delphi diw4000 series dc/dc power modules: 24, 48vin, 5~6w dip the delphi diw4000, 24v and 48v 4:1 wide input, single or dual output, dip form factor, isolated dc/dc converter is the latest offering from a world leader in power systems technology and manufacturing D delta electronics, inc. the diw4000 series operate from 24v or 48v (4:1) and provides 3.3v, 5v, 12v, or 15v of single output or 5v, 12v, or 15v of dual output in an industrial standard, metal case encapsulated dip package (body size: 1.25"x 0.80?x0.40?). this series provides up to 6w of output power with 1500v isolation and a typical full-load efficiency up to 86%. with creative design technology and optimization of component placement, these converters possess outstanding electrical and thermal performance, as well as extremely high reliability under highly stressful operating conditions. applications ? industrial ? transportation ? process/ automation ? telecom ? data networking datasheet ds_diw4000_12032008 features ? efficiency up to 86% ? industry standard form factor and pinout ? size: 31.8 x20.3 x10.2mm (1.25? x0.80? x0.40?) ? input: 24v, 48v (4:1) ? output: 3.3, 5, 12, 15, 5, 12, 15v ? low ripple and noise ? 1500v isolation ? short circuit protection ? ul 94v-0 package material ? iso 9001 and iso14001 certified manufacturing facility ? csa 60950-1 recognized options
2 technical specifications t a = 25c, airflow rate = 0 lfm, nominal vin, nominal vout, resistive load unless otherwise noted. parameter notes and conditions diw4000 (standard) min. typ. max. units absolute maximum ratings input voltage transient 24v input model, 1000ms -0.7 50 vdc transient 48v input model, 1000ms -0.7 100 vdc internal power dissipation 2500 mw operating temperature ambient -40 85 c case -40 100 c storage temperature -40 125 c humidity 95 % lead temperature in assembly 1.5mm from case for 10 seconds 260 c input/output isolation voltage 1500 vdc input characteristics operating input voltage 24v model 18 24 36 48v model 36 48 75 vdc turn-on voltage threshold 24v model 7 8 9 vdc 48v model 14 16 18 vdc turn-off voltage threshold 24v model --- --- 8.5 vdc 48v model --- --- 16 vdc maximum input current please see model list table on page 6 no-load input current 24v model 20 ma 48v model 10 ma input reflected ripple current 24v model 10 ma 48v model 10 ma short circuit input power all models 2.5 w reverse polarity input current 0.5 a output characteristics output voltage set point accuracy 0.5 1.0 % output voltage balance dual output models 0.5 2.0 % output voltage regulation over load io=10% to 100% 0.3 1.0 % over line vin= min to max 0.2 0.5 % over temperature tc=-40c to 100c 0.01 0.02 %/c output voltage ripple and noise 5hz to 20mhz bandwidth peak-to-peak full load, 0.47f ceramic 50 75 mv peak-to-peak, over line, load, temperature full load, 0.47f ceramic 100 mv rms full load, 0.47f ceramic 15 mv output over current/power protection auto restart 110 250 350 % output short circuit continuous output voltage current transient step change in output current 25% step change 3 % settling time (within 1% vout nominal) 250 500 us maximum output capacitance si ngle output models 3000 f dual output models, each output 680 f efficiency 100% load please see model list table on page 6 isolation characteristics isolation voltage input to output, 60 seconds 1500 vdc isolation voltage test flash test for 1 seconds 1650 vdc isolation resistance 500vdc 1000 m ? isolation capacitance 100khz, 1v 350 550 pf feature characteristics switching frequency 340 khz general specifications mtbf mil-hdbk-217f; ta=25c, ground benign 1 m hours weight 17.3 grams case material non-conductive black plastic flammability ul94v-0 input fuse 24v model, 1500ma slow blown type 48v model, 750ma slow blown type
3 electrical charact eristics curves input voltage (v) nom low high 50 60 70 80 90 100 efficiency (%) 50 60 70 80 90 100 efficiency (%) input voltage (v) nom low high figure 1: efficiency vs. input voltage (single output) figure 2: efficiency vs. input voltages (dual output) 20 30 40 50 60 70 80 90 load current (%) efficiency (%) 100 60 40 20 10 80 20 30 40 50 60 70 80 90 load current (%) efficiency (%) 100 60 40 20 10 80 figure 3: efficiency vs. output load (single output) figure 4: efficiency vs. output load (dual output)
4 test configurations input reflected-ripple current test setup +out -out +vin -vin dc / dc converter load battery + lin + cin to oscilloscope current probe input reflected-ripple current is measured with a inductor lin (4.7uh) and cin (220uf, esr < 1.0 ? at 100 khz) to simulate source impedance. capacitor cin is to offset possible battery impedance. curr ent ripple is measured at the input terminals of the module and measurement bandwidth is 0-500 khz. peak-to-peak output noise measurement scope measurement should be made by using a bnc socket, measurement bandwidth is 0-20 mhz. position the load between 50 mm and 75 mm from the dc/dc converter. a cout of 0.47uf ceramic capacitor is placed between the terminals shown below. +out -out +vin -vin single output dc / dc converter resistive load scope copper strip cout +out -out +vin -vin dual output dc / dc converter resistive load scope copper strip cout com. scope cout design & feature considerations the diw4000 circuit block diagrams are shown in figures 5 and 6. pfm isolation ref.amp lc filter +vin -vin -vo +vo figure 5: block diagram of diw3000 single output modules. +vo pfm isolation ref.amp lc filter +vin -vin com. -vo figure 6: block diagram of diw3000 dual output modules 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. + +out -out +vin -vin dc / dc converter load dc power source + - cin in applications where power is supplied over long lines and output loading is high, it may be necessary to use a capacitor at the input to ensure startup. capacitor mounted close to the input of the power module helps ensure stability of the unit, it is recommended to use a good quality low equivalent series resistance (esr < 1.0 ? at 100 khz) capacitor of a 4.7uf for the 24v input devices, and a 2.2uf for the 48v devices.
