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Data Sheet April 2008
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CW025 Triple-Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W
Options
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Isolated case ground pin 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
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Description
The CW025 Triple-Output-Series Power Modules use advanced, surface-mount technology and deliver high-quality, compact, dc-dc conversion at an economical price.
Features
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The CW025 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. The maximum total output power of the CW025 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.
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 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 meets 73/23/EEC and 93/68/EEC directives
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Applications
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Distributed power architectures Telecommunications
* UL is a registered trademark of Underwriters Laboratories, Inc. CSA is a registered trademark of 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.)
CW025 Triple-Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W
Data Sheet April 2008
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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 Input Voltage Continuous I/O Isolation Voltage: dc Transient (1 minute) Operating Case Temperature Storage Temperature Symbol VI -- -- TC Tstg Min -- -- -- - 40 - 55 Max 80 500 850 100 125 Unit Vdc V V C 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 Operating Input Voltage Maximum Input Current (VI = 0 V to 75 V; IO = IO, max) Inrush Transient Input Reflected-ripple Current, Peak-to-peak (5 Hz to 20 MHz, 12 H source impedance; TC = 25 C; see Figure 18 and Design Considerations section.) Input Ripple Rejection (120 Hz) Symbol VI II, max i2 t -- Min 36 -- -- -- Typ 48 -- -- 25 Max 72* 2.0 0.2 -- Unit Vdc A A2s mAp-p
--
--
60
--
dB
* 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.
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Data Sheet April 2008
CW025 Triple-Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W
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Electrical Specifications (continued)
Table 2. Output Specifications Parameter Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life. See Figure 20.) Output Voltage Set Point (VI = 48 V; TC = 25 C; IO1 = 2.0 A, IO2 = IO3 = 0.5 A) Device CW025ABK-M CW025ACL-M Symbol VO1 VO2 VO3 VO1 VO2 VO3 VO1, set VO2, set VO3, set VO1, set VO2, set VO3, set -- VO1 VO1 Min 4.80 10.80 -10.80 4.80 13.77 -13.77 4.90 11.83 -11.83 4.90 14.84 -14.84 -- -- -- Typ -- -- -- -- -- -- 5.00 12.20 -12.20 5.00 15.30 -15.30 0.1 0.1 0.5 Max 5.20 13.70 -13.70 5.20 17.20 -17.20 5.10 12.57 -12.57 5.10 15.76 -15.76 0.2 0.2 1.5 Unit Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc % % %
CW025ABK-M CW025ACL-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) Output Current (At IO < IO, min, the modules may exceed output ripple specifications.) Output Current-limit Inception (VO = 90% of VO, nom and minimum load on other outputs.) Output Short-circuit Current (VO = 1 V and minimum load on other outputs.) 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
All All All
All All CW025ABK-M CW025ACL-M CW025ABK-M CW025ACL-M CW025ABK-M CW025ACL-M
VO1 VO2, VO3 VO1 VO2, VO3 IO1 IO2, IO3 IO1 IO2, IO3 IO1 IO2, IO3 IO1 IO2, IO3 IO1 IO2, IO3 IO1 IO2, IO3
-- -- -- -- 0.5 0.1 0.5 0.1 -- -- -- -- -- -- -- --
-- -- -- -- -- -- -- -- 6 2 6 2 8 3 8 3
25 30 100 150 5.0 1.0 5.0 0.83 7.5 3.0 7.5 3.0 10.5 4.5 10.5 4.5
mVrms mVrms mVp-p mVp-p A A A A A A A A A A A A
CW025ABK-M CW025ACL-M

80 80
82 83
-- --
% %
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CW025 Triple-Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W
Data Sheet April 2008
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Electrical Specifications (continued)
Table 2. Output Specifications (continued) Parameter Dynamic Response (yIO/yt = 1 A/10 s, 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 Isolation Capacitance Isolation Resistance Min -- 10 Typ 0.02 -- Max -- -- Unit F M3/4 Device Symbol Min Typ Max Unit
All All
VO1 --
-- --
80 1
-- --
mV ms
All All
VO1 --
-- --
80 0.5
-- --
mV ms
General Specifications
Parameter Calculated MTBF (IO = 80% of IO, max; TC = 40 C) Weight -- Min Typ 2,906,000 -- 113 (4.0) Max Unit hours g (oz.)
