DATASHEET Rev. A DHW40 SERIES 4:1 Ultra Wide Input Voltage Ranges Single & Dual Outputs, Efficiency up to 90% 2.0” x 1.0” x 0.4” Encapsulated Shielded Metal Package 40 Watt DC/DC Power Converters FEATURES • RoHS Compliant • 2.0” x 1.0” x 0.4” Package Size • 40 Watts Output Power • Trimmable Output Voltage • 4:1 Ultra Wide Input Voltage Ranges • Shielded Metal Case with Isolated Base-plate • Single & Dual Outputs • -40°C to +80°C Operating Temperature Range • Remote ON/OFF Control • Over Load, Short Circuit, Over Voltage, and Over • 1500VDC I/O Isolation Temperature Protection • High Efficiency up to 90% • UL/IEC/EN 60950-1 Safety Approvals (Pending) • Under Voltage Lockout (UVLO) • Heatsink (Optional) DESCRIPTION The DHW40 series is the latest generation of high performance DC/DC converters setting a new standard concerning power density. These converters offer 40 Watts of continuous output power in a 2.0” x 1.0” x 0.4” encapsulated, shielded metal package. The DHW40 series has single and dual output models with 4:1 ultra wide input voltage ranges of 9-36VDC and 18-75VDC. Advanced circuit topology provides a very high efficiency up to 90% and an operating temperature range of -40°C to +80°C. Further features include remote on/off, trimmable output voltage, under-voltage lockout as well as over load, over voltage, short circuit, and over-temperature protection. These converters are RoHS compliant and are ideal for use in battery operated equipment, instrumentation, distributed power architectures in communication and industrial electronics and many other space critical applications. 10/31/2012 Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 1 of 12 DHW40 Series Single & Dual Outputs 4:1 Ultra Wide Input Ranges 40 Watt DC/DC Power Converters Rev. A SPECIFICATIONS: DHW40 SERIES All specifications are based on 25°C, Nominal Input Voltage, and Maximum Output Current unless otherwise noted. We reserve the right to change specifications based on technological advances. SPECIFICATION TEST CONDITIONS Min Typ Max 24VDC nominal input models 9 24 36 48VDC nominal input models 18 48 75 24VDC nominal input models -0.7 50 48VDC nominal input models -0.7 100 Unit INPUT SPECIFICATIONS Input Voltage Range Input Surge Voltage (100ms max.) Start-up Threshold Voltage Under Voltage Lockout (UVLO) Start-up Time Power Up Remote On/Off 24VDC nominal input models 9 48VDC nominal input models 18 24VDC nominal input models 8.3 48VDC nominal input models 16.5 VDC VDC VDC VDC 30 Nominal Vin and constant resistive load ms 30 Input Current See Table Reflected Ripple Current (Page 10) Internal Filter See Table for EN55022 Class A compliance see page 4 LC Filter 24VDC nominal input models Input Fuse (Note 3) 8000mA slow-blow type 48VDC nominal input models 4000mA slow-blow type Short Circuit Current Hiccup mode 1.5Hz typ. OUTPUT SPECIFICATIONS Output Voltage See Table Output Voltage Balance Dual Output Models, Balanced loads ±2.0 % Line Regulation Low line to high line at full load ±0.5 % Single Output Models ±0.5 Load Regulation Dual Output Models Minimum load to full load % ±1.0 Load Cross Regulation (Dual Output Models) Asymmetrical load 25% / 100% full load ±5.0 % Output Voltage Setting Accuracy At 50% load and nominal Vin ±1.0 %Vnom Output Voltage Trim (Page 9) % of nominal output voltage ±10 % Output Power See Table Output Current See Table Single Output Models Minimum Load No minimum load required Dual Output Models Ripple & Noise (0-20MHz) (Page 11) Transient Recovery Time (Note 2) Measured with a 1µF M/C and a 10µF T/C in parallel See Table 3.3 & 5VDC Output Models 100 12 & 15VDCOutput Models 150 Dual Output Models 150 25% load step change mVp-p 250 µs Temperature Coefficient ±0.02 %/°C PROTECTION Input Polarity Protection none Over Voltage Protection (page 10) See Table Over Load Protection Current limitation at 150% typ. of Io max., hiccup Thermal Protection Shutdown temperature Short Circuit Protection 110 °C Hiccup, automatic recovery REMOTE ON/OFF (Page 10) Positive Logic Control Input Current Converter On 4.7~12V or open circuit Converter Off 0V ~ 1.2 or short circuit On Vctrl = 5.0V 0.5 Off Vctrl = 0V -0.5 Control Common Stand-by Input Current 10/31/2012 mA Referenced to negative input Nominal Vin Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 2.5 mA Page 2 of 12 DHW40 Series Single & Dual Outputs 4:1 Ultra Wide Input Ranges 40 Watt DC/DC Power Converters Rev. A SPECIFICATIONS: DHW40 SERIES All specifications are based on 25°C, Nominal Input Voltage, and Maximum Output Current unless otherwise noted. We reserve the right to change specifications based on technological advances. SPECIFICATION TEST CONDITIONS Min Typ Max Unit GENERAL Efficiency (see efficiency curves on pages 6~8) See Table Switching Frequency 320 Isolation Voltage (Input to Output) 60 seconds 1500 Isolation Resistance 500VDC 1000 Isolation Capacitance 100kHz, 1V KHz VDC MΩ 1500 Maximum Capacitive Load pF See Table ENVIRONMENTAL SPECIFICATIONS Operating Temperature (W/O Heatsink) (see derating curves on page 5) Operating Temperature (W/ Heatsink) (see derating curves on page 5) Thermal Impedance (W/O Heatsink) Thermal Impedance (W/ Heatsink) Natural air convection (20LFM) Nominal Vin and full load Natural air convection (20LFM) Nominal Vin and full load DHWXXS3.3-26 DHW24S5-40, DHW48S5-40, DHW48S12-40, DHW48S15-40 DHW24S12-40, DHW24S15-40 DHW24D12-40, DHW24D15-40, DHW48D12-40, DHW48D15-40 DHWXXS3.3-26 DHW24S5-40, DHW48S5-40, DHW48S12-40, DHW48S15-40 DHW24S12-40, DHW24S15-40 DHW24D12-40, DHW24D15-40, DHW48D12-40, DHW48D15-40 -40 +66 -40 +51 -40 +45 -40 +40 -40 +73 -40 +61 -40 +57 °C °C +52 Natural convection (20LFM) 12.0 100LFM convection 10.0 200LFM convection 9.0 400LFM convection 5.4 Natural convection (20LFM) 8.0 100LFM convection 4.5 200LFM convection 6.0 400LFM convection 3.0 Case Temperature °C/W °C/W +105 Storage Temperature -50 °C 95 % RH Humidity (non-condensing) RFI °C +125 Six-sided shielded metal case Cooling Natural convection is about 20LFM and is not still air (0LFM) Lead Temperature 1.5mm from case for 10 seconds MTBF (calculated) MIL-HDBK-217F at 25°C, Ground Benign natural convection 260 328,000 °C hours PHYSICAL SPECIFICATIONS Weight 1.06oz (30g) Dimensions (L x W x H) 2.0 x 1.0 x 0.43 inches (50.8 x 25.4 x 11 mm) Case Material Aluminum alloy, black anodized coating Base Material FR4 PCB (flammability to UL 94V-0 rated) Potting Material Epoxy (UL94-V0) Pin Material Copper alloy with gold plate over nickel underplate Heatsink (optional) See page 8 SAFETY Safety Approvals (pending) 10/31/2012 UL/cUL 60950-1 recognition (CSA certificate), IEC/EN 60950-1 (CB-scheme) Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 3 of 12 DHW40 Series Single & Dual Outputs 4:1 Ultra Wide Input Ranges 40 Watt DC/DC Power Converters Rev. A MODEL SELECTION TABLE SINGLE OUTPUT MODELS Model Number Input Voltage Output Voltage DHW24S3.3-26 Output Current