POWER ELECTRONICS DIVISION
TWR A-Series
2-5W, Triple Output DC/DC Converters
Featuring C&D’s ultra-wide, 8-72V, input voltage range, this Family of
A-Series, TWR (triple-output) DC/DC converters deliver up to 5 Watts.
FEATURES
n
cost! Highly Reliable!
Low
n
Output voltages: +5V/±2V or +5V/±5V
n
Ultra-wide, 8-72V, input voltage ranges
n
Small, 2" x 2" x 0.45" packages
n
Guaranteed efficiencies to 80%
n
isolated, 500Vdc guaranteed
Fully
n
to +00°C operating temperature
–40
n
Proven SMT-on-pcb construction
n
Shielded (5-side) metal cases with insulated
PRODUCT OVERVIEW
These devices each have a primary +5V output
that can source from Amp to .5 Amps (model
dependent) and auxiliary ±2/5V outputs that can
source from ±50 to ±250mA (model dependent).
All models can simultaneously source maximum
rated current from both primary and auxiliary
outputs. The nominal input voltage for each model
is 48V.
As members of C&D’s new A-Series, the 2-5W
triples exhibit both low cost and outstanding long-
term reliability. Their design combines straight-
forward circuit topologies, proven SMT-on-pcb
construction methods, the newest components, and
highly repeatable automatic-assembly techniques.
The A-Series TWR’s superior durability is substanti-
SIMPLIFIED SCHEMATIC
+
V
IN
(1)
+5V
(6)
ated by a rigorous in-house qualification program
that includes HALT (Highly-Accelerated Life Testing),
which is designed to detect any potential electrical,
mechanical or process weakness.
Packaged in standard, 2" x 2" x 0.45", shielded
metal cases with non-conductive coatings, these
fully isolated (000Vdc minimum) DC/DC’s offer
excellent line and load regulation. Additionally,
these A-Series triples have non-latching output
current limiting, input overvoltage shutdown, input
reverse-polarity protection, and output overvoltage
clamping to protect both the power converters and
their loads. All A-Series TWR models are fully EMI
characterized and designed to meet UL950, IEC
950, CSA 950 and EN60950.
baseplates
n
Designed to meet UL 950 and EN60950
n
Tested; HALT tested; EMC tested
Qual
n
Modifications and customs for OEM's
–
V
IN
(2)
PWM
CONTROLLER
–12V (–15V)
(8)
+12V (+15V)
(5)
COMMON
(7)
OPTO
FEEDBACK
ERROR
AMPLIFIER
Typical topography is shown.
For full details go to
www.cd4power.com/rohs
DC/DC CONVERTERS
MDC_TWR12-15.A03
Page of 5
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POWER ELECTRONICS DIVISION
TWR A-Series
2-5W, Triple Output DC/DC Converters
Output
R/N (mVp-p)
Typ.
Max.
50
75
50
75
50
75
50
75
00
75
00
75
00
75
00
75
PERFORMANCE SPECIFICATIONS AND ORDERING GUIDE
Input
Regulation (Max.)
Line
Load
±%
±5%
±%
±5%
±%
±5%
±%
±5%
±%
±5%
±%
±5%
±%
±5%
±%
±5%
Model
TWR-5/1200-12/250-D48A
TWR-5/1500-12/250-D48A
TWR-5/1000-15/250-D48A
TWR-5/1500-15/250-D48A
V
OUT
(V)
±5
±2
±5
±2
±5
±5
±5
±5
I
OUT
(mA)
200
±250
500
±250
000
±250
500
±250
V
IN
Nom.
(Volts)
48
48
48
48
Range
(Volts)
8-72
8-72
8-72
8-72
I
IN
(mA)
50/340
50/388
50/354
50/425
Efficiency
Min.
79%
78%
79%
79%
Typ.
8%
79%
80%
8%
Package
(Case/
Pinout)
C4, P8
C4, P8
C4, P8
C4, P8
Typical @ T
A
= +25°C under nominal line voltage and full-load conditions unless otherwise noted.
Ripple/Noise (R/N) measured over a 20MHz bandwidth, specified with 0.2µF ceramic output capaci-
For the +5V output, listed spec applies over the 0% to 00% load range. For the ±2V and ±5V
tors.
outputs, listed spec applies for balanced loads over the 20% to 00% load range.
PART NUMBER STRUCTURE
MECHANICAL SPECIFICATIONS
2.00
(50.80)
ME T A L C A S E
T WR
-
5
/
1000
-
15
/
250
-
D48 A
-
C
Output
Configuration:
T
= Triple
Wide Range Input
Nominal Primary Output:
Voltage (+5V)
Maximum Primary Output
Current in mA
RoHS-6 Compliant*
A Series
High Reliability
Input Voltage Range:
D48
= 8-72V (48V nominal)
Maximum Auxilliary Output:
Currents in mA from each output
* Contact C&D Technologies
for availability.
