nUltra-wide input voltage ranges: 9-36V or 18-75V
nDesigned to meet UL1950/EN60950.
BASIC insulation (all 48VIN models)
nCE mark available (75V input models)
nSmall packages, 2" x 2" x 0.45"
Fully isolated, 1500Vdc guaranteed
n
nGuaranteed efficiencies to 82%
n–40 to +100°C operating temperature
nModifications and customs for OEM’s
TWR A-Series
20W, Triple Output DC/DC Converters
Among the three families of triple-output DC/DC converters in C&D’s
A-Series, the 20W 2" x 2" devices are distinguished by their unique
"power-sharing" architecture. This feature enables devices to deliver
the full 20 Watts of output power under a variety of output-loading
conditions.
PRODUCT OVERVIEW
Each unit’s primary +5V output can source any current up to 3 Amps (primary power = 15W); while its
auxiliary ±12/15V outputs can source currents up to
±500mA (auxiliary power = 12/15W). Devices deliver
any combination of primary plus auxiliary power as
long as the total output power does not exceed 20
Watts. This feature enables designers to select a
single device to fulfill any number of different requirements.
As members of C&D’s new A-Series, the 20W triples
exhibit both low cost and outstanding long-term reliability. Their design combines straightforward circuit
topologies, the newest components, proven SMT-onpcb construction methods, and highly repeatable automatic-assembly techniques. Their superior durability
SIMPLIFIED SCHEMATIC
is substantiated by a rigorous in-house qualification
program that includes HALT (Highly Accelerated Life
Testing).
Each device has a +5V primary output and either
±12V or ±15V auxiliary outputs. "D12A" models
achieve fully rated performance with inputs ranging
from 9 to 36 Volts. "D48A" models operate over an
input range of 18-75 Volts.
These full-featured triples have non-latching output
current limiting, input overvoltage shutdown, input
reverse-polarity protection, and output overvoltage
clamping to protect both the power converters and
their loads.
www.cd4power.com/rohs
www.cd4power.com
For full details go to
D C / D C C O N V E R T E R S
MDC_TWR20W.A03 Page 1 of 8
Page 2
P O W E R E L E C T R O N I C S D I V I S I O N
BO T TO M VIE W
1.8 00
(4 5.72)
0.1 0
(2 .54)
2.0 0
(5 0.80)
8
5
6
7
0.4 0
(1 0.16)
0.2 00
(5 .08)
0.4 00
(1 0.16)
0.1 00
(2 .54)
1
2
4
ME T AL C AS E
IN SU LA T ED B AS E
0.0 40 ±0.00 2 D IA.
(1 .016 ±0. 051)
2.0 0
(5 0.80)
0.2 0 MI N
(5 .08)
0.4 5
(1 1.43)
1.2 00
(3 0.48)
3 E Q . S P. @
0.4 00 (1 0.16 )
Output Power (Watts)
Ambient Temperature (°C)
–40 0 40 45 50 55 60 65 70 75 80 85 90 95 100
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
PERFORMANCE SPECIFICATIONS AND ORDERING GUIDE
OutputInput
R/N (mVp-p) Regulation
Model Family
TWR-5/3000-12/500-D12A
TWR-5/3000-12/500-D48A
TWR-5/3000-15/500-D12A
TWR-5/3000-15/500-D48A
Typical @ TA = +25°C under nominal line voltage and full-load conditions unless otherwise noted.
For testing and specification purposes, "full load" is defined as 2.75A on the primary +5V output
and ±250/200mA on the auxiliary ±12/15V outputs. This corresponds to a total output power of
19.75W.
(V)
+5300050100±1%±2%
±12
+5300050100±1%±2%
±12
+5300050100±1%±2%
±15
+5300050100±1%±2%
±15
VOUT
IOUT
(mA)
Typ.Max.LineLoad
±50075125±1%±5%
±50075125±1%±5%
±50075150±1%±5%
±50075150±1%±5%
TWR A-Series
20W, Triple Output DC/DC Converters
Package
VIN Nom.