Input Current Output Power Efficiency Maximum Capacitive Load 3.9 VDC 26.4W 89% 21000µF 6.2 VDC 40W 90% 13600µF 1.87A 15 VDC 40W 89% 2400µF 105mA 1.87A 18 VDC 40W 89% 1500µF 8A 55mA 620mA 3.9 VDC 26.4W 89% 21000µF 8A 55mA 930mA 6.2 VDC 40W 90% 13600µF 930mA 15 VDC 40W 90% 2400µF 930mA 18 VDC 40W 90% 1500µF Output Power Efficiency Maximum (1) Capacitive Load ±15 VDC 40W 88% 1200µF* ±18 VDC 40W 88% 750µF* ±15 VDC 40W 88% 1200µF* ±18 VDC 40W 88% 750µF* Min Max 3.3 VDC 0mA 8A 90mA 1.24A 24 VDC 5 VDC 0mA 8A 90mA 1.85A (9 – 36 VDC) 12 VDC 0mA 3.33A 95mA DHW24S15-40 15 VDC 0mA 2.67A DHW48S3.3-26 3.3 VDC 0mA 48 VDC 5 VDC 0mA (18 – 75 VDC) 12 VDC 0mA 3.33A 60mA 15 VDC 0mA 2.67A 65mA DHW24S5-40 DHW24S12-40 DHW48S5-40 DHW48S12-40 DHW48S15-40 No Load Max Load Reflected Ripple Over Voltage Current (Typ) Protection 30mA 20mA DUAL OUTPUT MODELS Model Number Input Voltage Output Voltage Output Current Min Max Input Current Reflected Ripple Over Voltage Protection No Load Max Load Current (Typ) 24 VDC ±12 VDC ±145mA ±1.67A DHW24D15-40 (9 – 36 VDC) ±15 VDC ±110mA ±1.33A 65mA 1.89A DHW48D12-40 48 VDC ±12 VDC ±145mA ±1.67A 45mA 950mA DHW24D12-40 DHW48D15-40 65mA 1.89A 30mA (18 – 75 VDC) ±15 VDC ±110mA ±1.33A 20mA 45mA 950mA NOTES 1. “*” for each output 2. Transient recovery time is measured to within 1% error band for a step change in output load from 75% to 100%. 3. All DC/DC converters should be externally fused at the front end for protection. 4. To order the converter with a heatsink, please add the suffix “HS” to the model number. (Ex: DHW24S12-40HS) 5. To order the converter without Remote on/off control, please add the suffix “N” to the model number. (Ex: DHW24S12-40N) Due to advances in technology, specifications subject to change without notice. EMI-FILTER TO MEET EN55022, CLASS A; FCC PART 15, LEVEL A Conducted and Radiated Emissions EN55022 Class A Part No DHW24SXX-40 DHW48SXX-40 Part No DHW24DXX-40 DHW48DXX-40 C1 4.7µF/50V 1812 MLCC 2.2µF/100V 1812 MLCC C1 4.7µF/50V 1812 MLCC 2.2µF/100V 1812 MLCC C2, C3 1000pF/2KV 1808 MLCC 1000pF/2KV 1808 MLCC C2, C4 1000pF/2KV 1808 MLCC 1000pF/2KV 1808 MLCC 10/31/2012 Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 4 of 12 DHW40 Series Single & Dual Outputs 4:1 Ultra Wide Input Ranges 40 Watt DC/DC Power Converters Rev. A POWER DERATING CURVES DHW24S3.3-26, DHW48S3.3-26 Derating Curve without Heatsink DHW24S3.3-26, DHW48S3.3-26 Derating Curve with Heatsink DHW24S5-40, DHW48S5-40, DHW48S12-40, DHW48S15-40 Derating Curve without Heatsink DHW24S5-40, DHW48S5-40, DHW48S12-40, DHW48S15-40 Derating Curve with Heatsink DHW24S12-40, DHW24S15-40 Derating Curve without Heatsink DHW24S12-40, DHW24S15-40 Derating Curve with Heatsink DHW24D12-40, DHW24D15-40, DHW48D12-40, DHW48D15-40 Derating Curve without Heatsink DHW24D12-40, DHW24D15-40, DHW48D12-40, DHW48D15-40 Derating Curve with Heatsink 10/31/2012 Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 5 of 12 DHW40 Series Single & Dual Outputs 4:1 Ultra Wide Input Ranges 40 Watt DC/DC Power Converters Rev. A EFFICIENCY CURVES @ 25°C (24VDC INPUT MODELS) 10/31/2012 DHW24S3.3-26 Efficiency vs Load Current DHW24S5-40 Efficiency vs Load Current DHW24S12-40 Efficiency vs Load Current DHW24S15-40 Efficiency vs Load Current DHW24D12-40 Efficiency vs Load Current DHW24D15-40 Efficiency vs Load Current Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 6 of 12 DHW40 Series Single & Dual Outputs 4:1 Ultra Wide Input Ranges 40 Watt DC/DC Power