Data Sheet April 2008 DW025 Dual Output-Series Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W Options n n Higher-accuracy output voltage clamp set point Short pins: 2.79 mm ± 0.25 mm (0.110 in. ± 0.010 in.) n Heat sink available for extended operation n Negative logic remote on/off Description The DW025-Series Power Modules use advanced, surfacemount technology and deliver high-quality, compact, dc-dc conversion at an economical price. Features n Small size: 71.1 mm x 61.0 mm x 12.7 mm (2.80 in. x 2.40 in. x 0.50 in.) n Low output noise n Industry-standard pinout n Metal case with separate case ground pin n 2:1 input voltage range n Remote on/off (positive logic) n n n n UL* Recognized, CSA † Certified, and VDE Licensed Within FCC and CISPR Class A Radiated Limits CE mark meets 73/23/EEC and 93/68/EEC directives‡ Two tightly regulated outputs The DW025-Series Power Modules are a family of dc-dc converters that operate over an input voltage range of 36 Vdc to 75 Vdc and provide two regulated outputs. These modules offer low noise levels with industry-standard pinouts in a small footprint. Each highly reliable and efficient unit features remote on/off and current limit. Each output is individually regulated by its own control circuit and has an independent overvoltage clamp. With standard outputs of +3.3 V, ±5 V, ±12 V, and ±15 V, the DW025-Series is flexible enough to provide modified standard units with any combination of output voltages from 2 V to 15 V. Efficiency greater than 80%, a wide operating temperature range, and a metal case are additional features of these modules. They have UL, CSA, and VDE recognition and operate within FCC and CISPR Class A limits for radiated emissions. The DW025AJ-M, BK-M, and CL-M Power Modules are available with common output ground pins (pinout A); the DW025AA-M, AB-M, AF-M, BB-M, and CC-M Power Modules are available with separate output ground pins (pinout B). Applications n Distributed power architectures n Telecommunications * UL is a registered trademark of Underwriters Laboratories, Inc. † CSA is a registered trademark of the Canadian Standards Association. ‡ This product is intended for integration into end-use equipment. All the required procedures for CE marking of end-use equipment should be followed. (The CE mark is placed on selected products.) DW025 Dual Output-Series Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W Data Sheet April 2008 Absolute Maximum Ratings Stresses in excess of the absolute maximum ratings can cause permanent damage to the device. These are absolute stress ratings only. Functional operation of the device is not implied at these or any other conditions in excess of those given in the operations sections of the data sheet. Exposure to absolute maximum ratings for extended periods can adversely affect device reliability. Parameter Symbol Min Max Unit Input Voltage Continuous Transient (<10 ms) VI VI, trans — — 80 100 V V I/O Isolation Voltage dc Transient (1 minute) — — — — 500 850 V V Operating Case Temperature TC –40 100 °C Storage Temperature Tstg –55 125 °C Electrical Specifications Note: Two pinouts are available for the DW025-Series Power Modules. The DW025AJ-M, AB-M, BK-M, and CL-M Power Modules, which have both positive and negative outputs, have a common output ground pin (pinout A). The DW025AA-M, AB-M, AF-M, BB-M, and CC-M Power Modules, which have dual positive outputs, have separate output ground pins (pinout B). See Outline Diagrams section. Unless otherwise indicated, specifications apply to all modules over all operating input voltage, resistive load, and temperature conditions. Table 1. Input Specifications Parameter Symbol Min Typ Max Unit VI 36 48 75 Vdc II, max — — 2.0 A Inrush Transient i2 t — — 0.8 A2s Input Reflected-ripple Current, Peak-to-Peak (5 Hz to 20 MHz, 12 µH source impedance; TC = 25 °C) (See