ZFW SERIES 30 Watts DC/DC Converter Single and Dual Outputs Rev F Size: 2.0in x 1.6in x 0.4in (50.8mm x 0.40mm x 10.2mm) OPTIONS • Heatsink (“HS” Suffix) • Negative Remote ON/OFF (“R” Suffix) • Special Electrical Screening (“ES” Suffix) • Case connected to -Vout pin for improved shielding (“-C Suffix) APPLICATIONS • • • • • FEATURES • • • • • • • • High Efficiency up to 88% Fixed Switching Frequency Six-Sided Continuous Shield 4:1 Wide Input Voltage Range Single and Dual Outputs Available Standard 2.0” x 1.6” x 0.4” Package PCB Mountable Heatsink Available • • • • • ISO9001 Certified Manufacturing Facilities RoHS II & REACH Compliant UL60950-1, EN60950-1, and IEC60950-1 Safety Approvals CE Marked Over Voltage, Over Load, Over Temperature and Short Circuit Protection • Negative Remote ON/OFF available • Electrical Screening available DESCRIPTION Wireless Network Telecom/Datacom Industry Control System Measurement Equipment Semiconductor Equipment The ZFW series of high efficiency DC/DC converters provide up to 30 watts of output power. This series has single and dual output models available. These converters are ideal for telecom and networking applications. The ZFW series is designed for a 4:1 input range, either nominal 24VDC (10VDC-40VDC), or nominal 48VDC (18VDC-75VDC). These units are also PCB mountable, with a package size of 2” x 1.6” x 0.4”. Standard specifications include L-C type input filter, external trim of ±10%, excellent load regulation, and short-circuit protection. The isolation voltage meets standard telecom requirements of >1600VDC. Special electrical screening (“ES” suffix) is also available please call factory for more details. MODEL SELECTION TABLE Single Output Model Number ZFW24S1.5-8000 ZFW24S1.8-8000 ZFW24S2.5-8000 ZFW24S3.3-6000 ZFW24S5-6000 ZFW24S12-2500 ZFW24S15-2000 ZFW48S1.5-8000 ZFW48S1.8-8000 ZFW48S2.5-8000 ZFW48S3.3-6000 ZFW48S5-6000 ZFW48S12-2500 ZFW48S15-2000 5/12/2016 Input Voltage Range 24VDC (10~40VDC) 48VDC (18~75VDC) Output Voltage 1.5VDC 1.8VDC 2.5VDC 3.3VDC 5VDC 12VDC 15VDC 1.5VDC 1.8VDC 2.5VDC 3.3VDC 5VDC 12VDC 15VDC Output Current Min Load Max Load 0mA 8000mA 0mA 8000mA 0mA 8000mA 0mA 6000mA 0mA 6000mA 0mA 2500mA 0mA 2000mA 0mA 8000mA 0mA 8000mA 0mA 8000mA 0mA 6000mA 0mA 6000mA 0mA 2500mA 0mA 2000mA Ripple & Noise(1) 60mVp-p 60mVp-p 60mVp-p 60mVp-p 75mVp-p 100mVp-p 100mVp-p 60mVp-p 60mVp-p 60mVp-p 60mVp-p 75mVp-p 100mVp-p 100mVp-p Input Current No Load(2) Full Load(3) 35mA 658mA 35mA 759mA 40mA 1029mA 50mA 994mA 65mA 1506mA 65mA 1506mA 70mA 1488mA 20mA 329mA 20mA 380mA 25mA 508mA 30mA 497mA 30mA 744mA 35mA 753mA 45mA 744mA Output Power 30W 30W Maximum Efficiency(1) Capacitive Load(4) 65,000µF 65,000µF 33,000µF 19,500µF 10,200µF 3,300µF 1,100µF 65,000µF 65,000µF 33,000µF 19,500µF 10,200µF 3,300µF 1,100µF Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] 80% 83% 85% 87% 87% 87% 88% 80% 83% 86% 87% 88% 87% 88% Page 1 of 7 ZFW SERIES 30 Watts DC/DC Converter Single and Dual Outputs Rev F MODEL SELECTION TABLE Dual Output Model Number ZFW24D12-1250 ZFW24D15-1000 ZFW48D12-1250 ZFW48D15-1000 Input Voltage Range Output Voltage 24VDC (10~40VDC) ±12VDC ±15VDC ±12VDC ±15VDC 48VDC (18~75VDC) Output Current Min Load Max Load 0mA ±1250mA 0mA ±1000mA 0mA ±1250mA 0mA ±1000mA Ripple & Noise(1) 100mVp-p 100mVp-p 100mVp-p 100mVp-p Input Current No Load(2) Full Load(3) 30mA 1563mA 35mA 1543mA 30mA 772mA 35mA 762mA Output Power Maximum Efficiency(1) Capacitive Load(4) ±1000µF ±680µF ±1000µF ±680µF 30W 30W 84% 85% 85% 86% SPECIFICATIONS 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 10 18 24 48 40 75 