DW025ACL-M

Data Sheet March 31, 2008 DS04-028 ver. 1.1 (Replaces DS04-028 ver. 1.0) DW025 Triple Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W Options n Short pins: 2.79 mm ± 0.25 mm (0.110 in. ± 0.010 in.) n Negative logic remote on/off n Heat sink available for extended operation Description The DW025 Triple Output-Series Power Modules use advanced, surface-mount technology and deliver high-quality, compact, dc-dc conversion at an economical price. Features n Small size: 71.1 mm x 61.0 mm x 12.7 mm (2.80 in. x 2.40 in. x 0.50 in.) n Low output noise n Industry-standard pinout n Metal case with separate case ground pin n 2:1 input voltage range n Remote on/off (positive logic) n The maximum total output power of the DW025 Triple Output-Series Power Modules is limited to 25 W. The main output (VO1) is designed to deliver the entire 25 W. The auxiliary outputs (VO2 and VO3) can provide a total of 22.5 W, as long as the total output power does not exceed 25 W. Efficiency greater than 80%, a wide operating temperature range, and a metal case are additional features of these modules. UL* Recognized, CSA† Certified, and VDE Licensed n Within FCC and CISPR Class A Radiated Limits n Higher accuracy output voltage clamp set point n The DW025 Triple Output-Series Power Modules are dc-dc converters that operate over an input voltage range of 36 Vdc to 75 Vdc and provide three outputs. These modules offer extremely low noise levels with industry-standard pinouts in a small footprint. Each highly reliable and efficient unit features remote on/off and current limit. CE mark meets 73/23/EEC and 93/68/EEC directives‡ Applications n Distributed power architectures n Telecommunications * UL is a registered trademark of Underwriters Laboratories, Inc. † CSA is a registered trademark of the Canadian Standards Association. ‡ This product is intended for integration into end-use equipment. All the required procedures for CE marking of end-use equipment should be followed. (The CE mark is placed on selected products.) DW025 Triple Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W Data Sheet March 31, 2008 Absolute Maximum Ratings Stresses in excess of the absolute maximum ratings can cause permanent damage to the device. These are absolute stress ratings only. Functional operation of the device is not implied at these or any other conditions in excess of those given in the operations sections of the data sheet. Exposure to absolute maximum ratings for extended periods can adversely affect device reliability. Parameter Symbol Min Max Unit Input Voltage Continuous VI — 80 Vdc I/O Isolation Voltage: dc Transient (1 minute) — — — — 500 850 V V Operating Case Temperature TC –40 100 °C Storage Temperature Tstg –55 125 °C Electrical Specifications Unless otherwise indicated, specifications apply to all modules over all operating input voltage, resistive load, and temperature conditions. Table 1. Input Specifications Parameter Symbol Min Typ Max Unit VI 36 48 72* Vdc II, max — — 2.0 A Inrush Transient i 2t — — 0.2 A2s Input Reflected-ripple Current, Peak-to-peak (5 Hz to 20 MHz, 12 µH source impedance; TC = 25 °C; see Figure 18 and Design Considerations section.) — — 25 — mAp-p Input Ripple Rejection (120 Hz) — — 60 — dB Operating Input Voltage Maximum Input Current (VI = 0 V to 75 V; IO = IO, max) * Operation is specified to 75 V, provided the minimum load on Output 1 is at least 0.75 A. Safety agency reports specify 75 V maximum input. Fusing Considerations CAUTION: This power module is not internally fused. An input line fuse must always be used. This encapsulated power module can be used in a wide variety of applications, ranging from simple stand-alone operation to an integrated part of a sophisticated power architecture. To preserve maximum flexibility, internal fusing is not included; however, to achieve maximum safety and system protection, always use an input line fuse. The safety agencies require a normal-blow, dc fuse with a maximum rating of 5 A in series with the ungrounded input lead. Based on the information provided in this data sheet on inrush energy and maximum dc input current, the same type of fuse with a lower rating can be used. Refer to the fuse manufacturer’s data for further information. 