TECHNICAL DATASHEET Rev A MDW48S12-1670 20W DC/DC Converter 18-75 VDC Input 12 VDC Single Output at 1670mA Features: UL TUV CB CE MARK (Pending) Applications: • RoHS Directive Compliant • 1.67A Single Output Current • No Minimum Load Requirement • 20 Watts Output Power • Adjustable Output Voltage • High Efficiency up to 87% • Low Profile: 2.00 x 1.00 x 0.40 Inches • Input to Output Isolation: 1600VDC min • 4:1 Ultra Wide Input Voltage Range • Fixed Switching Frequency • Computer Equipment • Input Under Voltage Protection • Communications Equipment • Output Over Voltage Protection • Distributed Power Architectures • Over Current Protection, Auto-Recovery • Output Short Circuit Protection Options: • Remote ON/OFF Control • Negative Remote ON/OFF • Six-Sided Shielding • Heatsinks Available for Extended Operation • Case Grounding Description: The MDW48S12-1670 is a single output DC/DC converter that provides 20 watts of output power in a low profile 2 x 1 x 0.4 inch package. The MDW48S12-1670 features a 4:1 wide input voltage range of 18-75VDC as well as positive or negative remote on/off, 1600VDC I/O isolation, trimmable output voltage, and six-sided shielding. This converter is also protected against over current, over voltage, input under voltage, and short circuit conditions. The MDW48S12-1670 is particularly suited for telecommunications, industrial, mobile telecom, and test equipment applications. (888) 597-WALL www.wallindustries.com Page 1 of 14 TECHNICAL DATASHEET MDW48S12-1670 Rev. A Technical Specifications MDW48S12-1670 Model No. 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 INPUT (Vin) Operating Voltage Range UVLO Turn-on Threshold UVLO Turn-off Threshold Input Standby Current Input Current Input Voltage Input Voltage Variation Reflected Ripple Current Start Up Time (Nominal Vin and constant resistive load) OUTPUT (Vo) Output Voltage Range Load Regulation Line Regulation Voltage Adjustability (see page 5) Output Ripple & Noise (20MHz) Output Current Output Voltage Overshoot PROTECTION Over Voltage Protection Over Current Protection Short Circuit Protection DYNAMIC LOAD RESPONSE Peak Deviation Setting Time (Vout < 10% peak deviation) REMOTE ON/OFF Negative Logic (Option) Positive Logic (Standard) Related condition ISOLATION Isolation Voltage (Input-Output) Isolation Voltage (Output to Case) Isolation Voltage (Input to Case) Isolation Resistance Isolation Capacitance ENVIRONMENTAL Operating Ambient Temperature (with derating) Operating Case Temperature Storage Temperature Temperature Coefficient MTBF Bellcore TR-NWT-000332, TC=40°C MIL-HDBK-217F MECHANICAL Weight Nominal Vin and Full Load; Ta = 25°C 0% to 100% Full Load LL to HL at Full Load Max Unit 18 48 18 15 15 75 Vdc Vdc Vdc mA mA 503 75 100 5 20 11.88 -0.5 -0.2 -10 Measured with a 0.1µF/50V MLCC (See the Test Setup section - pg 9) 12 0 0 Zener diode clamp Test at nominal Vin and 25°C Load step change from 75 to 100% or 100 to 75 % of FL Load step change from 75 to 100% or 100 to 75 % of FL The ON/OFF pin voltage is referenced to -Vin (See the Remote ON/OFF Control section - pg 6) DC/DC ON DC/DC OFF DC/DC ON DC/DC OFF Vdc V/ms mApk-pk 20 20 ms 12.12 +0.5 +0.2 +10 Vdc % % % 75 LL to HL at Full Load and 25°C mVpk-pk 1670 5 mA % Vout 15 Vdc 150 % FL Hiccup, automatic-recovery 200 250 0 3 3 0 mV µs 1.2 12 12 1.2 2.5 -0.5 Nominal Vin, and full load; Ta=25°C (See the Test Setup section – pg 9) 0.5 -40 -55 -0.02 Vdc Vdc mA mA 400 KHz 87 % 1600 1600 1600 1 1500 Vdc Vdc Vdc GΩ pF 105 105 125 +0.02 °C °C °C % / °C See the MTBF and Reliability section (pg 13) 1,621,000 hours 659,000 hours See Figure 1 27 grams 2.00 x 1.00 x 0.40 inches 50.8 x 25.4 x 10.2 mm Dimensions (888) 597-WALL Nom Nominal Vin and No Load Nominal Vin and Full Load Continuous Transient (100ms) Complies with ETS300 132 part 4.4 5 to 20MHz, 12µH source impedance (See the Test Setup section - pg 9) Power Up Remote On/Off Remote OFF Input Current Input Current of Remote Control Pin GENERAL Switching Frequency Efficiency Min www.wallindustries.com Page 2 of 14 TECHNICAL DATASHEET MDW48S12-1670 Rev. A Figure 1: Mechanical Dimensions Unit: inches (mm) 1.00 (25.4) 0.50 (12.7) 0.400 (10.16) 0.40 (10.2) PIN CONNECTION DIA. 0.04 (1.0) 0.400 (10.16) 4 1 5 2 6 0.800 (20.32) 2.00 (50.8) 3 PIN SINGLE OUTPUT 1 + INPUT 2 - INPUT 3 +OUTPUT 4 TRIM 5 -OUTPUT 6 CTRL EXTERNAL OUTPUT TRIMMING 0.60 (15.2) Output can be externally trimmed by using the method shown below. 