Data Sheet
June 1997
DW025 Dual Output-Series Power Modules: dc-dc Converters;
36 Vdc to 75 Vdc Input; Dual Outputs; 25 W
The DW025-Series Power Modules use advanced, surface-
mount technology and deliver high-quality, compact, dc-dc
conversion at an economical price.
Features
■
Small size: 71.1 mm x 61.0 mm x 12.7 mm
(2.80 in. x 2.40 in. x 0.50 in.)
■
Low output noise
■
Industry-standard pinout
■
Metal case with separate case ground pin
■
2:1 input voltage range
■
Remote on/off (positive logic)
■
UL*
Recognized,
CSA
†
Certified, and VDE
Licensed
■
Within FCC and CISPR Class A Radiated Limits
■
CE mark meets 73/23/EEC and 93/68/EEC
directives
‡
■
Two tightly regulated outputs
Applications
■
Distributed power architectures
■
Telecommunications
Options
■
Higher-accuracy output voltage clamp set point
■
Short pins: 2.79 mm ± 0.25 mm
(0.110 in. ± 0.010 in.)
■
Heat sink available for extended operation
■
Negative logic remote on/off
Description
The DW025-Series Power Modules are a family of
dc-dc converters that operate over an input voltage
range of 36 Vdc to 75 Vdc and provide tw o regulated
outputs. These modules offer low noise levels with
industry-standard pinouts in a small footprint. Each
highly reliable and efficient unit features remote
on/off and current limit.
Each output is individually regulated by its own con-
trol circuit and has an independent overvoltage
clamp. With standard outputs of +3.3 V, ±5 V, ±12 V,
and ±15 V, the DW025-Series is flexible enough to
provide modified standard units with an y combination
of output voltages from 2 V to 15 V.
Efficiency greater than 80%, a wide operating tem-
perature range, and a metal case are additional fea-
tures of these modules . They ha v e
UL
,
CSA
, and VDE
recognition and operate within FCC and CISPR Class
A limits f or r adiated emissions .
The DW025AJ-M, BK-M, and CL-M Power Modules
are available with common output ground pins
(pinout A); the DW025AA-M, AB-M, AF-M, BB-M,
and CC-M Power Modules are available with sepa-
rate output ground pins (pinout B).
*
UL
is a registered trademark of Underwriters Laboratories, Inc.
†
CSA
is a registered trademark of the Canadian Standards Asso-
ciation.
‡ This product is intended for integration into end-use equipment.
All the required procedures for CE marking of end-use equip-
ment should be followed. (The CE mark is placed on selected
products.)
2 Tyco Electronics Corp.
Data Sheet
June 1997
36 Vdc to 75 Vdc Input; Dual Outputs; 25 W
DW025 Dual Output-Series Power Modules: dc-dc Converters;
Absolute Maximum Ratings
Stresses in excess of the absolute maximum ratings can cause permanent damage to the device. These are abso-
lute 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.
Electrical Specifications
Note:
Two pinouts are available for the DW025-Series Power Modules. The DW025AJ-M, AB-M, BK-M, and
CL-M Power Modules, which have both positive and negative outputs, have a common output ground pin
(pinout A). The DW025AA-M, AB-M, AF-M, BB-M, and CC-M Power Modules, which have dual positive out-
puts, have separate output ground pins (pinout B). See Outline Diagrams section.
Unless otherwise indicated, specifications apply to all modules over all operating input voltage, resistive load, and
temperature conditions.
Table 1. Input Specifications
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 fus-
ing 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 (see Safety Considerations section).
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.
Parameter Symbol Min Max Unit
Input Voltage
Continuous
Transient (<10 ms) V
I
V
I, trans
—
—80
100 V
V
I/O Isolation Voltage
dc
Transient (1 minute) —
——
—500
850 V
V
Operating Case Temperature T
C
–40 100 °C
Storage Temperature T
stg
–55 125 °C
Parameter Symbol Min Typ Max Unit
Operating Input Voltage V
I
36 48 75 Vdc
Maximum Input Current
(V
I
= 0 V to 75 V; I
O
= I
O
,
max
; see Figure 1.) I
I, max
— — 2.0 A
Inrush Transient i
2
t — — 0.8 A
2
s
Input Reflected-ripple Current, Peak-to-Peak
(5 Hz to 20 MHz, 12 µH source impedance;
T
C
= 25 °C) (See Figure 11 and Design
Considerations section.)
— — 25 — mAp-p
Input Ripple Rejection (120 Hz) — — 60 — dB
Tyco Electronics Corp. 3
Data Sheet
June 1997 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W
DW025 Dual Output-Series Power Modules: dc-dc Converters;
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 13.)
