FEATURES Efficiency up to 88% Industry standard form factor and pinout Size: 31.8 x20.3 x10.2mm (1.25" x0.80" x0.40") Input: 12V, 24V, 48V (2:1) Output: 3.3, 5, 5.1, 12, 15, 12, 15V Low ripple and noise 1500V isolation Output OCP, OVP, short circuit protection UL 94V-0 Package Material ISO 9001 and ISO14001 certified manufacturing facility CSA 60950-1 Recognized Delphi DIW5000 Series DC/DC Power Modules: 12, 24, 48Vin, 10W DIP The Delphi DIW5000, 12V, 24V, and 48V 2:1 wide input, single or dual output, DIP form factor, isolated DC/DC converter is the latest offering from a world leader in power systems technology and manufacturing Delta Electronics, Inc. The DIW3000 series operate from 12V, 24V, or 48V (2:1) and provides 3.3V, 5V, 12V, or 15V of single output or 5V, 12V, or 15V of dual output in an industrial standard, metal case encapsulated DIP package (body size: 1.25"x 0.80"x0.40"). This series provides up to 6W of output power with 1500V isolation and a typical full-load efficiency up to 86%. With creative design technology and optimization of component placement, these converters possess outstanding electrical and thermal performance, as well as extremely high reliability under highly stressful operating conditions. DATASHEET DS_DIW5000_12032008 OPTIONS APPLICATIONS Industrial Transportation Process/ Automation Telecom Data Networking TECHNICAL SPECIFICATIONS TA = 25C, airflow rate = 0 LFM, nominal Vin, nominal Vout, resistive load unless otherwise noted. PARAMETER NOTES and CONDITIONS DIW5000 (Standard) Min. ABSOLUTE MAXIMUM RATINGS Input Voltage Transient Transient Transient Internal Power Dissipation Operating Temperature Storage Temperature Humidity Lead Temperature in Assembly Input/Output Isolation Voltage INPUT CHARACTERISTICS Operating Input Voltage Turn-On Voltage Threshold Turn-Off Voltage Threshold Maximum Input Current No-Load Input Current Input Reflected Ripple Current Short Circuit Input Power Reverse Polarity Input Current OUTPUT CHARACTERISTICS Output Voltage Set Point Accuracy Output Voltage Balance Output Voltage Regulation Over Load Over Load Over Line Over Temperature Output Voltage Ripple and Noise Peak-to-Peak Peak-to-Peak, over line, load, temperature RMS Output Over Current/Power Protection Output Short Circuit Output Voltage Current Transient Step Change in Output Current Settling Time (within 1% Vout nominal) Maximum Output Capacitance EFFICIENCY 100% Load ISOLATION CHARACTERISTICS Isolation Voltage Isolation Voltage Test Isolation Resistance Isolation Capacitance FEATURE CHARACTERISTICS Switching Frequency GENERAL SPECIFICATIONS MTBF Weight Case Material Flammability Input Fuse 12V input model, 1000ms 24V input model, 1000ms 48V input model, 1000ms -0.7 -0.7 -0.7 Ambient Case -40 -40 -40 Typ. Max. Units 25 50 100 2500 85 100 125 95 260 Vdc Vdc Vdc mW C C C % C Vdc 18 36 75 9 18 36 8.5 17 34 Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc 2.5 0.5 mA mA mA mA mA mA W A 0.6 0.5 1.2 2.0 % % 0.5 0.7 0.3 0.01 1.2 1.5 1.0 0.02 % % % %/C 50 85 100 15 180 mV mV mV % 5 500 2200 820 470 220 150 % uS F F F F F 1200 Vdc Vdc M pF 1.5mm from case for 10 seconds 1500 12V model 24V model 48V model 12V model 24V model 48V model 12V model 24V model 48V model Please see Model List table on page 6 12V model 24V model 48V model 12V model 24V model 48V model All models 9 18 36 7 14 30 ------- 40 20 10 60 40 40 Dual output models Io=10% to 100% Io=10% to 100%, 2.5V only Vin= min to max Tc=-40C to 100C 5Hz to 20MHz bandwidth Full Load, 0.47F ceramic Full Load, 0.47F ceramic Full Load, 0.47F ceramic Auto restart Continuous 12 24 48 8 16 33 ------- 110 25% step change 150 3 250 2.5V to 5.1V single output models 12V single output model 15V single output model 12V Dual output model, each output 15V Dual output model, each output Please see Model List table on page 6 Input to output, 60 Seconds Flash Test for 1 seconds 500VDC 100KHz, 1V MIL-HDBK-217F; Ta=25C, Ground Benign 1500 1650 1000 1000 400 kHz 17.3 M hours grams 1 Non-conductive black plastic UL94V-0 