Figure 11 and Design Considerations section.) — — 25 — mAp-p Input Ripple Rejection (120 Hz) — — 60 — dB Operating Input Voltage Maximum Input Current (VI = 0 V to 75 V; IO = IO, max; see Figure 1.) Fusing Considerations 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 preserve 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, dc fuse with a maximum rating of 5 A (see Safety Considerations section). Based on the information provided in this data sheet on inrush energy and maximum dc input current, the same type of fuse with a lower rating can be used. Refer to the fuse manufacturer’s data for further information. 2 Lineage Power DW025 Dual Output-Series Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W Data Sheet April 2008 Electrical Specifications (continued) Table 2. Output Specifications Parameter Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life. See Figure 13.) Device Symbol Min Typ Max Unit DW025AJ-M VO1 VO2 VO1 VO2 VO1 VO2 VO1 VO2 VO1 VO2 VO1 VO2 VO1 VO2 VO1 VO2 4.80 – 4.80 11.40 – 11.40 14.25 –14.25 4.80 4.80 4.80 11.40 4.80 3.16 11.40 11.40 14.25 14.25 — — — — — — — — — — — — — — — — 5.25 –5.25 12.60 –12.60 15.75 –15.75 5.25 5.25 5.25 12.60 5.25 3.45 12.60 12.60 15.75 15.75 Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc VO1, set VO2, set VO1, set VO2, set VO1, set VO2, set VO1, set VO2, set VO1, set VO2, set VO1, set VO2, set VO1, set VO2, set VO1, set VO2, set 4.90 – 4.90 11.76 –11.76 14.70 –14.70 4.90 4.90 4.90 11.76 4.90 3.23 11.76 11.76 14.70 14.70 5.0 –5.0 12.0 –12.0 15.0 –15.0 5.0 5.0 5.0 12.0 5.0 3.3 12.0 12.0 15.0 15.0 5.10 –5.10 12.24 –12.24 15.30 –15.30 5.10 5.10 5.10 12.24 5.10 3.37 12.24 12.24 15.30 15.30 Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc All All — — — — 0.1 0.1 0.2 0.4 % % DW025AJ-M, AA-M, BK-M, BB-M, CL-M, CC-M, AB-M — — 0.1 0.4 % DW025AF-M — — 0.4 0.8 % DW025AJ-M, AA-M, AF-M — — 15 70 mV DW025BK-M, BB-M — — 40 150 mV DW025CL-M, CC-M — — 40 190 mV DW025AB-M (5 V output) — — 15 70 mV DW025AB-M (12 V output) — — 40 150 mV DW025BK-M DW025CL-M DW025AA-M DW025AB-M DW025AF-M DW025BB-M DW025CC-M Output Voltage Set Point (VI = 48 V; IO = IO, max; TA = 25 °C) DW025AJ-M DW025BK-M DW025CL-M DW025AA-M DW025AB-M DW025AF-M DW025BB-M DW025CC-M Output Regulation: Line (VI = 36 V to 75 V) Load (IO1 = IO, min to IO, max, IO2 = IO, max) Load (IO2 = IO, min to IO, max, IO1 = IO, max) Temperature (TC = – 40 °C to +100 °C) Lineage Power 3 DW025 Dual Output-Series Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W Data Sheet April 2008 Electrical Specifications (continued) Table 2. Output Specifications (continued) Parameter Output Ripple and Noise (See Figure 12.): RMS Peak-to-peak (5 Hz to 20 MHz) Output Current (At IO < IO, min, the modules may exceed output ripple specifications.) Output Current-limit Inception (VO = 90% of VO, nom; see Figure 2.) Output Short-circuit Current (VO = 250 mV) Efficiency (VI = 48 V; IO = IO, max; TC = 25 °C; see Figures 3 and 13.) 4 Device Symbol Min Typ Max Unit DW025AJ-M, AA-M, AF-M — — — 15 mVrms DW025BK-M, BB-M — — — 20 mVrms DW025CL-M, CC-M — — — 25 mVrms DW025AB-M (5 V output) — — — 15 mVrms DW025AB-M (12 V output) — — — 20 mVrms DW025AJ-M, AA-M, AF-M — — — 150 mVp-p DW025BK-M, BB-M — — — 200 mVp-p DW025CL-M, CC-M — — — 250 mVp-p DW025AB-M (5 V output) — — — 150 mVp-p DW025AB-M (12 V output) — — — 200 mVp-p DW025AJ-M, AA-M, AF-M IO1 IO2 0.20 0.20 — — 2.50 2.50 A A DW025BK-M, BB-M IO1 IO2 0.10 0.10 — — 1.04 1.04 A A DW025CL-M, CC-M IO1 IO2 0.08 0.08 — — 0.83 0.83 A A DW025AB-M IO1 IO2 0.20 0.10 — — 2.50 1.04 A A DW025AJ-M, AA-M, AF-M — — 3.7 6.5 A DW025BK-M, BB-M — — 1.5 2.9 A DW025CL-M, CC-M — — 1.3 2.7 A DW025AB-M IO1 IO2 — — 3.7 1.5 6.5 2.9 A A DW025AJ-M, AA-M, AF-M — — 3.5 7.0 A DW025BK-M, BB-M — — 1.0 3.0 A DW025CL-M, CC-M — — 1.0 3.0 A DW025AB-M IO1 IO2 — — 3.5 1.0 7.0 3.0 A A DW025AJ-M, AA-M η 75 78 — % DW025AF-M η 68 75 — % DW025AB-M η 75 79 — % DW025BK-M, BB-M η 79 82 — % DW025CL-M, CC-M η 79 82 — % Lineage Power DW025 Dual Output-Series Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W Data Sheet April 2008 Electrical Specifications (continued) Table 2. Output Specifications (continued) Parameter Device Symbol Min Typ Max Unit DW025AJ-M, AA-M, AF-M — — 160 — mV DW025BK-M, BB-M — — 250 — mV DW025CL-M, CC-M — — 250 — mV DW025AB-M (5 V output) — — 160 — mV DW025AB-M (12 V output) — — 250 — mV All — — 3 — ms DW025AJ-M, AA-M, AF-M — — 160 — mV DW025BK-M, BB-M — — 250 — mV DW025CL-M, CC-M — — 250 — mV DW025AB-M (5 V output) — — 160 — mV DW025AB-M (12 V output) — — 250 — mV All — — 3 — ms Dynamic Response (ýIO/ýt = 1 A/10 µs, VI = 48 V, TA = 25 °C): Load Change from IO = 50% to 75% of IO, max: (See Figures 7 to 9.): Peak Deviation Settling Time (VO < 10% peak deviation) Load Change from IO = 50% to 25% of IO, max (See Figures 4 to 6.): Peak Deviation Settling Time (VO < 10% peak deviation) Table 3. Isolation Specifications Parameter Min Typ Max Unit Isolation Capacitance — 1200 — pF Isolation Resistance 10 — — M¾ Max Unit General Specifications Parameter Min Calculated MTBF (IO = 80% of IO, max; TC = 40 °C) Weight Lineage Power Typ 2,800,000 — — hours 113 (4.0) g (oz.) 5 DW025 Dual Output-Series Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W Data Sheet April 2008 Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See Feature Descriptions and Design Considerations for further information. Parameter Remote On/Off (positive logic) (VI = 0 V to 75 V; open collector or equivalent compatible; signal referenced to VI(–) terminal. See Figures 10, 14 and Feature Descriptions.): DW025xx-M Positive Logic: Logic Low—Module Off Logic High—Module On DW025xx1-M Negative Logic: Logic Low—Module On Logic High—Module Off Module Specifications: On/Off Current—Logic Low On/Off Voltage: Logic Low Logic High (Ion/off = 0) Open Collector Switch Specifications: Leakage Current During Logic High (Von/off = 10 V) Output Low Voltage During Logic Low (Ion/off = 1 mA) Turn-on Time (IO = 80% of IO, max; VO within ±1% of steady state) Output Voltage Overshoot Output Overvoltage Clamp Device Symbol Min Typ Max Unit All Ion/off — — 1.0 mA All All Von/off Von/off 0 — — — 1.2 10 V V All Ion/off — — 50 µA All Von/off — — 1.2 V All — — 30 — ms All — — 0 5 % DW025AJ-M VO1 VO2 VO1 VO2 VO1 VO2 VO1 VO2 VO1 VO2 VO1 VO2 VO1 VO2 VO1 VO2 — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — 7 –7 16 –16 20 –20 7 7 7 16 7 5 16 16 20 20 V V V V V V V V V V V V V V V V VUVLO VUVLO — 20 28 28 36 — V V DW025BK-M DW025CL-M DW025AA-M DW025AB-M DW025AF-M DW025BB-M DW025CC-M Input Undervoltage Lockout: Module On Module Off 6 All All Lineage Power Data Sheet April 2008 DW025 Dual Output-Series Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W Characteristic Curves 85 INPUT CURRENT, II (A) VO 1.0 1.0 0.8 0.8 0.6 0.6 II 0.4 0.4 0.2 0.2 0 0.0 0 10 20 30 40 50 60 NORMALIZED OUTPUT VOLTAGE 1.2 EFFICIENCY, η (%) 80 1.2 75 70 CC,CL BB,BK AA,AJ AF 65 60 55 50 45 0.1 70 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 NORMALIZED BOTH OUTPUT CURRENTS TO FULL LOAD, IO (A) INPUT VOLTAGE, VI (V) 8-993(C).a 8-995(C) Figure 3. DW025-Series Efficiency vs. Normalized Both Output Currents to Full Load at VI = 48 V and TA = 25 °C OUTPUT VOLTAGE, VO (mV) (50 mV/div) 1.2 1.0 0.8 0.6 VO = 3.3 V 5V 12 V 15 V 0.4 50 mV 5.0 V 0.2 0.0 0.0 0.5 1.0 1.5 2.0 2.5 NORMALIZED OUTPUT CURRENT TO FULL LOAD, IO (A) 8-994(C) Figure 2. DW025-Series Normalized Output Current vs. Normalized Output Voltage at VI = 48 V and TA = 25 °C OUTPUT CURRENT, IO (A) (0.5 A/div) NORMALIZED OUTPUT VOLTAGE, VO (V) Figure 1. DW025-Series Input Current and Normalized Output Voltage vs. Input Voltage at Full Load and TA = 25 °C 1.0 A ∆IO = 1 A/10 µs ∆t 0.5 A 0.5 ms 0.5 A TIME, t (0.5 ms/div) 