2 Lineage Power DW025 Triple Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W Data Sheet June 1997 Electrical Specifications (continued) Table 2. Output Specifications Parameter Device Symbol Min Typ Max Unit Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life. See Figure 20.) DW025ABK-M VO1 VO2 VO3 VO1 VO2 VO3 4.80 10.80 –10.80 4.80 13.77 –13.77 — — — — — — 5.20 13.70 –13.70 5.20 17.20 –17.20 Vdc Vdc Vdc Vdc Vdc Vdc Output Voltage Set Point (VI = 48 V; TC = 25 °C; IO1 = 2.0 A, IO2 = IO3 = 0.5 A) DW025ABK-M VO1, set VO2, set VO3, set VO1, set VO2, set VO3, set 4.90 11.83 –11.83 4.90 14.84 –14.84 5.00 12.20 –12.20 5.00 15.30 –15.30 5.10 12.57 –12.57 5.10 15.76 –15.76 Vdc Vdc Vdc Vdc Vdc Vdc All All — VO1 — — 0.1 0.1 0.2 0.2 % % All VO1 — 0.5 1.5 % All VO1 VO2, VO3 VO1 VO2, VO3 — — — — — — — — 25 30 100 150 mVrms mVrms mVp-p mVp-p IO1 IO2, IO3 IO1 IO2, IO3 0.5 0.1 0.5 0.1 — — — — 5.0 1.0 5.0 0.83 A A A A IO1 IO2, IO3 IO1 IO2, IO3 — — — — 6 2 6 2 7.5 3.0 7.5 3.0 A A A A IO1 IO2, IO3 IO1 IO2, IO3 — — — — 8 3 8 3 10.5 4.5 10.5 4.5 A A A A η η 80 80 82 83 — — % % DW025ACL-M DW025ACL-M Output Regulation: Line (VI = 36 V to 75 V) Load (IO1 = IO, min to IO, max, IO2 = IO3 = IO, min) Temperature (TC = –40 °C to +100 °C) Output Ripple and Noise (See Figure 19.): RMS Peak-to-peak (5 Hz to 20 MHz) All Output Current (At IO < IO, min, the modules may exceed output ripple specifications.) DW025ABK-M Output Current-limit Inception (VO = 90% of VO, nom and minimum load on other outputs.) DW025ABK-M Output Short-circuit Current (VO = 1 V and minimum load on other outputs.) DW025ABK-M Efficiency (VI = 48 V; TC = 25 °C; see Figures 13, 14, and 20.): IO1 = 2.5 A, IO2 = IO3 = 0.5 A IO1 = 2.0 A, IO2 = IO3 = 0.5 A Lineage Power DW025ACL-M DW025ACL-M DW025ACL-M DW025ABK-M DW025ACL-M DW025 Triple Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W Data Sheet March 31, 2008 Electrical Specifications (continued) Table 2. Output Specifications (continued) Parameter Device Symbol Min Typ Max Unit All All VO1 — — — 80 1 — — mV ms All All VO1 — — — 80 0.5 — — mV ms Min Typ Max Isolation Capacitance — 0.02 — µF Isolation Resistance 10 — — MΩ Max Unit 113 (4.0) g (oz.) Dynamic Response (ΔIO/Δt = 1 A/10 µs, VI = 48 V, TC = 25 °C): Load Change from IO = 50% to 75% of IO, max: Peak Deviation Settling Time (VO < 10% peak deviation) Load Change from IO = 50% to 25% of IO, max: Peak Deviation Settling Time (VO < 10% peak deviation) Table 3. Isolation Specifications Parameter Unit General Specifications Parameter Min Calculated MTBF (IO = 80% of IO, max; TC = 40 °C) Weight 4 Typ 2,906,000 — — hours Lineage Power DW025 Triple Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W Data Sheet June 1997 Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See Feature Descriptions and Design Considerations for further information. Parameter Device Symbol Min Typ Max Unit Remote On/Off (VI = 0 V to 75 V; open collector or equivalent compatible; signal referenced to VI(–) terminal. See Figure 21 and Feature Descriptions.): DW025XXX-M (positive logic) Logic Low—Module Off Logic High—Module On DW025XXX1-M (negative logic) Logic Low—Module On Logic High—Module Off Module Specifications: On/Off Current—Logic