DATASHEET Rev. A DCMCW60 SERIES 4:1 Ultra Wide Input Voltage Ranges -55°C to +95°C Operating Temperature Single Outputs, Standard Half-Brick Package 60 Watt DC/DC Power Converters FEATURES Single Outputs 4:1 Ultra Wide Input Voltage Range: 9-36VDC and 18-75VDC 60 Watts Output Power 1500VDC I/O Isolation Up to 86% High Efficiency Lead Free Design, RoHS Compliant Operating Temperature Range: -55°C to +95°C (with derating) APPLICATIONS Distributed Power Systems Measurement Equipment Telecom Wireless Networks Industry Control Systems Remote ON/OFF Standard 2.40” x 2.28” x 0.5” Half-Brick Package Five-Sided Shielded Metal Case ±10% Output Trim Short Circuit, Over Voltage, Over Load, and Over Temperature Protection Battery Operated Equipment Custom Designs Available Military / Defense Applications Optional Heatsink Available (Suffix “HS”) DESCRIPTION The DCMCW60 series of isolated DC/DC power converters provides 60 Watts of continuous output power in a standard 2.40” x 2.28” x 0.5” half-brick package. This series consists of 5V, 12V, and 24VDC single output models with 4:1 input voltage ranges of 9-36VDC or 18~75VDC. Some features include high efficiency up to 86%, remote on/off, adjustable output voltage, 1500VDC I/O isolation, -55°C~+95°C operating temperature range (with derating), and five-sided shielding. The DCMCW60 series is RoHS compliant and has short circuit, over load, over voltage, and over temperature protection. These converters are best suited for use in battery operated equipment, measurement equipment, telecom, wireless networks, industry control systems, military/defense applications and anywhere where isolated, tightly regulated voltages and compact size are required. 09/05/2012 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 1 of 5 DCMCW60 Series Half-Brick Package 4:1 Input Voltage Ranges 60 Watt DC/DC Power Converters Rev. A TECHNICAL SPECIFICATIONS: DCMCW60 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 9 18 24 48 36 75 50 100 Unit INPUT SPECIFICATIONS Input Voltage Range Input Surge Voltage Input Reflected Ripple Current Input Current Input Filter Remote ON/OFF Sourcing Current of Remote Control Pin Idle Input Current (at Remote OFF State) OUTPUT SPECIFICATIONS Output Voltage Voltage Accuracy Output Current Output Trim Minimum Load Capacitive Load Start-up Time Line Regulation Load Regulation Output Power Ripple & Noise Temperature Coefficient Transient Response Overshoot Transient Response Settling Time Remote Sense PROTECTION Over Voltage Protection Short Circuit Protection Over Load Protection Thermal Shutdown GENERAL SPECIFICATIONS Efficiency Isolation Voltage Isolation Resistance Isolation Capacitance Switching Frequency ENVIRONMENTAL SPECIFICATIONS Operating Temperature Storage Temperature Maximum Case Temperature Relative Humidity Cooling MTBF PHYSICAL SPECIFICATIONS Case Material Base Material Potting Material Soldering Temperature Weight Dimensions (L x W x H) 09/05/2012 24VDC nominal input models 48VDC nominal input models 24VDC nominal input models 48VDC nominal input models Nominal Vin and full load 100ms max. VDC VDC 200 mAp-p See Table Pi Type Open or 3.5V < Vr < 12V Short (to -Vin) or 0V < Vr < 1.2V 0.2 mA 20 mA Converter ON Converter: OFF Nominal Vin Nominal Vin See Table Full load and nominal Vin -1 See page 4 -10 Nominal Vin and constant resistive load LL to HL at full load 25% load to full load 5VDC & 12VDC models 15VDC models 20MHz Bandwidth -0.02 -8 di/dt=0.8A/µs 50% load step change 5VDC output models 12VDC output models 24VDC output models % of full load at nominal input -0.5 -0.5 0 +1 See Table +10 See Table See Table 150 +0.5 +0.5 60 100 200 +0.02 +8 7.7 See Page 4 6.2 15 27 Hiccup, automatic recovery Zener Diode Clamp 110 -55 -55 Forced air cooling Lead-free wave soldering ms % % W mVp-p %/°C % of Vo ms VDC See Table 1500 10 VDC GΩ pF KHz 250 300 With derating (see derating curve) % % °C 110 Nominal input Input to Output 500VDC % +95 +125 +105 95 °C °C °C % RH 1.5m/s 718,000 hours Aluminum FR4 PCB Silicon rubber (UL94V-0) 260°C/10sec max. 3.42oz (97g) 2.40 x 2.28 x 0.50 inches (61.0 x 57.9 x 12.7 mm) Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 2 of 5 DCMCW60 Series Half-Brick Package 4:1 Input Voltage Ranges 60 Watt DC/DC Power Converters Rev. A MODEL SELECTION TABLE Model Number Input Voltage DCMCW60-24S05 Output Voltage Output Current (1) Input Current Min Load Full Load Full Load Output Power Efficiency (2) No Load Maximum Capacitive Load 5 VDC 50mA 12000mA 110mA 3205mA 60W 82% 1000µF 12 VDC 50mA 5000mA 110mA 3086mA 60W 85% 330µF DCMCW60-24S24 24 VDC 90mA 2500mA 110mA 3086mA 60W 85% 100µF DCMCW60-48S05 5 VDC 50mA 12000mA 50mA 1582mA 60W 83% 1000µF 12 VDC 50mA 5000mA 50mA 1524mA 60W 86% 330µF 24 VDC 90mA 2500mA 50mA 1524mA 60W 86% 100µF DCMCW60-24S12 DCMCW60-48S12 24 VDC (9 – 36 VDC) 48 VDC (18 – 75 VDC) DCMCW60-48S24 NOTES 1. Output current below this value will not damage these converters; however, they may not meet all listed specifications. 