8-1019(C) Figure 4. DW025-Series Typical 5 V Output Voltage Response to a Step Load Change from 50% to 25% of IO, max at VI = VI, nom and TA = 25 °C Characteristic Curves (continued) Lineage Power 7 OUTPUT CURRENT, IO (A) OUTPUT VOLTAGE, VO (mV) (0.5 A/div) (50 mV/div) OUTPUT CURRENT, IO (A) (0.2 A/div) OUTPUT VOLTAGE, VO (V) (0.1 V/div) DW025 Dual Output-Series Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W 100 mV 12.0 V 0.416 A ∆IO = 1 A/10 µs ∆t 0.208 A 0.2 A 0.5 ms Data Sheet April 2008 50 mV 5.0 V 1.5 A ∆IO = 1 A/10 µs ∆t 1.0 A 0.5 ms 0.5 A TIME, t (0.5 ms/div) 8-1017(C) TIME, t (0.5 ms/div) 8-1018(C) OUTPUT VOLTAGE, VO (V) (0.1 V/div) 100 mV 15.0 V 0.333 A ∆IO= 1 A/10 µs ∆t 0.166 A 0.2 A 0.5 ms TIME, t (0.5 ms/div) 8-1017(C).a Figure 6. Typical DW025-Series 15 V Output Voltage Response to a Step Load Change from 50% to 25% of IO, max at VI = VI, nom and TA = 25 °C 8 Figure 7. Typical DW025-Series 5 V Output Voltage Response to a Step Load Change from 50% to 75% of IO, max at VI = VI, nom and TA = 25 °C OUTPUT CURRENT, IO (A) (0.2 A/div) OUTPUT CURRENT, IO (A) (0.2 A/div) OUTPUT VOLTAGE, VO (V) (0.1 V/div) Figure 5. Typical DW025-Series 12 V Output Voltage Response to a Step Load Change from 50% to 25% of IO, max at VI = VI, nom and TA = 25 °C 100 mV 12.0 V 0.624 A ∆IO = 1 A/10 µs ∆t 0.416 A 0.2 A 0.5 ms TIME, t (0.5 ms/div) 8-1017(C).b Figure 8. Typical DW025-Series 12 V Output Voltage Response to a Step Load Change from 50% to 75% of IO, max at VI = VI, nom and TA = 25 °C Lineage Power Data Sheet April 2008 DW025 Dual Output-Series Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W OUTPUT VOLTAGE, VO (V) (0.1 V/div) Characteristic Curves (continued) Test Configurations TO OSCILLOSCOPE 100 mV LTEST V I (+) 12 µH 15.0 V BATTERY CS 220 µF IMPEDANCE < 0.1 Ω @ 20 °C, 100 kHz OUTPUT CURRENT, IO (A) (0.2 A/div) V I (–) 0.500 A ∆IO = 1 A/10 µs ∆t 0.333 A 8-489(C).a Note: Measure input reflected-ripple current with a simulated source impedance (LTEST) of 12 µH. Capacitor CS offsets possible battery impedance. Current is measured at the input of the module. 0.2 A Figure 11. Input Reflected-Ripple Test Setup 0.5 ms TIME, t (0.5 ms/div) 8-1018(C).a NORMALIZED OUTPUT VOLTAGE, VO Figure 9. Typical DW025-Series 15 V Output Voltage Response to a Step Load Change from 50% to 75% of IO, max at VI = VI, nom and TA = 25 °C VO, set REMOTE ON/OFF, Von/off (V) (2 V/div) 0V 2V 0V ∆IO = 1 A/10 µs ∆t 1 ms TIME, t (1 ms/div) 8-1020(C) Figure 10. Typical DW025-Series Output Voltage Rise Time with Remote On/Off at VI = VI, nom, IO = 0.8 (IO, max) and TA = 25 °C Lineage Power 9 DW025 Dual Output-Series Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W Data Sheet April 2008 Test Configurations (continued) CONTACT AND DISTRIBUTION LOSSES VO1 V I (+) LOAD IO II COPPER STRIP COM SUPPLY VO1(+) LOAD 0.1 µF SCOPE RLOAD1 VO2 VI(–) CONTACT RESISTANCE COMM 8-753(C) 0.1 µF SCOPE RLOAD2 VO2(–) Note: All measurements are taken at the module terminals. When socketing, place Kelvin connections at module terminals to avoid measurement errors due to socket contact resistance. In addition, VI(–) is internally connected to case. 2 ∑ 8-808(C) A. Pinout A (DW025AJ-M, BK-M, CL-M) Configuration Pinout A η ∑ VO1(+) SCOPE RLOAD1 VO1(–) VO2(+) 0.1 µF =1 = J------------------------------------------------x 100 [VI(+) – VI(–)]II - 2 COPPER STRIP 0.1 µF [ V OJ – COM ] I OJ SCOPE RLOAD2 Pinout B η [ V OJ ( + ) – V OJ ( – ) ] I OJ J=1 = -------------------------------------------------------------- x 100 [VI(+) – VI(–)]II Figure 13. Output Voltage and Efficiency Measurement Test Setup VO2(–) Design Considerations 8-809(C) B. Pinout B (DW025AA-M, AB-M, AF-M, BB-M, CC-M) Configuration Note: Use a 0.1 µF ceramic capacitor. Scope measurement should be made by using a BNC socket. Position the load between 50 mm (2 in.) and 75 mm (3 in.) from the