Low On/Off Voltage: Logic Low Logic High (Ion/off = 0) Open Collector Switch Specifications: Leakage Current During Logic High (Von/off = 10 V) Output Low Voltage During Logic Low (Ion/off = 1 mA) Turn-on Time (IO = 80% of IO, max; VO within ±1% of steady state) Output Voltage Overshoot All Ion/off — — 1.0 mA All All Von/off Von/off 0 — — — 1.2 10 V V All Ion/off — — 50 µA All Von/off — — 1.2 V All — — 5 — ms All — — 0 5 % DW025ABK-M VO1 VO2 VO3 VO1 VO2 VO3 — — — — — — 6 15 –15 6 19 –19 6.8 17 –17 6.8 21 –21 V V V V V V — 90 — 110 %Vo, nom Output Overvoltage Clamp DW025ACL-M Output Voltage Set-point Adjustment Range Lineage Power All DW025 Triple Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W Data Sheet March 31, 2008 Characteristic Curves 12.30 12.25 OUTPUT VOLTAGE, VO (V) INPUT CURRENT, II (A) 1.0 0.9 0.8 0.7 0.6 0.5 0.4 12.20 12.15 12.10 12.05 0.3 12.00 0.2 11.95 -40 0.1 0.0 -20 0 20 40 60 80 100 CASE TEMPERATURE, T (°C) 0 10 20 30 40 50 60 70 80 INPUT VOLTAGE, VI (V) 8-1102(C) Figure 1. DW025 Triple Output-Series Typical Input Characteristics 8-1079(C) Figure 3. DW025 Triple Output-Series Typical Output Voltage Variation of 12 V Output Over Ambient Temperature Range 15.60 15.55 OUTPUT VOLTAGE, VO (V) OUTPUT VOLTAGE, VO1 (V) 5.01 5.00 4.99 4.98 4.97 15.40 15.35 15.30 15.25 15.20 15.10 -40 -20 0 20 40 60 80 100 CASE TEMPERATURE, T (°C) -20 0 20 40 60 80 100 CASE TEMPERATURE, T (°C) 8-1080(C) 8-1078(C) Figure 2. DW025 Triple Output-Series Typical Output Voltage Variation of 5 V Output Over Ambient Temperature Range 6 15.45 15.15 4.96 4.95 -40 15.50 Figure 4. DW025 Triple Output-Series Typical Output Voltage Variation of 15 V Output Over Ambient Temperature Range Lineage Power DW025 Triple Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W Data Sheet March 31, 2008 Characteristic Curves (continued) OUTPUT VOLTAGE, VO2 (V) 16.3 OUTPUT VOLTAGE, VO2 (V) 13.5 13.0 VI = 54 V, IO1 = 2.5 A, IO3 = 0.5 A 12.5 12.0 VI = 54 V, IO1 = 0.5 A, IO3 = 0.1 A 11.5 11.0 0.0 15.8 VI = 54 V, IO1 = 2.5 A, IO3 = 0.45 A 15.3 14.8 14.3 VI = 54 V, IO1 = 0.5 A, IO3 = 0.1 A 13.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 OUTPUT CURRENT, IO2 (A) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 OUTPUT CURRENT, IO2 (A) 8-1103(C) 8-1105(C) Figure 7. DW025ACL-M Typical Load Regulation Figure 5. DW025ABK-M Typical Load Regulation OUTPUT VOLTAGE, VO2 (V) 16.8 OUTPUT VOLTAGE, VO1 (V) 13.5 13.0 VI = 54 V, IO2 = IO3 = 0.1 A 12.5 12.0 16.3 15.8 VI = 54 V, IO2 = IO3 = 0.1 A 15.3 VI = 54 V, IO2 = IO3 = 0.45 A 14.8 14.3 VI = 54 V, IO2 = IO3 = 0.5 A 13.8 0.0 11.5 11.0 0.4 0.9 1.4 1.9 2.4 2.9 3.4 3.9 4.4 OUTPUT CURRENT, IO1 (A) 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 8-1106(C) Figure 8. DW025ACL-M Typical Cross Regulation with Respect to IO1 OUTPUT CURRENT, IO1 (A) 8-1104(C) Figure 6. DW025ABK-M Typical Cross Regulation with Respect to IO1 Note: Given the same load conditions, Output 3 has regulation characteristics similar to Output 2, except the polarity is negative. Lineage Power DW025 Triple Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W Data Sheet March 31, 2008 Characteristic Curves (continued) OUTPUT VOLTAGE, VO1 (V) 5.0 4.5 4.0 VI = 36 V, IO2 = IO3 = 0.5 A 3.5 VI = 54 V 3.0 VI = 72 V VI = 72 V, IO2 = IO3 = 0.1 A VI = 54 V VI = 36 V 2.5 2.0 1.5 1.0 0.5 0 0 1 2 3 4 6 5 8 7 9 OUTPUT CURRENT, IO1 (A) 8-1107(C) Figure 9. DW025ABK-M Typical 5 V Output Characteristics 14 12 10 8 6 4 2 0 0 0.5 1.0 2.5 3.5 4.0 OUTPUT CURRENT, IO2 (A) 8-1108(C) Figure 10. DW025ABK-M Typical 12 V Output Characteristics 8-1109(C) Figure 11. DW025ACL-M Typical 5 V Output Characteristics 8 Lineage Power DW025 Triple Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W Data Sheet March 31, 2008 