Datasheet UWR-5-4000-D48A, UWR-5-4000-D12A, UWR-5-3000-D5A, UWR-5.2-3000-D5A, UWR-3.3-4850-D48A Datasheet (DATEL)

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Page 1

A- SERIES

INNOVATION and EX C ELL E N C E

Single Output

A-Series, UWR Models

High-Reliability, 2" x 2"

14-20 Watt, DC/DC Converters

Features

••

•

Low cost! Highly reliable!

••

•

Proven SMT-on-pcb construction

••

•

Qual tested; HAL T tested; EMC tested

••

•

Designed to meet UL1950 and

••

EN60950 (basic insulation)

•

mark available (75V-input models)

••

•

Output voltages: 3.3/5/5.2/12/15 V olts

••

•

Ultra-wide input voltage ranges:

••

4.7-7.5V , 9-36V or 18-75V

••

•

Small packages, 2" x 2" x 0.45"

••

•

Industry-standard pinouts

••

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Fully isolated, 1500Vdc guaranteed

••

•

Guaranteed efficiencies to 84%

••

•

–40 to +100°C operating temperature

••

•

Modifications and customs for OEM’ s

••

DATEL's new A-Series switching DC/DC converters are designed to meet the demanding long-term-reliability and low-cost requirements of modern telecom, datacom, computer/networking and industrial-electronics applications. These highlyefficient, rugged devices combine straightforward circuit topologies, new components, proven SMT-on-pcb construction methods, and highly repeatable automatic-assembly techniques. The flexibility of the designs and their assembly methods readily permit minor modifications to optimize performance for specific applications.

The single-output, 14-20 Watt Models of the A-Series deliver both high power densities and impressive MTBF’s . Their superior durability is substantiated b y a rigorous in-house qualification program including HAL T (Highly Accelerated Lif e Testing), which is designed to detect any potential electrical, mechanical, or process weaknesses.

Packaged in standard, 2" x 2" x 0.45", shielded metal cases with non-conductive coatings, these fully isolated (1500Vdc minimum) DC/DC’ s offer e xcellent line/load regulation, full I/O protection, thermal shutdown, and industry-standard pinouts.

Output voltages include 3.3, 5, 5.2, 12 or 15 Volts. Input voltage ranges are D ATEL's traditional ultra-wide 9-36V and 18-75V, as well as 4.7-7.5V . Each device provides remote on/off control and V characterized and UL1950, CSA 950 and IEC 950 safety approved.

A-Series DC/DC’s are extremely reliable , easy-to-use, cost-effectiv e power converters. Use them to improve the reliability of existing equipment or to develop new systems that exceed design objectives.

OUT trim capability . All A-Series UWR models are fully EMI

–V

ON/OFF

CONTROL

DATEL, Inc., Mansfield, MA 02048 (USA) • Tel: (508)339-3000, (800)233-2765 Fax: (508)339-6356 • Email: sales@datel.com • Internet: www.datel.com

PWM

CONTROLLER

Figure 1. Simplified Schematic

OPTO

ISOLATION

REFERENCE &

ERROR AMP

OUT

COMMON

TRIM

OUT

Page 2

BOTTOM VIEW

1.800

(45.72)

0.10

(2.54)

2.00

(50.80)

0.40

(10.16)

0.200 (5.08)

0.400

(10.16)

0.100 (2.54)

1 2

METAL CASE

INSULATED BASE

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)

A Series

14-20W, SINGLE OUTPUT DC/DC CONVERTERS

Performance Specifications and Ordering Guide

Output

VOUT

(Volts)

IOUT

(mA)

R/N (mVp-p) Typ.

Max.

➀

Regulation (Max.)

➁

Line

Load

➂

VIN Nom.

(Volts)

Input

Range

(Volts)Model

IIN ➃

(mA)

Efficiency

Min.

Typ.

