DW025BK-M1 - Tyco Electronics

Data Sheet

June 28, 2004

DS04-028 ver. 1.0 (Replaces DS76-051EPS)

PDF: DW025triple.pdf

DW025 Triple Output-Series Power Modules:

36 Vdc to 75 Vdc Input; 25 W

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

■Small size: 71.1 mm x 61.0 mm x 12.7 mm

(2.80 in. x 2.4 0 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

■Higher accuracy output voltage clamp set point

■CE mark m ee ts 73/2 3/ EEC an d 93 /6 8 /EEC

directives‡

Applications

■Distributed power architectures

■Telecommunications

Options

■Short pins: 2.79 mm ± 0.25 mm

(0.110 in. ± 0.010 in.)

■Negative logic remote on/off

■Heat sink available for extended operation

Description

The DW025 Triple Output-Series Pow er Modu les are

dc-dc converters that operate over an input voltage

range of 36 Vdc to 75 Vdc and provide t hree 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.

The maximum total output power of the DW025 Triple

Output-Series Pow er 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

prov ide 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

tempera ture range, and a metal case are additional

features of these modules.

* 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.)

22 Tyco Electronics Power Systems

Data Sheet

June 28, 2004

36 Vdc to 75 Vdc Input; 25 W

DW025 Triple Output-Series Power Modules:

Absolute Maximum Ratings

Stresses in excess of the absolute maximum ratings can cause permanent damage to t he d evice. 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 sectio ns of the data sheet. Exposure to absolute maximum r atings for extended

periods can adversely affect device reliability.

Electrical Specifications

Unless otherwise indicated, specifications apply to all modules over all operating inpu t voltage, resistive load, and

temperature conditions.

* 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 fus-

ing is not included; ho w ev er, to achieve ma xim um safety and system pr otection, alw ays use an input line fuse . Th e

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.

Parameter Symbol Min Max Unit

Input Voltage Continuous VI—80Vdc

I/O Isolation Voltage:

Transient (1 minute) —

——

—500

850 V

Operating Case Temperature TC–40 100 °C

Storage Temp eratu re Tstg –55 125 °C

Table 1. Input Specifications

Parameter Symbol Min Typ Max Unit

Operat ing Input Voltage VI36 48 72* Vdc

Maximu m Input Current

(VI = 0 V to 75 V; IO = IO, max)II, max ——2.0A

Inrush Transient i2t——0.2A

Input Reflec te d- ripple Curr en t, 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

Tyco Electronics Power Systems

Data Sheet

June 1997 36 Vdc to 75 Vdc Input; 25 W

DW025 Triple Output-Series Power Modules:

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

DW025ACL-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

Output Voltage Set Point

(VI = 48 V; TC = 25 °C;

IO1 = 2.0 A, IO2 = IO3 = 0.5 A)

DW025ABK-M

DW025ACL-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

Output Regulati on:

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)

All

—

VO1

—

0.1

0.5

0.2

1.5

Output Ripple and Noise

(See Figure 19.):

RMS

Peak-to-peak (5 Hz to 20

MHz)

All

VO1

VO2, VO3

VO1

VO2, VO3

—

100

150

mVrms

mVp-p

Output Curren t

(At IO < IO, min, the modules may

exceed output ripple

specifications.)

DW025ABK-M

DW025ACL-M

IO1

IO2, IO3

IO1

IO2, IO3

0.5

0.1

0.5

0.1

—

5.0

1.0

5.0

0.83

Output Current-limit Inception

(VO = 90% of VO, nom and

minimum load on other

outputs.)

DW025ABK-M

DW025ACL-M

IO1

IO2, IO3

IO1

IO2, IO3

—

7.5

3.0

7.5

3.0

Output Short-circuit Current

(VO = 1 V and minim um load on

other outputs.)