DW025AJ-M
DW025BK-M
DW025CL-M
DW025AA-M
DW025AB-M
DW025AF-M
DW025BB-M
DW025CC-M
V
O1
V
O2
V
O1
V
O2
V
O1
V
O2
V
O1
V
O2
V
O1
V
O2
V
O1
V
O2
V
O1
V
O2
V
O1
V
O2
4.80
–4.80
11.40
–11.40
14.25
–14.25
4.80
4.80
4.80
11.40
4.80
3.16
11.40
11.40
14.25
14.25
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
5.25
–5.25
12.60
–12.60
15.75
–15.75
5.25
5.25
5.25
12.60
5.25
3.45
12.60
12.60
15.75
15.75
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Output Voltage Set Point
(V
I
= 48 V; I
O
= I
O, max
; T
A
= 25 °C) DW025AJ-M
DW025BK-M
DW025CL-M
DW025AA-M
DW025AB-M
DW025AF-M
DW025BB-M
DW025CC-M
V
O1, set
V
O2, set
V
O1, set
V
O2, set
V
O1, set
V
O2, set
V
O1, set
V
O2, set
V
O1, set
V
O2, set
V
O1, set
V
O2, set
V
O1, set
V
O2, set
V
O1, set
V
O2, set
4.90
–4.90
11.76
–11.76
14.70
–14.70
4.90
4.90
4.90
11.76
4.90
3.23
11.76
11.76
14.70
14.70
5.0
–5.0
12.0
–12.0
15.0
–15.0
5.0
5.0
5.0
12.0
5.0
3.3
12.0
12.0
15.0
15.0
5.10
–5.10
12.24
–12.24
15.30
–15.30
5.10
5.10
5.10
12.24
5.10
3.37
12.24
12.24
15.30
15.30
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
Output Regulation:
Line (V
I
= 36 V to 75 V)
Load (I
O1
= I
O, min
to I
O, max,
I
O2 =
I
O, max
)All
All —
——
—0.1
0.1 0.2
0.4 %
%
Load (I
O2
= I
O, min
to I
O, max,
I
O1 =
I
O, max
) DW025AJ-M,
AA-M, BK-M,
BB-M, CL-M,
CC-M, AB-M
— — 0.1 0.4 %
DW025AF-M — — 0.4 0.8 %
Temperature
(T
C
= –40 °C to +100 °C) DW025AJ-M,
AA-M, AF-M — — 15 70 mV
DW025BK-M,
BB-M — — 40 150 mV
DW025CL-M,
CC-M — — 40 190 mV
DW025AB-M
(5 V output) — — 15 70 mV
DW025AB-M
(12 V output) — — 40 150 mV
4 Tyco Electronics Corp.
Data Sheet
June 1997
36 Vdc to 75 Vdc Input; Dual Outputs; 25 W
DW025 Dual Output-Series Power Modules: dc-dc Converters;
Electrical Specifications
(continued)
Table 2. Output Specifications
(continued)
Parameter Device Symbol Min Typ Max Unit
Output Ripple and Noise
(See Figure 12.):
RMS DW025AJ-M,
AA-M, AF-M — — — 15 mVrms
DW025BK-M, BB-M — — — 20 mVrms
DW025CL-M, CC-M — — — 25 mVrms
DW025AB-M
(5 V output) — — — 15 mVrms
D W025AB-M
(12 V output) — — — 20 mVrms
Peak-to-peak (5 Hz to 20 MHz) DW025AJ-M,
AA-M, AF-M — — — 150 mVp-p
DW025BK-M, BB-M — — — 200 mVp-p
DW025CL-M, CC-M — — — 250 mVp-p
DW025AB-M
(5 V output) — — — 150 mVp-p
D W025AB-M
(12 V output) — — — 200 mVp-p
Output Current
(At I
O
< I
O , min
, the modules ma y e xceed
output ripple specifications.)