0.100 (2.54) 0.22 (5.6) 0.200 (5.08) 1. Tolerance: X.XX±0.02 (X.X±0.5) X.XXX±0.01 (X.XX±0.25) 2. Pin pitch tolerance ±0.01 (0.25) 3. Pin dimension tolerance: ±0.014 (0.35) Equip Heatsink (7G-0020C-F) for lower temperature and higher reliability of the module. Consider space and airflow in order to choose which heatsink is needed. Figure 2 Unit: inches (mm) (888) 597-WALL www.wallindustries.com Page 3 of 14 TECHNICAL DATASHEET Rev. A MDW48S12-1670 DESIGN CONSIDERATIONS: Output Over Current Protection When excessive output current occurs in the system, circuit protection is required on all power supplies. Normally, overload current is maintained at approximately 140% of rated current for the MDW single output series. Hiccup mode is a method of operation in a power supply whose purpose is to protect the power supply from being damaged during an over-current fault condition. It also enables the power supply to restart when the fault is removed. There are other ways of protecting the power supply when it is over loaded such as maximum current limiting or current fold-back methods. One of the problems resulting from over current is that excessive heat may be generated in power devices; especially MOSFET and Schottky diodes and the temperature of those devices may exceed their specified limits. A protection mechanism has to be used to prevent those power devices from being damaged. The operation of hiccup is as follows. When the current sense circuit sees an over current event, the controller shuts off the power supply for a given time and then tries to start up the power supply again. If the over load condition has been removed, the power supply will start up and operate normally; otherwise, the controller will see another over current event and shut off the power supply again repeating the previous cycle. Hiccup operation has none of the drawbacks of the other two protection methods, although its circuit is more complicated because it requires a timing circuit. The excess heat due to over load lasts for only a short duration in the hiccup cycle, hence the junction temperature of the power devices is much lower. The hiccup operation can be done in various ways. For example, one can start the hiccup operation any time an over current event is detected, or prohibit hiccup during a designated start-up which is usually larger than during normal operation and it is easier for an over current event to be detected, or prohibit hiccup during a designated start-up interval (usually a few milliseconds). The reason for the latter operation is that during start-up the power supply needs to provide extra current to charge up the output capacitor thus the current demand is usually larger than during normal operation making it easier for an over current event to occur. If the power supply starts to hiccup once there is over current it might never start up successfully. Hiccup mode protection will give the best protection for a power supply against over current situations since it will limit the average current to the load at a low level reducing power dissipation and case temperature in the power devices. Output Over Voltage Protection The output over voltage protection consists of an output Zener diode that monitors the voltage on the output terminals. If the voltage on the output terminals exceeds the over voltage protection threshold, then the Zener diode will clamp the output voltage. Short Circuit Protection Continuous, hiccup, and auto-recovery mode. The average current during this condition will be very low and the device is still safe in this condition. Input Source Impedance The power module should be connected to a low impedance input source. Highly inductive source impedance can affect the stability of the power module. Input external L-C filter is recommended to minimize input reflected ripple current. The inductor is simulated source impedance of 12µH and capacitor is Nippon chemi-con KZE series 220µF/100V. The capacitor must be connected as close as possible to the input terminals of the power module for lower impedance. (888) 597-WALL www.wallindustries.com Page 4 of 14 TECHNICAL DATASHEET MDW48S12-1670 