Characteristic Curves (continued) 16 OUTPUT VOLTAGE, VO2 (V) 14 VI = 72 V, IO1 = 2.5 A, IO3 = 0.45 A VI = 72 V, IO1 = 0.5 A, IO3 = 0.1 A 12 VI = 54 V VI = 54 V 10 VI = 36 V VI = 36 V 8 6 5 4 3 0 0.5 1.5 1.0 2.5 2.0 OUTPUT CURRENT, IO2 (A) 8-1110(C) Figure 12. DW025ACL-M Typical 15 V Output Characteristics 85 85 VI = 36 V VI = 54 V VI = 54 V 75 VI = 72 V 70 65 60 55 VI = 36 V 80 EFFICIENCY, η (%) EFFICIENCY, η (%) 80 75 VI = 72 V 70 65 60 0 20 40 60 80 100 120 PERCENT OF FULL LOAD (%) 55 0 20 40 60 80 100 120 PERCENT OF FULL LOAD (%) 8-1111(C) 8-1112(C) Note: Loads varied proportionately from minimum to 50% of full load. Note: Loads varied proportionately from minimum to 50% of full load. Figure 13. DW025ABK-M Typical Converter Efficiency Figure 14. DW025ACL-M Typical Converter Efficiency Lineage Power DW025 Triple Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W Data Sheet March 31, 2008 102% 100% 50% 6 0% 101% 99% 75% 50% REMOTE ON/OFF (2 V/div) 4 100% OUTPUT CURRENT, IO (A) (% OF IO, max) OUTPUT VOLTAGE, VO (V) (% OF VO, set) OUTPUT VOLTAGE, VO (V) (% OF VO, set) Characteristic Curves (continued) 2 0 25% TIME, t (2 ms/div) 8-1100(C) TIME, t (100 µs/div) 8-1098(C) Figure 15. DW025 Triple Output-Series Typical Output Voltage for a Step Load Change from 75% to 50% of Full Load on Output 1 Figure 17. DW025 Triple Output-Series Typical Output Voltage Start-Up when Signal Applied to Remote On/Off Test Configurations OUTPUT VOLTAGE, VO (V) (% OF VO, set) TO OSCILLOSCOPE LTEST VI (+) 12 µH BATTERY 101% OUTPUT CURRENT, IO (A) (% OF IO, max) 100% CS 220 µF IMPEDANCE < 0.1 Ω @ 20 °C, 100 kHz VI (-) 99% 75% 8-489(C).a Note: Input reflected-ripple current is measured with a simulated source impedance (LTEST) of 12 µH. Capacitor CS offsets possible battery impedance. Current is measured at the input of the module. 50% 25% Figure 18. Input Reflected-Ripple Test Setup TIME, t (100 µs/div) 8-1099(C) Figure 16. DW025 Triple Output-Series Typical Output Voltage for a Step Load Change from 25% to 50% of Full Load on Output 1 10 Lineage Power DW025 Triple Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W Data Sheet June 1997 Test Configurations (continued) Design Considerations Input Source Impedance COPPER STRIP VO1(+) SCOPE 0.1 µF R LOAD1 COM The power module should be connected to a low ac-impedance input source. Highly inductive source impedances can affect the stability of the power module. A 33 µF electrolytic capacitor (ESR < 0.7 Ω at 100 kHz) mounted close to the power module helps to ensure the stability of the unit. SCOPE 0.47 µF SCOPE R LOAD2 VO2(+) Safety Considerations R LOAD3 0.47 µF VO3(-) 8-811(C).a Note: Use the specified ceramic capacitor. Scope measurement should be made by using a BNC socket. Position the load between 50 mm (2 in.) and 75 mm (3 in.) from the module. Figure 19. Output Noise Measurement Test Setup For safety-agency approval of the system in which the power module is used, the power module must be installed in compliance with the spacing and separation requirements of the end-use safety agency standard, i.e., UL-1950, CSA 22.2-950, and EN60950. For the converter output to be considered meeting the requirements of safety extra-low voltage (SELV), one of the following must be true: n n SENSE COM SENSE VO1(+) VO1(+) VI(+) COM n CONTACT AND DISTRIBUTION LOSSES IO1 LOAD1 II SUPPLY LOAD2 VI(-) CONTACT RESISTANCE VO2(+) IO2 LOAD3 IO3 SENSE VO3(-) 8-749(C).b Note: All measurements are taken at the module terminals. When socketing, place Kelvin connections at module terminals to avoid measurement errors due to socket contact resistance. 