Datasheet TWR-5-3000-15-500-D48A, TWR-5-3000-12-500-D12A, TWR-5-3000-15-500-D12A Datasheet (DATEL)

Figure 1. Simplified Schematic

Features

High-Reliability, P ower-Sharing

20 Watt, DC/DC Conv erters

Triple Output

A-Series, TWR Models

INNOVATION and EX C ELL E N C E

®

®

Among the three families of triple-output DC/DC converters in DATEL ’s ne w
A-Series, the 20W 2" x 2" devices are distinguished by their unique "power-sharing"
architecture. This f eature enables devices to deliv er the full 20 W atts of output power
under a variety of output-loading conditions. 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 W atts. This feature enab les designers to select a single device to fulfill any
number of different requirements.

As members of DATEL’s new A-Series, the 20W triples e xhibit both low 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 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 V olts. "D48A" models oper ate over an input range of 18-75 V olts.

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.

OPTO

ISOLATION

+5V

–12V (–15V)

ERROR

AMPLIFIER

PWM

CONTROLLER

+V

IN

–

V

IN

+12V (+15V)

COMMON

ON/OFF

CONTROL

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

A- SERIES

Low cost! Highly reliable!
Full 20 W atts output power
Power "user-allocated" among outputs
Proven SMT-on-pcb construction
Qual tested; HAL T tested; EMC tested
Output voltages: +5V/±12V or +5V/±15V
Ultra-wide input voltage ranges:

9-36V or 18-75V

Designed to meet UL1950 and
EN60950 (basic insulation)

mark available (75V-input models)

Small packages, 2" x 2" x 0.45"
Fully isolated, 1500Vdc guaranteed
Guaranteed efficiencies to 82%
–40 to +100°C operating temperature
Modifications and customs for OEM’ s

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20W, TRIPLE OUTPUT DC/DC CONVERTERS

A SeriesA Series

A SeriesA Series

A Series

Output Power (Watts)

Ambient Temperature (°C)

–40 0 40 45 50 55 60 65 7 0 7 5 8 0 8 5 9 0 9 5 1 00

20
19
18
17
16
15
14
13
12
11
10

9
8
7
6
5
4
3
2
1
0

2

Function P13

+Input
–Input

No Pin
On/Off Control
+12V/15V Out

+5V Out

Common

–12V/15V Out

Pin

1
2
3
4
5
6
7
8

Notes:

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

IN).

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

IN).

I/O Connections

BOTTOM VIEW

1.800

(45.72)

0.10

(2.54)

2.00

(50.80)

8

5

6

7

0.40

(10.16)

0.200
(5.08)

0.400

(10.16)

0.100
(2.54)

1
2

4

METAL CASE

INSULATED BA S

E

0.040 ±0.002 DIA.
(1.016 ±0.051)

2.00

(50.80)

0.20 MIN
(5.08)

0.45

(11.43)

1.200

(30.48)

3 EQ. SP. @

0.400 (10.16)

Output
Configuration:

T = Triple

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 V oltage Range:

D12 = 9-36 Volts

(24V nominal)

D48 = 18-75 Volts

(48V nominal)

Nominal Primary Output

Voltage (+5 Volts)

5T WR 3000 15 500-/ - / D48 A-

A-Series

High Reliability

TWR-5/3000-12/500-D12A

TWR-5/3000-12/500-D48A

TWR-5/3000-15/500-D12A

TWR-5/3000-15/500-D48A

Performance Specifications and Ordering 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.

9-36

18-75

9-36

18-75

24

48

24

48

75/1118

40/559

75/1118

40/559

81%

82%

81%

81%

C4, P13

C4, P13

C4, P13

C4, P13

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

+5

±12

+5

±12

+5

±15

+5

±15

3000
±500
3000
±500
3000
±500
3000
±500

100
125
100
125
100
150
100
150

±1.0%
±1.0%
±1.0%
±1.0%
±1.0%
±1.0%
±1.0%
±1.0%

➀

T ypical @ 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 .

➁

Ripple/Noise (R/N) measured over a 20MHz bandwidth.

➂

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 .

➃

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

50
75
50
75
50
75
50
75

82%

83%

82%

82%

PART NUMBER STRUCTURE

MECHANICAL SPECIFICATIONS

TEMPERATURE DERATING

Case C4

20W, TRIPLE OUTPUT DC/DC CONVERTERS

TWR Models

3

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.
T ypical values are listed belo w . In man y applications, using values greater than
those listed will yield better results.

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.