DW025ABK-M

DW025ACL-M

IO1

IO2, IO3

IO1

IO2, IO3

—

10.5

4.5

10.5

4.5

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 DW025ABK-M

DW025ACL-M η

η80

80 82

83 —

—%

4Tyco Electronics Power Systems

Data Sheet

June 28, 2004

36 Vdc to 75 Vdc Input; 25 W

DW025 Triple Output-Series Power Modules:

General Specifications

Dynamic Response

(∆IO/∆t = 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)

All

VO1

—

VO1

—

0.5

—

Table 3. Isolation Specifications

Parameter Min Typ Max Unit

Isolation Capacitance — 0.02 — µF

Isolation Resistance 10 — — MΩ

Parameter Min Typ Max Unit

Calculated MTBF (IO = 80% of I O, max; TC = 40 °C) 2,906,000 hours

Weight — — 113 (4.0) g (oz.)

Table 2. Output Specifications (continued)

Parameter Device Symbol Min Typ Max Unit

Electrical Specifications (continued)

Tyco Electronics Power Systems

Data Sheet

June 1997 36 Vdc to 75 Vdc Input; 25 W

DW025 Triple Output-Series Power Modules:

Feature Specifications

Unless otherwise indica ted, specifications apply o ver 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 (positiv e 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

Von/off

Ion/off

Von/off

—

1.0

1.2

—

µA

Output Overvoltage Clamp DW025ABK-M

DW025ACL-M

VO1

VO2

VO3

VO1

VO2

VO3

—

–15

–19

6.8

–17

6.8

–21

Output Voltage Set-point Adjustment Range All — 90 — 110 %Vo, nom

66 Tyco Electronics Power Systems

Data Sheet

June 28, 2004

36 Vdc to 75 Vdc Input; 25 W

DW025 Triple Output-Series Power Modules:

Characteristic Curves

8-1102(C)

Figure 1. DW025 Triple Output-Series Typical Input

Characteristics

8-1078(C)

Figure 2. DW025 Triple Output-Series Typical Out-

put Voltage Variation of 5 V Output Over

Ambient Temperature Range

8-1079(C)

Figure 3. DW025 Triple Output-Series Typical Out-

put Voltage Variation of 12 V Output Over

Ambient Temperature Range

8-1080(C)

Figure 4. DW025 Triple Output-Series Typical Out-

put Voltage Variation of 15 V Output Over

Ambient Temperature Range

01020 80

0.0

1.0

INPUT VOLTAGE, VI (V)

INPUT CURRENT, II (A)

30 70

0.1

0.8

0.9

40 50 60

0.2

0.3

0.4

0.5

0.6

0.7

-40-20 0 20406080100

4.95

4.97

4.99

5.01

CASE TEMPERATURE, T (°C)

OUTPUT VOLTAGE, VO1 (V)

5.00

4.98

4.96

-40 -20 0 20 40 60 80 100

11.95

12.10

12.20

12.30

CASE TEMPERATURE, T (°C)

OUTPUT VOLTAGE, VO (V)

12.00

12.25

12.15

12.05

-40-20 0 20406080100

15.10

15.20

15.40

15.50

15.60

CASE TEMPERA TURE, T (°C)

OUTPUT VOLTAGE, VO (V)

15.30

15.55

15.45

15.35

15.25

15.15

Tyco Electronics Power Systems

Data Sheet

June 28, 2004 36 Vdc to 75 Vdc Input; 25 W

DW025 Triple Output-Series Power Modules:

Characteristic Curves (continued)

8-1103(C)

Figure 5. DW025ABK-M Typical Load Regulation

8-1104(C)

Figure 6. DW025ABK-M Typical Cross Regulation

with Respect to IO1

0.0 0.1 0.2 1.0

11.0

13.5

OUTPUT CURRENT, I O2 (A)

0.3 0.7

12.5

13.0

0.4 0.5 0.6

11.5

12.0

VI = 54 V, I O1 = 0.5 A, IO3 = 0.1 A

0.8 0.9

VI = 54 V, IO1 = 2.5 A, IO3 = 0.5 A

OUTPUT VOLTAGE, VO2 (V)

0 0.5 1.0 4.5

11.0

13.5

OUTPUT CURRENT , IO1 (A)

1.5 3.5 4.0

12.0

12.5

13.0

11.5

2.0 2.5 3.0

VI = 54 V, I O2 = IO3 = 0.5 A

VI = 54 V, IO2 = IO3 = 0.1 A

OUTPUT VOLTAGE, VO1 (V )

8-1105(C)

Figure 7. DW025ACL-M Typical Load Regulation

8-1106(C)