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Data Sheet April 2008
CW025 Triple-Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W
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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 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.): CW025XXX-M (positive logic): Logic Low--Module Off Logic High--Module On CW025XXX1-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 Output Overvoltage Clamp Device Symbol Min Typ Max Unit
All All All All All All All CW025ABK-M CW025ACL-M
Ion/off Von/off Von/off Ion/off Von/off -- -- VO1 VO2 VO3 VO1 VO2 VO3 --
-- 0 -- -- -- -- -- -- -- -- -- -- -- 90
-- -- -- -- -- 5 0 6 15 -15 6 19 -19 --
1.0 1.2 10 50 1.2 -- 5 6.8 17 -17 6.8 21 -21 110
mA V V A V ms % V V V V V V %VO, nom
Output Voltage Set-point Adjustment Range
All
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CW025 Triple-Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W
Data Sheet April 2008
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Characteristic Curves
12.30
1.0 0.9
OUTPUT VOLTAGE, VO (V)
12.25 12.20 12.15 12.10 12.05 12.00 11.95 -40
INPUT CURRENT, II (A)
0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.0 0 10 20 30 40 50 60 70 80 INPUT VOLTAGE, VI (V)
8-1102(C)
-20
0
20
40
60
80
100
CASE TEMPERATURE, T (C)
8-1079(C)
Figure 1. CW025 Triple-Output-Series Typical Input Characteristics
Figure 3. CW025 Triple-Output-Series Typical Output Voltage Variation of 12 V Output Over Ambient Temperature Range
15.60
5.01
OUTPUT VOLTAGE, VO (V)
15.55 15.50 15.45 15.40 15.35 15.30 15.25 15.20 15.15 15.10 -40 -20 0 20 40 60 80 100
OUTPUT VOLTAGE, VO1 (V)
5.00 4.99 4.98 4.97 4.96 4.95 -40
-20
0
20
40
60
80
100
CASE TEMPERATURE, T (C)
8-1080(C)
CASE TEMPERATURE, T (C)
8-1078(C)
Figure 2. CW025 Triple-Output-Series Typical Output Voltage Variation of 5 V Output Over Ambient Temperature Range
Figure 4. CW025 Triple-Output-Series Typical Output Voltage Variation of 15 V Output Over Ambient Temperature Range
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Data Sheet April 2008
CW025 Triple-Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W
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Characteristic Curves (continued)
16.3
OUTPUT VOLTAGE, VO2 (V)
13.5
15.8
VI = 54 V, IO1 = 2.5 A, IO3 = 0.45 A
OUTPUT VOLTAGE, VO2 (V)
13.0 VI = 54 V, IO1 = 2.5 A, IO3 = 0.5 A 12.5
15.3
14.8
12.0 VI = 54 V, IO1 = 0.5 A, IO3 = 0.1 A
14.3
VI = 54 V, IO1 = 0.5 A, IO3 = 0.1 A
11.5
13.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 OUTPUT CURRENT, IO2 (A)
11.0 0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9 1.0
8-1105(C)
OUTPUT CURRENT, IO2 (A)
8-1103(C)
Figure 7. CW025ACL-M Typical Load Regulation
Figure 5. CW025ABK-M Typical Load Regulation
16.8
OUTPUT VOLTAGE, VO2 (V)
16.3 VI = 54 V, IO2 = IO3 = 0.1 A 15.8 15.3 14.8 14.3 13.8 0.0 VI = 54 V, IO2 = IO3 = 0.45 A
13.5
OUTPUT VOLTAGE, VO2 (V)
13.0 VI = 54 V, IO2 = IO3 = 0.1 A 12.5
12.0 VI = 54 V, IO2 = IO3 = 0.5 A 11.5
0.4
0.9
1.4
1.9
2.4
2.9
3.4
3.9
4.4
OUTPUT CURRENT, IO1 (A)
8-1106(C)
11.0 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 OUTPUT CURRENT, IO1 (A)
8-1104(C)
Figure 8. CW025ACL-M Typical Cross Regulation with Respect to IO1
Figure 6. CW025ABK-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.