T o Reduce Input Ripple

"D12A" Models 20µF, 50V
"D48A" Models 10µF, 100V

T o Reduce Output Ripple

+5V Output 47µF, 10V, Low ESR
±12/15V Outputs 33µF, 20V, Low ESR

Performance/Functional Specifications

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

➀

➀

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 .

➁

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

➂

Applying a voltage to the Control pin when no input power is applied to the converter can
cause permanent damage to the converter.

➃

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

Input

Input V oltage Range:

"D12A" Models 9-36 Volts (24V nominal)
"D48A" Models 18-75 Volts (48V nominal)

Input Current See Ordering Guide
Input Filter T ype

➁

Pi

Overvoltage Shutdown:

"D12A" Models 40 Volts
"D48A" Models 80 Volts

Reverse-Polarity Protection Y es (Instantaneous , 6A maximum)
On/Off (Sync.) Control (Pin 4)

➂

TTL high = off, low (or open) = on

Output

VOUT Accuracy (50% loads):

+5V Output ±1%
±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

➃

1500Vdc, minimum

Isolation Capacitance 500pF
Current Limiting Auto-recovery
Overvoltage Protection Zener/transorb clamps, magnetic feedback

Dynamic Characteristics

Transient Response (50% load step) 300µsec max. to ±2% of final value
Switching Frequency 165kHz (±15kHz)

Environmental

Operating Temperature (ambient):

Without Derating –40 to +55°C
With Derating to +100°C (See Derating Curve)

Storage Temperature –40 to +105°C

Physical

Dimensions 2" x 2" x 0.45" (51 x 51 x 11.4mm)
Shielding 5-sided
Case Connections:

"D12A" Models Pin 2 (–V

IN)

"D48A" Models Pin 1 (+VIN)

Case Material Corrosion resistant steel with

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

Pin Material Brass, solder coated
Weight 2.7 ounces (77 grams)

Input Voltage:

"D12" Models 44 Volts
"D48" Models 88 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 ±15 V olts, limited duration
±15V Outputs ±18 V olts, limited duration

Output Current Current limited.

Max. currents are
model dependent. Units can
withstand a continuous output
short on any output for 3 minutes.

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 oper ation under conditions other than those listed in the
Performance/Functional Specifications T able is not implied.

Absolute Maximum Ratings

TECHNICAL NOTES

20W, TRIPLE OUTPUT DC/DC CONVERTERS

A SeriesA Series

A SeriesA Series

A Series

4

84
83
82
81
80
79
78
77
76

Efficiency vs. ±12V Output Loading

(+5V output loaded @ 2.75A)

25 50 100 150 200 250

±12V Output Currents (±mA)

Efficiency (%)

VIN = 18V

V

IN

= 48V

V

IN

= 72V

89
86
83
80
77
74
71
68
65

Efficiency vs. ±12V Output Loading

(+5V output loaded @ 0.55A)

25 50 100 150 200 250

±12V Output Currents (±mA

)

Efficiency (%)

VIN = 18V

V

IN

= 48V

V

IN

= 72V

Typical P erformance Curves (TA = +25°C)

88
86
84
82
80
78
76
74
72

Efficiency (%)

Efficiency vs. +5V Output Loading

(±12V outputs loaded @ ±250mA )

0.25 0.75 1.25 1.75 2.25 2.75

+5V Output Cu rre n t (A mps)

V

IN

= 18V

V

IN

= 48V

V

IN

= 72V

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.

84.0

83.5

83.0

82.5

82.0

81.5

81.0

80.5

80.0

Efficiency (%)

Efficiency vs. Input Voltage

(+5V output loaded @ 2.75A, ±12V outputs loaded @ ±250mA )

18 24 36 48 60 72

Input Voltage (Volts)

Input Fusing

Certain applications and/or safety agencies may require the installation of fuses
at the inputs of power conversion components. F or D ATEL 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 V olts, 250µA max.) applied to pin 4 disables the con verter.
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.

Synchronization

In critical applications employing multiple switching DC/DC converters, it may
be desirable to intentionally synchronize the switching of selected conver ters
(so the system noise can be reduced with notch filtering) or to purposely
desynchronize the converters (to lessen the current-carrying requirements on
intermediate dc buses). For multiple A-Series Converters, an external clock
can be applied to pin 4 (Control) of each device. It should be a square wave
with a maximum 1µsec "high" duration and an amplitude between +2V and
+5V (see On/Off Control) referenced to pin 2 (–Input). The frequency of the
synchronizing clock should be higher than that of any individual converter.
Therefore, it should be 185kHz ±5kHz.