Figure 8. DW025ACL-M Typical Cross Regulation

with Respect to IO1

00.10.2 0.8

13.8

16.3

OUT PUT CU RRENT, IO2 (A)

0.3 0.7

14.3

14.8

15.3

0.4 0.5 0.6

VI = 54 V, IO1 = 2.5 A, I O3 = 0. 45 A

VI = 54 V, IO1 = 0.5 A, IO3 = 0.1 A

15.8

OUTPUT VOLTAGE, VO2 (V)

0.0 0.4 0.9 4.4

13.8

14.8

16.8

OUTPUT CURRENT, IO1 (A)

1.4 1.9 2.4

15.3

15.8

16.3

14.3

VI = 54 V, IO2 = IO3 = 0.45 A

2.9 3.4 3.9

VI = 54 V, I O2 = IO3 = 0.1 A

OUTPUT VOLTAGE, VO2 (V)

Note: Giv en the same load conditions, Output 3 has regulation characteristics similar to Output 2, except the

polarity is negative.

88 Tyco Electronics Power Systems

Data Sheet

June 28, 2004

36 Vdc to 75 Vdc Input; 25 W

DW025 Triple Output-Series Power Modules:

Characteristic Curves (continued)

8-1107(C)

Figure 9. DW025ABK-M Typical 5 V Output Characteristics

8-1108(C)

Figure 10. DW025ABK-M Typical 12 V Output Characteristics

8-1109(C)

Figure 11. DW025ACL-M Typical 5 V Output Characteristics

0 8

5.0

OUTPUT CURRENT, IO1

(

)

4.0

4.5

3.0

3.5

2.5

2.0

0.5

OUTPUT VOLTAGE, VO1 (V)

1.5

1.0

34 6

VI = 36 V, IO2 = IO3 = 0.5 A

VI = 54 V

VI = 72 V VI = 54 V

VI = 36 V

VI = 72 V, IO2 = IO3 = 0.1 A

04.0

OUTPUT CURRENT, IO2

(

)

1.00.5

2.5 3.5

1.5 2.0 3.0

OUTPUT VOLTAGE, VO2 (V)

VI = 36 V, IO1 = 2. 5 A , IO3 = 0.5 A

VI = 54 V

VI = 72 V

VI = 72 V, IO1 = 0.5 A, I O3 = 0.1 A

VI = 54 V

VI = 36 V

0 8

5.0

OUTPUT CURRENT, IO1 (A)

OUTPUT VOLTAGE, VO1 (V)

4.0

4.5

3.0

3.5

VI = 7 2 V, IO2 = IO3 = 0. 45 A

VI = 54 V

VI = 3 6 V

2.5

2.0

0.5

1.5

1.0

34 6

VI = 72 V,

IO2 = IO3 = 0.1 A

VI = 54 V

VI = 36 V

Data Sheet

June 28, 2004

Tyco Electronics Power Systems

36 Vdc to 75 Vdc Input; 25 W

DW025 Triple Output-Series Power Modules:

Characteristic Curves (continued)

8-1110(C)

Figure 12. DW025ACL-M Typical 15 V Output Characteristics

02.5

OUTP UT CURRENT, IO2 (A)

1.0

0.5

1.5 2.0

VI = 72 V, I O1 = 2. 5 A, IO3 = 0.45 A

VI = 54 V

VI = 36 V

OUTPUT VOLTAGE, VO2 (V)

VI = 72 V, I O1 = 0. 5 A, IO3 = 0.1 A

VI = 54 V

VI = 36 V

8-1111(C)

Note: Loads varied proportionately from minimum to 50% of full load.

Figure 13. DW025ABK-M Typical Converter

Efficiency

02040 120

PERCENT OF FULL LOAD (%)

EFFICIENC Y, (%)

60 80 100

VI = 36 V

VI = 54 V

VI = 72 V

8-1112(C)

Note: Loads varied proportionately from minimum to 50% of full

load.