3 ∑ [ V Oj ( + ) – V COM ]I Oj j=1 η = -------------------------------------------------------------------- × 100 [ V I ( + ) + ( – V I ( – ) ) ]II Figure 20. Triple Output Voltage and Efficiency Measurement Test Setup Lineage Power All inputs are SELV and grounded, with the output also grounded. Any non-SELV input must be provided with reinforced insulation from any other hazardous voltages, including the ac mains, and must have a SELV reliability test performed on it in combination with the converters. Inputs must meet SELV requirements. If the input meets extra-low voltage (ELV) requirements, then the converter’s output is considered ELV. The input to these units is to be provided with a maximum 5 A normal-blow fuse in the ungrounded lead. VO3(-) SENSE VO2(+) All inputs are SELV and floating, with the output also floating. DW025 Triple Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W Feature Descriptions Output Overvoltage Clamp The output overvoltage clamp consists of control circuitry, independent of the primary regulation loop, that monitors the voltage on the output terminals. The control loop of the clamp has a higher voltage set point than the primary loop (see Feature Specifications table). This provides a redundant voltage control that reduces the risk of output overvoltage. With an external resistor connected between the TRIM and VO1(+) pins (Radj-down), the output voltage set point (VO, adj) decreases. R adj-down ( V O, adj – 2.5 ) × 16.94 = ⎛ -------------------------------------------------⎞ k Ω ⎝ V O, nom – V O, adj ⎠ Note: The output voltage adjustment must be 90% or more of the nominal output voltage between the VO1(+) and common terminals. Current Limit To provide protection in a fault (output overload) condition, the unit is equipped with internal current-limiting circuitry. At the point of current-limit inception, the unit shifts from voltage control to current control. If the output voltage is pulled very low during a severe fault, the current-limit circuit can exhibit either foldback or tailout characteristics (output current decrease or increase). The unit operates normally once the output current is brought back into its specified range. Output Voltage Set-Point Adjustment The output voltage adjustment feature provides the capability of increasing or decreasing the output voltage set point of a module. When the output voltage adjustment feature is used, the output voltage set point of all three outputs is adjusted. The output voltage adjustment can be accomplished by using an external resistor connected between the TRIM pin and either the VO1(+) or common pins. With an external resistor between the TRIM and common pins (Radj-up), the output voltage set point (VO, adj) increases. R adj-up = Data Sheet March 31, 2008 42.35 ⎛ --------------------------------⎞ kΩ ⎝ V O, adj – V O, nom-⎠ Note: The output voltage adjustment range must not exceed 110% of the nominal output voltage between the VO1(+) and common terminals. Remote On/Off Two remote on/off options are available. Positive logic remote on/off turns the module on during a logic high voltage on the REMOTE ON/OFF pin, and off during a logic low. Negative logic remote on/off, suffix code “1,” turns the module off during a logic high and on during a logic low. To turn the power module on and off, the user must supply a switch to control the voltage between the on/off terminal and the VI(–) terminal (Von/off). The switch can be an open collector or equivalent (see Figure 21). A logic low is Von/off = 0 V to 1.2 V. The maximum Ion/off during a logic low is 1 mA. The switch should maintain a logic low voltage while sinking 1 mA. During a logic high, the maximum Von/off generated by the power module is 10 V. The maximum allowable leakage current of the switch at Von/off = 10 V is 50 µA. VI(+) VI(-) Von/off + Ion/off REMOTE ON/OFF 