module. Figure 12. Output Noise Measurement Test Setup 10 Input Source Impedance The power module should be connected to a low acimpedance input source. Highly inductive source impedances can affect the stability of the power module. A 33 µF electrolytic capacitor (ESR < 0.7 Ω at 100 kHz) mounted close to the power module helps ensure stability of the unit. Lineage Power Data Sheet April 2008 DW025 Dual Output-Series Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W Design Considerations (continued) Current Limit Safety Considerations To provide protection in a fault (output overload) condition, the unit is equipped with internal current-limiting circuitry and can endure current-limiting for an unlimited duration. At the point of current-limit inception, the unit shifts from voltage control to current control. If the output voltage is pulled very low during a severe fault, the current-limit circuit can exhibit either foldback or tailout characteristics (output current decrease or increase). The unit operates normally once the output current is brought back into its specified range. For safety-agency approval of the system in which the power module is used, the power module must be installed in compliance with the spacing and separation requirements of the end-use safety agency standard, i.e., UL-1950, CSA 22.2-950, EN60950. For the converter output to be considered to be meeting the requirements of safety extra-low voltage (SELV), one of the following must be true: ■ All inputs are SELV and floating with the output also floating. ■ All inputs are SELV and grounded with the output also grounded. ■ Any non-SELV input must be provided with reinforced insulation from any other hazardous voltages, including the ac mains, and must have a SELV reliability test performed on it in combination with the converters. If the input meets extra-low voltage (ELV) requirements, then the converter’s output is considered ELV. The input to these units is to be provided with a maximum 5 A normal-blow fuse in the ungrounded lead. Input/Output Voltage Reversal CAUTION: Applying a reverse voltage across the module input or output forward biases an internal diode. Attempting to start the module under this condition can damage the module. Remote On/Off Two remote on/off options are available. Positive logic remote on/off turns the module on during a logic high voltage on the remote on/off pin, and off during a logic low. Negative logic remote on/off, code suffix “1,” turns the module off during a logic high and on during a logic low. To turn the power module on and off, the user must supply a switch to control the voltage between the on/off terminal and the VI(–) terminal (Von/off). The switch can be an open collector or equivalent (see Figure 14). A logic low is Von/off = 0 V to 1.2 V. The maximum Ion/off during a logic low is 1 mA. The switch should maintain a logic-low voltage while sinking 1 mA. During a logic high, the maximum Von/off generated by the power module is 10 V. The maximum allowable leakage current of the switch at Von/off = 10 V is 50 µA. VI(+) VI(–) – Feature Descriptions Output Overvoltage Clamp The output overvoltage clamp consists of control circuitry, independent of the primary regulation loop, that monitors the voltage on the output terminals. The control loop of the clamp has a higher voltage set point than the primary loop (see Feature Specifications table). This provides a redundant voltage control that reduces the risk of output overvoltage. Lineage Power VO1 LOAD Von/off COM + Ion/off LOAD ON/OFF VO2 8-754(C) Figure 14. Remote On/Off Implementation 11 Data Sheet April 2008 DW025 Dual Output-Series Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W Thermal Considerations WIND TUNNEL WALL MEASURE CASE TEMPERATURE AT CENTER OF UNIT AIRFLOW CONNECTORS TO LOADS, POWER SUPPLIES, AND DATALOGGER, 6.35 (0.25) TALL 203.2 (8.00) AIRFLOW 50.8 (2.00) 101.6 (4.00) AIR VELOCITY PROBE AMBIENT TEMPERATURE THERMOCOUPLE 12.7 (0.50) 203.2 (8.00) 9.7 (0.38) 19.1 (0.75) 8-866(C).a Note: Dimensions are in millimeters and (inches). Drawing is not to scale. Figure 15. Thermal Test Setup The 25 W dual output power modules are designed to operate in a variety of thermal environments. As with any electronic component, sufficient cooling must be provided to help ensure reliable operation of the unit. Heat-dissipating components inside the module are thermally coupled to the case. Heat is removed by conduction, convection, and radiation to the surrounding environment. 12 The thermal data presented is based on measurements taken in a wind tunnel. The test setup shown in Figure 15 was used to collect data. Actual performance can vary depending on the particular application environment. Lineage Power Data Sheet April 2008 DW025 Dual Output-Series Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W Thermal Considerations (continued) Air Velocity Basic Thermal Performance The air velocity required to maintain a desired maximum case temperature for a given power dissipation and ambient temperature can be calculated using Figure 21 and the following equation: The DW025-Series Dual Output Power Modules have a separate power stage for each of the outputs. This means that the maximum operating temperature can be predicted quite closely by treating each output individually and then summing the results. Figures 16 through 21 are used to predict the safe operating condition for many different operating and environmental conditions. The method used to determine the maximum ambient temperature at a given air velocity is a four-step process. 1. Find the power dissipated for output 1 by using the appropriate chart (Figures 16 through 19) for a particular output condition (IO1). 2. Repeat step 1 for output 2 using Figures 16 through 19. 3. Find the total power dissipated by summing the power dissipated on each of the outputs: (PDOUT1 + PDOUT2) = PDtotal T C, max – T A P D total θCA = -------------------------------where θCA is the thermal resistance from case-to-ambient air (°C/W), TC, max is the desired maximum case temperature (°C), TA is the ambient inlet temperature (°C), and PDtotal is the total power dissipated from the module (W). For example, to maintain a maximum case temperature of 85 °C with an ambient inlet temperature of 55 °C and a power dissipation of 6.7 W, the thermal resistance is: 85 °C – 55 °C θCA ≤ ------------------------------------ = 4.5 °C/W 6.7 W This corresponds to an air velocity greater than 0.46 ms–1 (90 fpm) in Figure 21. 4. Use the total power dissipated with Figure 20 to determine the maximum ambient temperature at different air velocities. For example, the DW025AF-M power module operating at full load on both outputs with 54 V input has a power dissipation of 3.6 W (from Figure 17) plus 3.1 W (from Figure 16) for a total of 6.7 W. Using Figure 20, it can be determined that the maximum ambient temperature at natural convection that the DW025AF-M can operate at is approximately 56 °C. Keep in mind that these are approximations of the temperatures and airflows required to keep the case temperature below its maximum rating. The maximum case temperature at the point shown in Figure 15 must be kept at 100 °C or less. Lineage Power 13 DW025 Dual Output-Series Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W Data Sheet April 2008 Thermal Considerations (continued) 3.0 POWER DISSIPATION, PD (W) Air Velocity (continued) POWER DISSIPATION, PD (W) 4.0 3.5 3.0 VI = 72 V VI = 54 V VI = 36 V 2.5 2.0 2.5 2.0 1.5 VI = 36 V 1.0 VI = 54 V VI = 72 V 0.5 0.0 0.0 1.5 0.2 0.4 1.0 0.6 1.0 0.8 1.2 OUTPUT CURRENT, IO (A) 8-1005(C).a 0.5 0 0 0.5 1.0 1.5 2.0 2.5 Figure 18. 12 V Output Power Dissipation vs. Output Current OUTPUT CURRENT, IO (A) 8-986(C).a Figure 16. 