Rev A CMMMW Series 4:1 Input Voltage Ranges 18~30 Watt, Single Output Chassis Mount DC/DC Converter FEATURES ● Soft Start ● Output Trim ● Single Output ● 1500VDC Isolation ● Efficiency up to 89% ● Remote On/Off Control ● MTBF > 1,000,000 Hours ● CSA1950 Safety Approval ● 4:1 Wide Input Voltage Range ● Complies with EN55022 Class A ● Call Factory for More Output Power Options ● Short Circuit, Over Voltage, and Over Temperature Protected ● Chassis Mount Options: Open Frame, U Channel, and Enclosed Types Available DESCRIPTION The CMMMW series of chassis mount DC/DC converters offers up to 30 watts of output power. These converters operate over input voltage ranges of 10-40VDC and 18-75VDC. This series also provides regulated single outputs of 3.3, 5, 12, and 15VDC. Other features include remote on/off control, output trim function, 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 are best suited for data communication equipment, mobile battery driven equipment, distributed power systems, telecommunications equipment, mixed analog/digital subsystems, process/machine control equipment, computer peripheral systems, and industrial robot systems. Chassis mounts come in open frame, U channel, and enclosed types. SPECIFICATIONS: CMMMW 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 OUTPUT (Vo) Output Voltage See Table Output Voltage Accuracy ±0.5 ±1.0 % 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 Table 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 % Temperature Coefficient ±0.01 ±0.02 %/°C 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 Table Over Temperature Protection Case Temperature, automatic 107 112 117 °C Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 CMMMW Series 4:1 Input Voltage Ranges 18~30 Watt, Single Output Chassis Mount DC/DC Converter Rev A 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 Lead Temperature Humidity Cooling RFI MTBF Conducted EMI PHYSICAL Weight Dimensions (L x W x H) Case Material of DC/DC Cnverter Flammability TEST CONDITIONS Min 290 1500 1650 1000 60 seconds Flash Test for 1 second 500VDC 100KHz, 1V Nom Max Unit See Table 330 360 KHz VDC VDC MΩ pF mW 1200 1500 5,500 See Table -40 -40 -50 1.5mm from case for 10 seconds MIL-HDBK-217F @ 25°C, Ground Benign +50 °C +105 °C +125 °C 260 °C 95 % Free air convection Six-sided shielding, metal case 1000 Khours EN55022 Class A Approximately 7oz 4.00 x 2.25 x 0.81 inches Metal with non-conductive baseplate UL94V-0 MODEL SELECTION TABLE Model Number Input Voltage CMMMW24S3.3-5500 CMMMW24S5-5000 24 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 922 mA 1225 mA 20 mA CMMMW24S12-2500 Efficiency Over Voltage Maximum (Typ) Protection Capacitive Load 82% 3.9 VDC 10000 μF 85% 6.8 VDC 10000 μF 15 VDC 1000 μF 50 mA 12 VDC 166 mA 2500 mA 1404 mA 89% CMMMW24S15-2000 15 VDC 133 mA 2000 mA 1404 mA 89% 18 VDC 1000 μF CMMMW48S3.3-5500 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 CMMMW48S5-5000 (10 ~ 40 VDC) 48 VDC 613 mA 10 mA CMMMW48S12-2500 CMMMW48S15-2000 (18 ~ 75 VDC) 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 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 CMMMW 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. Other input and output voltages may be available, please contact factory. 4. Heatsink is optional. Please consult factory for ordering details. 5. Chassis Mount Options: No suffix for open frame, “U” suffix for U Channel, and “E” suffix for Enclosed type. Due to advances in technology, specifications subject to change without notice. Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 CMMMW Series 4:1 Input Voltage Ranges 18~30 Watt, Single Output Chassis Mount DC/DC Converter Rev A BLOCK DIAGRAM INPUT VOLTAGE TRANSIENT RATING Single Output 150 140 130 48VDC Input Models 110 100 Vin ( VDC ) +Vin 120 +Vo LC Filter -Vo OVP OTP 90 80 24VDC Input Models 70 60 50 OVP 40 30 -Vin 20 PWM On/Off Isolation Ref.Amp 10 Trim 0 10uS 100uS 1mS 10mS 100mS EFFICIENCY GRAPHS Efficiency vs Input Voltage (Single Output) Efficiency vs Output Load (Single Output) 100 100 90 Efficiency (%) 80 70 80 70 60 50 60 50 40 30 Low Nom High 10 20 40 60 Load Current (%) Input Voltage (V) DERATING CURVE 100 400LFM 80 Output Power (%) Efficiency (%) 90 Natural convection 60 100LFM 200LFM 40 20 0 ~ ¡ã -40 50 60 70 80 90 Ambient Temperature (°C) Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 100 110 80 100 CMMMW Series 4:1 Input Voltage Ranges 18~30 Watt, Single Output Chassis Mount DC/DC Converter Rev A MECHANICAL DRAWING Unit: inches [mm] TRM + Out -Out -Vin CNTL + Vin 4.00 [101.6] MODEL NAME LABEL 2.25 [57.2] .17 [4.3] 1.13 [28.6] 3.66 [93.0] .16 [4.06] 2X Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 .81 [20.6] CMMMW Series 4:1 Input Voltage Ranges 18~30 Watt, Single Output Chassis Mount DC/DC Converter Rev A 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 - +Vin + +Out DC / DC Converter Load Cin -Vin -Out 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. Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 CMMMW Series 4:1 Input Voltage Ranges 18~30 Watt, Single Output Chassis Mount DC/DC Converter Rev A 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. +Vin +Out -Vin -Out Trim Down Trim Up/Down Trim Up Enable 10K 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: (33 x Vout) - (30 x Vadj) Rup = 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 CMMMW 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 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 Cin Current Probe +Out DC / DC Converter -Vin Load -Out Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 CMMMW Series 4:1 Input Voltage Ranges 18~30 Watt, Single Output Chassis Mount DC/DC Converter Rev A 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 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 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Rev A CMMMW Series 4:1 Input Voltage Ranges 18~30 Watt, Single Output Chassis Mount 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: (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