8-758(C).a Figure 21. Remote On/Off Implementation 12 Lineage Power DW025 Triple Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W Data Sheet March 31, 2008 Thermal Considerations 12.7 (0.50) 27.9 (1.1) WIND TUNNEL WALL MEASURE CASE TEMPERATURE AT THIS POINT 27.9 (1.1) AIRFLOW dc-dc POWER MODULE CONNECTORS TO LOADS, POWER SUPPLIES, AND DATALOGGER, 6.35 (0.25) TALL MADE IN USA 203.2 (8.00) AIRFLOW 101.6 (4.00) 50.8 (2.00) AIR VELOCITY PROBE AMBIENT TEMPERATURE THERMOCOUPLE 12.7 (0.50) 203.2 (8.00) 9.7 (0.38) 19.1 (0.75) Note: Dimensions are in millimeters and (inches). Drawing is not to scale. 8-866(C).b Figure 22. Thermal Test Setup The 25 W triple output power modules are designed to operate in a variety of thermal environments. As with any electronic component, sufficient cooling must be provided to ensure reliable operation. Heat dissipating components inside the module are thermally coupled to the case to enable heat removal by conduction, convection, and radiation to the surrounding environment. The thermal data presented is based on measurements taken in a wind tunnel. The test setup shown in Figure 22 was used to collect data. Actual performance can vary depending on the particular application environment. Basic Thermal Performance The maximum operating temperature of the DW025 Triple Output-Series Power Modules at a given operating condition can be predicted by combining the power dissipation curves (Figures 23 through 27), the power derating curve (Figure 28), and the thermal resistance curve (Figure 28). Use Figures 23 through 28 and the steps below to predict the safe operating region for many different operating and environmental conditions. 1. Calculate the total output power. POtotal = (IO1 x VO1) + (IO2 x VO2) + (IO3 x VO3) 2. Lineage Power Use POtotal with the appropriate figure (Figure 23 or 24) to determine the fixed losses (PP) associated with operating at POtotal. These losses are independent of which output the load is being drawn from. DW025 Triple Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W Data Sheet March 31, 2008 Thermal Considerations (continued) Air Velocity Basic Thermal Performance (continued) The air velocity required to maintain a desired maximum case temperature for a given power dissipation and ambient temperature can be calculated using Figure 28 and the following equation: 3. 4. 5. Use the desired output current (IO1) with Figure 25 to determine PS1, which is the additional power being dissipated due to loading of the main output. Repeat Step 3 for outputs 2 and 3 using the appropriate figure (Figure 26 or 27) to determine PS2 and PS3, which is the power dissipated due to loading of the auxiliary outputs. Find the total power dissipated (PDtotal) by adding the four power dissipations obtained in Steps 2 through 4. T C, max – T A P D total θ CA = -----------------------------where: n n n 6. Use the estimated total power dissipated (PDtotal) along with Figure 28 to determine the maximum ambient temperature allowable for a given air velocity. For example, consider the DW025ABK-M power module operating with 54 V input and output currents IO1 = 2.5 A, IO2 = 0.5 A, IO3 = 0.5 A. The total output power (POtotal) is 24.5 W. The total power dissipation is PDtotal = 4.74 W, which is obtained by adding: PP PS1 PS2 PS3 = 4.4 W (from Figure 23) = 0.22 W (from Figure 25) = 0.06 W (from Figure 26) = 0.06 W (from Figure 26) Figure 28 shows that, in natural convection, the maximum ambient temperature that this module can operate at is approximately 67 °C. Keep in mind that the procedure above provides approximations of the temperature and air velocities required to keep the case temperature below its maximum rating. The maximum case temperature, as