Converters Rev. A EFFICIENCY CURVES @ 25°C (48VDC INPUT MODELS) 10/31/2012 DHW48S3.3-26 Efficiency vs Load Current DHW48S5-40 Efficiency vs Load Current DHW48S12-40 Efficiency vs Load Current DHW48S15-40 Efficiency vs Load Current DHW48D12-40 Efficiency vs Load Current DHW48D15-40 Efficiency vs Load Current Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 7 of 12 Rev. A DHW40 Series Single & Dual Outputs 4:1 Ultra Wide Input Ranges 40 Watt DC/DC Power Converters MECHANICAL DRAWING 10/31/2012 Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 8 of 12 DHW40 Series Single & Dual Outputs 4:1 Ultra Wide Input Ranges 40 Watt DC/DC Power Converters Rev. A EXTERNAL OUTPUT TRIM Output can be externally trimmed by using the method shown below DHWXXS3.3-26 TRIM TABLE DHWXXS5-40 TRIM TABLE Trim Trimup Rup Trimdown Rdown Trim Trimup Rup Trimdown Rdown 1% 3.333V 70.50kΩ 3.267V 63.59kΩ 1% 5.050V 36.57kΩ 4.950V 45.53kΩ 2% 3.366V 29.28kΩ 3.234V 30.28kΩ 2% 5.100V 16.58kΩ 4.900V 20.61kΩ 3% 3.399V 16.87kΩ 3.201V 18.19kΩ 3% 5.150V 9.92kΩ 4.850V 12.31kΩ 4% 3.432V 10.90kΩ 3.168V 11.95kΩ 4% 5.200V 6.59kΩ 4.800V 8.15kΩ 5% 3.465V 7.38kΩ 3.135V 8.13kΩ 5% 5.250V 4.59kΩ 4.750V 5.66kΩ 6% 3.498V 5.06kΩ 3.102V 5.56kΩ 6% 5.300V 3.25kΩ 4.700V 4.00kΩ 7% 3.531V 3.42kΩ 3.069V 3.70kΩ 7% 5.350V 2.30kΩ 4.650V 2.81kΩ 8% 3.564V 2.20kΩ 3.036V 2.31kΩ 8% 5.400V 1.59kΩ 4.600V 1.92kΩ 9% 3.597V 1.25kΩ 3.003V 1.21kΩ 9% 5.450V 1.03kΩ 4.550V 1.23kΩ 10% 3.630V 0.49kΩ 2.970V 0.34kΩ 10% 5.500V 0.59kΩ 4.500V 0.68kΩ DHWXXS12-40 TRIM TABLE DHWXXS15-40 TRIM TABLE Trim Trimup Rup Trimdown Rdown Trim Trimup Rup Trimdown Rdown 1% 12.120V 368.92kΩ 11.880V 394.50kΩ 1% 15.150V 392.98kΩ 14.850V 572.67kΩ 2% 12.240V 161.92kΩ 11.760V 179.74kΩ 2% 15.300V 182.12kΩ 14.700V 248.63kΩ 3% 12.360V 94.97kΩ 11.640V 106.08kΩ 3% 15.450V 108.73kΩ 14.550V 145.60kΩ 4% 12.480V 61.86kΩ 11.520V 68.86kΩ 4% 15.600V 71.43kΩ 14.400V 94.97kΩ 5% 12.600V 42.12kΩ 11.400V 46.39kΩ 5% 15.750V 48.85kΩ 14.250V 64.87kΩ 6% 12.720V 29.00kΩ 11.280V 31.36kΩ 6% 15.900V 33.71kΩ 14.100V 44.92kΩ 7% 12.840V 19.66kΩ 11.160V 20.60kΩ 7% 16.050V 22.86kΩ 13.950V 30.72kΩ 8% 12.960V 12.66kΩ 11.040V 12.51kΩ 8% 16.200V 14.69kΩ 13.800V 20.10kΩ 9% 13.080V 7.23kΩ 10.920V 6.21kΩ 9% 16.350V 8.33kΩ 13.650V 11.86kΩ 10% 13.200V 2.89kΩ 10.800V 1.17kΩ 10% 16.500V 3.23kΩ 13.500V 5.28kΩ 10/31/2012 Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 9 of 12 Rev. A DHW40 Series Single & Dual Outputs 4:1 Ultra Wide Input Ranges 40 Watt DC/DC Power Converters TEST CONFIGURATIONS Input Reflected-Ripple Current Test Setup Input reflected-ripple current is measured with an inductor Lin (4.7µH) and Cin (220µF, ESR < 1.0Ω at 100 KHz) to simulate source impedance. Capacitor Cin offsets possible battery impedance. Current ripple is measured at the input terminals of the module. Measurement bandwidth is 0-500 KHz. Peak-to-Peak Output Noise Measurement Test Use a 1µF ceramic capacitor and a 10µF tantalum capacitor. Scope measurement should be made by using a BNC socket, measurement bandwidth is 0-20MHz. Position the load between 50mm and 75mm from the DC/DC converter. DESIGN & FEATURE CONSIDERATIONS Remote On/Off Positive logic remote on/off turns the module on during a logic high voltage on the remote on/off pin and off during a logic low. To turn the module on and off, the user must supply a switch to control the voltage between the on/off terminal and the –Vin terminal. The switch can be an open collector or equivalent. A logic low is 