0.200
(5.08)
0.45
(11.43)
Case C4
IN S U LA T E D B A S E
0.20 MIN
(5.08)
0.040 ±0.002 D IA .
(1.016 ±0.051)
1.800
(45.72)
0.10
(2.54)
Nominal Auxiliary Output:
Voltages (±2 or ±5V)
5
1
6
TEMPERATURE DERATING
20
19
18
17
16
15
2
7
0.500 (12.7)
1.200
(30.48)
3 E Q . SP. @
0.400 ( 10.16)
2.00
(50.80)
8
0.40
(10.16)
B O T T O M V IE W
DIMENSIONS ARE IN INCHES (MM)
Output Power (Watts)
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
–40
0
40
45
50
55
60
65
70
75
80
85
90
95
100
Note:
The case is connected to pin 1 (+V
IN
).
INPUT/OUTPUT CONNECTIONS
Pin
2
3
4
5
6
7
8
Ambient Temperature (°C)
Function P8
+Input
-Input
No Pin
No Pin
+2V/5V Output
+5V Output
Common
-2V/5V Output
Dimensions are in inches (mm)
DC/DC CONVERTERS
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MDC_TWR12-15.A03
Page 2 of 5
POWER ELECTRONICS DIVISION
TWR A-Series
2-5W, Triple Output DC/DC Converters
Performance/Functional Specifications
Typical @ T
A
= +25°C under nominal line voltage and full-load conditions, unless noted.
Input
Input Voltage Range
Input Current
Input Filter Type
Reverse-Polarity Protection
8-72 Volts (48V nominal)
See Ordering Guide
Pi
Yes (Instantaneous, 6A maximum)
Absolute Maximum Ratings
Input Voltage:
Input Reverse-Polarity Protection
Output Overvoltage Protection
+5V Output
±12V Outputs
±%
±3%
±0.02% per °C
See Ordering Guide
See Ordering Guide
See Ordering Guide
500Vdc, minimum
680pF
Auto-recovery
Zener/transorb clamps, magnetic feed
back
200µsec max. to ±2% of final value
65kHz (±5kHz)
T E C H N I C A L
N O T E S
80 Volts
Current must be <6A. Brief
duration only. Fusing recommended.
6.8 Volts, limited duration
±13 Volts, limited duration
±16 Volts, limited duration
Current limited.
Max. current and
Output
V
OUT
Accuracy
(50% loads):
+5V Output
±2V or ±5V Outputs
Temperature Coefficient
Ripple/Noise
(20MHz BW)
Line/Load Regulation
Efficiency
Isolation Voltage
Isolation Capacitance
Current Limiting
Overvoltage Protection
±15V Outputs
Output Current
short-circuit duration are model
dependent
Storage Temperature
Lead Temperature
(soldering, 10 sec.)
–40 to +105°C
+300°C
These are stress ratings. Exposure of devices to any of these conditions may adversely
affect long-term reliability. Proper operation under conditions other than those listed in the
Performance/Functional Specifications Table is not implied.
Dynamic Characteristics
Transient Response
(50% load step)
Switching Frequency
Environmental
Operating Temperature
(ambient):
Without Derating
With Derating
Storage Temperature
–40 to +50-70°C (Model dependent)
to +00°C (See Derating Curve)
–40 to +05°C
2" x 2" x 0.45" (5 x 5 x .4mm)
5-sided
Pin (+V
IN
)
Corrosion resistant steel with
non-conductive, epoxy-based, black
enamel finish and plastic baseplate
Gold plate copper alloy with
nickel underplate
2.6 ounces (74 grams)
Filtering and Noise Reduction
All TWR A-Series 12-15 Watt DC/DC Converters achieve their rated ripple
and noise specifications without the use of external input/output capacitors.
In critical applications, input/output ripple and noise may be further reduced
by installing electrolytic capacitors across the input terminals and/or low-
ESR tantalum or electrolytic capacitors across the output terminals. Output
capacitors should be connected between their respective output pin (pin 5, 6
or 8) and Common (pin 7) as shown in Figure 2. The caps should be located
as close to the power converters as possible. Typical values are listed below.
In many applications, using values greater than those listed will yield better
results.
To Reduce Input Ripple
To Reduce Output Ripple
+5V Output
±12/15V Outputs
10µF, 100V
47µF, 10V, Low ESR
22µF, 20V, Low ESR
Physical
Dimensions
Shielding
Case Connection
Case Material
Pin Material
Weight
These power converters require a minimum 0% loading on their primary output and a
minimum 20% loading on their auxiliary outputs to maintain specified regulation. Opera-
tion under no-load conditions will not damage these devices; however they may not meet
all listed specifications.
