Rev C MMW Series Single and Dual Output 4:1 Input Voltage Range 25~30 Watt DC/DC Converter FEATURES ● Soft Start ● Output Trim ● RoHS Compliant ● Six-Sided Shielding ● Efficiency up to 89% ● Single & Dual Outputs ● Remote On/Off Control ● MTBF > 1,000,000 Hours ● Low Profile: 0.37” (9.3mm) ● CSA1950 Safety Approval ● UL60950-1 Safety Approvals ● 4:1 Wide Input Voltage Range ● Complies with EN55022 Class A ● 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 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. 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 INPUT (Vin) 24V nominal input models 10 24 40 VDC Input Voltage Range 48V nominal input models 18 48 75 VDC 24V nominal input models 9.4 9.7 10 VDC Start Voltage 48V nominal input models 17 17.5 18 VDC 24V nominal input models 9 9.3 9.5 VDC Under Voltage Shutdown 48V nominal input models 16 16.5 17 VDC Reverse Polarity Input Current All models 2 A Short Circuit Input Power 4500 mW 24V nominal input models -0.7 50 VDC Input Surge Voltage 48V nominal input models -0.7 100 VDC Input Filter Pi Filter OUTPUT (Vo) Output Voltage Range See Rating Chart Output Voltage Accuracy ±0.5 ±1.0 % Output Voltage Balance Dual Outputs, Balanced Loads ±0.5 ±2.0 % Output Trim % of nominal output ±9.0 ±10.0 ±11.0 % Load Regulation Io = 50% to 100% ±0.3 ±1.0 % Line Regulation Vin = min. to max. ±0.2 ±0.5 % Output Power 30 W Output Current Range See Rating Chart Ripple & Noise (20MHz) 55 80 mVpk-pk Ripple & Noise (20MHz) Over Line, Over Load, and Over Temperature 100 mVpk-pk Ripple & Noise (20MHz) 10 mVrms Transient Recovery Time 25% load step change 150 300 μs Transient Response Deviation ±2 ±4 % REMOTE ON/OFF Supply On 2.5 to 100VDC or Open Circuit Supply Off -1 1 VDC Standby Input Current 2 5 mA Control Input Current (On) Vin – RC = 5.0V 5 μA Control Input Current (Off) Vin – RC = 0V -100 μA Control Common Referenced to negative input PROTECTION Over Power Protection 120 180 % Short Circuit Protection Continuous Over Voltage Protection See Rating Chart 24V nominal input models 5000mA slow-blow type Input Fuse Recommendation 48V nominal input models 3000mA slow-blow type 11/14/2011 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 1 of 8 MMW Series Single and Dual Output 4:1 Input Voltage Range 25~30 Watt DC/DC Converter Rev C SPECIFICATION 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 TEST CONDITIONS Min 290 1500 1650 1000 60 seconds Flash Test for 1 second 500VDC 100KHz, 1V Nom Max See Rating Chart 330 360 1200 1500 5,500 See Rating Chart Unit KHz VDC VDC MΩ pF mW -40 -40 -50 107 +50 °C +105 °C +125 °C 112 117 °C 260 °C 95 % Free air convection Six-sided shielding, metal case ±0.01 ±0.02 %/°C 1000 Khours EN55022 Class A Case Temperature, automatic 1.5mm from case for 10 seconds MIL-HDBK-217F @ 25°C, Ground Benign 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 MODEL SELECTION TABLES SINGLE OUTPUT MODELS Model Number MMW24S3.3-5500 MMW24S5-5000 MMW24S12-2500 MMW24S15-2000 MMW48S3.3-5500 MMW48S5-5000 MMW48S12-2500 MMW48S15-2000 Model Number MMW24D12-1250 MMW24D15-1000 MMW48D12-1250 MMW48D15-1000 Input Voltage Output Current Input Current Reflected Min Max No Load Max Load Ripple Current 400 mA 5500 mA 922 mA 350 mA 5000 mA 1225 mA 20 mA 50 mA 166 mA 2500 mA 1404 mA 133 mA 2000 mA 1404 mA 400 mA 5500 mA 461 mA 350 mA 5000 mA 613 mA 10 mA 25 mA 166 mA 2500 mA 702 mA 133 mA 2000 mA 702 mA Output Voltage 3.3 VDC 5 VDC 12 VDC 15 VDC 3.3 VDC 48 VDC 5 VDC (18 ~ 75 VDC) 12 VDC 15 VDC 24 VDC (10 ~ 40 VDC) Input Voltage DUAL OUTPUT MODELS Output Current Input Current Output Voltage ±12 VDC 24 VDC (10 ~ 40 VDC) ±15 VDC ±12 VDC 48 VDC (18 ~ 75 VDC) ±15 VDC Min Max ±83 ±65 ±83 ±65 ±1250 ±1000 ±1250 ±1000 Reflected No Load Max Load Ripple Current 20mA 20mA 10mA 10mA 1404 mA 1404 mA 702 mA 702 mA Efficiency (Typ) Over Voltage Maximum Protection Capacitive Load 82% 85% 89% 89% 82% 85% 89% 89% 3.9 VDC 6.8 VDC 15 VDC 18 VDC 3.9 VDC 6.8 VDC 15 VDC 18 VDC Efficiency (Typ) Over Voltage Protection 89% 89% 89% 89% ±15 VDC ±18 VDC ±15 VDC ±18 VDC 50mA 25mA 10000 μF 10000 μF 1000 μF 1000 μF 10000 μF 10000 μF 1000 μF 1000 μF Maximum Capacitive Load 330 μF # 330 μF # 330 μF # 330 μF # # 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. 