DW025AJ-M,
AA-M, AF-M I
O1
I
O2
0.20
0.20 —
—2.50
2.50 A
A
DW025BK-M, BB-M I
O1
I
O2
0.10
0.10 —
—1.04
1.04 A
A
DW025CL-M, CC-M I
O1
I
O2
0.08
0.08 —
—0.83
0.83 A
A
DW025AB-M I
O1
I
O2
0.20
0.10 —
—2.50
1.04 A
A
Output Current-limit Inception
(V
O
= 90% of V
O, nom
; see Figure 2.) DW025AJ-M,
AA-M, AF-M — — 3.7 6.5 A
DW025BK-M, BB-M — — 1.5 2.9 A
DW025CL-M, CC-M — — 1.3 2.7 A
DW025AB-M I
O1
I
O2
—
—3.7
1.5 6.5
2.9 A
A
Output Short-circuit Current
(V
O
= 250 mV) DW025AJ-M,
AA-M, AF-M — — 3.5 7.0 A
DW025BK-M, BB-M — — 1.0 3.0 A
DW025CL-M, CC-M — — 1.0 3.0 A
DW025AB-M I
O1
I
O2
—
—3.5
1.0 7.0
3.0 A
A
Efficiency (V
I
= 48 V; I
O
= I
O, max
;
T
C
= 25 °C; see Figures 3 and 13.) DW025AJ-M, AA-M
η
75 78 — %
DW025AF-M
η
68 75 — %
DW025AB-M
η
75 79 — %
DW025BK-M, BB-M
η
79 82 — %
DW025CL-M, CC-M
η
79 82 — %
Tyco Electronics Corp. 5
Data Sheet
June 1997 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W
DW025 Dual Output-Series Power Modules: dc-dc Converters;
Electrical Specifications
(continued)
Table 2. Output Specifications
(continued)
Table 3. Isolation Specifications
General Specifications
Parameter Device Symbol Min Typ Max Unit
Dynamic Response
(
∆
I
O
/
∆
t = 1 A/10 µs, V
I
= 48 V,
T
A
= 25 °C):
Load Change from I
O
= 50% to 75% of
I
O, max
: (See Figures 7 to 9.):
Peak Deviation DW025AJ-M,
AA-M, AF-M — — 160 — mV
DW025BK-M,
BB-M — — 250 — mV
DW025CL-M,
CC-M — — 250 — mV
DW025AB-M
(5 V output) — — 160 — mV
D W025AB-M
(12 V output) — — 250 — mV
Settling Time (V
O
< 10% peak
deviation) All — — 3 — ms
Load Change from I
O
= 50% to 25% of
I
O, max
(See Figures 4 to 6.):
Peak Deviation DW025AJ-M,
AA-M, AF-M — — 160 — mV
DW025BK-M,
BB-M — — 250 — mV
DW025CL-M,
CC-M — — 250 — mV
DW025AB-M
(5 V output) — — 160 — mV
D W025AB-M
(12 V output) — — 250 — mV
Settling Time (V
O
< 10% peak
deviation) All — — 3 — ms
Parameter Min Typ Max Unit
Isolation Capacitance — 1200 — pF
Isolation Resistance 10 — — M
Ω
Parameter Min Typ Max Unit
Calculated MTBF (I
O
= 80% of I
O, max
; T
C
= 40 °C) 2,800,000 hours
Weight — — 113 (4.0) g (oz.)
6 Tyco Electronics Corp.
Data Sheet
June 1997
36 Vdc to 75 Vdc Input; Dual Outputs; 25 W
DW025 Dual Output-Series Power Modules: dc-dc Converters;
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 (positive logic)
(V
I
= 0 V to 75 V; open collector or
equivalent compatible; signal
referenced to V
I
(–) terminal. See
Figures 10, 14 and Feature
Descriptions.):
DW025xx-M Positive Logic:
Logic Low—Module Off
Logic High—Module On
DW025xx1-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 (I
on/off
= 0)
Open Collector Switch Specifications:
Leakage Current During Logic High
(V
on/off
= 10 V)
Output Low Voltage During Logic
Low (I
on/off
= 1 mA)
Turn-on Time (I
O
= 80% of I
O, max
; V
O
within ±1% of steady state)
Output Voltage Overshoot
All
All
All
All
All
All
All
Ion/off
Von/off
Von/off
Ion/off
Von/off
—
—
—
0
—
—
—
—
—
—
—
—
—
—
30
0
1.0
1.2
10
50
1.2
—
5
mA
V
V
µA
V
ms
%
Output Overvoltage Clamp DW025AJ-M
DW025BK-M
DW025CL-M
DW025AA-M
DW025AB-M
DW025AF-M
DW025BB-M
DW025CC-M
VO1
VO2
VO1
VO2
VO1
VO2
VO1
VO2
VO1
VO2
VO1
VO2
VO1
VO2
VO1
VO2
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
7
–7
16
–16
20
–20
7
7
7
16
7
5
16
16
20
20
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
Input Undervoltage Lockout:
Module On
Module Off All
All VUVLO
VUVLO —
20 28
28 36
—V
V
Tyco Electronics Corp. 7
Data Sheet
June 1997 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W
DW025 Dual Output-Series Power Modules: dc-dc Converters;
Characteristic Curves
8-993(C).a
Figure 1. DW025-Series Input Current and Normal-
ized Output Voltage vs. Input Voltage at
Full Load and TA = 25 °C
8-994(C)
Figure 2. DW025-Series Normalized Output Current
vs. Normalized Output Voltage at
VI = 48 V and TA = 25 °C
8-995(C)
Figure 3. DW025-Series Efficiency vs. Normalized
Both Output Currents to Full Load at
VI = 48 V and TA = 25 °C
8-1019(C)
Figure 4. DW025-Series Typical 5 V Output Voltage
Response to a Step Load Change from
50% to 25% of IO, m ax at VI = VI, nom and
TA = 25 °C
Characteristic Curves (continued)
0 1020304050 70
0
0.2
0.4
0.6
0.8
1.0
1.2
INPUT VOLTAGE, V
I
(V)
INPUT CURRENT, I
I
(A)
0.8
0.6
0.4
0.2
0.0
1.0
1.2
V
O
60
I
I
NORMALIZED OUTPUT VOLTAGE
0.0 0.5 1.0 1.5 2.0 2.5
0.0
0.2
0.4
0.6
0.8
1.2
NORMALIZED OUTPUT CURRENT TO FULL LOAD, I
O
(A)
1.0
V
O
= 3.3 V
5 V
12 V
15 V
NORMALIZED OUTPUT VOLTAGE, V
O
(V)
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 1.0
45
50
55
60
65
85
NORMALIZED BOTH OUTPUT CURRENTS TO
FULL LOAD, I
O
(A)
EFFICIENCY, η (%)
0.9
70
75
80
CC,CL
BB,BK
AA,AJ
AF
0.5 A 0.5 ms
50 mV
1.0 A
0.5 A
TIME, t (0.5 ms/div)
5.0 V
∆I
O
∆t= 1 A/10 µs
OUTPUT CURRENT, I
O
(A)
(0.5 A/div) OUTPUT VOLTAGE, V
O
(mV)
(50 mV/div)