Package

(Case,

Pinout)

UWR-3.3/4250-D5A 3.3 4250 50 100 ±1.0% ±1.0% 5 4.7-7.5 80/3720 76% 77% C4, P6 UWR-3.3/4850-D12A 3.3 4850 50 75 ±0.5% ±1.0% 24 9-36 35/852 77% 79% C4, P6 UWR-3.3/4850-D48A 3.3 4850 50 100 ±1.0% ±1.0% 4 8 18-75 15/419 79% 80% C4, P6 UWR-5/3000-D5A 5 3000 5 0 100 ±1.0% ±1.0% 5 4.7-7. 5 80/ 3800 78% 79% C4, P6 UWR-5/4000-D12A 5 4000 5 0 100 ±0.3% ±0.5% 2 4 9-36 15/1020 81% 82% C4, P6 UWR-5/4000-D48A 5 4000 5 0 100 ±0.3% ±0.5% 4 8 18-75 15/496 82% 84% C4, P6 UWR-5/4000-D48E

➄

5 4000 5 0 100 ±0.3% ±0.5% 4 8 36-75 15/484 84% 86% C4, P6

UWR-5.2/3000-D5A 5.2 3000 50 100 ±1.0% ±1.0% 5 4.7-7 . 5 80/3900 79% 80% C4, P6 UWR-12/1250-D5A 12 1250 75 120 ±1.0% ±1.0% 5 4. 7 - 7 . 5 80/3660 80% 82% C4, P6 UWR-12/1650-D12A 12 1650 5 0 100 ±0.3% ±0.5% 24 9-36 15/1000 79.5% 82.5% C4, P6 UWR-12/1650-D48A 12 1650 7 5 100 ±0.3% ±0.5% 48 18-75 15/491 84% 85% C4, P6 UWR-15/1000-D5A 15 1000 75 150 ±1.0% ±1.0% 5 4. 7 - 7 . 5 80/3660 80% 82% C4, P6 UWR-15/1300-D12A 15 1300 5 0 100 ±0.3% ±0.5% 24 9-36 20/967 84% 85% C4, P6 UWR-15/1300-D48A 15 1300 7 5 100 ±0.3% ±0.5% 48 18-75 10/484 84% 86% C4, P6

➀

T ypical at TA = +25°C under nominal line voltage and full-load conditions unless otherwise noted.

➁

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

➂

10% to 100% load.

PART NUMBER STRUCTURE

➃

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

➄

See Technical Notes for an explanation of trading off input voltage ranges for higher full-power operating temperature.

MECHANICAL SPECIFICATIONS

5U WR 4000 D12 A-

Output Configuration:

U = Unipolar

Wide Range Input

Nominal Output Voltage:

3.3, 5, 12 or 15 Volts

A-Series

High Reliability

Input Volta ge Range:

D5 = 4.7-7.5 Volts (5V nominal) D12 = 9-36 Volts (24V nominal) D48 = 18/36-75 Volts (48V nominal)

Maximum Output Current

in mA

TEMPERATURE DERATING

Output Power (Watts)

Notes:

UWR-3.3/4250-D5A F UWR-3.3/4850-D12A A UWR-3.3/4850-D48A A UWR-5/3000-D5A E UWR-5/4000-D12A C UWR-5/4000-D48A B UWR-5/4000-D48E G UWR-5.2/3000-D5A D UWR-12/1250-D5A E UWR-12/1650-D12A C UWR-12/1650-D48A B UWR-15/1000-D5A E UWR-15/1300-D12A C UWR-15/1300-D48A B

–40 0 40 45 50 55 60 65 70 75 80 85 90 95 10

Ambient Temperature (°C)

D, E, F

BB, G

1. The UWR-3.3/4850-D48A (18-75V input, curve A) and UWR-3.3/4850-D12A (9-36V input, curve A) will derate curve AA if used over the limited input ranges of 20-60V or 10-30V , respectively.

2. "D48A" models (18-75V input ranges) that derate along curve B will derate along curve BB if used over the more limited input range of 24-60V.

Case C4

I/O Connections

Function P6

+Input

–Input

No Pin

On/Off Control

No Pin

+Output

Common

Trim

Notes:

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

IN).

For "D48A" and "D48E" models, the case is connected to pin 1 (+V

IN).