(Volts)
12
Range
(Volts)
IIN
(mA)
9-3675/111881%82%C4, P13
Efficiency
Min.Typ.
4818-7540/55982%83%C4, P13
12
9-3675/111881%82%C4, P13
4818-7540/55981%82%C4, P13
Ripple/Noise (R/N) measured over a 20MHz bandwidth.
For the +5V output, listed spec applies over the 10% to 100% load range. For the ±12/15V outputs,
listed spec applies for balanced loads over the 20% to 100% load range.
Nominal line voltage, no-load/full-load conditions.
Case Material Corrosion resistant steel with
non-conductive, epoxy-based, black
enamel finish and plastic baseplate
Pin Material Copper alloy with gold plate over nickel
underplate
Weight 2.7 ounces (77 grams)
These converters require 10% min. loading on their primary output and 20% min.
loading on their auxiliary outputs to maintain specified regulation. Operation under no-load
conditions will not damage the devices; however they may not meet all listed specifications. For
testing and specification purposes, "full load" is defined as 2.75A on the primary +5V output and
±250/200mA on the auxiliary ±12/15V outputs. This corresponds to a total output power of 19.75W.
Application-specific internal input/output filtering can be recommended or perhaps added
internally upon request. Contact C&D Applications Engineering for details.
Applying a voltage to the Control pin when no input power is applied to the converter can
cause permanent damage to the converter.
D48A models have BASIC, D12A models have Functional insulation.Devices can be screened
or modified for higher guaranteed isolation voltages. Contact C&D Applications Engineering
for details.
To avoid damage to the surface finish, please do not use certain cleaning agents such as Vigon.
These are stress ratings. Exposure of devices to any of these conditions may adversely
affect long-term reliability. Proper operation under conditions other than those listed in
the Performance/Functional Specifications Table is not implied.
Technical Notes
Filtering and Noise Reduction
All A-Series TWR 20 Watt DC/DC Converters achieve their rated ripple and
noise specifications without the use of external input/output capacitors. In
critical applications, input/output noise may be further reduced by installing
electrolytic capacitors across the input terminals and/or low-ESR tantalum or
-
electrolytic capacitors across the output terminals. Output capacitors should
be connected between their respective output pin (pin 5, 6 or 8) and Common
(pin 7). The caps should be located as close to the power converters as
possible. Typical values are listed below. In many applications, using values
greater than those listed will yield better results.
To Reduce Input Ripple
D12A Models 20µF, 50V
D48A Models 10µF, 100V
To Reduce Output Ripple
+5V Output 47µF, 10V, Low ESR
±12/15V Outputs 33µF, 20V, Low ESR
In critical, space-sensitive applications, C&D may be able to tailor the internal
input/output filtering of these units to meet your specific requirements. Contact our Applications Engineering Group for additional details.
Input Fusing
Certain applications and/or safety agencies may require the installation of
fuses at the inputs of power conversion components. For C&D A-Series TWR
20 Watt DC/DC Converters, you should use slow-blow type fuses with values
no greater than 4A for "D12A" models and 2A for "D48A" models.
On/Off Control
The On/Off Control pin (pin 4) may be used for remote on/off operation. A TTL
logic high (+2 to +5 Volts, 250µA max.) applied to pin 4 disables the converter.
A TTL logic low (0 to +0.8 Volts, 70µA max.), or no connection, enables the
converter. Control voltages should be referenced to pin 2 (–Input). Applying a
voltage to the Control pin when no input power is applied to the converter can
cause permanent damage to the converter.
The performance curves below were derived from actual test data for a single model number (TWR-5/3000-12/250-D48).
Since all devices in this series have the same circuit architecture, the performance curves are representative for all devices.