Figure 14. DW025ACL-M Typical Converter

Efficiency

02040 120

PERCENT OF FULL LOAD (%)

EFFICIENCY, (%)

60 80 100

VI = 72 V

VI = 36 V

VI = 54 V

1010 Tyco Electronics Power Systems

Data Sheet

June 28, 2004

36 Vdc to 75 Vdc Input; 25 W

DW025 Triple Output-Series Power Modules:

Characteristic Curves (continued)

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

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

8-1100(C)

Figure 17. DW025 Triple Output-Series Typical

Output Voltage Start-Up when Signal

Applied to Remote On/Off

Test Configurations

8-489(C).a

Note: Input reflected-ripple current is measured with a simulated

source impedance (LTEST) of 12 µH. Capacitor CS offsets pos-

sible battery impedance. Current is measured at the input of

the module.

Figure 18. Input Reflected-Ripple Test Setup

TIME, t (100 µs /div)

OUTPU T VOLTAGE, VO (V)

(% OF VO, set)

OUTPUT CURRENT, IO (A)

(% OF IO, max)

75%

50%

25%

99%

100%

101%

102%

TIME, t (100 µ s/div)

OUTPUT VOLTAGE, VO (V)

(% OF VO, set)

OUTPUT CURRENT, IO (A)

(% OF IO, max)

101%

100%

99%

75%

50%

25%

REMOTE ON/OFF

(2 V/div)

TIME, t (2 ms/div)

OUTPUT VOLTAGE, VO (V)

(% OF VO, set)

50%

100%

TO OSCILLOSCOPE

CS 220 µF

IMPEDANCE < 0.1

@ 20 °C, 100 kH z

VI(+)

VI(-)

LTEST

BATTERY

12 µH

Tyco Electronics Power Systems

Data Sheet

June 1997 36 Vdc to 75 Vdc Input; 25 W

DW025 Triple Output-Series Power Modules:

Test Configurations (continued)

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

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.

Figure 20. Triple Output Voltage and Efficiency

Measurement Test Setup

Design Considerations

Input Source Impedance

The power module should be connected to a low

ac-impedance input source. Highly inductive source im-

pedances can aff ect the stability of the pow er module. A

33 µF electrolytic capacitor (ESR < 0.7 Ω at 100 kHz)

mounted close to th e power mo dule helps to ensure the

stability of the unit.

Safety Considerations

For safety-agency approval of the system in which the

power module is used, the power module must be

installed in complia nce with the spacin g and separ ation

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 e xtr a-lo w v oltage (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 pr ovided with reinf orced

insulation from any other hazardous voltages, includ-

ing the ac mains, and must ha ve a SELV reliability

test performed on it in combination with the convert-

ers. Inputs must meet SELV requirements.

If the input meet s extr a-low v oltage (ELV) requirements ,

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.

(+)

SCOPE

0.1 µF

COP PER S TRIP

0.47 µF

LOAD1

(-)

0.47 µF SCOPE

LOAD2

(+)

SCOPE

COM

LOAD3

VI(+)

IO1

SUPPLY

CONTACT

RESISTANCE

CONTACT AND

DISTRIBUTION LOSSES

LOAD2

SENSE

VO1(+)

SENSE

COM

VO1(+)

VI(-)

COM

VO2(+)

VO3(-)

LOAD1

LOAD3

IO2

IO3

SENSE

VO3(-)

SENSE

VO2(+)

VOj +() VCOM–[]IOj

j1=

∑

VI+() VI–()–()+[]II

--------------------------------------------------------------------100×=

1212 Tyco Electronics Power Systems

Data Sheet

June 28, 2004

36 Vdc to 75 Vdc Input; 25 W

DW025 Triple Output-Series Power Modules:

Feature Descriptions

Output Overvoltage Clamp

The output overvoltage clamp consists of control cir-

cuitry, independent of the primary regulation loop, that

monitors the voltage on the output terminals. The con-

trol loop of the clamp has a higher voltage set point

than the primary loop (see Feature Specifications

tabl e). 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. 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 foldbac k 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 volt-

age set point of a module. When the output voltage

adjustment f eature is used, the output voltage set point

of all three output s is adju ste d.

The output v oltage adjustmen t can be accomplished b y

using an external resistor connected between the TRIM

pin and either the VO1(+) or common pin s. With an

external resistor between the TRIM and common pins

(Radj-up), the output voltage set point (VO, adj) increases.

Note: The output voltage adjustment range must not

exceed 110% of the nominal output voltage

between the VO1(+) and common terminals.

