Datasheet TWR-5-1000-15-200-D48A, TWR-5-1000-15-200-D24A, TWR-5-1000-15-200-D12A, TWR-5-1000-15-150-D5A, TWR-5-1000-12-210-D48A Datasheet (DATEL)

Figure 1. Simplified Schematic

Features

Among the three families of triple-output DC/DC converters in DATEL’s new
A-Series, the 8-11W, 2" x 1" de vices stand out as the industry’s smallest
full-featured triples. Housed in miniature 2" x 1" x 0.375", 5-side shielded, metal
packages with electrically non-conductive coatings, these power converters offer non­latching output current limiting, input overvoltage shutdown (except D5A models), input
reverse-polarity protection, and output overvoltage clamping to protect both the power
converters and their loads.

As members of DATEL ’ s new A-Series, the 8-11W triples feature both lo w cost and
outstanding long-term reliability. Their design combines straightforw ard circuit topolo­gies, the newest components, pro ven SMT-on-pcb construction methods, and highly
repeatable automatic-assembly techniques. Their superior durability is substantiated by
a rigorous in-house qualification program that includes HAL T (Highly Accelerated Lif e
T esting).

Each of these fully line and load-regulated switching DC/DC converters has a +5V
primary output (with output current as high as 1A) and either ±12V or ±15V auxiliary
outputs (with currents as high as ±210mA). These devices were designed to power
small analog/digital partitions in equipment employing distributed-power architectures
with bus voltages between 4.7 and 72 V olts. Applications include computer/networking,
telecom/datacom equipment, industrial instrumentation and automatic test equipment.

INNOVATION and EX C ELL E N C E

®

®

Triple Output

A-Series, TWR Models

High-Reliability, 2" x 1"

8-11 Watt, DC/DC Converters

DATEL, Inc., Mansfield, MA 02048 (USA) • Tel: [phone] Fax: [phone] • Email: [e-mail] • Internet: www.datel.com

OPTO

ISOLATION

+5V

–12V (–15V)

ERROR

AMPLIFIER

PWM

CONTROLLER

+V

IN

–

V

IN

+12V (+15V)

COMMON

A- SERIES

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The smallest, full-featured triples
Low cost! Highly reliable!
Proven SMT-on-pcb construction
Qual tested; HAL T tested; EMC tested
Output voltages: +5V/±12V or +5V/±15V
Four input voltage ranges:

4.7-7V , 9-18V , 18-36V or 36-72V
Small packages, 2" x 1" x 0.375"
–40 to +100°C operating temperature
Fully isolated, 1500Vdc guaranteed
Guaranteed efficiencies to 82%
Designed to meet UL1950 and EN60950
Modifications and customs for OEM’ s

8-11W, TRIPLE OUTPUT DC/DC CONVERTERS

A SeriesA Series

A SeriesA Series

A Series

TWR-5/1000-12/125-D5A

TWR-5/1000-12/210-D12A

TWR-5/1000-12/210-D24A

TWR-5/1000-12/210-D48A

TWR-5/800-15/150-D5A

TWR-5/1000-15/200-D12A

TWR-5/1000-15/200-D24A

TWR-5/1000-15/200-D48A

METAL CASE

INSULATED BASE

0.040 ±0.002 DIA.
(1.016 ±0.051)

2.00

(50.80)

0.375
(9.53)

0.20 MIN
(5.08)

0.10

(2.54)

1.800

(45.72)

BOTTOM VIEW

0.200
(5.08)

0.800

(20.32)

0.600

(15.24)

0.300

(7.62)

1.00

(25.40)

1
2

4
5

0.10

(2.54)

6

7

Case C3

2

Function P5

+Input
–Input

No Pin
+12V/15V Out
–12V/15V Out

Common

+5V Out

Pin

1
2
3
4
5
6
7

I/O Connections

Output
Configuration:

T = T riple

Nominal Auxiliary Output

Voltages (±12 or ±15 Volts)

Wide Range Input

Maximum Primary Output

Current in mA

Maximum Auxiliary Output

Currents in mA from each output

Input Volta ge Range:

