com ---- Reference 1812 MLCC 1206 MLCC th Date: December 16 , 2008 / Rev.: 1.2 / Page 30 / 38 Application Note 40W, Single and Dual Output EMC Considerations (Continued) C5 L1 4 ＋INPUT C1 －INPUT 3 C2 +Vin C3 1 2 +Vout C4 Load -Vin -Vout D/D Converter C6 Suggested Schematic to comply with Conducted Noise according to EN55022 Class B Recommended Layout with Input Filter T Following components are needed to comply with EN55022 Class B conducted noise: TEN 40-24xxWI Component Value Voltage Reference C1, C3 4.7uF 50V 1812 MLCC C5, C6 1000pF 2KV 1206 MLCC L1 450uH ---Common Choke, P/N: TCK-048 TEN 40-48xxWI Component C1, C2 C3, C4 C5, C6 L1 Value 2.2uF 2.2uF 1000pF 830uH Voltage 100V 100V 2KV ---- Reference 1812 MLCC 1812 MLCC 1206 MLCC Common Choke, P/N: TCK-053 This Common Choke L1 has been define as follows: ■ TCK-048: L: 450µH ±35% / DCR: 25mΩ, max A height: 9.8 mm, max ■ TCK-053: L: 830µH ±35% / DCR: 31mΩ, max A height: 8.8 mm, Max ■ Test condition: 100KHz / 100mV ■ Recommended through hole: Φ0.8mm ■ All dimensions in millimetres Created by Traco Electronic AG Arp. www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 31 / 38 Application Note 40W, Single and Dual Output Input Source Impedance The power module should be connected to a low impedance input source. Highly inductive source impedance can affect the stability of the power module. Input external L-C filter is recommended to minimize input reflected ripple current. The inductor is simulated source impedance of 12µH and capacitor is Nippon chemi-con KZE series 47µF/100V. The capacitor must as close as possible to the input terminals of the power module for lower impedance. Output Over Current Protection When excessive output currents occur in the system, circuit protection is required on all converters. Normally, overload current is maintained at approximately 150 percent of rated output current . Hiccup-mode is a method of operation in a converter whose purpose is to protect the converter from being damaged during an over-current fault condition. It also enables the converter to restart after the fault is removed. One of the problems resulting from over current is that excessive heat may be generated in the converter; especially MOSFET and Schottky diodes and the temperature of those devices may exceed their specified limits. A protection mechanism has to be used to prevent those power devices from being damaged due to over heating. Output Over Voltage Protection The output over-voltage protection consists of output Zener diode that monitors the voltage on the output terminals. If the voltage on the output terminals exceeds the over-voltage protection threshold, then the Zener diode clamps the output voltage. This protection is only available on the TEN 40-WI single output. Thermal Consideration The TEN 40-WI operates in a variety of thermal environments. However, sufficient cooling should be provided to ensure reliable operation of the unit. Heat is removed by conduction, convection, and radiation to the surrounding environment. Proper cooling can be verified by measuring the point as shown in the figure below. The temperature at this point should not exceed 105°C. When operating, adequate cooling must be provided to maintain the test point temperature at or below 105°C. Although the maximum point temperature of the power modules is 105°C, you can limit this temperature to a lower value for higher reliability. TEMPERATURE MEASURE POINT Measurement shown in inches and (millimeters) Created by Traco Electronic AG Arp. TOP VIEW www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 32 / 38 Application Note 40W, Single and Dual Output Heat Sink Consideration Equip heat-sink for lower temperature and higher reliability of the module. Considering space and air-flow is the way to choose which heat-sink is needed. Order Code: TEN-HS3 All dimensions in millimeters Remote ON/OFF Control The Remote ON/OFF Pin is controlled DC/DC power module to turn on and off; the user must use a switch to control