12V model, 2000mA slow blown type 24V model, 1000mA slow blown type 48V model, 500mA slow blown type 2 ELECTRICAL CHARACTERISTICS CURVES 90 90 Efficiency (%) 100 Efficiency (%) 100 80 70 60 50 80 70 60 Low Nom 50 High Low Nom Input Voltage (V) Figure 2: Efficiency vs. Input Voltages (Dual Output) 90 90 80 80 70 70 Efficiency (%) Efficiency (%) Figure 1: Efficiency vs. Input Voltage (Single Output) 60 50 60 50 40 40 30 30 20 10 20 40 60 High Input Voltage (V) 80 Load Current (%) Figure 3: Efficiency vs. Output Load (Single Output) 100 20 10 20 40 60 80 100 Load Current (%) Figure 4: Efficiency vs. Output Load (Dual Output) 3 Test Configurations Design & Feature Considerations Input Reflected-Ripple Current Test Setup The DIW5000 circuit block diagrams are shown in Figures 5 and 6. To Oscilloscope + + Battery +Vin Lin DC / DC Converter Current Probe Cin +Out -Vin Load +Vin +Vo LC Filter -Out Input reflected-ripple current is measured with a inductor Lin (4.7uH) and Cin (220uF, ESR < 1.0 at 100 KHz) to simulate source impedance. Capacitor Cin is to offset possible battery impedance. Current ripple is measured at the input terminals of the module and measurement bandwidth is 0-500 KHz. Peak-to-Peak Output Noise Measurement Scope measurement should be made by using a BNC socket, measurement bandwidth is 0-20 MHz. Position the load between 50 mm and 75 mm from the DC/DC Converter. A Cout of 0.47uF ceramic capacitor is placed between the terminals shown below. -Vo PFM -Vin Isolation Ref.Amp Figure 5: Block diagram of DIW5000 single output modules. +Vin +Vo LC Filter Com. -Vo +Vin +Out Single Output DC / DC Converter -Vin Copper Strip Cout Resistive Scope Load PFM -Vin Isolation Ref.Amp -Out Figure 6: Block diagram of DIW5000 dual output modules +Vin +Out Dual Output DC / DC Converter Com. -Vin -Out Copper Strip Cout Scope Cout Scope Input Source Impedance Resistive Load The power module should be connected to a low acimpedance input source. Highly inductive source impedances can affect the stability of the power module. + DC Power Source - +Vin + +Out DC / DC Converter Load Cin -Vin -Out In applications where power is supplied over long lines and output loading is high, it may be necessary to use a capacitor at the input to ensure startup. Capacitor mounted close to the input of the power module helps ensure stability of the unit, it is recommended to use a good quality low Equivalent Series Resistance (ESR < 1.0 at 100 KHz) capacitor of a 12uF for the 12V input devices, a 4.7uF for the 24V input devices, and a 2.2uF for the 48V devices. 4 Design & Feature Considerations Maximum Capacitive Load Soldering and Cleaning Considerations The DIW5000 series has limitation of maximum connected capacitance at the output. The power module may be operated in current limiting mode during start-up, affecting the ramp-up and the startup time. Post solder cleaning is usually the final board assembly process before the board or system undergoes electrical testing. Inadequate cleaning and/or drying may lower the reliability of a power module and severely affect the finished circuit board assembly test. Adequate cleaning and/or drying is especially important for un-encapsulated and/or open frame type power modules. For assistance on appropriate soldering and cleaning procedures, please contact Delta's technical support team. Output Ripple Reduction A good quality low ESR capacitor placed as close as practicable across the load will give the best ripple and noise performance. To reduce output ripple, it is recommended to use 3.3uF capacitors at the output. + +Vin +Out Single Output DC / DC Converter DC Power Source -Vin -Out + +Vin +Out Dual Output DC / DC Com. Converter DC Power Source - -Vin -Out 1. These power converters require a minimum output load to maintain specified regulation (please see page 6 for the suggested minimum load). Operation under no-load conditions will not damage these modules; however, they may not meet all specifications listed above. 