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CW025 Triple-Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W
Data Sheet April 2008
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Characteristic Curves (continued)
5.0 4.5
OUTPUT VOLTAGE, VO1 (V)
4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0 0 1
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
2
3
4
5
6
7
8
9
OUTPUT CURRENT, IO1 (A)
8-1107(C)
Figure 9. CW025ABK-M Typical 5 V Output Characteristics
14 12
OUTPUT VOLTAGE, VO2 (V)
10 8 6 4 2 0 0
VI = 36 V, IO1 = 2.5 A, IO3 = 0.5 A VI = 54 V VI = 72 V
VI = 72 V, IO1 = 0.5 A, IO3 = 0.1 A VI = 54 V VI = 36 V
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
OUTPUT CURRENT, IO2 (A)
8-1108(C)
Figure 10. CW025ABK-M Typical 12 V Output Characteristics
5.0 4.5
VI = 72 V, IO2 = IO3 = 0.45 A VI = 54 V VI = 36 V
OUTPUT VOLTAGE, VO1 (V)
4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0 0 1 2 3 4 OUTPUT CURRENT, IO1 (A)
VI = 72 V, IO2 = IO3 = 0.1 A VI = 54 V VI = 36 V
5
6
7
8
8-1109(C)
Figure 11. CW025ACL-M Typical 5 V Output Characteristics 8 Lineage Power
Data Sheet April 2008
CW025 Triple-Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W
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Characteristic Curves (continued)
16 14 VI = 72 V, IO1 = 2.5 A, IO3 = 0.45 A 12 VI = 54 V 10 VI = 36 V 8 6 5 4 3 0 0.5 1.0 1.5 2.0 2.5 OUTPUT CURRENT, IO2 (A)
8-1110(C)
OUTPUT VOLTAGE, VO2 (V)
VI = 72 V, IO1 = 0.5 A, IO3 = 0.1 A VI = 54 V VI = 36 V
Figure 12. CW025ACL-M Typical 15 V Output Characteristics
85 80
EFFICIENCY, (%)
85
VI = 36 V VI = 54 V
EFFICIENCY, (%)
80 75 70 65 60 55
VI = 36 V VI = 54 V
75 70 65 60 55 0 20 40 60 80 100 120 PERCENT OF FULL LOAD (%)
8-1111(C)
VI = 72 V
VI = 72 V
0
20
40
60
80
100
120
PERCENT OF FULL LOAD (%)
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. CW025ABK-M Typical Converter Efficiency
Figure 14. CW025ACL-M Typical Converter Efficiency
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CW025 Triple-Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W
Data Sheet April 2008
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Characteristic Curves (continued)
OUTPUT VOLTAGE, VO (V) (% OF VO, set)
OUTPUT VOLTAGE, VO (V) (% OF VO, set)
100%
50%
102% 101%
6 4 100%
REMOTE ON/OFF (2 V/div)
0%
OUTPUT CURRENT, IO (A) (% OF IO, max)
2 0
75% 50% 25%
99%
TIME, t (2 ms/div)
8-1100(C)
TIME, t (100 s/div)
8-1098(C)
Figure 15. CW025 Triple-Output-Series Typical Output Voltage for a Step Load Change from 75% to 50% of Full Load on Output 1
Figure 17. CW025 Triple-Output-Series Typical Output Voltage Start-Up when Signal Applied to Remote On/Off
Test Configurations
TO OSCILLOSCOPE
OUTPUT VOLTAGE, VO (V) (% OF VO, set)
LTEST VI(+) 12 H CS 220 F IMPEDANCE < 0.1 @ 20 C, 100 kHz
BATTERY
101% 100%
VI(-)
OUTPUT CURRENT, IO (A) (% OF IO, max)
75% 50% 25%
99%
8-489(C).a
Note: Input reflected-ripple current is measured with a simulated source impedance (LTEST) of 12 H. Capacitor CS offsets possible battery impedance. Current is measured at the input of the module.
Figure 18. Input Reflected-Ripple Test Setup
TIME, t (100 s/div)
8-1099(C)
Figure 16. CW025 Triple-Output-Series Typical Output Voltage for a Step Load Change from 25% to 50% of Full Load on Output 1
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Data Sheet April 2008
CW025 Triple-Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W
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Test Configurations (continued)
COPPER STRIP VO2 (+)
0.47 F SCOPE
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 module. A 33 F electrolytic capacitor (ESR < 0.7 at 100 kHz) mounted close to the power module helps to ensure the stability of the unit.
RLOAD3
VO2, VO3, COM
0.47 F SCOPE
RLOAD2
VO3 (-)
Safety Considerations
VO1 (+)
0.1 F SCOPE
RLOAD1
VO1 (-)
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: s All inputs are SELV and floating, with the output also floating. s All inputs are SELV and grounded, with the output also grounded. s 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.