Page 3

14-20W, SINGLE OUTPUT DC/DC CONVERTERS

Performance/Functional Specifications

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

➀

UWR Models

Input

Input V oltage Range:

"D5A" Models 4.7-7.5 V olts (5V nominal) "D12A" Models 9-36 Volts (24V nominal) "D48A/D48E" Models 18/36-75 Volts (48V nominal)

Input Current See Ordering Guide Input Filter T ype Overvoltage Shutdown:

"D5A" Models 10 Volts "D12A" Models 40 Volts "D48A and /D48E" Models 80 Volts

Reverse-Polarity Protection Yes (Instantaneous, 10A maximum) On/Off (Sync.) Control (Pin 4)

➁

➂

Pi (C-type for "D5A" models)

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

Output

VOUT Accuracy (50% load) ±1%, maximum Temperature Coefficient ±0.02% per °C Ripple/Noise (20MHz BW) Line/Load Regulation See Ordering Guide Efficiency See Ordering Guide Isolation V oltage Isolation Capacitance 550pF Current Limiting Auto-recovery Overvoltage Protection Zener/transorb clamp, magnetic feedback

➁

➃

See Ordering Guide

1500Vdc guaranteed

Dynamic Characteristics

Transient Response (50% load step) 200µsec max. to ±1.5% of final value Switching Frequency 165kHz (±15kHz)

Environmental

Operating Temperature (Ambient):

Without Derating –40 to +40/50/55/65°C (Model dependent) With Derating to +100°C (See Derating Curves)

Storage Temperature –40 to +105°C

Physical

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

"D5A", "D12A" Models Pin 2 (–V "D48A", "D48E" Models Pin 1 (+VIN)

Case Material Corrosion resistant steel with

Pin Material Brass, solder coated Weight 2.7 ounces (76.5 grams)

➀

These converters require a minimum 10% loading 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 and perhaps added internally upon request. Contact DATEL 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.

➄

Except for 3.3V outputs which have no protection.

IN)

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

Absolute Maximum Ratings

Input Vo ltage:

"D5A" Models 11 Volts "D12A" Models 44 Volts "D48A" and "D48E" Models 88 Volts

Input Reverse-Polarity Protection Current must be <10A. Brief

duration only. Fusing recommended.

Output Overvoltage Protection:

3.3V Outputs No protection 5V/5.2V Outputs 6.8 Volts, limited duration 12V Outputs 15 Volts, limited duration 15V Outputs 18 Volts, limited duration

Output Current Current limited. Max. current and

short-circuit duration are 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.

TECHNICAL NOTES

Floating Outputs

Since these are isolated DC/DC converters, their outputs are "floating." Users may ground either the Common (pin 7) for normal usage or the positive side (+Output, pin 6) to effectively re verse the output polarity .

Filtering and Noise Reduction

All A-Series UWR 14-20 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. 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

"D5A" Models 47µF, 16V "D12A" Models 20µF, 50V "D48A" Models 20-50µF, 100V

To Reduce Output Ripple

3.3V Outputs 100µF, 6V, Lo w ESR 5V/5.2V Outputs 47µF, 10V, Lo w ESR 12/15V Outputs 22µF, 20V, Lo w ESR

In critical, space-sensitive applications, D A TEL may be ab le to tailor the internal input/output filtering of these units to meet your specific requirements. Contact our Applications Engineering Group for additional details.

Page 4

A Series

14-20W, SINGLE OUTPUT DC/DC CONVERTERS

Input Fusing

Certain applications and/or safety agencies may require the installation of fuses at the inputs of power conversion components. For DATEL A-Series UWR 14-20 Watt DC/DC Converters, you should use slow-blow type fuses with values no greater than the following:

IN Range Fuse Value

"D5A" 6A

"D12A" 4A

"D48A/D48E" 2A

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.

Synchronization

In critical applications employing multiple switching DC/DC converters, it may be desirable to intentionally synchronize the switching of selected converters (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). F or 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.

TR IM

Trim Down

Trim Up

+O U TP UT

+INPUT

IN PU T

COM MON

Figure 2a. Trim Connections Using a Trimpot

+O U TP UT

+INPUT

IN PU T

COM MON

Figure 2b. Trim Connections Using Fixed Resistors

20k 5-10 Turns

Ω

LO A D

Output Trimming

OUT may be trimmed ±5% via a single external trimpot or fixed resistor. The

V trimpot should be connected as shown in Figure 2a with its wiper connected to pin 8 (Trim). A trimpot can be used to determine the value of a single fixed resistor which should be connected as shown in Figure 2b. Connect the resistor between pin 8 (Trim) and pin 6 (+Output) to trim "down" the output voltage. Connect the resistor between pins 8 and 7 (Common) to trim "up" the output voltage. Fixed resistors should be metal-film types with absolute TCR’s less than 100ppm/°C to ensure stability.