With an external resistor conne cte d be t w ee n the TRIM

and VO1(+) pins (Radj-down), t he output voltage set point

(VO, adj) decrease s.

Note: The output voltage adjustment must be 90% or

more of the nomina l 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 hi gh 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 V on/off = 0 V to 1.2 V. The max-

imum 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.

8-758(C).a

Figure 21. Remote On/Off Implementation

Radj-up 42.35

VO, adj VO, nom–

----------------------------------





kΩ=

Radj-down VO, adj 2.5–()16.94×

VO, nom VO, adj–

-------------------------------------------------





kΩ=

Ion/off

Von/off

REMOTE

ON/OFF

VI(+)

VI( -)

Data Sheet

June 28, 2004

Tyco Electronics Power Systems

36 Vdc to 75 Vdc Input; 25 W

DW025 Triple Output-Series Power Modules:

Thermal Considerations

Note: Dimensions are in millimeters and (inches). Drawing is not to scale. 8-866(C).b

Figure 22. Thermal Test Setup

50.8

(2.00)

12.7 (0.50)

101.6

(4.00)

203.2 (8.00)

AIRFLOW

MEASU RE CASE

TEMPERATURE AT

THIS POINT

CONNECTORS TO

LOADS, POWER

SUPPLIES, AN D

DATALOGGER,

6.35 (0.25) TALL

203.2

(8.00)

9.7 (0.38)

19.1 (0.75)

WIND TUNNEL WALL

AIR VELOC IT Y PR OBE

AMBIENT TEMPERAT URE

THERMOCOUPLE

AIR-

FLOW

27.9

(1.1)

27.9

(1.1)

dc-dc POWER MO DU LE

MADE IN USA

12.7 (0.50)

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, con-

vection, 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 22 was used to collect data. Actual perf ormance

can vary depending on the particular application

environment.

Basic Thermal Performance

The maximum ope rating tem peratur e of the DW025 Tri-

ple Output-Series Power Modules at a given operating

condition can be predicted by combining the pow er dis-

sipation curves (Figures 23 th ro ugh 27 ), the p ower der-

ating curve (Figure 28), and the thermal resistance

curve (Figure 28).

Use Figures 23 through 28 and the steps below to pre-

dict the safe operating region for many different operat-

ing and environmental cond itio ns.

1. Calculate the total output power.

POtotal = (IO1 x VO1) + (IO2 x VO2) + (IO3 x VO3)

2. Use POtotal wit h the a pprop riate figur e (Fig ure 23

or 24) to determine th e fixed losses (PP) associ-

ated with operating at POtotal. These losses are

independent of which output the load is being

drawn from.

1414 Tyco Electronics Power Systems

Data Sheet

June 28, 2004

36 Vdc to 75 Vdc Input; 25 W

DW025 Triple Output-Series Power Modules:

Thermal Considerations (continued)

Basic Thermal Performance (continued)

3. Use the desired output current (IO1) with

Figure 25 to determine PS1, which is the addi-

tional power being dissipated due to loading of

the main output.

4. Repeat Step 3 for outputs 2 and 3 using the

appropriate figure (Figure 26 or 27) to determine

PS2 and PS3, whi ch is the p o wer di ssipated du e to

loading of the auxiliary outputs.

5. Find the total power dissipated (PDtotal) by add-

ing the four power dissipations obtained in Steps

2 through 4.

PDtotal = PP + PS1 + PS2 + PS3

6. Use the estimated tot al power dissipated (P Dtotal)

along with Figure 28 t o 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= 4.4 W (from Figure 23)

PS1 = 0.22 W (from Figure 25)

PS2 = 0.06 W (from Figure 26)

PS3 = 0.06 W (from Figure 26)

Figure 28 show s that, in natural convection, the maxi-

mum ambient temperat ure that this module can oper-

ate 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 ma xi-

mum rating. The maximum case temperature, as moni-

tored at the point shown in Figure 22, should be

maintained at 100 °C or less under all conditions.

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 28 and the following equatio n:

where:

■θCA is the thermal resistance from case-to-ambient

air (°C/W).

■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.