8-810(C).c
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
SENSE VO3(-)
SENSE VO2, VO3 SENSE VO2(+) COM CONTACT AND DISTRIBUTION LOSSES VO2(+) VO2, VO3 IO2 IO3 LOAD2 LOAD3
VI(+) II SUPPLY
COM
VO3(+)
VI(-) CONTACT RESISTANCE
VO1(+) IO1 VO1(-) LOAD1
SENSE VO1(+)
SENSE VO1(-)
8-749(C).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.
j=1
3
[ VOj ( + ) - VCOM ]IOj
= --------------------------------------------------------------- x 100 [ VI ( + ) + ( - VI ( - ) ) ]II Figure 20. Triple Output Voltage and Efficiency Measurement Test Setup
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CW025 Triple-Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W
Data Sheet April 2008
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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.
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 A.
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.
VI (+) VI (-)
-
Von/off
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.
+
REMOTE ON/OFF Ion/off
8-758(C).a
Figure 21. Remote On/Off Implementation CAUTION: To avoid damaging the module or external circuitry, the VI(-) pin must be connected to the -48 V source before or simultaneously to connecting the ON/OFF pin to the -48 V source (either directly or through the external on/off circuitry).
Radj-up = --------------------------------- k VO, adj - VO, nom
42.35 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 connected between the TRIM and VO1(+) pins (Radj-down), the output voltage set point (VO, adj) decreases. Radj-down
Grounding Considerations
For modules without the isolated case ground pin option, the case is internally connected to the VI(+) pin. For modules with the isolated case ground pin option, the VI(+) is not connected to the case.
( VO, adj - 2.5 ) x 16.94 = ------------------------------------------------ k VO, nom - VO, adj -
Note: The output voltage adjustment must be 90% or more of the nominal output voltage between the VO1(+) and common terminals. 12 Lineage Power
Data Sheet April 2008
CW025 Triple-Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W
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Thermal Considerations
12.7 (0.50)
WIND TUNNEL WALL 27.9 (1.1) 27.9 (1.1) AIRFLOW CONNECTORS TO LOADS, POWER SUPPLIES, AND DATALOGGER, 6.35 (0.25) TALL
dc-dc POWER MODULE MADE IN USA
MEASURE CASE TEMPERATURE AT THIS POINT
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.
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CW025 Triple-Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W
Data Sheet April 2008
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Thermal Considerations (continued)
Basic Thermal Performance
The maximum operating temperature of the CW025 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 29). 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. 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. 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. PDtotal = PP + PS1 + PS2 + PS3 6. Use the estimated total power dissipated (PDtotal) along with Figure 28 to determine the maximum ambient temperature allowable for a given air velocity.
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.
Air Velocity
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: CA = -----------------------------PDtotal where:
s
TC, max - TA
3.
CA 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.
s
s
4.
s
5.
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 CA ------------------------------------- = 4.2 C/W 4.74 W This corresponds to an airflow greater than 0.36 ms-1 (70 fpm) in Figure 28.
For example, consider the CW025ABK-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)
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Data Sheet April 2008
CW025 Triple-Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W 3
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Thermal Considerations (continued)
1.4
POWER DISSIPATION, PD (W)
Air Velocity (continued)
5.5
POWER DISSIPATION, PD (W)
1.2 1.0 VI = 54 V 0.8 VI = 36 V 0.6 0.4 0.2 0.0 0.0 VI = 72 V
5.0 4.5 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)
VI = 72 V VI = 54 V
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. CW025ABK-M, CW025ACL-M Losses, Associated with 5 V Output, PS1
Figure 23. CW025ABK-M Fixed Losses, PP
POWER DISSIPATION, PD (W)
0.45 0.40 0.35 0.30 0.25 0.20 0.15 0.10 0.05
POWER DISSIPATION, PD (W)
6.0 5.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0 5 10 15 20 25 30 OUTPUT POWER, PO (W)
8-1114(C)
VI = 72 V
VI = 36 V VI = 54 V
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)
8-1116(C)
Figure 26. CW025ABK-M, Losses Associated with 12 V Output, PS2/PS3