monitored at the point shown in Figure 22, should be maintained at 100 °C or less under all conditions. n TC, max is the desired maximum case temperature (°C). TA is the ambient inlet temperature (°C). PDtotal is the total power dissipated by the module (W) at the desired operating condition. For example, to maintain a maximum case temperature of 85 °C with an ambient inlet temperature of 65 °C and a power dissipation of 4.74 W, the thermal resistance is: 85 °C – 65 °C θ CA ≤ ------------------------------------- = 4.2 °C/W 4.74 W This corresponds to an airflow greater than 0.36 ms–1 (70 fpm) in Figure 28. 5.5 5.0 POWER DISSIPATION, PD (W) PDtotal = PP + PS1 + PS2 + PS3 θCA is the thermal resistance from case-to-ambient air (°C/W). VI = 72 V 4.5 VI = 54 V 4.0 3.5 3.0 2.5 2.0 VI = 36 V 1.5 1.0 0 5 10 15 20 25 30 OUTPUT POWER, PO (W) 8-1113(C) Figure 23. DW025ABK-M Fixed Losses, PP 14 Lineage Power DW025 Triple Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W Data Sheet June 1997 Thermal Considerations (continued) 0.45 POWER DISSIPATION, PD (W) POWER DISSIPATION, PD (W) Air Velocity (continued) 6.0 5.5 5.0 VI = 72 V 4.5 4.0 3.5 0.40 0.35 0.30 0.25 0.20 0.15 0.10 0.05 3.0 0.00 0.0 VI = 36 V 2.5 VI = 54 V 2.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 OUTPUT CURRENT, IO2 OR IO3 (A) 8-1116(C) 1.5 1.0 0.9 1.0 0 5 10 15 20 25 30 Figure 26. DW025ABK-M, Losses Associated with ±12 V Output, PS2/PS3 OUTPUT POWER, PO (W) 8-1114(C) Figure 24. DW025ACL-M Fixed Losses, PP POWER DISSIPATION, PD (W) 0.45 POWER DISSIPATION, PD (W) 1.4 1.2 1.0 VI = 54 V 0.8 VI = 36 V 0.6 0.35 0.30 0.25 0.20 0.15 0.10 0.05 0.4 VI = 72 V 0.2 0.0 0.0 0.40 0.00 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 OUTPUT CURRENT, IO2 OR IO3 (A) 8-1117(C) 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 OUTPUT CURRENT, IO1 (A) 8-1115(C) Figure 25. DW025ABK-M, DW025ACL-M Losses, Associated with 5 V Output, PS1 Lineage Power Figure 27. DW025ACL-M Losses Associated with ±15 V Output, PS2/PS3 DW025 Triple Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W Data Sheet March 31, 2008 Use of Heat Sinks and Cold Plates Air Velocity (continued) The DW025 Triple Output-Series case includes through-threaded M3 x 0.5 mounting holes, allowing attachment of heat sinks or cold plates from either side of the module. The mounting torque must not exceed 0.56 N/m (5 in.-lb). TOTAL POWER DISSIPATION, PD TOTAL (W) Thermal Considerations (continued) 8.0 7.0 The following thermal model can be used to determine the required thermal resistance of the sink to provide the necessary cooling: 6.0 5.0 4.0 3.0 2.0 1.0 0.0 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (°C) 8-1118(C) Figure 28. Total Power Dissipation vs. Local Ambient Temperature and Air Velocity • θCS TA θSA where PD is the power dissipated by the module, θCS represents the interfacial contact resistance between the module and the sink, and θSA is the sink-to-ambient thermal impedance (°C/W). For thermal greases or foils, a value of θCS = 0.1 °C/W to 0.3 °C/W is typical. The required θSA is calculated from the following equation: TC – TA θ SA = -------------------- – θ CS P D total Note that this equation assumes that all dissipated power must be shed by the sink. Depending on the user-defined application environment, a more accurate model including heat transfer from the sides and rear of the module can be used. This equation provides a conservative estimate in such instances. 