F or example, to maint ain a maxim u m case temperature

of 85 °C with an ambien t inlet te mperat ure of 6 5 °C and

a pow er dissipation of 4.74 W, the thermal resistance is:

This corresponds to an airflow greater than 0.36 ms–1

(70 fpm) in Figure 28.

8-1113(C)

Figure 23. DW025ABK-M Fixed Losses, PP

θCA TCmax,TA–

PDtotal

------------------------------=

θCA ≤ 85 °C65 °C–

4.74 W

------------------------------------- 4.2 °C/W=

0510 30

1.0

3.5

5.5

OUTPUT POWER, PO (W)

POWER DISSIPATI ON, PD (W)

15 20 25

4.0

4.5

5.0

1.5 VI = 36 V

VI = 72 V

VI = 54 V

3.0

2.5

2.0

Tyco Electronics Power Systems

Data Sheet

June 1997 36 Vdc to 75 Vdc Input; 25 W

DW025 Triple Output-Series Power Modules:

Thermal Considerations (continued)

Air Velocity (continued)

8-1114(C)

Figure 24. DW025ACL-M Fixed Losses, PP

8-1115(C)

Figure 25. DW025ABK-M, DW025ACL-M Losses,

Associated with 5 V Output, PS1

8-1116(C)

Figure 26. DW025ABK-M, Losses Associated wit h

±12 V Output, PS2/PS3

8-1117(C)

Figure 27. DW025ACL-M Losses Associated with

±15 V Output, PS2/PS3

0510 30

1.0

1.5

2.0

4.0

6.0

OUTPUT POWER, PO (W)

POWER DISSIPATION, PD (W)

15 20 25

4.5

5.0

5.5

2.5

3.0

3.5

VI = 36 V

VI = 72 V

VI = 54 V

0.0 0.5 1.0 5.0

0.0

0.2

0.4

0.6

1.4

OUTPUT CURRENT , IO1 (A)

POWER DISSIPATION, PD (W)

1.5 2.0 2.5

0.8

1.0

1.2

3.0 3.5 4.0 4.5

VI = 36 V

VI = 54 V

VI = 72 V

0.0 0.1 0.2 1.0

0.00

0.05

0.15

0.20

0.25

0.45

OUTPUT CURRENT, I O2 OR IO3 (A)

POWER DISSIPATION, PD (W)

0.3 0.4 0.5

0.30

0.35

0.40

0.6 0.7 0.8 0.9

0.10

0.0 0.1 0.2 1.0

0.00

0.05

0.15

0.20

0.25

0.45

OUTPUT CURRENT, IO2 OR IO3 (A)

POWER DISSIPATION, PD (W)

0.3 0.4 0.5

0.30

0.35

0.40

0.6 0.7 0.8 0.9

0.10

1616 Tyco Electronics Power Systems

Data Sheet

June 28, 2004

36 Vdc to 75 Vdc Input; 25 W

DW025 Triple Output-Series Power Modules:

Thermal Considerations (continued)

Air Velocity (continued)

8-1118(C)

Figure 28. Total Power Dissipation vs. Local

Ambient Temperature and Air Velocity

8-1101(C)

Figure 29. Case-to-Ambient Thermal Resistance

vs. Air Velocity

Use of Heat Sinks and Cold Plates

The DW025 Triple Output-Series case includes

through-th readed M3 x 0.5 mounting holes, allowing

attachment of heat sinks or cold plate s 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-ambie nt

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 fr om the following equa-

tion:

Note that this equatio n assumes that all dissipated

power must be shed by the sink. Depending on the

user-defined applicat ion en viron ment, a more a ccurat e

model including heat tr ansf er from the sides and rear of

the module can be used. This equation p rovides a con-

servative 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 60 100

0.0

1.0

2.0

3.0

4.0

8.0

LOCAL AMBIENT TEMPERATURE, TA (°C)

TOTAL POWER DISSIPATION, PD TOTAL (W)

70 80 90

5.0

6.0

7.0

2.03 ms -1 (400 ft./min.)

NAT URAL CONVECTION

1.02 ms -1 (200 ft./min.)

0.51 ms -1 (100 ft./min.)

NAT

CONV 0.25

(50.0) 0.51

(100.0) 2.03

(400.0)

0.0

8.0

VELOCITY, m s -1 (ft./min.)

