TWR-5/3-12/300-D24-C

Input Voltage:
Continuous or transient
12V Models –0.3V minimum or +18V maximum
24V Models –0.3V minimum or +36V maximum
48V Models –0.3V minimum or +75V maximum
On/Off Control (Pin 1) –0.3V minimum or +V
IN maximum
Input Reverse-Polarity Protection None. Install external fuse.
Output Overvoltage Protection V
OUT +20% maximum
Output Current Current limited. Devices can
withstand sustained output short
circuits without damage.
Storage Temperature –40 to +120°C
Lead Temperature (soldering 10 sec. max.) +280°C
These are stress ratings. Exposure of devices to greater than any of these conditions may
adversely affect long-term reliability. Proper operation under conditions other than those
listed in the Performance/Functional Specifi cations Table is not implied.
Absolute Maximum Ratings
TECHNICAL NOTES
Load Dependency and Regulation
The high voltage bipolar output section derives its regulation as a slave
to the low voltage unipolar output. Be aware that large load changes on
the unipolar section will change the voltage somewhat on the bipolar
section. To retain proper regulation, the bipolar voltage section must have
a minimum load of at least 10% of rated full output. With this minimal
load (or greater), the high voltage bipolar section will meet all its regula-
tion specifi cations. If there is no load, the output voltage may exceed the
regulation somewhat.
Input Fusing
Certain applications and/or safety agencies require fuses at the inputs
of power conversion components. Fuses should also be used if there is the
possibility of sustained, non-current limited reverse input polarity. DATEL
recommends fast-blow type fuses approximately twice the maximum input
current at nominal input voltage but no greater than 5 Amps. Install these
fuses in the high side (ungrounded input) power lead to the converter.
Input Voltage Fuse Value
12 Volts 4 Amps
24 Volts 2 Amps
48 Volts 1 Amp
Input Source Impedance
The external source supplying input power must have low AC imped-
ance. Failure to insure adequate low AC impedance may cause stability
problems, increased output noise, oscillation, poor settling and aborted
start-up. The converter’s built-in front end fi ltering will be suffi cient in most
applications. However, if additional AC impedance reduction is needed,
consider adding an external capacitor across the input terminals mounted
close to the converter. The capacitor should have low internal Equivalent
Series Resistance (ESR) and low inductance. Often, two or more capaci-
tors are used in parallel. A ceramic capacitor gives very low AC impedance
while a parallel electrolytic capacitor offers improved energy storage.
Input Undervoltage Shutdown and Start-Up Threshold
Under normal start-up conditions, devices will not begin to regulate
until the ramping-up input voltage exceeds the Start-Up Threshold Voltage.
Once operating, devices will not turn off until the instantaneous input
voltage drops below the Undervoltage Shutdown limit. Subsequent restart
will not occur until the input is brought back up to the Start-Up Threshold.
This built-in hysteresis avoids any unstable on/off situations occurring at a
single input voltage. However, you should be aware that poorly regulated
input sources and/or higher input impedance sources (including long power
leads) which have outputs near these voltages may cause cycling of the
converter outputs.
Ripple Current and Output Noise
All TWR converters are tested and specifi ed for input refl ected ripple cur-
rent (also called Back Ripple Current) and output noise using specifi ed fi lter
components and test circuit layout as shown in the fi gures below. Input
capacitors must be selected for low ESR, high AC current-carrying capabil-
ity at the converter’s switching frequency and adequate bulk capacitance.
The switching nature of DC/DC converters requires this low AC impedance
to absorb the current pulses refl ected back from the converter’s input.
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Figure 2. Measuring Input Ripple Current
Output Overcurrent Detection
Overloading the power converter’s output for extended periods (but not a
short circuit) at high ambient temperatures may overheat the output com-
ponents and possibly lead to component failure. Brief moderate overcurrent
operation (such as charging up reasonably-sized external bypass capacitors
when fi rst starting) will not cause problems. The TWR series include current
limiting to avoid heat damage. However, you should remove a sustained
overcurrent condition promptly as soon as it is detected. Combinations of
low airfl ow and/or high ambient temperature for extended periods may
cause overheating even though current limiting is in place.
