DATASHEET Rev. A MMW SERIES 4:1 Ultra Wide Input Voltage Ranges Single Outputs, Efficiency up to 92% 2.0” x 1.6” x 0.37” Shielded Metal Package 25~30 Watt DC/DC Power Converters FEATURES ● Soft Start ● MTBF > 1,000,000 Hours ● Output Trim ● Low Profile: 0.37” (9.3mm) ● 1500VDC Isolation ● CSA1950 Safety Approval ● Six-Sided Shielding ● UL60950-1 Safety Approvals ● Efficiency up to 89% ● 4:1 Wide Input Voltage Range ● Single & Dual Outputs ● Complies with EN55022 Class A ● Remote On/Off Control ● Short Circuit, Over Voltage, and Over Temperature Protected DESCRIPTION The MMW series power modules are low-profile dc/dc converters that offer up to 30 watts of output power in a 2.0 x 1.6 x 0.37 inch package. These converters operate over input voltage ranges of 10-40VDC and 18-75VDC. This series also provides regulated single and dual output voltages of 3.3, 5, 12, 15, ±12 and ±15VDC. Other features include remote on/off control, output trim function, six-sided shielding, and efficiencies up to 89%. All models are over voltage, over temperature and short circuit protected. The EN55022 Class A conducted noise compliance minimizes design time, cost, and eliminates the need for external filter components. These converters have UL60950-1 approvals and are best suited for data communication equipment, distributed power systems, telecommunications equipment, mixed analog/digital subsystems, process/machine control equipment, computer peripheral systems, and industrial robot systems. 09/14/2012 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 1 of 9 DH40 Series 2:1 Wide Input Ranges 2.0” x 1.0” x 0.4” Package Size 40 Watt DC/DC Power Converters Rev. A SPECIFICATIONS: MMW 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 Nom Max Unit 24V nominal input models 48V nominal input models 24V nominal input models 48V nominal input models 24V nominal input models 48V nominal input models All models 10 18 9.4 17 9 16 24 48 9.7 17.5 9.3 16.5 24V nominal input models 48V nominal input models -0.7 -0.7 40 75 10 18 9.5 17 2 4500 50 100 VDC VDC VDC VDC VDC VDC A mW VDC VDC INPUT (Vin) Input Voltage Range Start Voltage Under Voltage Shutdown Reverse Polarity Input Current Short Circuit Input Power Input Surge Voltage Input Filter OUTPUT (Vo) Output Voltage Range Output Voltage Accuracy Output Voltage Balance Output Trim Load Regulation Line Regulation Output Power Output Current Range Ripple & Noise (20MHz) Ripple & Noise (20MHz) Ripple & Noise (20MHz) Transient Recovery Time Transient Response Deviation REMOTE ON/OFF Supply On Supply Off Standby Input Current Control Input Current (On) Control Input Current (Off) Control Common PROTECTION Over Power Protection Short Circuit Protection Over Voltage Protection Input Fuse Recommendation GENERAL Efficiency Switching Frequency Isolation Voltage Rated Isolation Voltage Test Isolation Resistance Isolation Capacitance Internal Power Dissipation Max. Capacitive Load ENVIRONMENTAL Operating Temperature (Ambient) Operating Temperature (Case) Storage Temperature Over Temperature Protection Lead Temperature Humidity Cooling RFI Temperature Coefficient MTBF Conducted EMI PHYSICAL Weight Dimensions (L x W x H) Case Material Flammability Heatsink material Heatsink finish SAFETY & EMI Safety Approvals EMI Requirements 09/14/2012 Pi Filter Dual Outputs, Balanced Loads % of nominal output Io = 50% to 100% Vin = min. to max. ±9.0 Over Line, Over Load, and Over Temperature 25% load step change -1 Vin – RC = 5.0V Vin – RC = 0V 120 24V nominal input models 48V nominal input models See Table ±0.5 ±1.0 ±0.5 ±2.0 ±10.0 ±11.0 ±0.3 ±1.0 ±0.2 ±0.5 30 See Table 55 80 100 10 150 300 ±2 ±4 2.5 to 100VDC or Open Circuit 1 2 5 5 -100 Referenced to negative input 180 Continuous See Table 5000mA slow-blow type 3000mA slow-blow type % % % % % W mVpk-pk mVpk-pk mVrms μs % VDC mA μA μA % See Table 60 seconds Flash Test for 1 second 500VDC 100KHz, 1V 290 1500 1650 1000 330 360 1200 1500 5,500 KHz VDC VDC MΩ pF mW See Table Case Temperature, automatic 1.5mm from case for 10 seconds MIL-HDBK-217F @ 25°C, Ground Benign -40 -40 -50 107 +50 +105 +125 112 117 260 95 Free air convection Six-sided shielding, metal