88 Tyco Electronics Corp.
Data Sheet
June 1997
36 Vdc to 75 Vdc Input; Dual Outputs; 25 W
DW025 Dual Output-Series Power Modules: dc-dc Converters;
8-1017(C)
Figure 5. T ypical DW025-Series 12 V Output Voltage
Response to a Step Load Change from
50% to 25% of IO, m ax at VI = VI, nom and
TA = 25 °C
8-1017(C).a
Figure 6. T ypical DW025-Series 15 V Output Voltage
Response to a Step Load Change from
50% to 25% of IO, m ax at VI = VI, nom and
TA = 25 °C
8-1018(C)
Figure 7. Typical DW025-Series 5 V Output Voltage
Response to a Step Load Change from
50% to 75% of IO, m ax at VI = VI, nom and
TA = 25 °C
8-1017(C).b
Figure 8. T ypical DW025-Series 12 V Output Voltage
Response to a Step Load Change from
50% to 75% of IO, m ax at VI = VI, nom and
TA = 25 °C
TIME, t (0.5 ms/div)
∆I
O
∆t= 1 A/10 µs
0.416 A
0.208 A
12.0 V
0.2 A 0.5 ms
100 mV
OUTPUT VOLTAGE, V
O
(V)
(0.1 V/div)
OUTPUT CURRENT, I
O
(A)
(0.2 A/div)
TIME, t (0.5 ms/div)
∆I
O
∆t= 1 A/10 µs
0.333 A
0.166 A
15.0 V
0.2 A 0.5 ms
100 mV
OUTPUT VOLTAGE, V
O
(V)
(0.1 V/div)
OUTPUT CURRENT, I
O
(A)
(0.2 A/div)
∆I
O
∆t= 1 A/10 µs
0.5 ms
50 mV
0.5 A
1.5 A
1.0 A
TIME, t (0.5 ms/div)
5.0 V
OUTPUT CURRENT, I
O
(A)
(0.5 A/div) OUTPUT VOLTAGE, V
O
(mV)
(50 mV/div)
∆I
O
∆t= 1 A/10 µs
0.5 ms
100 mV
0.2 A
0.624 A
0.416 A
12.0 V
OUTPUT CURRENT, I
O
(A)
(0.2 A/div) OUTPUT VOLTAGE, V
O
(V)
(0.1 V/div)
TIME, t (0.5 ms/div)
Tyco Electronics Corp. 9
Data Sheet
June 1997 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W
DW025 Dual Output-Series Power Modules: dc-dc Converters;
Characteristic Curves (continued)
8-1018(C).a
Figure 9. T ypical DW025-Series 15 V Output Voltage
Response to a Step Load Change from
50% to 75% of IO, m ax at VI = VI, nom and
TA = 25 °C
8-1020(C)
Figure 10. Typical DW025-Series Output Voltage
Rise Time with Remote On/Off at
VI = VI, nom, IO = 0.8 (IO, max) and TA = 25 °C
Test Configurations
8-489(C).a
Note: Measure input reflected-ripple current with a simulated source
impedance (LTEST) of 12 µH. Capacitor CS offsets possible
battery impedance. Current is measured at the input of the
module.