5 design & feature considerations maximum capacitive load the diw3000 series has limitation of maximum connected capacitance at the output. the power module may be operated in current limiting mode during start-up, affecting the ramp-up and the startup time. for optimum performance we recommend 680uf maximum capacitive load for dual outputs and 3000uf capacitive load for single outputs. output ripple reduction a good quality low esr capacitor placed as close as practicable across the load will give the best ripple and noise performance. to reduce output ripple, it is recommended to use 3.3uf capacitors at the output. +out -out +vin -vin load dc power source + - cout single output dc / dc converter +out -out +vin -vin load dc power source + - cout com. dual output dc / dc converter overcurrent protection to provide protection in a fault (output overload) condition, 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. the unit operates normally once the output current is brought back into its specified range. soldering and cleaning considerations post solder cleaning is usually the final board assembly process before the board or system undergoes electrical testing. inadequate cleaning and/or drying may lower the reliability of a power module and severely affect the finished circuit board assembly test. adequate cleaning and/or drying is especially important for un-encapsulated and/or open frame type power modules. for assistance on appropriate soldering and cleaning procedures, please contact delta?s technical support team. notes: 1. these power converters require a minimum output load to maintain specified regulation (please see page 6 for the suggested minimum load). operation under no-load conditions will not damage these modules; however, they may not meet all specifications listed above. 2. these dc/dc converters should be externally fused at the front end for protection.
6 thermal considerations thermal management is an important part of the system design. to ensure proper, reliable operation, sufficient cooling of the power module is needed over the entire temperature range of the module. convection cooling is usually the dominant mode of heat transfer. hence, the choice of equipment to characterize the thermal performance of the power module is a wind tunnel. thermal testing setup delta?s dc/dc power modules are characterized in heated vertical wind tunnels that simulate the thermal environments encountered in most electronics equipment. this type of equipment commonly uses vertically mounted circuit cards in cabinet racks in which the power modules are mounted. the following figure shows the wind tunnel characterization setup. the power module is mounted on a test pwb and is vertically positioned within the wind tunnel. the space between the facing pwb and pwb is constantly kept at 25.4mm (1??). figure 7: wind tunnel test setup thermal derating heat can be removed by in creasing airflow over the module. to enhance system reliability, the power module should always be operated below the maximum operating temperature. if t he temperature exceeds the maximum module temperature, reliability of the unit may be affected. thermal curves diw4000series output current vs. ambient temperature and air velocity (either orientation) 0% 20% 40% 60% 80% 100% 120% 25 35 45 55 65 75 85 ambient temperature ( ) output power (%) natural convection figure 8: derating curve
7 model list input output full load efficiency vdc (v) max (ma) vdc (v) max (ma) min (ma) % diw4021 212 3.3 1200 120 78 diw4022 257 5 1000 100 81 diw4023 291 12 500 50 86 diw4024 294 15 400 40 85 diw4025 257 5 500 50 81 diw4026 291 12 250 25 86 DIW4027 294 15 200 20 85 diw4031 106 3.3 1200 120 78 diw4032 129 5 1000 100 81 diw4033 145 12 500 50 86 diw4034 147 15 400 40 85 diw4035 123 5 500 50 81 diw4036 145 12 250 25 86 diw4037 147 15 200 20 85 24 (9 ~ 36) 48 (18 ~ 75)
8 mechanical drawing 31.8 [1.25"] 10.2 [0.40"] 15.22 [0.60"] 20.3 [0.80"] 4.5 [0.18"] 2.54 [0.10"] 4.1 [0.16"] side view 23 11 23 22 14 bottom view 2.5 [0.10"] 9 16 0.5 [0.02"] contact : www.delta.com.tw/dcdc usa: telephone: east coast: (888) 335 8201 west coast: (888) 335 8208 fax: (978) 656 3964 email: dcdc@delta-corp.com europe: phone: +41 31 998 53 11 fax: +41 31 998 53 53 email: dcdc@delta-es.com asia & the rest of world: telephone: +886 3 4526107 ext 6220~6224 fax: +886 3 4513485 email: dcdc@delta.com.tw warranty delta offers a two (2) year limited warranty. complete warranty information is listed on our web site or is available upon requ est from delta. information furnished by delta is believed to be accurate and re liable. however, no responsibility is assumed by delta for its use, nor for any infringements of patents or other rights of third parties, which may result from its use. no license is granted by implication or otherwise under any patent or patent rights of delta. delta reserves the right to revise these specifications at any time, without notice. pin sin g le output dual output 2-vin -vin 3-vin -vin 9 no pin common 11 nc -vout 14 +vout +vout 16 -vout common 22 +vin +vin 23 +vin +vin
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