Custom Capabilities

DATEL’s world-class design, development and manufacturing team stands ready to work with you to deliver the exact power converter you need for your demanding, large volume, OEM applications. More importantly . . . 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, railway, aerospace and industrial applications. We may already have the converter you need.

Page 5

14-20W, SINGLE OUTPUT DC/DC CONVERTERS

)

UWR Models

EMI Radiated EmissionsTypical P erf ormance Curves (TA = +25°C)

The performance curves below were derived from actual test data for a single model number (UWR-5/4000-D12A). Since all devices in the 14-20W UWR A-Series have the same circuit topology, the performance curves are representative of all devices.

If you’re designing with EMC in mind, please note that all of D ATEL’s UWR 14-20 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,

EFFICIENCY

Efficiency vs. Output Current and Input Voltage

87 84 81 78 75

Efficiency (%)

VIN = 24V

VIN = 36V

= 12V

69 66 63

0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0

5V Output Current (Amps)

LINE REGULATION

Output Voltage vs. Input Voltage and Output Current

5.015

5.010

5.005

(Volts)

OUT

5.000

4.995

4.990

4.985

OUT

= 2A

OUT

= 4A

4.980

4.975

9 12 15 18 21 24 27 30 33 3

VIN (Volts)

LOAD REGULATION

Output Voltage vs. Output Current and Input Voltag e

5.015

5.010

5.005

5.000

(Volts)

4.995

OUT

4.990 VIN = 36V

VIN = 24V

4.985

4.980

4.975

0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0

5V Output Current (Amps)

= 12V

OUT

= 1A

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 UWR-5/4000-D12A appear below. Published EMC test reports are available for each model number. Contact DATEL's Applications Engineering Department for more details.

Radiated Emissions (dBµV/M)

–10

–20

–10

–20

UWR-5/4000-D12A Radiated Emissions

FCC Part 15 Class B, 3 Meters

Converter Output = 5Vdc @ 3.6A

FCC Class B Limit

100

Radiated Emissions

1000

Frequency (MHz

UWR-5/4000-D12A Radiated Emissions

EN 55022 Class B, 10 Meters

Converter Output = +5Vdc @ 3.6A

EN 55022 Class B Limit

Radiated Emissions

100

Frequency (MHz)

1000

Page 6

A Series

14-20W, SINGLE OUTPUT DC/DC CONVERTERS

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:

technology" is determined. DATEL has invested in a Qualmark OVS-1 HAL T tester capab le 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.

1. T o work from an approved components/v endors list ensuring the use of reliable components and the rigorous qualification of new components.

2. T o design with saf ety margins by adhering to a strict set of derating guidelines and performing theoretical worst-case analyses.

3. T o locate potential design weaknesses early in the product-development cycle by using extensiv e HAL T (Highly Accelerated Lif e Testing).

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 .

4. T o pro ve that early design improvements are eff ective by emplo ying a thorough FRACA (Failure Reporting Analysis and Corrective Action) system.

HAL T T esting

The goal of the accelerated-stress techniques used by D A TEL is to f orce device maturity , in a short period of time, by exposing de vices to excessive le vels of "every stimulus of potential value ." W e use HAL T (Highly Accelerated Lif e 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

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

* Interim electrical test at 200 hours.

simulate field environments but to expose any weaknesses in a product’s electro/mechanical design and/or assembly processes. The goal of HAL T 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

Typical HALT Profile

100

Temperature (°C)

–20

–40

10 20 30 40 50 60 70 80 90

Test Time (minutes)

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

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,

Random Vibration (G's)

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 .

Qualification Testing

INNOVATION and EX C ELL E N C

DATEL, Inc. 11 Cabot Boulevard, Mansfield, MA 02048-1151 Tel: (508) 339-3000 (800) 233-2765 Fax: (508) 339-6356 Internet: www.datel.com Email: sales@datel.com Data Sheet Fax Back:(508) 261-2857

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 s ubject to change without notice. The DATEL logo is a registered DATEL, Inc. trademark.

SO 9001

ISO 9001

REGISTERED

DATEL (UK) LTD. Tadley, England Tel: (01256)-880444 DATEL S.A.R.L. Montigny Le Bretonneux, France Tel: 01-34-60-01-01 DATEL GmbH München, Germany Tel: 89-544334-0 DATEL KK Tokyo, Japan Tel: 3-3779-1031, Osaka Tel: 6-354-2025

DS-0361 9/98