FEATURES
Efficiency up to 64%
Industry standard form factor and pinout
Size:
31.8 x20.3 x10.2mm (1.25” x0.80” x0.40”)
Input: 5V, 12V, 15V (±10%)
Output: 5, 12, 15,
±5, ±12, ±15V
Low ripple and noise
Short circuit protection
6000V isolation
UL 94V-0 Package Material
ISO 9001 and ISO14001 certified
manufacturing facility
Delphi DIR500 Series DC/DC Power
Modules: 5, 12, 24Vin, 2W DIP
6000V isolation, single/dual output
The Delphi DIR500, 5V, 12V, and 24V 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
―
Delta Electronics, Inc. The DIR500 series operate from 5V, 12V, or
15V (
±
10%) and provides 5V, 12V, or 15V of single output or
±
5V,
±
12V, or
±
15V of dual output in an industrial standard, plastic case
encapsulated DIP package. This series provides up to 2W of output
power with 6000V isolation and a typical full-load efficiency up to
64%. 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.
OPTIONS
APPLICATIONS
Industrial
Transportation
Process/ Automation
DATASHEET
DS_DIR500_12032008
TECHNICAL SPECIFICATIONS
T
A
= 25°C, airflow rate = 0 LFM, nominal Vin, nominal Vout, resistive load unless otherwise noted.
PARAMETER
ABSOLUTE MAXIMUM RATINGS
Input Voltage
Transient
Transient
Transient
Internal Power Dissipation
Operating Temperature
Storage Temperature
Humidity
Lead Temperature in Assembly
Input/Output Isolation Voltage
INPUT CHARACTERISTICS
Operating Input Voltage
Maximum Input Current
No-Load Input Current
Reflected Input Repple Current
Short circuit input power
Reverse Polarity Input Current
OUTPUT CHARACTERISTICS
Output Voltage Set Point Accuracy
Output Voltage Balance
Output Voltage Regulation
Over Load
Over Line
Over Temperature
Output Voltage Ripple and Noise
Peak-to-Peak
Peak-to-Peak, over line, load, temperature
RMS
Output Over Current/Power Protection
Output Short Circuit
Output Voltage Current Transient
Step Change in Output Current
Settling Time (within 1% Vout nominal)
Maximum Output Capacitance
EFFICIENCY
100% Load
ISOLATION CHARACTERISTICS
Isolation Voltage
Isolation Voltage Test
Leakage Current
Isolation Resistance
Isolation Capacitance
FEATURE CHARACTERISTICS
Switching Frequency
GENERAL SPECIFICATIONS
MTBF
Weight
Case Material
Flammability
Input Fuse
NOTES and CONDITIONS
Min.
5V input model, 1000ms
12V input model, 1000ms
24V input model, 1000ms
Ambient
Case
-0.7
-0.7
-0.7
-40
-40
-40
DIR500 (Standard)
Typ.
Max.
7.5
15
30
2000
85
100
125
95
260
5
12
24
100
50
30
15
8
3
2
0.5
5.5
13.2
26.4
Units
Vdc
Vdc
mW
°C
°C
°C
%
°C
Vdc
Vdc
Vdc
Vdc
mA
mA
mA
mA
mA
mA
W
A
%
%
%
%
%/C
mV
mV
mV
%
%
uS
µF
µF
1.5mm from case for 10 seconds
6000
5V input model
12V input model
24V input model
Please see Model List table on page 6
5V model
12V model
24V model
5V model
12V model
24V model
4.5
10.8
21.6
Dual output models
Io=10% to 100%
Vin = min to max
Tc=-40°C to 100°C
5Hz to 20MHz bandwidth
Full Load, 0.33µF ceramic
Full Load, 0.33µF ceramic
Full Load, 0.33µF ceramic
Auto restart
Continuous
50% step change
Single output models
Dual output models, each output
Please see Model List table on page 6
Input to output, 60 Seconds
Flash Test for 1 seconds
240VAC, 60Hz
500VDC
100KHz, 1V
6000
8000
±2.0
±2.0
±0.5
±0.3
±0.01
30
120
±4.0
±4.0
±1.0
±0.5
±0.02
50
100
5
±6
50
680
270
2
10
20
25
30
80
12
Vdc
Vdc
µA
GΩ
pF
kHz
M hours
grams
MIL-HDBK-217F; Ta=25°C, Ground Benign
Non-conductive black plastic
UL94V-0
5V model, 100mA slow blown type
12V model, 500mA slow blown type
24V model, 250mA slow blown type
0.6
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.
2
ELECTRICAL CHARACTERISTICS CURVES
80
70
Efficiency (%)
60
50
40
30
80
70
Efficiency (%)
Low
Nom
Input Voltage (V)
High
60
50
40
30
Low
Nom
Input Voltage (V)
High
Figure 1:
Efficiency vs. Input Voltage (Single Output)
Figure 2:
Efficiency vs. Input Voltage (Dual Output)
90
80
Efficiency (%)
90
80
Efficiency (%)
10
20
40
60
80
100
70
60
50
40
30
20
70
60
50
40
30
20
10
20
40
60
80
100
Load Current (%)
Load Current (%)
Figure 3:
Efficiency vs. Output Load (Single Output)
Figure 4:
Efficiency vs. Output Load (Dual Output)
+Vin
LC
Filter
-Vin
Bipolar
Push-Pull
Inverter
Low
Dropout
Regulator
+Vo
+Vin
LC
Filter
-Vin
Bipolar
Push-Pull
Inverter
Positive
Regulator
+Vo
Com.
-Vo
Negative
Regulator
-Vo
Figure 5:
Block diagram of DIR500 single output modules.
Figure 6:
Block diagram of DIR500 dual output modules.
3
Design & Feature Considerations
The DIR500 circuit block diagrams are shown in
Figures 5 and 6.
Maximum Capacitive Load
The DIR500 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.
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 0.33uF ceramic capacitor is
placed between the terminals shown below.
+Vin
Single Output
DC / DC
Converter
-Vin
-Out
+Out
Copper Strip
Cout
Scope
Resistive
Load
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 1.5uF
capacitors at the output.
+
DC Power
Source
+Vin
Single Output
DC / DC
Converter
-Vin
-Out
+Out
Cout
Load
+Vin
Dual Output
DC / DC
Converter
-Vin
+Out
Com.
Copper Strip
Cout
Cout
Scope
Resistive
Load
Scope
-
+
DC Power
Source
-
+Vin
+Out
Dual Output
DC / DC
Com.
Converter
Cout
Load
-Out
-Vin
-Out
Input Source Impedance
Soldering and Cleaning Considerations
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.
+
DC Power
Source
-
+
Cin
-Vin
-Out
+Vin
DC / DC
Converter
+Out
Load
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.
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 < 1.0Ω at 100 KHz) capacitor
of a 4.7uF for the 5V input devices, a 2.2uF for the 12V
and 24V devices.
4
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 CURVES
DIR500series Output Current vs. Ambient Temperature and Air Velocity
(Either Orientation)
120%
Output Power (%)
100%
80%
60%
Natural
Convection
40%
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’’).
20%
0%
25
35
45
55
65
75
85
Ambient Temperature (℃)
Figure 8:
Derating Curve
Figure 7:
Wind tunnel test setup
Thermal Derating
Heat can be removed by increasing airflow over the
module. To enhance system reliability, the power
module should always be operated below the maximum
operating temperature. If the temperature exceeds the
maximum module temperature, reliability of the unit
may be affected.
5
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