3.3 V Output Power Dissipation vs. Output Current POWER DISSIPATION, PD (W) 3.0 POWER DISSIPATION, PD (W) 4.0 3.5 3.0 VI = 72 V VI = 54 V VI = 36 V 2.5 2.0 1.5 2.5 2.0 1.5 VI = 36 V VI = 54 V VI = 72 V 1.0 0.5 0.0 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 OUTPUT CURRENT, IO (A) 0.5 8-999(C).a 0 0 0.5 1.0 1.5 2.0 2.5 Figure 19. 15 V Output Power Dissipation vs. Output Current OUTPUT CURRENT, IO (A) 8-987(C).a Figure 17. 5 V Output Power Dissipation vs. Output Current 14 Lineage Power Data Sheet April 2008 DW025 Dual Output-Series Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W Use of Heat Sinks and Cold Plates Air Velocity (continued) The DW025-Series case includes through-threaded M3 x 0.5 mounting holes allowing attachment of heat sinks or cold plates from either side of the module. The mounting torque must not exceed 0.56 N/m (5 in.-lb.). TOTAL POWER DISSIPATION, PD (W) Thermal Considerations (continued) 10.0 9.0 The following thermal model can be used to determine the required thermal resistance of the sink to provide the necessary cooling: 8.0 7.0 6.0 2.03 ms –1 (400 ft./min) 4.0 1.02 ms –1 (200 ft./min) –1 3.0 0.51 ms (100 ft./min) 0.31 ms –1 (60 ft./min) 2.0 NATURAL CONVECTION 1.0 PD 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (°C) 8-988(C) Figure 20. Total Power Dissipation vs. Local Ambient Temperature and Air Velocity TA θSA where PD is the power dissipated by the module, θCS represents the interfacial contact resistance between the module and the sink, and θSA is the sink-to-ambient thermal impedance (°C/W). For thermal grease or foils, a value of θCS = 0.1 °C/W—0.3 °C/W is typical. The required θSA is calculated from the following equation: θSA = [(Tc – TA)/PD] – θCS Note that this equation assumes that all dissipated power must be shed by the heat sink. Depending on the user-defined application environment, a more accurate model including heat transfer from the sides and bottom of the module can be used. This equation provides a conservative estimate in such instances. 7.0 THERMAL RESISTANCE CASE TO AMBIENT (°C/W) l θCS 0.0 40 Ts Tc 5.0 6.0 5.0 For further information, refer to the Thermal Energy Management CC-, CW-, DC-, and DW-Series 25 W to 30 W Board-Mounted Power Modules Technical Note. 4.0 3.0 2.0 1.0 0.0 NAT 0.25 CONV (50) 0.51 0.76 (100) (150) 1.02 (200) 1.27 1.52 1.78 2.03 (250) (300) (350) (400) VELOCITY ms –1 (ft./min.) 8-989(C) Figure 21. Case-to-Ambient Thermal Resistance vs. Air Velocity Lineage Power 15 DW025 Dual Output-Series Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W Data Sheet April 2008 Outline Diagrams Dimensions are in millimeters and (inches). Copper paths must not be routed beneath the power module standoffs. Tolerances: x.x ± 0.5 mm (0.02 in.), x.xx ± 0.25 mm (0.010 in.). Pinout A (DW025AJ-M, BK-M, CL-M) Top View 71.1 (2.80) MAX PIN 1 INDICATOR 61.0 (2.40) MAX M3 DC-DC Power Module MADE IN USA Side View 0.51 (0.020) 12.7 (0.50) MAX 5.1 (0.20) MIN Bottom View 1.02 (0.040) ± 0.08 (0.003) DIA TIN-PLATED BRASS, 8 PLACES STAND-OFF, 4 PLACES 4.8 (0.19) 5.1 (0.20) 7.1 (0.28) 5 VO2(–) 4 20.32 (0.800) VI(–) 10.16 (0.400) 3 6 VI(+) 10.16 (0.400) 2 20.32 (0.800) 50.8 (2.00) 7 ON/OFF 20.32 (0.800) VO1(+) CASE 1 30.5 (1.20) COM 10.16 (0.400) MOUNTING INSERTS M3 x 0.5 THROUGH, 4 PLACES 8 NC 48.3 (1.90) 11.4 (0.45) 63.50 ± 0.38 (2.500 ± 0.015) 3.8 (0.15) 8-845(C).a 16 Lineage Power DW025 Dual Output-Series Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W Data Sheet April 2008 Outline Diagrams (continued) Dimensions are in millimeters and (inches). Copper paths must not be routed beneath the power module standoffs. Tolerances: x.x ± 0.5 mm (0.02 in.), x.xx ± 0.25 mm (0.010 in.). Pinout B (DW025AA-M, AB-M, AF-M, BB-M, CC-M) Top View 71.1 (2.80) MAX PIN 1 INDICATOR Lucent 61.0 (2.40) MAX M3 DC-DC Power