Figure 24. CW025ACL-M Fixed Losses, PP
Lineage Power
15
CW025 Triple-Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W
Data Sheet April 2008
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Thermal Considerations (continued)
8.0
THERMAL RESISTANCE (C/W) CASE-TO-AMBIENT
Air Velocity (continued)
0.45
7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0 1.02 1.27 1.52 0.25 0.51 2.03 0.76 1.78 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)
POWER DISSIPATION, PD (W)
0.40 0.35 0.30 0.25 0.20 0.15 0.10 0.05 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)
Figure 29. Case-to-Ambient Thermal Resistance vs. Air Velocity
Figure 27. CW025ACL-M Losses Associated with 15 V Output, PS2/PS3
Use of Heat Sinks and Cold Plates
The CW025 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). The following thermal model can be used to determine the required thermal resistance of the sink to provide the necessary cooling: Ts Tc TA PD CS SA
TOTAL POWER DISSIPATION, PD TOTAL (W)
8.0 7.0 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)
2.03 ms -1 (400 ft./min.) 1.02 ms -1 (200 ft./min.) 0.51 ms -1 (100 ft./min.) NATURAL CONVECTION
*
where PD is the power dissipated by the module, CS represents the interfacial contact resistance between the module and the sink, and SA is the sink-to-ambient thermal impedance (C/W). For thermal greases or foils, a value of CS = 0.1 C/W to 0.3 C/W is typical. The required SA is calculated from the following equation: TC - TA SA = ------------------- - CS PDtotal 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. 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. Lineage Power
Figure 28. Total Power Dissipation vs. Local Ambient Temperature and Air Velocity
16
Data Sheet April 2008
CW025 Triple-Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W
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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.). Note: For standard modules, VI(+) is internally connected to the case and the CASE GROUND pin is not present. If the CASE GROUND pin is chosen, device code suffix 7, then VI(+) is not connected to the case and the CASE GROUND pin is floating. Top View
PIN 1 INDICATOR 71.1 (2.80) MAX
61.0 (2.40) MAX
M3 DC-DC Power Module
MADE IN USA
Side View
12.7 (0.50) MAX 0.51 (0.020) 1.02 (0.040) 0.08 (0.003) DIA TIN-PLATED BRASS, 9 PLACES
5.1 (0.020) MIN
Bottom View
4.8 (0.19)
STANDOFF, 4 PLACES 5.1 (0.20) CASE PIN OPTIONAL TRIM VO1(-) 27.94 (1.100) 17.78 (0.700) 50.8 (2.00)
7.1 (0.28)
25.40 (1.000) 10.16 (0.400) 61.0 (2.40) MAX 24.1 (0.95)
VI(-) VO1(+) VI(+) 15.24 (0.600) ON/OFF VO3(-) MOUNTING INSERTS VO2 & VO3 M3 x 0.5, COM 4 PLACES
VO2(+)
7.62 (0.300)
5.08 (0.200)
12.70 (0.500) 20.32 (0.800)
48.3 (1.90) 11.4 (0.45) 63.50 0.38 (2.500 0.015) 3.8 (0.15) 71.1 (2.80) MAX
8-1053(C).a
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17
CW025 Triple-Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W
Data Sheet April 2008
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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)
24.1 (0.95) 61.0 (2.40) MAX 15.24 (0.600) 5.08 (0.200) 10.16 (0.400) 25.4 (1.000) 7.62 (0.300) 17.78 (0.700) 12.70 (0.500)
20.32 (0.800)
50.8 (2.00) 27.94 (1.100)
5.1 (0.20) 48.3 (1.90) 63.50 0.38 (2.500 0.015) 3.8 (0.15) 71.1 (2.80) MAX
8-1053(C).a
11.4 (0.45)
18
Lineage Power
Data Sheet April 2008
CW025 Triple-Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W
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Ordering Information
Table 4. Ordering Information Table Input Voltage 36 V--75 V 36 V--75 V Output Voltage +5 V, 12 V +5 V, 15 V Output Power 25 W 25 W Remote On/Off Logic positive positive Device Code CW025ABK-M CW025ACL-M Comcode 107587206 107587875
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 Short pins: 2.79 mm 0.25 mm (0.110 in. 0.010 in.) Isolated case ground pin Negative remote on/off logic Device Code Suffix 8 7 1
Please contact your Lineage Power Account Manager or Field Application Engineer for pricing and availability.
Lineage Power
19
CW025 Triple-Output-Series Power Modules: 36 Vdc to 75 Vdc Input; 25 W
Data Sheet April 2008
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A sia-Pacific Head qu art ers T el: +65 6 41 6 4283 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 arters T el: +91 8 0 28411633
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
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. (c) 2008 Lineage Power Corpor ation, (Mesquite, Texas ) All International Rights Res er ved.
April 2008
DS97-424EPS (Replaces DS97-423EPS)

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