Figure 11. Input Reflected-Ripple Test Setup
∆IO
∆t= 1 A/10 µs
0.5 ms
100 mV
0.2 A
0.500 A
0.333 A
TIME, t (0.5 ms/div)
15.0 V
OUTPUT VOLTAGE, VO (V)
(0.1 V/div)
OUTPUT CURRENT, IO (A)
(0.2 A/div)
∆IO
∆t= 1 A/10 µs
2 V
0 V
TIME, t (1 ms/div)
0 V
1 ms
VO, set
NORMALIZED
OUTPUT VOLTAGE, VO
REMOTE ON/OFF,
Von/off (V) (2 V/div)
TO OSCILLOSCOPE
C
S
220 µF
IMPEDANCE < 0.1 Ω
@ 20 °C, 100 kHz
V
I
(+)
V
I
(–)
L
TEST
BATTERY
12 µH
1010 Tyco Electronics Corp.
Data Sheet
June 1997
36 Vdc to 75 Vdc Input; Dual Outputs; 25 W
DW025 Dual Output-Series Power Modules: dc-dc Converters;
Test Configurations (continued)
8-808(C)
A.Pinout A (DW025AJ-M, BK-M, CL-M) Configura-
tion
8-809(C)
B.Pinout B (DW025AA-M, AB-M, AF-M, BB-M,
CC-M) Configuration
Note: Use a 0.1 µF 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 12. Output Noise Measurement Test Setup
8-753(C)
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.
In addition, VI(–) is internally connected to case.
Figure 13. Output Voltage and Efficiency Measure-
ment Test Setup
Design Considerations
Input Source Impedance
The power module should be connected to a low ac-
impedance input source. Highly inductive source
impedances can affect the stability of the power mod-
ule. A 33 µF electrolytic capacitor (ESR < 0.7 Ω at
100 kHz) mounted close to the power module helps
ensure stability of the unit.
VO1(+)
VO2(–)
SCOPE
0.1 µF
COPPER STRIP
0.1 µF SCOPE
COMM
RLOAD1
RLOAD2
V
O1
(+)
V
O2
(–)
SCOPE
0.1 µF
COPPER STRIP
0.1 µF SCOPE
R
LOAD1
R
LOAD2
V
O1
(–)
V
O2
(+)
V
I
(+)
I
I
I
O
SUPPLY
CONTACT
RESISTANCE
CONTACT AND
DISTRIBUTION LOSSES
LOAD
V
I
(–)
V
O1
V
O2
COM
LOAD
η
VOJ COM–[]IOJ
J1=
2
∑
VI+() VI–()–[]II
-------------------------------------------------- x100=
Pinout A
η
VOJ +()
V
OJ
–
()
–
[]
I
OJ
J1=
2
∑
V
I
+
()
V
I
–
()
–
[]
I
I
--------------------------------------------------------------
x
100
=
Pinout B
Tyco Electronics Corp. 11
Data Sheet
June 1997 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W
DW025 Dual Output-Series Power Modules: dc-dc Converters;
Design Considerations
(continued)
Safety Considerations
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, EN60950.
For the converter output to be considered to be meet-
ing the requirements of safety extra-low voltage
(SELV), one of the following must be true:
■
All inputs are SELV and floating with the output also
floating.
■
All inputs are SELV and grounded with the output
also grounded.
■
Any non-SELV input must be provided with rein-
f orced insulation from an y other hazardous voltages,
including the ac mains, and must have a SELV reli-
ability test performed on it in combination with the
converters.
If the input meets extra-low voltage (ELV) require-
ments, then the converter’s output is considered ELV.
The input to these units is to be provided with a maxi-
mum 5 A normal-blow fuse in the ungrounded lead.
Input/Output V oltage Reversal
CAUTION: Applying a reverse voltage across the
module input or output forward biases
an internal diode. Attempting to start
the module under this condition can
damage the module.
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.
Current Limit
To provide protection in a fault (output overload) condi-
tion, the unit is equipped with internal current-limiting
circuitry and can endure current-limiting for an unlimited
duration. At the point of current-limit inception, the unit
shifts from voltage control to current control. If the out-
put 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.
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, code suffix “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 V
I
(–) terminal (V
on/off
). The
switch can be an open collector or equivalent (see
Figure 14). A logic low is V
on/off
= 0 V to 1.2 V. The
maximum I
on/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 V
on/off
generated by
the power module is 10 V. The maximum allowable
leakage current of the switch at V
on/off
= 10 V is 50 µA.
8-754(C)
Figure 14. Remote On/Off Implementation
COM LOAD
+
I
on/off
–
V
on/off
ON/OFF
V
I
(+)
V
I
(–)
V
O2
LOAD
V
O1
12 Tyco Electronics Corp.
Data Sheet
June 1997
36 Vdc to 75 Vdc Input; Dual Outputs; 25 W
DW025 Dual Output-Series Power Modules: dc-dc Converters;
Thermal Considerations
8-866(C).a
Note: Dimensions are in millimeters and (inches). Drawing is not to scale.