EFFICIENCY VS. INPUT VOLTAGE AND OUTPUT LOAD

20W, TRIPLE OUTPUT DC/DC CONVERTERS

TWR Models

5

–12V Output Voltage (Volts)

–12V Output Load Regulation

(+5V output loaded @ 0.55A )

VIN = 72V

25 50 100 150 200 250

±12V Output Currents (±mA

)

VIN = 18V

V

IN

= 48V

–11.60
–11.70
–11.80
–11.90
–12.00
–12.10
–12.20
–12.30
–12.40

–12.00
–12.15
–12.30
–12.45
–12.60
–12.75
–12.90
–13.05
–13.20

–12V Output Voltage (Volts)

–12V Output Load Regulation

(+5V output loaded @ 2.75A )

VIN = 18V

V

IN

= 48V

V

IN

= 72V

±12V Output Cur re n ts (± m A)

25 50 100 150 200 250

+5.02
+5.01
+5.00
+4.99
+4.98
+4.97
+4.96
+4.95
+4.94

+5V Output Voltage (Volts)

+5V Output Load Regulation

(±12V outputs loaded @ ±250mA )

VIN = 18V

V

IN

= 48V

V

IN

= 72V

0.25 0.75 1.25 1.75 2.25 2.75

+5V Output Current (Amps)

+5.00
+4.99
+4.98
+4.97
+4.96
+4.95
+4.94
+4.93
+4.92

+5V Output Voltage (Volts)

+5V Output Load Regulation

(±12V outputs loaded @ ±25mA )

VIN = 18V

V

IN

= 48V

V

IN

= 72V

+5V Output Current (Amps)

0.25 0.75 1.25 1.75 2.25 2.75

+12.35
+12.25
+12.15
+12.05
+11.95
+11.85
+11.75
+11.65
+11.55

+12V Output Volta g e (V olts)

+12V Output Load Regulation

(+5V output loaded @ 0.55A )

VIN = 18V

V

IN

= 48V

V

IN

= 72V

25 50 100 150 200 250

±12V Output Currents (±mA

)

+13.20
+13.05
+12.90
+12.75
+12.60
+12.45
+12.30
+12.15
+12.00

+12V Output Volta g e (V olts)

+12V Output Load Regulation

(+5V output loaded @ 2.75A )

VIN = 18V

V

IN

= 48V

V

IN

= 72V

±12V Output Currents (±mA

)

25 50 100 150 200 250

LOAD REGULATION

20W, TRIPLE OUTPUT DC/DC CONVERTERS

A SeriesA Series

A SeriesA Series

A Series

6

If you’re designing with EMC in mind, note that all of D ATEL’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 D A TEL’s Applications Engineering for details.

–12.025
–12.050
–12.075
–12.100
–12.125
–12.150
–12.175
–12.200

–12V Output Voltage (Volts)

–12V Line Regulation

(+5V output loaded @ 2.75A, ±12V outputs loaded @ ±250mA )

18 24 36 48 60 7

2

Input Voltage (Volts)

Line Regulation

+5.010
+5.005
+5.000
+4.995
+4.990
+4.985
+4.980
+4.975

+5V Output Voltage (Volts)

+5V Line Regulation

(+5V output loaded @ 2.75A, ±12V outputs loaded @ ±250mA )

18 24 36 48 60 7

2

Input Voltage (Volts)

+12.150
+12.125
+12.100
+12.075
+12.050
+12.025
+12.000
+11.975

+12V Output Voltage (Volts)

+12V Line Regulation

(+5V output loaded @ 2.75A, ±12V outputs loaded @ ±250mA )

18 24 36 48 60 7

2

Input Voltage (Volts)

LINE REGULATION

80

70

60

50

40

30

20

10

0

–10

–20

Frequency (MHz)

100

1000

FCC Class B Limit

TWR-5/3000-15/500-D12A Radiated Emissions

FCC Part 15 Class B, 3 Meters

Converter Output = +5Vdc @ 2.7A and ±15Vdc @ ±450mA

Radiated Emissions (dBµV/M)

Radiated Emissions

TWR-5/3000-15/500-D12A Radiated Emissions

EN 55022 Class B, 10 Meters

Converter Output = +5Vdc @ 2.7A and ±15Vdc @ ±450mA

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)

EMI RADIATED EMISSIONS

20W, TRIPLE OUTPUT DC/DC CONVERTERS

TWR Models

Quality and Reliability

The A-Series are the first DC/DC Converters to emerge from DATEL’s ne w,
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 approv ed 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 O VS-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
Temperature/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

7

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]

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

®

®

DS-0326 10/98

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

8

ISO 9001

I

SO 9001

REGISTERED

20W, TRIPLE OUTPUT DC/DC CONVERTERS

A SeriesA Series

A SeriesA Series

A Series