Application-specific internal input/output filtering can be recommended and perhaps
added internally upon request. Contact C&D Applications Engineering for details.
Devices can be screened or modified for higher guaranteed isolation voltages.
Contact C&D Applications Engineering for details.
In critical, space-sensitive applications, C&D may be able to tailor the inter-
nal input/output filtering of these units to meet your specific requirements.
Contact our Applications Engineering Group for additional details.
DC/DC CONVERTERS
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MDC_TWR12-15.A03
Page 3 of 5
POWER ELECTRONICS DIVISION
TWR A-Series
2-5W, Triple Output DC/DC Converters
TWR-5/1500-15/250-D48A Radiated Emissions
FCC Part 15 Class B 3 Meters
Converter Output = +5Vdc @ 1.35A and ±15Vdc @ 225mA
+
6
80
+12/15V
1
+
2
COMMON
+INPUT
5
C
OUT
Radiated Emissions (dBµV/M)
70
60
50
40
30
20
10
0
–10
–20
+5V
C
IN
7
+
8
+
C
OUT
FCC Class B Limit
–INPUT
C
OUT
–12/15V
Figure 2. Using External Capacitors
to Reduce Input/Output Ripple/Noise
Radiated Emissions
100
1000
Frequency (MHz)
Input Fusing
Certain applications and/or safety agencies may require the installation of
fuses at the inputs of power conversion components. For C&D A-Series TWR
12-15 Watt DC/DC Converters, you should use slow-blow type fuses with
values no greater than 2A.
C U S T O M
C A P A B I L I T I E S
Radiated Emissions (dBµV/M)
TWR-5/1500-15/250-D48A Radiated Emissions
EN55022 Class B 10 Meters
Converter Output = +5Vdc @ 1.35A and ±15Vdc @ 225mA
80
70
60
50
EN 55022 Class B Limit
C&D’s world-class design, development and manufacturing team stands
ready to work with you to deliver the exact power converter you need for
your demanding, large volume, OEM applications. And . . . we’ll do it on time
and within budget!
Our experienced applications and design staffs; quick-turn prototype
capability; highly automated, SMT assembly facilities; and in-line SPC qual-
ity-control techniques combine to give us the unique ability to design and
deliver any quantity of power converters to the highest standards of quality
and reliability.
We have compiled a large library of DC/DC designs that are currently used
in a variety of telecom, medical, computer, railway, aerospace and industrial
applications. We may already have the converter you need.
Contact us. Our goal is to provide you the highest-quality, most cost-effec-
tive power converters available.
E M I R A D I AT E D E M I S S I O N S
40
30
20
10
0
Radiated Emissions
–10
–20
100
1000
Frequency (MHz)
Quality and Reliability
The A-Series are the first DC/DC Converters to emerge from C&D’s new,
company-wide approach to designing and manufacturing the most reliable
power converters available. The five-pronged program draws our Quality
Assurance function into all aspects of new-product design, development,
characterization, qualification and manufacturing.
Design for Reliability
Design for Reliability is woven throughout our multi-phased, new-product-
development process. Design-for-reliability practices are fully documented and
begin early in the new-product development cycle with the following goals:
1. To work from an approved components/vendors list ensuring the use of
reliable components and the rigorous qualification of new components.
2. To design with safety margins by adhering to a strict set of derating guide-
lines and performing theoretical worst-case analyses.
3. To locate potential design weaknesses early in the product-development
If you’re designing with EMC in mind, please note that all of C&D’s TWR
A-Series 12-15 Watt DC/DC Converters have been characterized for radi-
ated and conducted emissions in our new EMI/EMC laboratory. Testing is
conducted in an EMCO 5305 GTEM test cell utilizing EMCO automated EMC
test software. Radiated emissions are tested to the limits of FCC Part 15,
Class B and CISPR 22 (EN 55022), Class B. Correlation to other specifica-
tions can be supplied upon request. Radiated emissions plots to FCC and
CISPR 22 for model TWR-5/1500-15/250-D48A appear below. Published
EMC test reports are available for each model number. Contact C&D’s Appli-
cations Engineering Department for more details.
DC/DC CONVERTERS
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MDC_TWR12-15.A03
Page 4 of 5
POWER ELECTRONICS DIVISION
TWR A-Series
2-5W, Triple Output DC/DC Converters
the HALT chamber and its ability to rapidly cool devices to verify their "cold-start"
capabilities.
Qualification
For each new product, electrical performance is verified via a comprehensive
characterization process and long-term reliability is confirmed via a rigorous quali-
fication procedure. The qual procedure includes such strenuous tests as thermal
shock and 500 hour life. Qual testing is summarized below.
Qualification Testing
Qualification Test
HALT
High Temperature Storage
Thermal Shock
Temperature/Humidity
Lead Integrity
Life Test
Marking Permanency
End Point Electrical Tests
* Interim electrical test at 200 hours.
cycle by using extensive HALT (Highly Accelerated Life Testing).