Figure 15. Thermal Test Setup
50.8
(2.00)
12.7 (0.50)
101.6
(4.00)
203.2 (8.00)
AIRFLOW
MEASURE CASE
TEMPERATURE AT
CENTER OF UNIT
CONNECTORS TO
LOADS, POWER
SUPPLIES, AND
DATALOGGER,
6.35 (0.25) TALL
203.2
(8.00)
9.7 (0.38)
19.1 (0.75)
WIND TUNNEL WALL
AIR VELOCITY PROBE
AMBIENT TEMPERATUR
E
THERMOCOUPLE
AIR-
FLOW
The 25 W dual output power modules are designed to
operate in a variety of thermal environments. As with
any electronic component, sufficient cooling must be
provided to help ensure reliable operation of the unit.
Heat-dissipating components inside the module are
thermally coupled to the case. Heat is removed by con-
duction, convection, and radiation to the surrounding
environment.
The thermal data presented is based on measure-
ments taken in a wind tunnel. The test setup shown in
Figure 15 was used to collect data. Actual perf ormance
can vary depending on the particular application
environment.
Tyco Electronics Corp. 13
Data Sheet
June 1997 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W
DW025 Dual Output-Series Power Modules: dc-dc Converters;
Thermal Considerations
(continued)
Basic Thermal Performance
The D W025-Series Dual Output P ower Modules hav e a
separate power stage for each of the outputs. This
means that the maximum operating temperature can
be predicted quite closely by treating each output indi-
vidually and then summing the results. Figures 16
through 21 are used to predict the safe operating con-
dition for many different operating and environmental
conditions.
The method used to determine the maximum ambient
temperature at a given air velocity is a four-step pro-
cess.
1. Find the power dissipated for output 1 by using the
appropriate chart (Figures 16 through 19) for a par-
ticular output condition (I
O1
).
2. Repeat step 1 for output 2 using Figures 16 through
19.
3. Find the total power dissipated by summing the
power dissipated on each of the outputs:
(P
DOUT1
+ P
DOUT2
) = P
D
total
4. Use the total power dissipated with Figure 20 to
determine the maximum ambient temperature at dif-
ferent air velocities.
For example, the D W025AF-M power module oper ating
at full load on both outputs with 54 V input has a power
dissipation of 3.6 W (from Figure 17) plus 3.1 W (from
Figure 16) for a total of 6.7 W. Using Figure 20, it can
be determined that the maximum ambient temperature
at natural con vection that the D W025AF-M can operate
at is approximately 56 °C.
Keep in mind that these are approximations of the tem-
peratures and airflows required to keep the case tem-
perature below its maxim um rating. The maxim um case
temperature at the point shown in Figure 15 must be
kept at 100 °C or less.
Air Velocity
The air velocity required to maintain a desired maxi-
mum case temperature for a given power dissipation
and ambient temperature can be calculated using
Figure 21 and the following equation:
θ
CA
=
where
θCA is the thermal resistance from case-to-ambi-
ent air (°C/W), TC, max is the desired maximum case
temperature (°C), TA is the ambient inlet temperature
(°C), and PDtotal is the total power dissipated from the
module (W).
F or example , to maintain a maximum case temperature
of 85 °C with an ambient inlet temperature of 55 °C and
a power dissipation of 6.7 W, the thermal resistance is:
θCA ≤ = 4.5 °C/W
This corresponds to an air velocity greater than
0.46 ms–1 (90 fpm) in Figure 21.
TC max,TA–
PDtotal
--------------------------------
85 °C 55 °C–
6.7 W
------------------------------------
1414 Tyco Electronics Corp.
Data Sheet
June 1997
36 Vdc to 75 Vdc Input; Dual Outputs; 25 W
DW025 Dual Output-Series Power Modules: dc-dc Converters;
Thermal Considerations (continued)
Air Velocity (continued)
8-986(C).a
Figure 16. 3.3 V Output Power Dissipation vs.
Output Current
8-987(C).a
Figure 17. 5 V Output Power Dissipation vs. Output
Current
8-1005(C).a
Figure 18. 12 V Output Power Dissipation vs.
Output Current
8-999(C).a
Figure 19. 15 V Output Power Dissipation vs.