11/14/2011 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 2 of 8 MMW Series Single and Dual Output 4:1 Input Voltage Range 25~30 Watt DC/DC Converter Rev C BLOCK DIAGRAMS Single Output +Vin Dual Output +Vo LC Filter +Vin +Vo LC Filter Com. -Vo OVP OTP -Vin OVP -Vin PWM On/Off -Vo OVP OTP OVP Isolation Ref.Amp PWM On/Off Trim Isolation Ref.Amp Trim MECHANICAL DRAWING Standard Models Unit: mm [inches] 10.16 [0.40] 10.16 [0.40] 5.08 [0.20] 10.16 [0.40] Physical Characteristics 1.1 [0.04] BOTTOM VIEW 1 3.6 [0.14] 2 5.08 [0.20] 1.0 [ 0.04] 8 7 Case Size: 2.0 x 1.6 x 0.4 inches (50.8 x 40.6 x 10.2 mm) Case Material: Metal with non-conductive baseplate Weight: 48g Flammability: UL94V-0 50.8 [2.00] 6 45.72 [1.80] 5 PIN 1 2 4 5 6 7 8 4 10.16 [0.40] PIN CONNECTIONS SINGLE OUTPUT DUAL OUTPUT +Vin +Vin -Vin -Vin Remote ON/OFF Remote ON/OFF No Pin +Vout +Vout Common -Vout -Vout Trim Trim 7.6 [0.30] 6.0 [0.24] 40.6 [1.60] 10.2 [0.40] Heatsink Option Unit: mm [inches] Physical Characteristics 23.0[0.91] Heatsink Material: Aluminum Finish: Anodic treatment (black) Weight: 2g The advantages of adding a Heatsink are: 1. To help heat dissipation and increase the stability and reliability of DC/DC converters at high operating temperature atmosphere 16.3[0.64] max. 2. To upgrade the operating temperature of DC/DC converters. 55.32[2.18] max. Heat-Sink Thermal pad Clamp Converter 11/14/2011 Tolerance: Millimeters X.X±0.5 X.XX±0.25 Inches X.XX±0.02 X.XXX±0.01 Pin Diameter: ±0.05 ±0.002 To order the converter with Heatsink please add the suffix “HS” to the model number Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 3 of 8 MMW Series Single and Dual Output 4:1 Input Voltage Range 25~30 Watt DC/DC Converter Rev C INPUT VOLTAGE TRANSIENT RATING 150 140 130 48VDC Input Models 120 110 Vin ( VDC ) 100 90 80 24VDC Input Models 70 60 50 40 30 20 10 0 10uS 100uS 1mS 10mS 100mS EFFICIENCY GRAPHS Efficiency vs Input Voltage (Dual Output) 100 100 90 90 Efficiency (%) Efficiency (%) Efficiency vs Input Voltage (Single Output) 80 70 80 70 60 60 50 50 Low Nom High Low Nom Input Voltage (V) 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 80 100 10 20 Load Current (%) 11/14/2011 High Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 40 60 80 100 Load Current (%) Page 4 of 8 MMW Series Single and Dual Output 4:1 Input Voltage Range 25~30 Watt DC/DC Converter Rev C DERATING CURVE 100 400LFM Output Power (%) 80 Natural convection 60 100LFM 200LFM 40 20 0 ~ ¡ã -40 50 60 70 90 80 100 110 Ambient Temperature (°C) 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. + DC Power Source - 11/14/2011 +Vin + +Out DC / DC Converter Load Cin -Vin -Out Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 5 of 8 MMW Series Single and Dual Output 4:1 Input Voltage Range 25~30 Watt DC/DC Converter Rev C Remote On/Off 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 -Out Trim Up Enable Trim 10K Trim Up/Down 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. 11/14/2011 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 6 of 8 MMW Series Single and Dual Output 4:1 Input Voltage Range 25~30 Watt DC/DC Converter Rev C 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 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 + + Battery +Vin Lin Current Probe Cin +Out DC / DC Converter -Vin Load -Out 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 Copper Strip Single Output DC / DC Converter -Vin +Vin Resistive Scope Load Cout -Out Copper Strip +Out Dual Output DC / DC Converter Com. -Vin -Out Cout Scope Cout Scope Resistive Load 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 + Cout Load +Vin Dual Output DC / DC Com. Converter DC Power Source -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 11/14/2011 50mm / 2in Air Flow DUT Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 7 of 8 Rev C MMW Series Single and Dual Output 4:1 Input Voltage Range 25~30 Watt DC/DC Converter 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: 11/14/2011 (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 8 of 8