D5 = 4.7-7 Volts (5V nominal)

D12 = 9-18 Volts (12V nominal)

D24 =18-36 Volts (24V nominal)
D48 =36-72 Volts (48V nominal)

Nominal Primary Output

Voltage (+5 Volts)

5T WR 1000 15 200-/ - / D12 A-

A-Series

High Reliability

5

12

24

48

5

12

24

48

+5

±12

+5

±12

+5

±12

+5

±12

+5

±15

+5

±15

+5

±15

+5

±15

Performance Specifications and Or dering Guide

IOUT

(mA)

R/N (mVp-p)

➁

Load

➂

VOUT

(Volts)

Output

Package

(Case,

Pinout)

Efficiency

Regulation (Max.)

Line

VIN Nom.

(Volts)

Range

(Volts)

Model

Input

IIN ➃

(mA)

➀

Max.Typ. Typ.Min.

4.7-7

9-18

18-36

36-72

4.7-7

9-18

18-36

36-72

100/2324

50/1087

50/534

50/267

100/2441

50/1187

50/572

50/286

74%

80.5%

82%

82%

74%

79%

82%

82%

C3, P5

C3, P5

C3, P5

C3, P5

C3, P5

C3, P5

C3, P5

C3, P5

1000
±125
1000
±210
1000
±210
1000
±210

800
±150
1000
±200
1000
±200
1000
±200

100
150
100
150
100
150
100
150
100
175
100
175
100
175
100
175

±1.0%
±5.0%
±1.0%
±5.0%
±1.0%
±5.0%
±1.0%
±5.0%
±1.0%
±5.0%
±1.0%
±5.0%
±1.0%
±5.0%
±1.0%
±5.0%

±2.0%
±5.0%
±2.0%
±5.0%
±2.0%
±5.0%
±2.0%
±5.0%
±2.0%
±5.0%
±2.0%
±5.0%
±2.0%
±5.0%
±2.0%
±5.0%

➀

Typical @ TA = +25°C under nominal line voltage and full-load conditions unless otherwise noted.

➁

20MHz bandwidth. ±12/15V outputs are specified with 10µF , 25V output capacitors.

➂

5V output, 10% to 100% load. ±12/15V outputs, balanced loads, 20% to 100% load .

➃

Nominal line voltage, no-load/full-load conditions.

Output Power (Watts)

Ambient Temperature (°C)

–40 0 40 45 50 55 60 65 7 0 75 8 0 8 5 9 0 9 5 1 0

0

20
19
18
17
16
15
14
13
12
11
10

9
8
7
6
5
4
3
2
1
0

D
B

C

A

TWR-5/1000-12/125-D5A A
TWR-5/1000-12/210-D12A B
TWR-5/1000-12/210-D24A B
TWR-5/1000-12/210-D48A B
TWR-5/800-15/150-D5A C
TWR-5/1000-15/200-D12A D
TWR-5/1000-15/200-D24A D
TWR-5/1000-15/200-D48A D

75

100

75

100

75

100

75

100

75

125

75

125

75

125

75

125

76%

82%

84%

84%

76%

82%

84%

84%

PART NUMBER STRUCTURE

MECHANICAL SPECIFICATIONS

TEMPERATURE DERATING

Notes:

For "D5A/D12A/D24A" models,
the case is connected to pin 2 (–V

IN).

For "D48A" models, the case
is connected to pin 1 (+V

IN).

8-11W, TRIPLE OUTPUT DC/DC CONVERTERS

TWR Models

3

Filtering and Noise Reduction

All A-Series TWR 8-11 Watt DC/DC Converters achieve their rated ripple and
noise specifications without the use of external input/output capacitors. In
critical applications, input/output ripple and 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 4, 5 or

7) and Common (pin 6) as shown in Figure 2. The caps should be located as
close to the power converters as possible. T ypical v alues are listed below . In
many applications, using values greater than those listed will yield better
results.

To Reduce Input Ripple

"D5A" Models 47µF, 10V
"D12A" Models 20µF, 25V
"D24A" Models 20µF, 50V
"D48A" Models 10µF, 100V

To Reduce Output Ripple

+5V Output 47µF, 10V, Low ESR
±12/15V Outputs 22µF , 20V , Low ESR

In critical, space-sensitive applications, DATEL 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.