Output Current
0 0.5 1.0 1.5 2.0 2.5
0
0.5
1.0
1.5
2.0
4.0
OUTPUT CURRENT, I
O
(
A
)
2.5
3.0
3.5
POWER DISSIPATION, P
D
(W)
V
I
= 54 V
V
I
= 72 V
V
I
= 36 V
0 0.5 1.0 1.5 2.0 2.5
0
0.5
1.0
1.5
2.0
4.0
OUTPUT CURRENT, IO
(
A
)
2.5
3.0
3.5
POWER DISSIPATION, PD (W)
VI = 54 V
VI = 72 V
VI = 36 V
0.0 0.2
0.0
0.5
1.0
1.5
2.0
3.0
OUTPUT CURRENT, I
O
(A)
2.5
0.80.4 0.6
V
I
= 54 V
V
I
= 72 V
V
I
= 36 V
1.0 1.2
P
O
WER DI
SS
IPATI
O
N, P
D
(
W
)
0.0 0.1 0.2 0.3 0.7 0.9
0.0
0.5
1.0
1.5
2.0
3.0
OUTPUT CURRENT, I
O
(A)
2.5
V
I
= 36 V
V
I
= 54 V
V
I
= 72 V
0.80.4 0.5 0.6
POWER DISSIPATION, P
D
(W)
Tyco Electronics Corp. 15
Data Sheet
June 1997 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W
DW025 Dual Output-Series Power Modules: dc-dc Converters;
Thermal Considerations (continued)
Air Velocity (continued)
8-988(C)
Figure 20. Total Power Dissipation vs. Local
Ambient Temperature and Air Velocity
8-989(C)
Figure 21. Case-to-Ambient Thermal Resistance vs.
Air Velocity
Use of Heat Sinks and Cold Plates
The DW025-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.).
The following thermal model can be used to determine
the required thermal resistance of the sink to provide
the necessary cooling:
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). F or thermal grease or f oils ,
a value of θCS = 0.1 °C/W—0.3 °C/W is typical.
The required θSA is calculated from the following equa-
tion:
θSA = [(Tc – TA)/PD] – θCS
Note that this equation assumes that all dissipated
power must be shed by the heat sink. Depending on
the user-defined application environment, a more accu-
rate model including heat transfer from the sides and
bottom of the module can be used. This equation pro-
vides a conservative estimate in such instances.
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.
40 50 60 90 100
0.0
4.0
5.0
6.0
10.0
LOCAL AMBIENT TEMPERATURE, T
A
(°C)
7.0
8.0
9.0
70 80
3.0
2.0
1.0
2.03 ms
–1
(400 ft./min)
NATURAL
CONVECTION
1.02 ms
–1
(200 ft./min)
TOTAL POWER DISSIPATION, P
D
(W)
0.51 ms
–1
(100 ft./min)
0.31 ms
–1
(60 ft./min)
NAT
CONV 0.25
(50) 0.51
(100) 0.76
(150) 1.78
(350) 2.03
(400)
0.0
1.0
2.0
3.0
7.0
VELOCITY ms –1 (ft./min.)
4.0
5.0
6.0
1.02
(200) 1.27
(250) 1.52
(300)
THERMAL RESISTANCE CASE
TO AMBIENT (°C/W)
PDθCS
T ATc
l
Ts
θSA
16 Tyco Electronics Corp.
Data Sheet
June 1997
36 Vdc to 75 Vdc Input; Dual Outputs; 25 W
DW025 Dual Output-Series Power Modules: dc-dc Converters;
Outline Diagrams
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.).
Pinout A (DW025AJ-M, BK-M, CL-M)
8-845(C).a
T op View
Side View
Bottom View
DC-DC Power Module
71.1 (2.80) MAX
61.0
(2.40)
MAX
MADE IN USA
Lucent
PIN 1 INDICATOR
M3
ON/OFF
CASE
V
I
(–)
V
O1
(+)
NC
V
O2
(–)
5.1 (0.20)
4.8 (0.19)
11.4 (0.45)
3.8 (0.15)
MOUNTING INSERTS
M3 x 0.5 THROUGH,
4 PLACES
STAND-OFF,
4 PLACES
10.16 (0.400)
48.3 (1.90)
63.50 ± 0.38 (2.500 ± 0.015)
10.16 (0.400)
10.16
(0.400) 50.8
(2.00)
20.32
(0.800)
20.32
(0.800)
20.32
(0.800)
30.5
(1.20)
7.1 (0.28)
COMV
I
(+)
4
5
1
2
3
8
7
6
1.02 (0.040) ± 0.08 (0.003) DIA
TIN-PLATED
BRASS, 8 PLACES
12.7 (0.50)
MAX
5.1 (0.20)
MIN
0.51
(0.020)
Tyco Electronics Corp. 17
Data Sheet
June 1997 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W
DW025 Dual Output-Series Power Modules: dc-dc Converters;
Outline Diagrams (continued)
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.).
Pinout B (DW025AA-M, AB-M, AF-M, BB-M, CC-M)
8-846(C).a
T op View
Side View
Bottom View
DC-DC Power Module
MADE IN USA
71.1 (2.80) MAX
61.0
(2.40)
MAX
Lucent
PIN 1 INDICATOR
M3
ON/OFF
CASE
VI(–)
VO1(+)
NC
VO2(–)
VO2(+)
5.1 (0.20)
4.8 (0.19)
11.4 (0.45 )
3.8 (0.15)
MOUNTING INSERTS
M3 x 0.5 THROUGH,
4 PLACES
STAND-OFF,
4 PLACES
10.16 (0.400)
48.3 (1.90)
63.50 ± 0.38 (2.500 ± 0.015)
10.16 (0.400)
50.8
(2.00)
20.32
(0.800)
20.32
(0.800)
20.32
(0.800)
30.5
(1.20)
7.1 (0.28)
10.16 (0.400)
10.16 (0.400)
VI(+) VO1(–)
1
2
4
3
9
8
6
7
5
1.02 (0.040) ± 0.08 (0.003) DIA
TIN-PLATED
BRASS, 9 PLACES
12.7 (0.50)
MAX
5.1 (0.20)
MIN
0.51
(0.020)