Rev. A Thermal Consideration The power module operates in a variety of thermal environments. However, sufficient cooling should be provided to help ensure reliable operation of the unit. Heat is removed by conduction, convention, and radiation to the surrounding environment. Proper cooling can be verified by measuring the point as the figure below. The temperature at this location should not exceed 105°C. When operating, adequate cooling must be provided to maintain the test point temperature at or below 105°C. Although the maximum point temperature of the power modules is 105°C, you can limit this temperature to a lower value for extremely high reliability. Figure 3 Measurement shown in inches (mm) Output Voltage Adjustment Output voltage set point adjustment allows the user to increase or decrease the output voltage set point of a module. This is accomplished by connecting an external resistor between the TRIM pin and either the +Vout or -Vout pins. With an external resistor between the TRIM and -Vout pin, the output voltage set point increases. With an external resistor between the TRIM and +Vout pin, the output voltage set point decreases. Figure 4 Table 1 MDW48S12-1670 (888) 597-WALL Trim Trimup Rup Trimdown Rdown 1% 12.120V 367.908 kΩ 11.880V 460.992 kΩ 2% 12.240V 165.954 kΩ 11.760V 207.946 kΩ 3% 12.360V 98.636 kΩ 11.640V 123.597 kΩ 4% 12.480V 64.977 kΩ 11.520V 81.423 kΩ 5% 12.600V 44.782 kΩ 11.400V 56.118 kΩ 6% 12.720V 31.318 kΩ 11.280V 39.249 kΩ 7% 12.840V 21.701 kΩ 11.160V 27.199 kΩ 8% 12.960V 14.488 kΩ 11.040V 18.162 kΩ 9% 13.080V 8.879 kΩ 10.920V 11.132 kΩ 10% 13.200V 4.391 kΩ 10.800V 5.509 kΩ www.wallindustries.com Page 5 of 14 TECHNICAL DATASHEET Rev. A MDW48S12-1670 Remote ON/OFF Control The remote ON/OFF pin allows the user to turn the DC/DC power module on and off from a remote switch device. The ON/OFF input can be switched by a number of switching devices. Figure 5 gives several examples of acceptable configurations. The remote ON/OFF pin is an open collector/drain logic input signal that is referenced to –Vin. A logic High on the remote ON/OFF pin turns the module ON and a logic Low on the remote ON/OFF pin turns the module OFF. If the remote ON/OFF feature is not being used please make an open circuit between the ON/OFF pin and the –input pin to turn the module on. Remote ON/OFF Implementation Figure 5 Isolated-Closure Remote ON/OFF (888) 597-WALL Level Control Using TTL Output www.wallindustries.com Level Control Using Line Voltage Page 6 of 14 TECHNICAL DATASHEET MDW48S12-1670 Rev. A MDW48S12-1670 Graphs. All test conditions are at 25°C Graph 2: Efficiency vs. Input Voltage (Full Load) Efficiency (%) Efficiency (%) Graph 1: Efficiency vs. Output Current Input Voltage (V) % Of Full Load Graph 4: Output Power vs. Ambient Temperature with Heatsink & Airflow (Nominal Vin) Output Power (%) Output Power (%) Graph 3: Output Power vs. Ambient Temperature & Airflow (Nominal Vin) Ambient Temperature, Ta (°C) Ambient Temperature, Ta (°C) Graph 6: Typical Output Ripple and Noise (Nominal Vin and Full Load) Power Dissipation (W) Graph 5: Power Dissipation Vs. Output Current % Of Full Load (888) 597-WALL www.wallindustries.com Page 7 of 14 TECHNICAL DATASHEET MDW48S12-1670 Rev. A MDW48S12-1670 Graphs (Continued). All test conditions are at 25°C Graph 7: Typical Input Start-Up and Output Rise Characteristic (Nominal Vin and Full Load) Graph 9: Transient Response to Dynamic Load Change from 100% to 75% to 100% of Full Load at Nominal Vin Graph 8: Using ON/OFF Voltage Start-Up and Vo Rise Characteristic (Nominal Vin and Full Load) Graph 10: Conducted Emission of EN55022 Class A (Nominal Vin and Full Load) Frequency (MHz) Graph 11: Conducted Emission of EN55022 Class B (Nominal Vin and Full Load) Frequency (MHz) (888) 597-WALL www.wallindustries.com Page 8 of 14 TECHNICAL DATASHEET MDW48S12-1670 Rev. A TEST SETUP: The MDW48S12-1670 specifications are tested with the following configurations: Input Reflected-Ripple Current Measurement Test Setup Figure 6 Component Value Voltage L 12µH ---- C 100µF 100V Reference ---Aluminum Electrolytic Capacitor Peak-to-Peak Output Ripple & Noise Measurement Setup Figure 8 Figure 7 Output Voltage and Efficiency Measurement Setup Figure 9 Vout × Iout Efficiency = × 100% Vin × Iin NOTE: All measurements