Performance/Functional Specifications

T ypical @ T A = +25°C under nominal line voltage and full-load conditions, unless noted.

➀

➀

These power converters require a minimum 10% loading on their primary output and a
minimum 20% loading on their auxiliary outputs to maintain specified regulation. Operation
under no-load conditions will not damage these devices; however they may not meet all
listed specifications.

➁

Application-specific internal input/output filtering can be recommended or perhaps added
internally upon request. Contact DA TEL Applications Engineering for details.

➂

Devices can be screened or modified for higher guaranteed isolation voltages.
Contact DA TEL Applications Engineering for details.

➃

On "D48A" models, the case is connected to pin 1 (+VIN).

Input

Input V oltage Ranges:

"D5A" Models 4.7-7 Volts (5V nominal)
"D12A" Models 9-18 Volts (12V nominal)
"D24A" Models 18-36 Volts (24V nominal)
"D48A" Models 36-72 Volts (48V nominal)

Input Current See Ordering Guide
Input Filter Type

➁

Pi

Reverse-Polarity Protection Y es (Instantaneous , 6A maximum)

Output

VOUT Accuracy (50% loads):

+5V Output ±0.5%
±12V or ±15V Outputs ±3%

Temperature Coefficient ±0.02% per °C
Ripple/Noise (20MHz BW)

➁

See Ordering Guide

Line/Load Regulation See Ordering Guide
Efficiency See Ordering Guide
Isolation V oltage

➂

1500Vdc, minimum

Isolation Capacitance 300pF
Current Limiting Auto-recovery
Overvoltage Protection Zener/transorb clamps, magnetic feedback

Dynamic Characteristics

Transient Response (50% load step) 200µsec max. to ±2% of final value
Switching Frequency 175kHz

Environmental

Operating Temperature (Ambient):

Without Derating –40 to +60/70°C (Model dependent)
With Derating to +100°C (See Derating Curve)

Storage Temperature –40 to +105°C

Physical

Dimensions 2" x 1" x 0.375" (51 x 25 x 9.5mm)
Shielding 5-sided
Case Connection Pin 2 (–VIN)

➃

Case Material Corrosion resistant steel with

non-conductive, epoxy-based, black
enamel finish and plastic baseplate

Pin Material Brass, solder coated
Weight 1.3 ounces (37 grams)

Input V oltage:

"D5A" Models 10 Volts
"D12A" Models 22 Volts
"D24A" Models 44 Volts
"D48A" Models 80 Volts

Input Reverse-Polarity Protection Current must be <6A. Brief

duration only. Fusing recommended.

Output Overvoltage Protection

+5V Output 6.8 Volts, limited duration
±12V Outputs ±13 Volts, limited duration
±15V Outputs ±16 Volts, limited duration

Output Current Current limited.

Max. current and
short-circuit duration model
dependent.

Storage Temperature –40 to +105°C
Lead Temperature (soldering, 10 sec.) +300°C

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.

Absolute Maximum Ratings

TECHNICAL NOTES

4

If you’re designing with EMC in mind, please note that all of D ATEL’s TWR
8-11 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-5/1000-12/125-D5A appear below . Published EMC test reports are
available f or each model number. Contact D A TEL’s Applications Engineering
Department for more details.

+INPUT

–INPUT

+12/15V

1

2

4

6

COMMON

7

C

IN

C

OUT

C

OUT

+

+

+

5

+

C

OUT

+5V

–12/15V

Figure 2. Using External Capacitors

to Reduce Input/Output Ripple/Noise

Input Fusing

Certain applications and/or safety agencies may require the installation of fuses
at the inputs of power conversion components . F or DATEL A-Series TWR 8-11
Watt DC/DC Converters, you should use slow-blow type fuses with values no
greater than 3A.