Module MADE IN USA Side View 12.7 (0.50) MAX 0.51 (0.020) 5.1 (0.20) MIN Bottom View 1.02 (0.040) ± 0.08 (0.003) DIA TIN-PLATED BRASS, 9 PLACES STAND-OFF, 4 PLACES 4.8 (0.19) 5.1 (0.20) 7.1 (0.28) 5 VO2(–) 4 6 VO2(+) VI(–) 10.16 (0.400) 10.16 (0.400) 7 3 VI(+) VO1(–) CASE VO1(+) 10.16 (0.400) 20.32 (0.800) 50.8 (2.00) 10.16 (0.400) 2 8 1 30.5 (1.20) 20.32 (0.800) ON/OFF MOUNTING INSERTS M3 x 0.5 THROUGH, 4 PLACES NC 20.32 (0.800) 9 48.3 (1.90) 11.4 (0.45 ) 63.50 ± 0.38 (2.500 ± 0.015) 3.8 (0.15) 8-846(C).a Lineage Power 17 DW025 Dual Output-Series Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W Data Sheet April 2008 Recommended Hole Patterns Component-side footprint. Dimensions are in millimeters and (inches). Recommended hole size for pin: 1.27 mm (0.050 in.). Pinout A (DW025AJ-M, BK-M, CL-M) M3 x 0.5 CLEARANCE HOLE 4 PLACES (OPTIONAL) CASE OUTLINE 1 8 2 7 3 6 30.5 (1.20) 20.32 (0.800) 10.16 (0.400) 61.0 (2.40) MAX 10.16 (0.400 ) 4 10.16 (0.400) 20.32 (0.800) 50.8 (2.00) 20.32 (0.800) 5 5.1 (0.20) 48.3 (1.90) 11.4 (0.45) 63.50 ± 0.38 (2.500 ± 0.015) 3.8 (0.15) 71.1 (2.80) MAX 8-845(C).a Pinout B (DW025AA-M, AB-M, AF-M, BB-M, CC-M) CASE OUTLINE CASE OUTLINE M3 x 0.5 CLEARANCE HOLE 4 PLACES (OPTIONAL) 1 9 2 8 3 7 4 6 30.5 (1.20) 20.32 (0.800) 10.16 (0.400) 61.0 (2.40) MAX 20.32 (0.800) 10.16 (0.400) 10.16 (0.400) 50.8 (2.00) 10.16 (0.400) 20.32 (0.800) 5 5.1 (0.20 ) 48.3 (1.90) 11.4 (0.45) 63.50 ± 0.38 (2.500 ± 0.015) 3.8 (0.15) 71.1 (2.80) MAX 8-846(C).a 18 Lineage Power DW025 Dual Output-Series Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W Data Sheet April 2008 Ordering Information Table 4. Ordering Information Table Input Voltage Output Voltage Output Power Remote On/Off Logic Device Code Pinout Comcode 36 V to 75 V 5.0 V, –5.0 V 25 W positive DW025AJ-M A 107587545 36 V to 75 V 12.0 V, –12.0 V 25 W positive DW025BK-M A 107587602 36 V to 75 V 15.0 V, –15.0 V 25 W positive DW025CL-M A 107587628 36 V to 75 V 5.0 V, –5.0 V 25 W positive DW025AA-M B 107731598 36 V to 75 V 5.0 V, 3.3 V 25 W positive DW025AF-M B 107587529 36 V to 75 V 12.0 V, 12.0 V 25 W positive DW025BB-M B 107587586 36 V to 75 V 15.0 V, 15.0 V 25 W positive DW025CC-M B TBD 36 V to 75 V 5.0 V, 12.0 V 25 W positive DW025AB-M B 107587503 Optional features may be ordered using the device code suffixes shown below. To order more than one option, list suffixes in numerically descending order followed by the -M suffix, indicating metric (M3 x 0.5 heat sink hardware). The heat sinks designed for this package have an M prefix, i.e., MHSTxxx45 and MHSLxxx45 (see Thermal Energy Management CC-, CW-, DC-, and DW-Series 25 W to 30 W Board-Mounted Power Modules Technical Note). Table 5. Options Table Option Short pins: 2.79 mm ± 0.25 mm (0.110 in. ± 0.010 in.) Negative Remote on/off logic Device Code Suffix 8 1 Please contact your Lineage Power Account Manager or Field Application Engineer for pricing and availability. Lineage Power 19 DW025 Dual Output-Series Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W Data Sheet April 2008 A sia-Pacific Head qu art ers T el: +65 6 41 6 4283 World W ide Headq u arters Lin eag e Po wer Co rp oratio n 30 00 Sk yline D riv e, Mes quite, T X 75149, U SA +1-800-526-7819 (Outs id e U .S.A .: +1- 97 2-2 84 -2626) www.line ag ep ower.co m e-m ail: tech sup port1@ lin ea gep ower.co m Eu ro pe, M id dle-East an d Afric a He ad qu arters T el: +49 8 9 6089 286 Ind ia Head qu arters T el: +91 8 0 28411633 Lineage Power reserves the right to make changes to the produc t(s) or information contained herein without notice. No liability is ass umed as a res ult of their use or applic ation. No rights under any patent acc ompany the sale of any s uc h pr oduct(s ) or information. © 2008 Lineage Power Corpor ation, (Mesquite, Texas ) All International Rights Res er ved. April 2008 DS96-078EPS (Replaces DS96-077EPS)