0.76

(150.0) 1.78

(350.0)

1.0

6.0

7.0

1.02

(200.0) 1.27

(250.0) 1.52

(300.0)

5.0

4.0

3.0

2.0

TH ERMAL R E SIST ANCE ( °C/W)

CASE-TO-AMBIENT

θCS

TATc Ts

θSA

•

θSA TCTA–

PDtotal

-------------------- θCS–=

Tyco Electronics Power Systems

Data Sheet

June 28, 2004 36 Vdc to 75 Vdc Input; 25 W

DW025 Triple Output-Series Power Modules:

Outline Diagram

Dimensions are in millimeters and (inches).

Copper paths must not be rout ed beneath the power module standoffs.

Tolerances: x.x ± 0.5 mm (0.02 in.), x.xx ± 0.25 mm (0.010 in.).

8-1119(C)

Top View

Side View

Bottom View

30.48

(1.20)

50.8

(2.00)

4.8 (0.19)

11.4 ( 0.45)

3.8 (0.15)

5.1 (0.20)

MOUNTING INSERTS

M3 x 0.5 THROUGH,

4PLACES

10.16 (0.400)

20.32

(0.800)

20.32

(0.800)

STAND-OFF,

4PLACES

10.16 (0.400)

20.32

(0.8 00)

10.16 (0.400)

48.3 (1.90)

63.50 ± 0.38 (2.500 ± 0.015)

7.1 ( 0.28)

ON/OFF

CASE

VI(- )

VO1(+)

TRIM

VO3(- )

VO2(+)

VI(+) COM

71.1 (2.80) MAX

61.0

(2.40 )

MAX

Tyco

MAD E IN USA

DC-D C Po w er Modu le

PIN 1 INDICATOR

12.7 (0.50)

MA X

5.1 (0.200 ) MIN

0.51

(0.020)

1.02 (0.04 0) ± 0 .08 (0.003)

DIA

TIN-PLATED BRASS

9PLACES

18 Tyco Electronics Power Systems

Data Sheet

June 28, 2004

36 Vdc to 75 Vdc Input; 25 W

DW025 Triple Output-Series Power Modules:

Recommended Hole Pattern

Component-side footprint.

Dimensions are in millimeters and (inches).

Recommended hole size for pin: 1.27 mm (0.050 in.).

8-1119(C)

30.48

(1.20)

20.32

(0.800)

50.8

(2.00)

11.4 (0.45)

3. 8 (0.15)

5. 1 (0 .20)

CASE OUT LIN E

10.16 (0.400) 10.16 (0.400)

20.32

(0.800)

10.16 (0.400) 20.32

(0.800 )

61.0

(2.40)

MAX

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 (OPT ION AL)

10.16 (0.400)

Tyco Electronics Power Systems

Data Sheet

June 28, 2004 36 Vdc to 75 Vdc Input; 25 W

DW025 Triple Output-Series Power Modules:

Or dering 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

suffixes in numerically descending order f ollo wed by the -M suffix, indicatin g metric (M3 x 0.5 heat sink hardw are) .

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

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

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 28, 2004

36 Vdc to 75 Vdc Input; 25 W

DW025 Triple Output-Series Power Modules:

Tyco Electronics Corporation 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 infor mation.

Printed in U.S.A.

June 28, 2004

DS04-028 ver. 1.0 (Replaces DS76-051EPS)

PDF: DW025triple.pdf

World Wide Headquarters

Tyco Electronics Power Systems, Inc.

3000 Skyline Drive, Mesquite, TX 75149, USA

+1-800-526-7819 FAX: +1-972-284-2900

(Outside U.S.A.: +1-972-284-2626

www.power.tycoelectronics.com

e-mail: techsupport1@tycoelectronics.com

Europe, Middle-East and Africa Headquarters

Tyco Electronics (UK) Ltd

Tel: +44 1344 469 300

Caribbean-Latin America-Brazil Headquarters

Tyco Electronics P ower Systems

Tel: +56 2 209 8211

Asia-Pacific Headquarters

Tyco Electro n ics S ingapore Pte Ltd

Tel: +65 6416 4283

India Headquarters

Tyco Electronic s Sy stems India Pte Ltd

Tel: +91 80 841 1633 x3001