2. These DC/DC converters should be externally fused at the front end for protection. Cout - Notes: Load Cout Load Overcurrent Protection 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. The unit operates normally once the output current is brought back into its specified range. Over voltage Protection The output over voltage clamp control is independent of the primary regulation loop. It monitors the voltage on the output terminals. The control loop of the clamp has a higher voltage set point than the primary loop. This provides a redundant voltage control that reduces the risk of output over voltage. 5 THERMAL CONSIDERATIONS Thermal management is an important part of the system design. To ensure proper, reliable operation, sufficient cooling of the power module is needed over the entire temperature range of the module. Convection cooling is usually the dominant mode of heat transfer. Hence, the choice of equipment to characterize the thermal performance of the power module is a wind tunnel. Thermal Testing Setup Delta's DC/DC power modules are characterized in heated vertical wind tunnels that simulate the thermal environments encountered in most electronics equipment. This type of equipment commonly uses vertically mounted circuit cards in cabinet racks in which the power modules are mounted. THERMAL CURVES DIW5000series Output Current vs. Ambient Temperature and Air Velocity (Either Orientation) 120% Output Power (%) 100% 80% Natural Convection 60% 40% 20% 0% 25 35 45 55 65 75 85 Ambient Temperature () Figure 8: Derating Curve The following figure shows the wind tunnel characterization setup. The power module is mounted on a test PWB and is vertically positioned within the wind tunnel. The space between the facing PWB and PWB is constantly kept at 25.4mm (1''). Figure 7: Wind tunnel test setup Thermal Derating Heat can be removed by increasing airflow over the module. To enhance system reliability, the power module should always be operated below the maximum operating temperature. If the temperature exceeds the maximum module temperature, reliability of the unit may be affected. 6 MODEL LIST INPUT Vdc (V) OUTPUT Full Load Efficiency Max (mA) Vdc (V) Max (mA) Min (mA) % DIW5021 1006 3.3 3000 300 82 DIW5022 1004 5 2000 200 83 1024 5.1 2000 200 83 957 12 833 83 87 968 15 666 67 86 957 12 416 42 86 DIW5027 968 DIW5030 377 15 2.5 333 3000 33 300 83 DIW5031 485 3.3 3000 300 85 DIW5032 479 5 2000 200 87 DIW5029 DIW5023 DIW5024 12 (9 ~ 18) DIW5026 DIW5039 83 489 5.1 2000 200 87 479 12 833 83 87 DIW5034 478 15 666 67 87 DIW5036 473 12 416 42 88 DIW5037 478 DIW5040 188 15 2.5 333 3000 33 300 83 DIW5041 243 3.3 3000 300 85 DIW5042 239 5 2000 200 87 DIW5033 DIW5049 24 (18 ~ 36) 87 244 5.1 2000 200 87 240 12 833 83 87 DIW5044 239 15 666 67 87 DIW5046 236 12 416 42 88 DIW5047 243 15 333 33 87 DIW5043 48 (36 ~ 75) 7 MECHANICAL DRAWING 4.1 [0.16"] 10.2 [0.40"] 31.8 [1.25"] Pin 2 3 9 11 14 16 22 23 0.5 [0.02"] Single Output -Vin -Vin No Pin NC +Vout -Vout +Vin +Vin Dual Output -Vin -Vin Common -Vout +Vout Common +Vin +Vin 4.5 [0.18"] 3 9 11 23 22 16 14 15.3 [0.60"] 2 20.3 [0.80"] 2.54 [0.10"] 2.5 [0.10"] SIDE VIEW BOTTOM VIEW CONTACT: www.delta.com.tw/dcdc USA: Europe: Asia & the rest of world: Telephone: East Coast: (888) 335 8201 West Coast: (888) 335 8208 Fax: (978) 656 3964 Email: DCDC@delta-corp.com Phone: +41 31 998 53 11 Fax: +41 31 998 53 53 Email: DCDC@delta-es.com Telephone: +886 3 4526107 ext 6220~6224 Fax: +886 3 4513485 Email: DCDC@delta.com.tw WARRANTY Delta offers a two (2) year limited warranty. Complete warranty information is listed on our web site or is available upon request from Delta. Information furnished by Delta is believed to be accurate and reliable. However, no responsibility is assumed by Delta for its use, nor for any infringements of patents or other rights of third parties, which may result from its use. No license is granted by implication or otherwise under any patent or patent rights of Delta. Delta reserves the right to revise these specifications at any time, without notice. 8