2. Typical value tested at nominal input and full load. 3. For Heatsink option, add the suffix “HS” to the model number. DERATING CURVES DCMCW60-24S5 Power Derating Curve (With Heatsink) 120 100 100 Output Power (%) Output Power (%) DCMCW60-24S5 Power Derating Curve (Without Heatsink) 120 80 60 40 20 80 60 40 20 0 -55 -35 -15 5 25 45 55 65 85 105 0 -55 125 -35 -15 Ambient Temperature (°C) 5 25 45 60 65 85 105 125 2.25 2.5 Ambient Temperature (°C) EFFICIENCY DCMCW60-24S5 Output Current vs. Efficiency 90 85 85 80 80 Efficiency (%) Efficiency (%) DCMCW60-24S5 Input Voltage vs. Efficiency 90 75 70 65 75 70 65 60 60 55 55 50 9 12 15 18 21 24 27 30 33 36 50 0.25 0.5 0.75 1.0 Input Voltage (VDC) 09/05/2012 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 1.25 1.5 1.75 2.0 Output Current (A) Page 3 of 5 DCMCW60 Series Half-Brick Package 4:1 Input Voltage Ranges 60 Watt DC/DC Power Converters Rev. A REMOTE SENSE APPLICATION CIRCUIT The Remote Sense function is used to compensate for the voltage drop incurred when the load is located physically far away from the DC/DC converter providing its power. The remote sense pins are connected as close to the load as possible. The DC/DC converter’s regulation specifications are maintained across the points where the remote sense wires are connected at the load. This will remove the effect of the voltage drop caused by the resistance of the wires used to conduct the power from the DC/DC converter to the load. This is represented by RCL1 and RCL2. With the use of remote sense, the effects of RCL1 and RCL2 are eliminated. If the Remote Sense function is not used, the +Sense has to be connected to +Vout and the -Sense has to be connected to -Vout as close to the DC/DC converter as possible. +Vout RCL1 +Sense +Vin Load -Vin -Sense -Vout R CL1 and R CL2 are line resistors RCL2 EXTERNAL OUTPUT TRIM The output is adjustable ±10% of rated output voltage. To trim the output voltage up, place the trim resistor between the Trim and -Vo pins. To trim the output voltage down, place the trim resistor between the Trim and +Vo pins. Trim Up Trim Down -Vo Trim Trim RU RD +Vo Trim DCMCW60-XXS05 TRIM TABLE Trimup Rup Trimdown Rdown 10% 5.5V 0.4kΩ 4.5V 0.48kΩ 7.5% 5.375V 5.175kΩ 4.625V 6.08kΩ 5% 5.25V 16.8kΩ 4.75V 17.28kΩ 2.5% 5.125V 49.59kΩ 4.875V 50.89kΩ DCMCW60-XXS12 TRIM TABLE DCMCW60-XXS24 TRIM TABLE Trim Trimup Rup Trimdown Rdown Trim Trimup Rup Trimdown Rdown 10% 13.2V 1.06kΩ 10.8V 1.19kΩ 10% 26.4V 5.4kΩ 21.6V 0kΩ 7.5% 12.9V 6.74kΩ 11.1V 23.01kΩ 7.5% 25.8V 13.2kΩ 22.2V 63.9kΩ 5% 12.6V 18.11kΩ 11.4V 66.64kΩ 5% 25.2V 28.8kΩ 22.8V 197kΩ 2.5% 12.3V 52.22kΩ 11.7V 197.5kΩ 2.5% 24.6V 75.6kΩ 23.4V 596kΩ 09/05/2012 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 4 of 5 DCMCW60 Series Half-Brick Package 4:1 Input Voltage Ranges 60 Watt DC/DC Power Converters Rev. A MECHANICAL DRAWINGS Standard Heatsink Option (Suffix “HS”) Unit: inches (mm) Unit: inches (mm) 2.26 (57.50) 3 7 1.90 (48.26) 0.04 (1.00) 0.19 (4.80) 0.58 (14.85) 8 2.39 (60.60) 5 6 0.50 (12.70) 2.00 (50.80) 0.40 0.20 (10.16) (5.08) 2.40 (61.00) BOTTOM VIEW 1.85 (46.89) 2 0.30 0.20 0.30 0.20 0.30 (7.62) (5.08) (7.62) (5.08) (7.62) 4 1 2.00±0.004 (50.80±0.10) 4-M3x0.5 (thru-hole) 0.20 (5.10) 0.50 (12.70) 0.39 (9.85) 1.9±0.004 (48.26±0.10) PHYSICAL Weight: 3.42oz (97g) Case Material: Aluminum Base Material: FR4 PCB Potting Material: Silicon rubber (UL94V-0) +Vin 2 -Vin 3 Remote ON/OFF 4 -Sense 5 +Sense 6 +Vout 7 -Vout 8 Trim 0.08 (2.00) 0.20 (5.10) 0.50 (12.70) 1.74 (44.30) Single 1 0.20 (5.10) NOTES 1. All dimensions are for reference only 2. Pin Diameter: 0.04 (1.0) 3. Tolerance: ±0.02 (±0.5) PIN CONNECTIONS Pin 0.93 (23.70) 2.28 (57.90) 0.43 (11.00) 1.80 (45.80) 1.85 (46.89) 2.78 (57.90) NOTES 1. All dimensions are for reference only 2. Weight: 1.23oz (35g) 3. Material: Aluminum 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: 09/05/2012 (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 5 of 5