the logic voltage high or low level of the pin referenced to -Vin. The switch can be open collector transistor, FET and Photo-Couple. The switch must be capable of sinking up to 1 mA at low-level logic Voltage. High-level logic of the ON/OFF signal maximum voltage is allowable leakage current of the switch at 15V is 50µA. Remote ON/OFF recommended Circuits Isolated-Closure Remote ON/OFF Level Control Using TTL Output Level Control Using Line Voltage The Positive logic structure turned on of the DC/DC module when the ON/OFF pin is at high-level logic and low-level logic is turned off it. TEN 40-WI module is turned off at Low-level logic Created by Traco Electronic AG Arp. TEN 40-WI module is turned on at High-level logic www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 33 / 38 Application Note 40W, Single and Dual Output Mechanical Data 2.00 (50.8) DIA. 0.04 (1.0) 1.10 (27.9) 0.40 (10.2) 3 2 0.40(10.2) 0.20 (5.1) 1 6 5 4 0.10 (2.5) 8 7 1.80 (45.7) 2.00 (50.8) BOTTOM VIEW 0.10 (2.5) 0.30 (7.6) 0.60 (15.2) 0.80 (20.3) PIN CONNECTION PIN Single Output Dual Output 1 +Vin (Vcc) +Vin (Vcc) 2 -Vin (GND) -Vin (GND) 3 CTRL CTRL 4 -Sense +Vout 5 +Sense Com 6 +Vout Com 7 -Vout -Vout 8 TRIM TRIM 0.20 (5.1) 0.22 (5.6) 1. All dimensions in Inches (mm) Tolerance: X.XX ±0.02 (X.X ±0.5) 2. Pin pitch tolerance ±0.014( 0.35) EXTERNAL OUTPUT Output can be externally trimmed by using the method shown below. TRIM UP TRIM DOWN 7 8 RU RD 6 8 Recommended Pad Layout TOP VIEW 1. All dimensions in Inches (mm) Tolerance: X.XX ±0.02 (X.X ±0.5) 2. Pin pitch tolerance ±0.014( 0.35) Created by Traco Electronic AG Arp. www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 34 / 38 Application Note 40W, Single and Dual Output Output Voltage Adjustment Output voltage set point adjustment allows the user to adjust the output voltage of a module. This is accomplished by connecting an external resistor between the TRIM pin and either the +SENSE or -SENSE pins. With an external resistor between the TRIM and -SENSE pin, the output voltage value will increases. With an external resistor between the TRIM and +SENSE pin, the output voltage value will decreases. TRIM DOWN TRIM UP 8 7 TRIM TABLE TEN 40-xx10WI Trim up (%) VOUT (Volts) = RU (kΩ) = Trim down (%) VOUT (Volts) = RD (kΩ) = TEN 40-xx11WI Trim up (%) VOUT (Volts) = RU (K Ohms) = Trim down (%) VOUT (Volts) = RD (kΩ) = TEN 40-xx12WI Trim up (%) VOUT (Volts) = RU (kΩ) = Trim down (%) VOUT (Volts) = RD (kΩ) = TEN 40-xx13WI Trim up (%) VOUT (Volts) = RU (kΩ) = Trim down (%) VOUT (Volts) = RD (kΩ) = TEN 40-xx22WI Trim up (%) VOUT (Volts)= RU (kΩ) = Trim down (%) VOUT (Volts)= RD (kΩ) = TEN 40-xx23WI Trim up (%) VOUT (Volts)= RU (kΩ) = Trim down (%) VOUT (Volts)= RD (kΩ) = RU RD 6 8 1 3.333 57.930 1 3.267 69.470 2 3.366 26.165 2 3.234 31.235 3 3.399 15.577 3 3.201 18.490 4 3.432 10.283 4 3.168 12.117 5 3.465 7.106 5 3.135 8.294 6 3.498 4.988 6 3.102 5.745 7 3.531 3.476 7 3.069 3.924 8 3.564 2.341 8 3.036 2.559 9 3.597 1.459 9 3.003 1.497 10 3.630 0.753 10 2.970 0.647 1 5.050 36.570 1 4.950 45.533 2 5.100 16.580 2 4.900 20.612 3 5.150 9.917 3 4.850 12.306 4 5.200 6.585 4 4.800 8.152 5 5.250 4.586 5 4.750 5.660 6 5.300 3.253 6 4.700 3.999 7 5.350 2.302 7 4.650 2.812 8 5.400 1.588 8 4.600 1.922 9 5.450 1.032 9 4.550 1.230 10 5.500 0.588 10 4.500 0.676 1 2 3 12.120 12.240 12.360 367.910 165.950 98.636 1 2 3 11.880 11.760 11.640 460.990 207.950 123.600 4 12.480 64.977 4 11.520 81.423 5 12.600 44.782 5 11.400 56.118 6 12.720 31.318 6 11.280 39.249 7 12.840 21.701 7 11.160 27.199 8 12.960 14.488 8 11.040 18.162 9 13.080 8.879 9 10.920 11.132 10 13.200 4.391 10 10.800 5.509 1 2 15.150 15.300 404.180 180.590 1 2 14.850 14.700 499.820 223.410 3 15.450 106.060 3 14.550 131.270 4 15.600 68.796 4 14.400 85.204 5 15.750 46.437 5 14.250 57.563 6 15.900 31.531 6 14.100 39.136 7 16.050 20.883 7 13.950 25.974 8 16.200 12.898 8 13.800 16.102 9 16.350 6.687 9 13.650 8.424 10 16.500 1.718 10 13.500 2.282 1 ±12.12 218.21 1 ±11.88 273.44 2 ±12.24 98.105 2 ±11.76 123.02 3 ±12.36 58.07 3 ±11.64 72.874 4 ±12.48 38.052 4 ±11.52 47.803 5 ±12.6 26.042 5 ±11.4 32.76 6 ±12.72 18.035 6 ±11.28 22.732 7 ±12.84 12.316 7 ±11.16 15.568 8 ±12.96 8.026 8 ±11.04 10.196 9 ±13.08 4.69 9 ±10.92 6.017 10 ±13.2 2.021 10 ±10.8 2.675 1 ±15.15 268.29 1 ±14.85 337.71 2 ±15.3 120.64 2 ±14.7 152.02 3 ±15.45 71.429 3 ±14.55 90.126 4 ±15.6 46.822 4 ±14.4 59.178 5 ±15.75 32.058 5 ±14.25 40.609 6 ±15.9 22.215 6 ±14.1 28.23 7 ±16.05 15.184 7 ±13.95 19.387 8 ±16.2 9.911 8 ±13.8 12.756 9 ±16.35 5.81 9 ±13.65 7.598 10 ±16.5 2.529 10 ±13.5 3.471 Created by Traco Electronic AG Arp. www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 35 / 38 Application Note 40W, Single and Dual Output Remote Sense Application Circuit (only single output converters) The Remote Sense function can be regulate terminals the voltage of load when output current through the line resistor to bring about drop voltage. The Remote Sense voltage range can’t be over 10% Vout, i.e.: [+Vout to -Vout] – [+Sense to -Sense] ≦ 10% Vout If the Remote Sense function is not used, then the +Sense has to be connected with +Vout and the -SENSE has to be connected with -Vout direct on the terminals of the TEN 40-WI modules. Operation with Output Voltage and Sense Function used Soldering and Reflow Consideration Lead free wave solder profile for TEN 40-WI converters Zone Preheat zone Actual heating Reference Parameter Rise temp. speed: 3°C/ sec max. Preheat temperature: 100~130°C Peak temperature: 250~260°C Peak time (T1+T2 time): 4~6 sec Reference Solder: Sn-Ag-Cu: Sn-Cu Hand Soldering: Soldering iron: Power 90W Welding Time: 2〜4 sec Temperature: 380〜400°C Created by Traco Electronic AG Arp. www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 36 / 38 Application Note 40W, Single and Dual Output Packaging Information 5 PCS per TUBE Part Number Structure TEN 40 – 48 11WI Max. Output Power 40 Watts Input Voltage Range 24 : 9 ~ 36V 48 : 18 ~ 75V Model Number TEN 40-2410WI TEN 40-2411WI TEN 40-2412WI TEN 40-2413WI TEN 40-2422WI TEN 40-2423WI TEN 40-4810WI TEN 40-4811WI TEN 40-4812WI TEN 40-4813WI TEN 40-4822WI TEN 40-4823WI Input Voltage Range 9 – 36 Vdc 9 – 36 Vdc 9 – 36 Vdc 9 – 36 Vdc 9 – 36 Vdc 9 – 36 Vdc 18 – 75 Vdc 18 – 75 Vdc 18 – 75 Vdc 18 – 75 Vdc 18 – 75 Vdc 18 – 75 Vdc Output Voltage 10 : 3.3Vdc 11 : 5Vdc 12 : 12Vdc 13 : 15Vdc 22 : ±12Vdc 23 : ±15Vdc Output Voltage 3.3 Vdc 5 Vdc 12 Vdc 15 Vdc ±12 Vdc ±15 Vdc 3.3 Vdc 5 Vdc 12 Vdc 15 Vdc ±12 Vdc ±15 Vdc Output Current Full Load 10000mA 8000mA 3333mA 2666mA ± 1667mA ± 1333mA 10000mA 8000mA 3333mA 2666mA ± 1667mA ± 1333mA Input Current Full Load (1) 1677mA 2008mA 2008mA 2008mA 2032mA 2032mA 838mA 992mA 1004mA 1004mA 1016mA 1016mA Efficiency (2) (%) 86 87 87 87 86 86 86 88 87 87 86 86 Note 1. Maximum value at nominal input voltage and full load. Note 2. Typical value at nominal input voltage and full load. Created by Traco Electronic AG Arp. www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 37 / 38 Application Note 40W, Single and Dual Output Safety and Installation Instruction Fusing Consideration Caution: The TEN 40-WI is not internally fused. An input line fuse must always be used. This encapsulated converter can be used in a wide variety of applications, ranging from simple stand-alone operation to an integrated part of sophisticated power architecture. To keep 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 normal-blow fuse with maximum rating of 8A for TEN 40-24xxWI modules and 5A for TEN 40-48xxWI modules. 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 40-WI DC/DC converters has been calculated according to: • Bellcore TR-NWT-000332 Case I: 50% stress, Operating Temperature at 40°C (Ground fixed and controlled environment). The resulting figure for MTBF is: 1’105’000 hours. • MIL-HDBK 217F NOTICE2 FULL LOAD, Operating Temperature at 25°C. The resulting figure for MTBF is: 151’100 hours. Created by Traco Electronic AG Arp. www.tracopower.com th Date: December 16 , 2008 / Rev.: 1.2 / Page 38 / 38