case ±0.01 ±0.02 1000 °C °C °C °C °C % %/°C Khours EN55022 Class A 48 grams (heatsink 2g) 2.0 x 1.6 x 0.37 inches (50.8 x 40.6 x 9.3 mm) Metal with non-conductive baseplate UL94V-0 Aluminum Anodic treatment (black) UL60950-1 EN55022 Class A Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 2 of 9 DH40 Series 2:1 Wide Input Ranges 2.0” x 1.0” x 0.4” Package Size 40 Watt DC/DC Power Converters Rev. A MODEL SELECTION TABLE SINGLE OUTPUT MODELS Model Number Input Voltage MMW24S3.3-5500 MMW24S5-5000 24 VDC (10 ~ 40 VDC) Output Voltage Output Current Min Max 3.3 VDC 400 mA 5500 mA 5 VDC 350 mA 5000 mA Input Current Reflected No Load Max Load Ripple Current Efficiency (Typ) Over Voltage Protection Maximum Capacitive Load 82% 3.9 VDC 10000 μF 85% 6.8 VDC 10000 μF 922 mA 1225 mA 20 mA 50 mA 12 VDC 166 mA 2500 mA 1404 mA 89% 15 VDC 1000 μF MMW24S15-2000 15 VDC 133 mA 2000 mA 1404 mA 89% 18 VDC 1000 μF MMW48S3.3-5500 3.3 VDC 400 mA 5500 mA 461 mA 82% 3.9 VDC 10000 μF 5 VDC 350 mA 5000 mA 85% 6.8 VDC 10000 μF MMW24S12-2500 MMW48S5-5000 MMW48S12-2500 48 VDC (18 ~ 75 VDC) MMW48S15-2000 613 mA 10 mA 25 mA 12 VDC 166 mA 2500 mA 702 mA 89% 15 VDC 1000 μF 15 VDC 133 mA 2000 mA 702 mA 89% 18 VDC 1000 μF Efficiency (Typ) Over Voltage Protection Maximum Capacitive Load 89% ±15 VDC 330 μF # 89% ±18 VDC 330 μF # 89% ±15 VDC 330 μF # 89% ±18 VDC 330 μF # DUAL OUTPUT MODELS Model Number MMW24D12-1250 MMW24D15-1000 MMW48D12-1250 MMW48D15-1000 Input Voltage Output Voltage Output Current Min Max Input Current Reflected Ripple Current No Load Max Load ±12 VDC 24 VDC (10 ~ 40 VDC) ±15 VDC ±83 ±1250 20mA 1404 mA ±65 ±1000 20mA 1404 mA ±12 VDC 48 VDC (18 ~ 75 VDC) ±15 VDC ±83 ±1250 10mA 702 mA 50mA 25mA ±65 ±1000 10mA 702 mA # For each output NOTES 1. Transient recovery time is measured to within 1% error band for a step change in output load of 75% to 100%. 2. The MMW series requires a minimum output loading to maintain specified regulations. Operation under no-load conditions will not damage these devices, however they may not meet all listed specifications. 3. All DC/DC converters should be externally fused at the front end for protection. 4. Other input and output voltages may be available, please contact factory. 5. Heatsink is optional. Please consult factory for ordering details. Due to advances in technology, specifications subject to change without notice. BLOCK DIAGRAMS Single Output +Vin Dual Output +Vo LC Filter +Vin +Vo LC Filter Com. -Vo OVP OTP OVP -Vin On/Off 09/14/2012 -Vo OVP OTP OVP -Vin PWM Isolation Ref.Amp Trim On/Off PWM Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Isolation Ref.Amp Trim Page 3 of 9 Rev. A DH40 Series 2:1 Wide Input Ranges 2.0” x 1.0” x 0.4” Package Size 40 Watt DC/DC Power Converters MECHANICAL DRAWING INPUT VOLTAGE TRANSIENT RATING 09/14/2012 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 4 of 9 DH40 Series 2:1 Wide Input Ranges 2.0” x 1.0” x 0.4” Package Size 40 Watt DC/DC Power Converters Rev. A 150 140 130 48VDC Input Models 120 110 Vin ( VDC ) 100 90 80 24VDC Input Models 70 60 50 40 30 20 10 0 100uS 10uS 1mS 100mS 10mS EFFICIENCY GRAPHS Efficiency vs Input Voltage (Dual Output) 100 100 90 90 Efficiency (%) Efficiency (%) Efficiency vs Input Voltage (Single Output) 80 70 70 60 60 50 80 50 Low Nom Low High Nom Input Voltage (V) Efficiency vs Output Load (Dual Output) 100 100 90 90 80 80 Efficiency (%) Efficiency (%) Efficiency vs Output Load (Single Output) 70 60 70 60 50 50 40 40 30 30 10 20 40 60 High Input Voltage (V) 80 100 10 20 Load Current (%) 40 60 80 100 Load Current (%) DERATING CURVE 09/14/2012 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 5 of 9 DH40 Series 2:1 Wide Input Ranges 2.0” x 1.0” x 0.4” Package Size 40 Watt DC/DC Power Converters Rev. A 100 400LFM Output Power (%) 80 Natural convection 60 100LFM 200LFM 40 20 0 ~ ¡ã -40 50 60 70 90 80 100 110 DESIGN & FEATURE CONSIDERATIONS Over Current Protection To provide protection in a fault (output overload) condition, the unit is equipped with internal current limiting circuitry and can endure current limiting for an unlimited duration. At the point of current-limit inception, the unit shifts from voltage control to current control. The unit operates normally once the output current is brought back into its specified range. Over Voltage Protection The output over voltage clamp consists of control circuitry that is dependent on 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 an output over voltage. The OVP level can be found in the protection specifications. 