Current Return Paths
Make sure to use adequately sized conductors between the output
load and the Common connection. Avoid simply connecting high current
returns only through the ground plane unless there is adequate copper
thickness. Also, route the input and output circuits directly to the Common
pins. Failure to observe proper wiring may cause instability, poor regulation,
increased noise, aborted start-up or other undefi ned operation.
Triple Output/
TWR Models
Isolated, High Reliability 1" x 2" DC/DC Converters
MDC_TWR22.C03 Page 4 of 9
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HI = ON
LO = OFF
(for positive
On/Off)
SIGNAL
GROUND
COMMON
ON/OFF
CONTROL
CMOS
LOGIC
CONTROLLER
Safety Considerations
The TWR’s must be installed with consideration for any local safety,
certifi cation or regulatory requirements. These vary widely but generally
are concerned with properly sized conductors, adequate clearance between
higher voltage circuits, life testing, thermal stress analysis of components and
ammability of components.
Remote On/Off Control
The TWR models include an input pin which can turn on or shut off the
converter by remote signal. For positive logic models (no model number
suffi x), if this pin is left open, the converter will always be enabled as long
as proper input power is present. On/Off signal currents are referred to the
Input Common pin on the converter. There is a short time delay of several mil-
liseconds (see the specifi cations) for turn on, assuming there is no signifi cant
external output capacitance.
The On/Off Control may also be supplied with negative logic (LO = on, HI =
off) using the “N” model number suffi x. For negative logic, the On/Off pin must
be grounded or pulled LOW to turn on the unit. Positive logic models must
have this control pin pulled down for shutoff. Negative logic models must pull
up this control pin for shutoff.
Dynamic control of this On/Off input is best done with either a mechani-
cal relay, solid state relay (SSR), an open collector or open drain transistor,
CPU bit or a logic gate. The pull down current is 18mA max. for "N" models.
Observe the voltage limits listed in the specifi cations for proper operation.
Suggested circuits are shown below.
Figure 3. On/Off Control With An External CMOS Gate
Figure 4. On/Off Control With An External Transistor (positive logic)
Isolation Considerations
These converters use both transformer and optical coupling to isolate the
inputs from the outputs. Ideal “fl oating” isolation implies ZERO CURRENT fl ow-
ing between the two Common return sections of the input and output up to the
working isolation voltage limit. Real-world isolation on this converter includes
both an AC current path (through some small coupling capacitance) and some
DC leakage current between the two ground systems. To avoid diffi culties
in your application, be sure that there are not wideband, high amplitude AC
difference voltages between the two ground systems. In addition, ground dif-
ference voltages applied by your external circuits which exceed the isolation
voltage, even momentarily, may damage the converter’s isolation barrier. This
can either destroy the converter or instantly render it non-isolated.
Current Limiting and Short Circuit Condition
As the output load increases above its maximum rated value, the converter
will enter current limiting mode. The output voltage will decrease and the
converter will essentially deliver constant power. This is commonly called
power limiting.
If the current continues to increase, the converter will enter short circuit
operation and the PWM controller will shut down. Following a time-out
period, the converter will automatically attempt to restart. If the short circuit
is detected again, the converter will shut down and the cycle will repeat. This
operation is called hiccup autorecovery. Please be aware that excessive exter-
nal output capacitance may interfere with the hiccup autorestart.
Output Filtering and Noise Reduction
All switching DC/DC converters produce wideband output noise which radi-
ates both through the wiring (conducted emission) and is broadcast into the
air (radiated emission). This output noise may be attenuated by adding a small
amount of capacitance in parallel with the output terminals. Please refer to the
maximum output capacitance in the Specifi cations.
The amount of capacitance to add depends on the placement of the cap
(near the converter versus near the load), the distance from the converter to
the load (and resulting series inductance), the topology and locations of load
elements if there are multiple parallel loads and the nature of the loads. For
switching loads such as CPU’s and logic, this last item recommends that small
bypass capacitors be placed directly at the load. Very high clock speeds sug-
gest smaller caps unless the instantaneous current changes are high. If the
load is a precision high-gain linear section, additional fi ltering and shielding
may be needed.