10 18 Unit INPUT SPECIFICATIONS Input Voltage Range Start-Up Voltage Shutdown Voltage Input Surge Voltage (100ms Max.) 24V Nominal input 48V Nominal input 24V Nominal input 48V Nominal input 24V Nominal input 48V Nominal input 24V nominal input 48V nominal input Input Reflected Ripple Current Input Filter OUTPUT SPECIFICATIONS Output Voltage Voltage Accuracy Line Regulation Low Line to High Line at Full Load Load Regulation No Load to Full Load Voltage Adjustability Cross Regulation Output Power Output Current Minimum Load Maximum Capacitive Load 5/12/2016 -1.0 -0.5 -0.5 -1.0 -10 -5.0 See Table +1.0 +0.5 +0.5 +1.0 +10 +5.0 See Table See Table 0 25% load step change Constant Resistive Load Over Temperature Protection Single Output Dual Output Asymmetrical load 25%/100% FL Dual Output Transient Response Recovery Time Over Voltage Protection VDC mAp-p L-C type 20MHz bandwidth with a 0.1µF/50V MLCC Temperature Coefficient REMOTE ON/OFF CONTROL(5) Positive Logic (Standard) Negative Logic (Option) Input Current of CTRL Pin Remote OFF Input Current PROTECTION Short Circuit Protection Over Load Protection VDC VDC 50 100 20 Ripple & Noise Start-Up Time 8 16 VDC -0.02 Power up Remote ON/OFF -0.02 DC-DC ON DC-DC OFF DC-DC ON DC-DC OFF -0.5 Zener Diode Clamp 1.5V, 1.8V, 2.5V, 3.3V Models 5V Models 12V Models 15V Models % % % A 1.5V, 1.8V, 2.5V, 3.3V Models 5V Models 12V, 15V Models % of lout rated % % See Table 60 75 100 +0.02 10 10 +0.02 Open 3~12VDC Short or 0~1.2VDC Short or 0~1.2VDC Open or 3~12VDC +0.5 3.0 mVp-p %/ºC ms %/ºC mA mA Continuous, Automatic Recovery 150 % 3.9 6.2 VDC 15 18 +155 ºC Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 2 of 7 ZFW SERIES 30 Watts DC/DC Converter Single and Dual Outputs Rev F SPECIFICATIONS 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 ENVIRONMENTAL SPECIFICATIONS Operating Ambient Temperature With Derating Storage Temperature Maximum Case Temperature Natural Convection Thermal Impedance(7) Natural Convection with Heatsink Relative Humidity Thermal Shock Vibration MTBF MIL-HDBK-217F, Full Load GENERAL SPECIFICATIONS Efficiency Switching Frequency Input to Output Isolation Voltage (1 minute) Input to Case Output to Case Isolation Resistance 500VDC Isolation Capacitance PHYSICAL SPECIFICATIONS Weight Typ -40 -55 Max Unit +85 +125 +100 ºC ºC ºC 10 8.24 5 ºC/W 95 MIL-STD-810F MIL-STD-810F 759,800 270 1600 1600 1600 1 % RH hours See Table 300 330 KHz VDC GΩ pF 1000 1.69oz (48g) 2.00in x 1.60in x 0.40in (50.8mm x 40.6mm x 10.2mm) Nickel-Coated Copper FR4 PCB Epoxy (UL94 V-0) Six-Sided Dimensions (L x W x H) Case Material Base Material Potting Material Shielding SAFETY & EMC CHARACTERISTICS UL60950-1 EN60950-1 IEC60950-1 Safety Approvals EMI(6) Class A Class B EN55022 ESD EN61000-4-2 Radiated Immunity Fast Transient(8) Surge(8) Conducted Immunity Power Frequency Magnetic Field EN61000-4-3 EN61000-4-4 EN61000-4-5 EN61000-4-6 EN61000-4-8 Air ±8kV Contact ±6kV 10 V/m ±2KV ±1kV 10 Vr.m.s 100A/m continuous; 1000A/m 1 Second Perf. Criteria B Perf. Criteria A Perf. Criteria A Perf. Criteria B Perf. Criteria A Perf. Criteria A NOTES (1) (2) (3) (4) (5) (6) Typical value at nominal input voltage and full load. Typical value at nominal input voltage and no load. Maximum value at nominal input voltage and full load Test by minimum Vin and constant resistive load. ON/OFF control function: The pin voltage is referenced to negative input. To order negative logic ON/OFF control add the suffix “R”. The ZFW series can meet EN55022 Class A with an external capacitor in parallel with the input pins. Recommended: 24Vin: 