0V to 1.2V. A logic high is 4.7V to 12V. The maximum sink current at on/off terminal (Pin 3) during a logic low is -100µA. The maximum allowable leakage current of a switch connected to the on/off terminal (Pin 3) at logic high (2.5V to 100V) is 5µA. Over Current Protection To provide protection in a fault (output overload) condition, the unit is equipped with internal current limiting circuitry and can endure overload for an unlimited duration. Over Voltage Protection The output over voltage clamp consists of control circuitry which is independent of the primary regulation loop that monitors the voltage on the output terminals. The control loop of the clamp has a higher voltage set point than the primary loop. This provides a redundant voltage control that reduces the risk of output over voltage. The OVP level can be found in the model selection table. 10/31/2012 Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 10 of 12 Rev. A DHW40 Series Single & Dual Outputs 4:1 Ultra Wide Input Ranges 40 Watt DC/DC Power Converters 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. 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 power module helps ensure stability of the unit, it is recommended to use a good quality low Equivalent Series Resistance (ESR < 1.0Ω at 100KHz) capacitor of a 10µF for the 24V and 48V devices. Output Ripple Reduction A good quality low ESR capacitor placed as close as possible across the load will give the best ripple and noise performance. To reduce output ripple, it is recommended to use 4.7µF capacitors at the output. Maximum Capacitive Load The DHW40 series has a limitation of maximum connected capacitance on the output. The power module may be operated in current limiting mode during start-up, affecting the ramp-up and the start-up time. The maximum capacitance can be found in the model selection table. Thermal Considerations Many conditions affect the thermal performance of the power module, such as orientation, airflow over the module, and board spacing. To avoid exceeding the maximum temperature rating of the components inside the power module, the case temperature must be kept below 105°C. The derating curves are determined from measurements obtained in a test setup. 10/31/2012 Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 11 of 12 Rev. A DHW40 Series Single & Dual Outputs 4:1 Ultra Wide Input Ranges 40 Watt DC/DC Power Converters COMPANY INFORMATION Wall Industries, Inc. has created custom and modified units for over 50 years. Our in-house research and development engineers will provide a solution that exceeds your performance requirements on-time and on budget. Our ISO9001-2008 certification is just one example of our commitment to producing a high quality, well-documented product for our customers. Our past projects demonstrate our commitment to you, our customer. Wall Industries, Inc. has a reputation for working closely with its customers to ensure each solution meets or exceeds form, fit and function requirements. We will continue to provide ongoing support for your project above and beyond the design and production phases. Give us a call today to discuss your future projects. Contact Wall Industries for further information: Phone: Toll Free: Fax: E-mail: Web: Address: 10/31/2012 (603)778-2300 (888)597-9255 (603)778-9797 [email protected] www.wallindustries.com 5 Watson Brook Rd. Exeter, NH 03833 Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 12 of 12