Many applications will need no additional capacitance. However, if more
capacitance is indicated, observe these factors:
1. Understand the noise-reduction objective. Are you improving the switching
threshold of digital logic to reduce errors? (This may need only a small
amount of extra capacitance). Or do you need very low noise for a precision
linear “front end”?
2. Use just enough capacitance to achieve your objective. Additional capaci-
tance trades off increasing instability (actually adding noise rather than
reducing it), poor settling response, possible ringing or outright oscilla-
tion by the converter. Excessive capacitance may also disable the hiccup
autorestart. Do not exceed the maximum output capacitance specifi cation.
Triple Output/
TWR Models
Isolated, High Reliability 1" x 2" DC/DC Converters
MDC_TWR22.C03 Page 5 of 9
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3. Any series inductance considerably complicates the added capacitance
therefore try to reduce the inductance seen at the converter’s output. You
may need to add BOTH a cap at the converter end and at the load (effec-
tively creating a Pi fi lter) for the express purpose of reducing the phase
angle which is seen by the converter’s output loop controller. This tends
to hide (decouple) the inductance from the controller. Make sure your
power conductors are adequate for the current and reduce the distance
to the load as much as possible. Very low noise applications may require
more than one series inductor plus parallel caps.
4. Oscillation or instabilility can occur at several frequencies. For this
reason, you may need both a large electrolytic or tantalum cap (car-
rying most of the capacitance) and a small wideband parallel ceramic
cap (with low internal series inductance). Always remember that inside
real world capacitors are distributed trace inductance (ESL) and series
resistance (ESR). Make sure the input AC impedance is very low before
trying to improve the output.
5. It is challenging to offer a complete set of simple equations in reason-
able closed form for the added output capacitance. Part of the diffi culty is
accurately modeling your load environment. Therefore your best success
may be a combination of previous experience and empirical approxima-
tion.
Maximum Current and Temperature Derating Curves
The curves shown below indicate the maximum average output current
available versus the ambient temperature and airfl ow. All curves are done
approximately at sea level and you should leave an additional margin for
higher altitude operation and possible fan failure. (Remember that fans are
less effi cient at higher altitudes). These curves are an average – current
may be greater than these values for brief periods as long as the average
value is not exceeded.
The “natural convection” area of the curve is that portion where self-
heating causes a small induced convective airfl ow around the converter
without further mechanical forced airfl ow from a fan. Natural convection
assumes that the converter is mounted with some spacing to adjacent com-
ponents and there are no nearby high temperature parts. Note that such
self-heating will produce an airfl ow of typically 25 Linear Feet per Minute
(LFM) without a fan. Heat is removed both through the mounting pins and
the surface of the converter.
Many systems include fans however it is not always easy to measure
the airfl ow adjacent to the DC/DC converter. Simply using the cubic feet
per minute (CFM) rating of the fan is not always helpful since it must be
matched to the volume of the enclosure, the outside ambient temperature,
board spacing, the intake area and total internal power dissipation.
Most PWM controllers, including those on the TWR’s, will tolerate opera-
tion up to about +100 degrees Celsius. If in doubt, attach a thermal sensor
to the package near the output components and measure the surface
temperature after allowing a proper warm-up period. Remember that the
temperature inside the output transistors at full power will be higher than
the surface temperature therefore do not exceed operation past approxi-
mately +100 deg. C on the surface. As a rough indication, any circuit which
you cannot touch briefl y with your fi nger warrants further investigation.
It is probably more important in your system that all heat is periodically
removed rather than having very high airfl ow. Consider having the total
enclosure completely recycled at least several times a minute. Failure to
remove the heat causes heat buildup inside your system and even a small
fan (relative to the heat load) is quite effective. A very rough guide for typi-
cal enclosures is one cubic foot per minute of exhausted airfl ow per 100
Watts of internal heat dissipation.
Effi ciency Curves
These curves indicate the ratio of output power divided by input power
at various input voltages and output currents times 100%. All curves are
measured at +25°C ambient temperature and adequate airfl ow.
Typical Performance Curves for TWR Series
Triple Output/
TWR Models
Isolated, High Reliability 1" x 2" DC/DC Converters
MDC_TWR22.C03 Page 6 of 9
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TWR-5/3-12/300-D24-C

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