are taken at the module terminals (888) 597-WALL www.wallindustries.com Page 9 of 14 TECHNICAL DATASHEET MDW48S12-1670 Rev. A EMC Considerations Suggested Schematic for EN55022 Conducted Emission Class A Limits Figure 10 Recommended Layout with Input Filter Figure 11 The following components are needed to meet conducted emissions EN55022 Class A MDW24Sxx-xxxx Component C1 C2, C3 Value --1000pF Voltage --2KV Reference --1808 MLCC MDW48Sxx-xxxx Component C1 C2, C3 (888) 597-WALL Value 1µF 1000pF Voltage 100V 2KV www.wallindustries.com Reference 1210 MLCC 1808 MLCC Page 10 of 14 TECHNICAL DATASHEET MDW48S12-1670 Rev. A EMC Considerations (Continued) Suggested Schematic for EN55022 Conducted Emission Class B limits Figure 12 Recommended Layout with Input Filter Figure 13 The following components are needed to meet conducted emissions EN55022 Class B Figure 14: Common Choke (L1) MDW24Sxx-xxxx Component Value Voltage Reference C1 4.7µF 50V 1812 MLCC C3, C4 1000pF 2KV 1808 MLCC L1 450µF --- Common Choke, P/N: PMT-048 MDW48Sxx-xxxx Component Value Voltage Reference C1, C2 2.2µF 100V 1812 MLCC C3, C4 1000pF 2KV 1808 MLCC L1 325µF --- Common Choke, P/N: PMT-050 PMT-048 Dimensions: mm L: 450µH±35% / DCR: 25Ω, max Height: 9.8mm, max. Test conditions: 100KHz / 100mV Recommended through hole: Φ0.8mm (888) 597-WALL www.wallindustries.com PMT-050 Dimensions: mm L: 325µH±35% / DCR: 35Ω, max Height: 8.8mm, max. Test conditions: 100KHz / 100mV Recommended through hole: Φ0.8mm Page 11 of 14 TECHNICAL DATASHEET MDW48S12-1670 Rev. A Recommended Pad Layout Figure 15 1. All dimensions in inches (mm) 2. Tolerance: X.XX±0.02 (X.X±0.5) X.XXX±0.01 (X.XX±0.25) 3. Pin Pitch Tolerance: ±0.01(0.25) Soldering and Reflow Considerations: Lead Free Wave Solder Profile for MDW Single Output Models Figure 16 TEMPERATURE (°C) Zone Preheat Zone Actual Heating Reference Parameter Rise temp. speed: 3°C/sec max. Preheat temp: 100~130°C Peak temp: 250~260°C Peak time (T1+T2 time): 4~6 sec Reference Solder: Sn-Ag-Cu; Sn-Cu Hand Welding: Soldering Iron: Power 90W Welding Time: 2~4 sec Temp: 380~400°C TIME (SEC) Packaging Information: Figure 17 Unit: mm 20 PCS per Tube (888) 597-WALL www.wallindustries.com Page 12 of 14 TECHNICAL DATASHEET MDW48S12-1670 Rev. A Safety and Installation Instructions: Fusing Consideration Caution: This power module is not internally fused. An input line fuse must always be used. This encapsulated power module can be used in a wide variety of applications, ranging from simple stand-alone operation to an integrated part of sophisticated power architecture. For maximum flexibility internal fusing is not included; however, to achieve maximum safety and system protection always use an input line fuse. The safety agencies require a normal-blow fuse with maximum rating of 6A. Based on the information provided in this data sheet on inrush energy and maximum DC input current; the same type of fuse with lower rating can be used. Refer to the fuse manufacturer’s data for further information. MTBF and Reliability The MTBF of the MDW single output series of DC/DC converters has been calculated using Bellcore TR-NWT-000332 Case I: 50% stress, Operating Temperature at 40°C (Ground fixed and controlled environment). The resulting figure for MTBF is 1,621,000 hours. MIL-HDBK 217F NOTICE2 FULL LOAD, Operating Temperature at 25°C. The resulting figure for MTBF is 659,000 hours. Ordering Information: Part Number Example: MDW 48 S 12 - 1670 R Series Designation Nominal Input Voltage Single Output Nominal Output Voltage Output Current Suffix Blank R (888) 597-WALL www.wallindustries.com Option Positive Remote ON/OFF (standard) Negative Remote ON/OFF Page 13 of 14 TECHNICAL DATASHEET Rev. A MDW48S12-1670 Company Information: Wall Industries, Inc. has created custom and modified units for over 40 years. Our in-house research and development engineers will provide a solution that exceeds your performance requirements on time and on budget. Our ISO9001-2000 certification is just one example of our commitment to producing a high quality, welldocumented 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: (888) 597-WALL (603)778-2300 (888)587-9255 (603)778-9797 [email protected] www.wallindustries.com 5 Watson Brook Rd. Exeter, NH 03833 www.wallindustries.com Page 14 of 14