4. To prove that early design improvements are effective by employing a
thorough FRACA (Failure Reporting Analysis and Corrective Action) system.
HALT Testing
The goal of the accelerated-stress techniques used by C&D is to force device
maturity, in a short period of time, by exposing devices to excessive levels
of "every stimulus of potential value." We use HALT (Highly Accelerated Life
Testing) repeatedly during the design and early manufacturing phases to
detect potential electrical and mechanical design weaknesses
that could result in possible future field failures.
During HALT, prototype and pre-production DC/DC converters are subjected
to progressively higher stress levels induced by thermal cycling, rate of
temperature change, vibration, power cycling, product-specific stresses (such
as dc voltage variation) and combined environments. The stresses are not
meant to simulate field environments but to expose any weaknesses in a
product’s electro/mechanical design and/or assembly processes. The goal of
HALT is to make products fail so that device weaknesses can be analyzed
and strengthened as appropriate. Applied stresses are continually stepped
up until products eventually fail. After corrective actions and/or design
changes, stresses are stepped up again and the cycle is repeated until the
"fundamental limit of the technology" is determined.
C&D has invested in a Qualmark OVS-1 HALT tester capable of applying
Typical HALT Profile
100
80
60
Temperature (°C)
40
20
0
–20
–40
10
20
30
40
50
60
70
80
90
Test Time (minutes)
0
20
Random Vibration (G's)
40
Method/Comments
C&D in-house procedure
Max. rated temp., 1,000 hours
10 cycles, –55 to +125°C
+85°C, 85% humidity, 48 hours
C&D in-house procedure
+70°C, 500 hours*
C&D in-house procedure
Per product specification
In-Line Process Controls and Screening
A combination of statistical sampling and 100% inspection techniques keeps
our assembly line under constant control. Parameters such as solder-paste
thickness, component placement, cleanliness, etc. are statistically sampled,
charted and fine tuned as necessary. Visual inspections are performed by
trained operators after pick-and-place, soldering and cleaning operations.
Units are 100% electrically tested prior to potting. All devices are temperature
cycled, burned-in, hi-pot tested and final-electrical tested prior to external
visual examination, packing and shipping.
Rapid Response to Problems
C&D employs an outstanding corrective-action system to immediately
address any detected shortcomings in either products or processes. When-
ever our assembly, quality or engineering personnel spot a product/process
problem, or if a product is returned with a potential defect, we immediately
perform a detailed failure analysis and, if necessary, undertake corrective
actions. Over time, this system has helped refine our assembly operation to
yield one of the lowest product defect rates in the industry.
voltage and temperature extremes as well as 6-axis, linear and rotational,
random vibration. A typical HALT profile (shown above) consists of thermal
cycling (–55 to +125°C, 30°C/minute) and simultaneous, gradually increas-
ing, random longitudinal and rotational vibration up to 20G’s with load cycling
and applied-voltage extremes added as desired. Many devices in C&D’s A-
Series could not be made to fail prior to reaching either the limits of the HALT
chamber or some previously known physical limit of the device. We also use
®
USA:
Canada:
UK:
France:
Tucson (Az), Tel: (800) 547 2537, email: sales@cdtechno.com
Toronto, Tel: (866) 740 232, email: toronto@cdtechno.com
Milton Keynes, Tel: +44 (0)908 65232, email: mk@cdtechno.com
Montigny Le Bretonneux, Tel: +33 (0) 34 60 0 0, email: france@cdtechno.com
Tokyo, Tel: 3-3779-03, email: sales_tokyo@cdtechno.com
Osaka, Tel: 6-6354-2025, email: sales_osaka@cdtechno.com
Website:
www.cd4power.jp
Shanghai, Tel: +86 25 027 3678, email: shanghai@cdtechno.com
Guangzhou, Tel: +86 208 22 8066, email: guangzhou@cdtechno.com
C&D Technologies, Inc.
Cabot Boulevard, Mansfield, MA 02048-5 U.S.A.
Tel: (508) 339-3000 (800) 233-2765 Fax: (508) 339-6356
www.cd4power.com
ISO 9001 REGISTERED
Germany:
München, Tel: +49 (0)89-544334-0, email: ped.munich@cdtechno.com
Japan:
email: sales@cdtechno.com
DS-0325
07/25/07
China:
© 2007 C&D Technologies, Inc.
C&D Technologies, Inc. makes no representation that the use of its products in the circuits described herein, or the use of other technical
information contained herein, will not infringe upon existing or future patent rights. The descriptions contained herein do not imply the
granting of licenses to make, use, or sell equipment constructed in accordance therewith. Specifications are subject to change without
notice.
DC/DC CONVERTERS
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