80

70

60

50

40

30

20

10

0

–10

–20

Frequency (MHz)

100

1000

FCC Class B Limit

TWR-5/1000-12/125-D5A Radiated Emissions

FCC Part 15 Class B, 3 Meters

Converter Output = +5Vdc @ 950mA and ±12Vdc @ ±114mA

Radiated Emissions (dBµV/M)

Radiated Emissions

TWR-5/1000-12/125-D5A Radiated Emissions

EN 55022 Class B, 10 Meters

Converter Output = +5Vdc @ 950mA and ±12Vdc @ ±114mA

80

70

60

50

40

30

20

10

0

–10

–20

Frequency (MHz)

100

1000

Radiated Emissions

EN 55022 Class B Limit

Radiated Emissions (dBµV/M)

DA TEL’s world-class design, development and manuf acturing team stands
ready to work with you to deliver the exact power converter you need for your
demanding, large volume, OEM applications. And ... we’ll do it on time and
within budget!

Our experienced applications and design staffs; quick-turn prototype capability;
highly automated, SMT assembly facilities; and in-line SPC quality-control
techniques combine to give us the unique ability to design and deliver any
quantity of power converters to the highest standards of quality and reliability .

We have compiled a large library of DC/DC designs that are currently used in a
variety of telecom, medical, computer, railwa y , aerospace and industrial
applications. We may already have the converter you need.

Contact us. Our goal is to provide you the highest-quality, most cost-effective
power converters available.

EMI RADIATED EMISSIONS

CUSTOM CAPABILITIES

8-11W, TRIPLE OUTPUT DC/DC CONVERTERS

A SeriesA Series

A SeriesA Series

A Series

5

DATEL makes no representation that the use of its products in the circuits described herein, or the use of other technical information contained herein, will not infringe upon existing or future patent rights. The descriptions contained herein
do not imply the granting of licenses to make, use, or sell equipment constructed in accordance therewith. Specifications are subject to change without notice. The DATEL logo is a registered DATEL, Inc. trademark.

INNOVATION and EX C ELL E N C

E

®

®

DS0324 10/98

DATEL (UK) LTD. Tadley, England Tel: [phone]
DATEL S.A.R.L. Montigny Le Bretonneux, France Tel: [phone]
DATEL GmbH München, Germany Tel: [phone]
DATEL KK Tokyo, Japan Tel: [phone], Osaka Tel: [phone]

Quality and Reliability

The A-Series are the first DC/DC Converters to emerge from DATEL’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 T esting).

4. To prove that early design improvements are effective b y employing a
thorough FRACA (Failure Reporting Analysis and Corrective Action) system.

HALT T esting

The goal of the accelerated-stress techniques used by DATEL is to force device
maturity , in a short period of time, by exposing devices to e xcessive lev els of
"every stimulus of potential value." We use HALT (Highly Accelerated Life
T esting) 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 HAL T , prototype and pre-production DC/DC con verters 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 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.
DATEL 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 increasing,
random longitudinal and rotational vibration up to 20G’s with load cycling and
applied-voltage extremes added as desired. Many devices in D A TEL’s new A­Series could not be made to fail prior to reaching either the limits of the HAL T
chamber or some previously known physical limit of the device. We also use
the HAL T chamber and its ability to rapidly cool devices to v erify their "cold­start" 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 .

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 perf ormed 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

DATEL 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 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 .

Typical HALT Profile

Qualification Test Method/Comments

HALT DATEL in-house procedure
High Temperature Storage Max. rated temp., 1,000 hours
Thermal Shock 10 cycles, –55 to +125°C
Temper ature/Humidity +85°C, 85% humidity, 48 hours
Lead Integrity DATEL in-house procedure
Life Test +70°C, 500 hours*
Marking Permanency DATEL in-house procedure
End Point Electrical Tests Per product specification

Qualification Testing

* Interim electrical test at 200 hours.

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

DATEL, Inc. 11 Cabot Boulev ard, Mansfield, MA 02048-1151
Tel: [phone] [phone] Fax: [phone]
Internet: www.datel.com Email: [e-mail]
Data Sheet Fax Back:[phone]

ISO 9001

I

SO 9001

REGISTERED

8-11W, TRIPLE OUTPUT DC/DC CONVERTERS

TWR Models