18 Tyco Electronics Corp.
Data Sheet
June 1997
36 Vdc to 75 Vdc Input; Dual Outputs; 25 W
DW025 Dual Output-Series Power Modules: dc-dc Converters;
Recommended Hole Patterns
Component-side footprint.
Dimensions are in millimeters and (inches).
Recommended hole size for pin: 1.27 mm (0.050 in.).
Pinout A (DW025AJ-M, BK-M, CL-M)
8-845(C).a
Pinout B (DW025AA-M, AB-M, AF-M, BB-M, CC-M)
8-846(C).a
11.4 (0.45)
3.8 (0.15)
5.1 (0.20)
CASE OUTLINE
48.3 (1.90)
63.50 ± 0.38 (2.500 ± 0.015)
71.1 (2.80) MAX
20.32
(0.800)
20.32
(0.800)
30.5
(1.20)
20.32
(0.800)
61.0
(2.40)
MAX
M3 x 0.5 CLEARANCE HOLE
4 PLACES (OPTIONAL)
10.16
(0.400)
18
10.16 (0.400) 50.8
(2.00)
10.16 (0.400 ) 4
3
2
5
6
7
CASE
OUTLINE
11.4 (0.45)
3.8 (0.15)
5.1 (0.20 )
CASE OUTLINE
10.16 (0.400)
10.16 (0.400)
48.3 (1.90)
63.50 ± 0.38 (2.500 ± 0.015)
71.1 (2.80) MAX
M3 x 0.5 CLEARANCE HOLE
4 PLACES (OPTIONAL)
10.16 (0.400)
10.16 (0.400)
50.8
(2.00)
20.32
(0.800)
20.32
(0.800)
30.5
(1.20)
20.32
(0.800)
61.0
(2.40)
MAX
4
3
1
2
5
6
8
7
9
Tyco Electronics Corp. 19
Data Sheet
June 1997 36 Vdc to 75 Vdc Input; Dual Outputs; 25 W
DW025 Dual Output-Series Power Modules: dc-dc Converters;
Ordering Information
Table 4. Ordering Information Table
Optional features may be ordered using the device code suffixes shown below. To order more than one option, list
suffix es in n umerically descending order follow ed 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
Please contact your Tyco Electronics’ Account Manager or Field Application Engineer for pricing and availability.
Input
Voltage Output
Voltage Output
Power Remote
On/Off Logic Device Code Pinout Comcode
36 V to 75 V 5.0 V, –5.0 V 25 W positive D W025AJ-M A 107587545
36 V to 75 V 12.0 V, –12.0 V 25 W positiv e DW025BK-M A 107587602
36 V to 75 V 15.0 V, –15.0 V 25 W positiv e D W025CL-M A 107587628
36 V to 75 V 5.0 V, –5.0 V 25 W positive D W025AA-M B 107731598
36 V to 75 V 5.0 V, 3.3 V 25 W positiv e D W025AF-M B 107587529
36 V to 75 V 12.0 V, 12.0 V 25 W positiv e DW025BB-M B 107587586
36 V to 75 V 15.0 V, 15.0 V 25 W positiv e D W025CC-M B TBD
36 V to 75 V 5.0 V, 12.0 V 25 W positive D W025AB-M B 107587503
Option Device Code
Suffix
Short pins: 2.79 mm ± 0.25 mm
(0.110 in. ± 0.010 in.) 8
Negative Remote on/off logic 1
Data Sheet
June 1997
36 Vdc to 75 Vdc Input; Dual Outputs; 25 W
DW025 Dual Output-Series Power Modules: dc-dc Converters;
Printed on
Recycled Paper
Tyco Electronics Power Systems, Inc.
3000 Skyline Drive, Mesquite, TX 75149, USA
+1-800-526-7819 FAX: +1-888-315-5182
(Outside U.S.A.: +1-972-284-2626, FAX: +1-972-284-2900
http://power.tycoeleectronics.com
Tyco Electronics Corportation reserves the right to make changes to the product(s) or information contained herein without notice. No liability is assumed as a result of their use or application.
No rights under any patent accompany the sale of any such product(s) or information.
© 2001 Tyco Electronics Corporation, Harrisburg, PA. All International Rights Reserved.
Printed in U.S.A.
June 1997
DS96-077EPS (Replaces DS93-225EPS)