Converter Output = +5Vdc @ 2.7A and ±15Vdc @ ±450mA
TWR-5/3000-15/500-D12A Radiated Emissions
EN 55022 Class B, 10 Meters
Converter Output = +5Vdc @ 2.7A and ±15Vdc @ ±450mA
LINE REGULATIONEMI RADIATED EMISSIONS
If you’re designing with EMC in mind, note that all of C&D’s TWR 20 Watt
A-Series DC/DC Converters have been characterized for radiated and conducted emissions in our new EMI/EMC laboratory. Testing is conducted in
an EMCO 5305 GTEM test cell utilizing EMCO automated EMC test software.
Radiated emissions are tested to the limits of FCC Part 15, Class B and
CISPR 22 (EN 55022) Class B. Correlation to other specifications can be
supplied upon request. Radiated emissions plots to FCC and CISPR 22 for
model TWR-5/3000-15/500-D12A appear below. Its performance is typical
of all models in the Series. Published EMC test reports are available for
each model number. Contact C&D’s Applications Engineering for details.
TWR A-Series
20W, Triple Output DC/DC Converters
www.cd4power.com
D C / D C C O N V E R T ER S
MDC_TWR20W.A03 Page 6 of 8
Page 7
P O W E R E L E C T R O N I C S D I V I S I O N
10 20 30 40 50 60 70 80 90
40
20
0
Random Vibration (G's)
Temperature (°C)
Test Time (minutes)
100
80
60
40
20
0
–20
–40
TWR A-Series
20W, Triple Output DC/DC Converters
Quality and Reliability
The A-Series are the first DC/DC Converters to emerge from C&D’s new,
company-wide approach to designing and manufacturing the most reliable
power converters available. The five-pronged program draws our Quality
Assurance function into all aspects of new-product design, development,
characterization, qualification and manufacturing.
Design for Reliability
Design for Reliability is woven throughout our multi-phased, new-productdevelopment process. Design-for-reliability practices are fully documented
and begin early in the new-product development cycle with the following
goals:
1. To work from an approved components/vendors list ensuring the use of
reliable components and the rigorous qualification of new components.
2. To design with safety margins by adhering to a strict set of derating
guidelines and performing theoretical worst-case analyses.
3. To locate potential design weaknesses early in the product-development
cycle by using extensive HALT (Highly Accelerated Life Testing).
4. To prove that early design improvements are effective by employing a
thorough FRACA (Failure Reporting Analysis and Corrective Action) system.
HALT Testing
The goal of the accelerated-stress techniques used by C&D is to force
device maturity, in a short period of time, by exposing devices to excessive
levels of "every stimulus of potential value." We use HALT (Highly Accelerated Life Testing) repeatedly during the design and early manufacturing
phases to detect potential electrical and mechanical design weaknesses
that could result in possible future field failures.
During HALT, prototype and pre-production DC/DC converters are subjected to progressively higher stress levels induced by thermal cycling,
rate of temperature change, vibration, power cycling, product-specific
stresses (such as dc voltage variation) and combined environments. The
stresses are not meant to simulate field environments but to expose any
weaknesses in a product’s electro/mechanical design and/or assembly processes. The goal of HALT is to make products fail so that device
weaknesses can be analyzed and strengthened as appropriate. Applied
Typical HALT Profile
stresses are continually stepped up until products eventually fail. After
corrective actions and/or design changes, stresses are stepped up again
and the cycle is repeated until the "fundamental limit of the technology" is
determined.
C&D has invested in a Qualmark OVS-1 HALT tester capable of applying
voltage and temperature extremes as well as 6-axis, linear and rotational,
random vibration. A typical HALT profile (shown above) consists of thermal
cycling (–55 to +125°C, 30°C/minute) and simultaneous, gradually increas
ing, random longitudinal and rotational vibration up to 20G’s with load
cycling and applied-voltage extremes added as desired. Many devices in
C&D’s A-Series could not be made to fail prior to reaching either the limits
of the HALT chamber or some previously known physical limit of the device.
We also use the HALT chamber and its ability to rapidly cool devices to
verify their "cold-start" capabilities.
Qualification
For each new product, electrical performance is verified via a comprehensive characterization process and long-term reliability is confirmed via a
rigorous qualification procedure. The qual procedure includes such strenuous tests as thermal shock and 500 hour life. Qual testing is summarized
below.
