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 conver ter is the latest offering from a world leader in power systems technology and manufacturing D 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 technol ogy 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 datasheet ds_dir500_12032008 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 options
2 technical specifications t a = 25c, airflow rate = 0 lfm, nominal vin, nominal vout, resistive load unless otherwise noted. parameter notes and conditions dir500 (standard) min. typ. max. units absolute maximum ratings input voltage transient 5v input model, 1000ms -0.7 7.5 vdc transient 12v input model, 1000ms -0.7 15 vdc transient 24v input model, 1000ms -0.7 30 internal power dissipation 2000 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 6000 vdc input characteristics operating input voltage 5v input model 4.5 5 5.5 vdc 12v input model 10.8 12 13.2 vdc 24v input model 21.6 24 26.4 vdc maximum input current please see model list table on page 6 no-load input current 5v model 100 ma 12v model 50 ma 24v model 30 ma reflected input repple current 5v model 15 ma 12v model 8 ma 24v model 3 ma short circuit input power 2 w reverse polarity input current 0.5 a output characteristics output voltage set point accuracy 2.0 4.0 % output voltage balance dual output models 2.0 4.0 % output voltage regulation over load io=10% to 100% 0.5 1.0 % over line vin = min to max 0.3 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, 0.33f ceramic 30 50 mv peak-to-peak, over line, load, temperature full load, 0.33f ceramic 100 mv rms full load, 0.33f ceramic 5 mv output over current/power protection auto restart 120 % output short circuit continuous output voltage current transient step change in output current 50% step change 6 % settling time (within 1% vout nominal) 50 us maximum output capacitance single output models 680 f dual output models, each output 270 f efficiency 100% load please see model list table on page 6 isolation characteristics isolation voltage input to output, 60 seconds 6000 vdc isolation voltage test flash test for 1 seconds 8000 vdc leakage current 240vac, 60hz 2 a isolation resistance 500vdc 10 g ? isolation capacitance 100khz, 1v 20 30 pf feature characteristics switching frequency 25 80 khz general specifications mtbf mil-hdbk-217f; ta=25c, ground benign 0.6 m hours weight 12 grams case material non-conductive black plastic flammability ul94v-0 input fuse 5v model, 100ma slow blown type 12v model, 500ma slow blown type 24v model, 250ma slow blown type 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 condi tions will not damage these modules; however, they may not meet all specifications listed above. 2. these dc/dc converters should be exter nally fused at the front end for protection.
3 electrical charact eristics curves 30 40 50 60 70 80 efficiency (%) input voltage (v) nom low high 30 40 50 60 70 80 efficiency (%) input voltage (v) nom low high figure 1: efficiency vs. input voltage (single output) figure 2: efficiency vs. input voltage (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) +vo bipolar push-pull inverter +vin -vin -vo low dropout regulator lc filter +vo bipolar push-pull inverter +vin -vin com. -vo positive regulator negative regulator lc filter figure 5: block diagram of dir500 single output modules. figure 6: block diagram of dir500 dual output modules.
4 design & feature considerations the dir500 circuit block diagrams are shown in figures 5 and 6. 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. +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 input source impedance the power module should be connected to a low ac- impedance input source. highly inductive source impedances can affect t he 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 5v input devices, a 2.2uf for the 12v and 24v devices. 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. 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. +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 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.
5 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 dir500series 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
6 model list input output full load efficiency vdc (v) max (ma) vdc (v) max (ma) min (ma) % dir501 645 5 400 62 DIR502 629 12 165 63 dir503 623 15 133 64 dir504 476 5 100 42 dir505 699 12 83 57 dir506 695 15 66 57 dir507 269 5 400 62 dir508 262 12 165 63 dir509 260 15 133 64 dir510 185 5 100 45 dir511 281 12 83 59 dir512 280 15 66 59 dir513 134 5 400 62 dir514 131 12 165 63 dir515 130 15 133 64 dir516 93 5 100 45 dir517 143 12 83 58 dir518 142 15 66 58 5 (4.5 ~ 5.5) 12 (10.8 ~ 13.2) 24 (21.6 ~ 26.4) 0 0 0
7 mechanical drawing s ide view 1 2 10 11 12 24 23 15 13 15.22 [0.60"] 20.30 [0.80"] 2.0 [0.08"] 2.54 [0.10"] 3.8 [0.15"] 31.8 [1.25"] 10.2 [0.40"] b ottom view 0.50 [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 single output dual output 1 +vin +vin 2 +vin +vin 10 no pin common 11 no pin common 12 -vout no pin 13 +vout -vout 15 no pin +vout 23 -vin -vin 24 -vin -vin
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