8.0 7.0 THERMAL RESISTANCE (°C/W) CASE-TO-AMBIENT Ts Tc PD 2.03 ms -1 (400 ft./min.) 1.02 ms -1 (200 ft./min.) 0.51 ms -1 (100 ft./min.) NATURAL CONVECTION 6.0 5.0 4.0 For further information, refer to the Thermal Energy Management CC-, CW-, DC-, and DW-Series 25 W to 30 W Board-Mounted Power Modules Technical Note. 3.0 2.0 1.0 0.0 0.76 1.78 1.02 1.27 1.52 0.25 0.51 2.03 NAT CONV (50.0) (100.0) (150.0) (200.0) (250.0) (300.0) (350.0) (400.0) VELOCITY, ms -1 (ft./min.) 8-1101(C) Figure 29. Case-to-Ambient Thermal Resistance vs. Air Velocity 16 Lineage Power DW025 Triple Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W Data Sheet March 31, 2008 Outline Diagram Dimensions are in millimeters and (inches). Copper paths must not be routed beneath the power module standoffs. Tolerances: x.x ± 0.5 mm (0.02 in.), x.xx ± 0.25 mm (0.010 in.). Top View 71.1 (2.80) MA X PIN 1 INDICATOR 61 .0 (2.40 ) MAX M3 DC-DC Power Module MADE IN USA Side View 0 .5 1 (0.020) 12.7 (0.50) MA X 1.02 (0.040) ± 0.0 8 (0.003) DIA TIN-P LATED BRASS 9 PLA CES 5.1 (0.200 ) MIN Bottom View STAND-OFF, 4 PLA CES 4.8 (0.19) 5.1 (0.2 0) 7.1 ( 0.2 8) 5 V O3 (-) 4 6 V O2 (+) VI (-) 10.1 6 (0 .4 00) 10.16 (0.400) 3 10.16 (0.400) 20.32 30.48 (0.8 00) (1 .20) 20.32 (0.8 00) 2 1 V I (+) 7 COM CASE 8 V O1 (+) ON/OFF MOUNTING INS ERTS M3 x 0.5 THROUGH, 4 P LACES 5 0.8 (2 .0 0) 10.1 6 (0 .4 00) 20.32 (0.800) 9 TRIM 4 8.3 (1.90 ) 11.4 ( 0.45) 63.50 ± 0.38 (2.500 ± 0.015) 3.8 (0.15) 8-1119(C) Lineage Power DW025 Triple Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W Data Sheet March 31, 2008 Recommended Hole Pattern Component-side footprint. Dimensions are in millimeters and (inches). Recommended hole size for pin: 1.27 mm (0.050 in.). CASE OUTLINE M3 x 0.5 CLEARANCE HOLE 4 PLACES (OPTIONAL) 30.48 (1.20) 20.32 (0.800) 61.0 (2.40) MAX 1 9 2 8 3 7 4 6 10.16 (0.400) 10.16 (0.400) 20.32 (0.800) 10.16 (0.400) 50.8 (2.00) 10.16 (0.400) 20.32 (0.800) 5 5.1 (0.20) 11.4 (0.45) 48.3 (1.90) 63.50 ± 0.38 (2.500 ± 0.015) 3.8 (0.15) 71.1 (2.80) MAX 8-1119(C) 18 Lineage Power DW025 Triple Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W Data Sheet March 31, 2008 Ordering Information Table 4. Ordering Information Table Input Voltage Output Voltage Output Power Remote On/Off Logic Device Code Comcode 36 V—75 V +5 V, ±12 V 25 W positive DW025ABK-M 107584252 36 V—75 V +5 V, ±15 V 25 W positive DW025ACL-M 107584260 Optional features may be ordered using the device code suffixes shown below. To order more than one option, list suffixes in numerically descending order followed by the -M suffix, indicating metric (M3 x 0.5 heat sink hardware). The heat sinks designed for this package have an M prefix, i.e., MHSTxxx45 and MHSLxxx45 (see Thermal Energy Management CC-, CW-, DC-, and DW-Series 25 W to 30 W Board-Mounted Power Modules Technical Note). Table 5. Options Table Option Device Code Suffix Short pins: 2.79 mm ± 0.25 mm (0.110 in. ± 0.010 in.) Negative remote on/off logic 8 1 Please contact your Lineage Power Account Manager or Field Application Engineer for pricing and availability. Lineage Power DW025 Triple Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W Data Sheet March 31, 2008 A sia-Pacific Head qu art ers T el: +65 6 41 6 4283 World W ide Headq u arters Lin eag e Po wer Co rp oratio n 30 00 Sk yline D riv e, Mes quite, T X 75149, U SA +1-800-526-7819 (Outs id e U .S.A .: +1- 97 2-2 84 -2626) www.line ag ep ower.co m e-m ail: tech sup port1@ lin ea gep ower.co m Eu ro pe, M id dle-East an d Afric a He ad qu arters T el: +49 8 9 6089 286 Ind ia Head qu arter s T el: +91 8 0 28411633 Lineage Power reserves the right to make changes to the produc t(s) or information contained herein without notice. No liability is ass umed as a res ult of their use or applic ation. No rights under any patent acc ompany the sale of any s uc h pr oduct(s ) or information. © 2008 Lineage Power Corpor ation, (M esquite, Texas ) All International Rights Res er ved. March 31, 2008 DS04-028 ver. 1.1 (Replaces DS04-028 ver. 1.0)