Qualification Testing
Qualification Test Method/Comments
HALT C&D in-house procedure
High Temperature Storage Max. rated temp., 1,000 hours
End Point Electrical Tests Per product specification
* Interim electrical test at 200 hours.
In-Line Process Controls and Screening
A combination of statistical sampling and 100% inspection techniques
keeps our assembly line under constant control. Parameters such as
solder-paste thickness, component placement, cleanliness, etc. are statistically sampled, charted and fine tuned as necessary. Visual inspections are
performed by trained operators after pick-and-place, soldering and cleaning
operations. Units are 100% electrically tested prior to potting. All devices
are temperature cycled, burned-in, hi-pot tested and final-electrical tested
prior to external visual examination, packing and shipping.
-
Rapid Response to Problems
C&D employs an outstanding corrective-action system to immediately
address any detected shortcomings in either products or processes. Whenever our assembly, quality or engineering personnel spot a product/process
www.cd4power.com
problem, or if a product is returned with a potential defect, we immediately
perform a detailed failure analysis and, if necessary, undertake corrective
actions. Over time, this system has helped refine our assembly operation to
yield one of the lowest product defect rates in the industry.
D C / D C C O N V E R T ER S
MDC_TWR20W.A03 Page 7 of 8
Page 8
P O W E R E L E C T R O N I C S D I V I S I O N
®
TWR A-Series
20W, Triple Output DC/DC Converters
20 Watt Converter Operational Details
There are several operational details of the 20W TWR series to be
aware of when applying these converters.
20 Watts maximum power
The total maximum power for all outputs is 20 Watts. This is the
sum of each separate output. Any one output may achieve its
maximum power as long as the sum of all outputs for the whole
converter does not exceed 20 Watts.
For example, using model TWR-5/3000-15/500-D12A, if the maxi
mum power is drawn from the two ±15 Volt supplies, this produces
15 Watts (7.5 W plus 7.5 W) total power. The 5V output may then
deliver 5 Watts maximum (not 15W) so that the total converter
power is 7.5W+7.5W+5W=20W.
Regulation Differences Between Outputs
Looking at the Schematic diagram, observe that magnetic energy
driven from the primary side affects all three outputs simultaneously since they share a common transformer in combination a with
magnetically coupled output inductor. We see that the regulation
feedback is derived directly from the 5 Volt output and indirectly
from the 12/15V outputs. Increasing current on the 12/15V outputs
absorbs magnetic energy driving the 5V output therefore reducing the 5V output voltage. Regulation compensates for this drop in
output voltage but not to the same extent as the 5V output regulation.
Short-circuit Conditions
Because of the interconnected regulation and common transformer,
a short circuit on one output will cause a voltage reduction on the
remaining unshorted outputs. This effect is more pronounced for
the 5V superior output vs. the 12/15V subordinate outputs. That is, a
5V short essentially places the PWM controller in power-limit mode
whereas a 12/15V short may leave some partial power available on
the remaining outputs.
Time limits on short circuits
The 5V output will tolerate 5 minutes maximum short circuit time
at +25 deg.C. For the 12/15V outputs, short ciruits must limit to 30
seconds at +25 deg.C. Failure to remove the short circuits within
these time limits may damage the converter or cause permanent
operational changes. Higher ambient temperatures require reduced
short circuit times. As long as shorts or overcurrents are removed
within these time limits, the outputs will automatically recover to
normal operation.
As a practical matter, since it is difficult to control short circuit
duration, make sure that the application is highly unlikely to cause
a short circuit or the input is disconnected by means of a circuit
breaker or fuse.
The Three Outputs are not isolated from each other
The three outputs share a common ground return which is fully
isolated from the primary input side but not between each other.
Therefore do not apply the outputs to applications which require
isolation between the 5V and 12/15V sections.
C&D Technologies, Inc.
11 Cabot Boulevard, Mansfield, MA 0204
Tel: (508) 339-3000 (800) 233-2765 Fax: (508) 339-6356