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. A 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 33μF for the 24V input models and a 10μF for the 48V input models. +Vin + DC Power Source - + +Out DC / DC Converter Load Cin -Vin -Out Remote On/Off 09/14/2012 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 6 of 9 DH40 Series 2:1 Wide Input Ranges 2.0” x 1.0” x 0.4” Package Size 40 Watt DC/DC Power Converters Rev. A Positive logic remote on/off turns the module on during a logic high voltage on the remote on/off pin, and turns the module off during a logic low. To turn the power 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 -1V to 1.0V. A logic high is 2.5V to 100V. The maximum sink current at the on/off terminal (pin 4) during a logic low is -100μA. The maximum allowable leakage current of the switch at the on/off terminal (pin 4) during a logic high (2.5 to 100V) is 5μA. Output Voltage Trim Output voltage trim allows the user to increase or decrease the output voltage set point of a module. The output voltage can be adjusted by placing an external resistor (R) between the Trim and +Vout or –Vout terminals. By adjusting R, the output voltage can be changed by ±10% of the nominal output voltage. +Out +Vin Trim Down -Vin 10K -Out Trim Up Enable Trim Up/Down Trim A 10K, 1 or 10 turn trimpot is usually specified for continuous trimming. Trim pin may be safely left floating if it is not being used. Connecting the external resistor (Rup) between the Trim and –Vout pins increases the output voltage to set the point as defined in the following equation: Rup = (33 x Vout) - (30 x Vadj) Vadj - Vout Connecting the external resistor (Rdown) between the Trim and +Vout pins decreases the output voltage set point as defined in the following equation: Rdown = Vout: Vadj: Units (36.667 x Vadj) - (33 x Vout) Vout - Vadj Nominal Output Voltage Adjusted Output Voltage VDC / KΩ Maximum Capacitive Load The MMW Series has a 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. For optimum performance we recommend 330μF maximum capacitive load for 12V and 15V outputs and 10,000μF capacitive load for 3.3V and 5V outputs. The maximum capacitance can be found in the Output Voltage / Current Rating Chart. TEST CONFIGURATIONS 09/14/2012 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 7 of 9 DH40 Series 2:1 Wide Input Ranges 2.0” x 1.0” x 0.4” Package Size 40 Watt DC/DC Power Converters Rev. A 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 100KHz) 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 ~ 500KHz. To Oscilloscope + Lin + Battery +Vin Current Probe Cin +Out DC / DC Converter Load -Out -Vin Peak-to-Peak Output Noise Measurement Test Use a Cout 1.0μF ceramic 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. +Vin +Out Single Output DC / DC Converter -Vin +Vin Copper Strip Resistive Scope Load Cout -Out +Out Copper Strip Scope Cout Dual Output DC / DC Converter Com. -Vin -Out Resistive Load Cout Scope 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. + +Vin Single Output DC / DC Converter DC Power Source - +Out -Vin + +Vin Dual Output DC / DC Com. Converter DC Power Source Cout Load -Out +Out - -Vin -Out Cout Load 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 an experimental apparatus. Position of air velocity probe and thermocouple 15mm / 0.6in 50mm / 2in Air Flow DUT COMPANY INFORMATION 09/14/2012 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 8 of 9 Rev. A DH40 Series 2:1 Wide Input Ranges 2.0” x 1.0” x 0.4” Package Size 40 Watt DC/DC Power Converters 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: 09/14/2012 (603)778-2300 (888)587-9255 (603)778-9797 [email protected] www.wallindustries.com 5 Watson Brook Rd. Exeter, NH 03833 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 9 of 9