6.8µF/50V 1812 MLCC 48Vin: 2.2µF/100V * 2PCS 1812 MLCC (7) Heatsink is optional. Please call factory for ordering details. (8) An external input filter capacitor is required if the module has to meet EN61000-4-4, EN61000-4-5. Suggested filter capacitor: Nippon chemi-con KY series, 220µF/100V, ESR 48mΩ. (9) Option to have case connected to -Vout pin for improved shielding, add the suffix “-C” to the part number and consult factory. (10) For special electrical screening add the suffix “ES” to the part number (see Appendix I on the bottom of page 5). Please call factory for more details. Due to advances in technology, specifications subject to change without notice. 5/12/2016 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 3 of 7 Rev F ZFW SERIES 30 Watts DC/DC Converter Single and Dual Outputs DERATING CURVES ZFW48S5-6000 Derating Curve ZFW48S5-6000 Derating Curve with Heatsink EFFICIENCY GRAPHS ZFW48S5-6000 Efficiency vs Input Voltage 5/12/2016 ZFW48S5-6000 Efficiency vs Output Load Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 4 of 7 ZFW SERIES 30 Watts DC/DC Converter Single and Dual Outputs Rev F MECHANICAL DRAWINGS PIN 1 2 4 5 6 7 8 PIN CONNECTION SINGLE DUAL +Vin +Vin -Vin -Vin Ctrl Ctrl No Pin +Vout +Vout Common -Vout -Vout Trim Trim EXTERNAL OUTPUT TRIMMING Output can be externally trimmed by using the method shown below. ( ) for dual output trim. Notes: 1. 2. 3. 4. All dimensions in inch (mm) Tolerance: x.xx±0.02 (x.x±0.5) x.xxx±0.01 (x.xx±0.25) Pin pitch tolerance ±0.01 (0.25) Pin dimension tolerance ±0.004 (0.1) HEATSINK OPTIONS Suffix “HS” 5/12/2016 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 5 of 7 ZFW SERIES 30 Watts DC/DC Converter Single and Dual Outputs Rev F RECOMMENDED FILTERS Recommended Filter for EN55022 Class B Compliance Recommended EN55022 Class B Filter Circuit Layout The components used in the figure above are as follows: Model C1 C2 C3 C4 C5 & C6 ZFW24xxx-xxxx 6.8uF/50V N/A 6.8uF/50V N/A 1000pF/2KV ZFW48xxx-xxxx 2.2uF/100V 2.2uF/100V 2.2uF/100V 2.2uF/100V 1000pF/2KV L1 450uH Common Choke 450uH Common Choke APPENDIX I 1. Electrical Screening (“ES” suffix) All parts will be 100% screened by the supplier to the following requirements, in the sequence specified. 1.1 Thermal Shock Thermal shock in accordance with MIL-STD-810, method 503.4, Procedure I, temperature extremes -46ºC (-50ºF) and +71ºC (+160ºF). Allow parts to stabilize to chamber temperature. Perform 30 thermal shock cycles. 1.2 Functional Test Perform functional test with the part loaded to 50% minimum load capacity and input voltage set to 28VDC ±1V. After 5 minutes of applied power and load, measure and record input current, output voltage and output current. Verify that the results are within the allowable specification for each part. 1.3 Burn-In Perform functional test in accordance with 1.2. Keep the part powered on for a period of (24) hours. After (24) hours, perform functional test in accordance with 1.2. 1.4 Power Cycling Perform functional test in accordance with 1.2. Remove power from the converter for (15) minutes, then repeat functional test. Repeat this power cycling with functional testing every (15) minutes for a period of (3) hours. 5/12/2016 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 6 of 7 Rev F ZFW SERIES 30 Watts DC/DC Converter Single and Dual Outputs 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: 5/12/2016 (603)778-2300 (888)597-9255 (603)778-9797 [email protected] www.wallindustries.com 37 Industrial Drive Exeter, NH 03833 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 7 of 7