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DATASHEET
Rev. A
DHW40 SERIES
4:1 Ultra Wide Input Voltage Ranges
Single & Dual Outputs, Efficiency up to 90%
2.0” x 1.0” x 0.4” Encapsulated Shielded Metal Package
40 Watt DC/DC Power Converters
FEATURES
• RoHS Compliant
• 2.0” x 1.0” x 0.4” Package Size
• 40 Watts Output Power
• Trimmable Output Voltage
• 4:1 Ultra Wide Input Voltage Ranges
• Shielded Metal Case with Isolated Base-plate
• Single & Dual Outputs
• -40°C to +80°C Operating Temperature Range
• Remote ON/OFF Control
• Over Load, Short Circuit, Over Voltage, and Over
• 1500VDC I/O Isolation
Temperature Protection
• High Efficiency up to 90%
• UL/IEC/EN 60950-1 Safety Approvals (Pending)
• Under Voltage Lockout (UVLO)
• Heatsink (Optional)
DESCRIPTION
The DHW40 series is the latest generation of high performance DC/DC converters setting a new standard
concerning power density. These converters offer 40 Watts of continuous output power in a 2.0” x 1.0” x 0.4”
encapsulated, shielded metal package. The DHW40 series has single and dual output models with 4:1 ultra wide
input voltage ranges of 9-36VDC and 18-75VDC. Advanced circuit topology provides a very high efficiency up to
90% and an operating temperature range of -40°C to +80°C. Further features include remote on/off, trimmable
output voltage, under-voltage lockout as well as over load, over voltage, short circuit, and over-temperature
protection. These converters are RoHS compliant and are ideal for use in battery operated equipment,
instrumentation, distributed power architectures in communication and industrial electronics and many other space
critical applications.
10/31/2012
Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 1 of 12
DHW40 Series
Single & Dual Outputs
4:1 Ultra Wide Input Ranges
40 Watt DC/DC Power Converters
Rev. A
SPECIFICATIONS: DHW40 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
Typ
Max
24VDC nominal input models
9
24
36
48VDC nominal input models
18
48
75
24VDC nominal input models
-0.7
50
48VDC nominal input models
-0.7
100
Unit
INPUT SPECIFICATIONS
Input Voltage Range
Input Surge Voltage (100ms max.)
Start-up Threshold Voltage
Under Voltage Lockout (UVLO)
Start-up Time
Power Up
Remote On/Off
24VDC nominal input models
9
48VDC nominal input models
18
24VDC nominal input models
8.3
48VDC nominal input models
16.5
VDC
VDC
VDC
VDC
30
Nominal Vin and constant resistive load
ms
30
Input Current
See Table
Reflected Ripple Current (Page 10)
Internal Filter
See Table
for EN55022 Class A compliance see page 4
LC Filter
24VDC nominal input models
Input Fuse (Note 3)
8000mA slow-blow type
48VDC nominal input models
4000mA slow-blow type
Short Circuit Current
Hiccup mode 1.5Hz typ.
OUTPUT SPECIFICATIONS
Output Voltage
See Table
Output Voltage Balance
Dual Output Models, Balanced loads
±2.0
%
Line Regulation
Low line to high line at full load
±0.5
%
Single Output Models
±0.5
Load Regulation
Dual Output Models
Minimum load to full load
%
±1.0
Load Cross Regulation (Dual Output Models)
Asymmetrical load 25% / 100% full load
±5.0
%
Output Voltage Setting Accuracy
At 50% load and nominal Vin
±1.0
%Vnom
Output Voltage Trim (Page 9)
% of nominal output voltage
±10
%
Output Power
See Table
Output Current
See Table
Single Output Models
Minimum Load
No minimum load required
Dual Output Models
Ripple & Noise (0-20MHz) (Page 11)
Transient Recovery Time (Note 2)
Measured with a 1µF M/C and
a 10µF T/C in parallel
See Table
3.3 & 5VDC Output Models
100
12 & 15VDCOutput Models
150
Dual Output Models
150
25% load step change
mVp-p
250
µs
Temperature Coefficient
±0.02
%/°C
PROTECTION
Input Polarity Protection
none
Over Voltage Protection (page 10)
See Table
Over Load Protection
Current limitation at 150% typ. of Io max., hiccup
Thermal Protection
Shutdown temperature
Short Circuit Protection
110
°C
Hiccup, automatic recovery
REMOTE ON/OFF (Page 10)
Positive Logic
Control Input Current
Converter On
4.7~12V or open circuit
Converter Off
0V ~ 1.2 or short circuit
On
Vctrl = 5.0V
0.5
Off
Vctrl = 0V
-0.5
Control Common
Stand-by Input Current
10/31/2012
mA
Referenced to negative input
Nominal Vin
Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
2.5
mA
Page 2 of 12
DHW40 Series
Single & Dual Outputs
4:1 Ultra Wide Input Ranges
40 Watt DC/DC Power Converters
Rev. A
SPECIFICATIONS: DHW40 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
Typ
Max
Unit
GENERAL
Efficiency
(see efficiency curves on pages 6~8)
See Table
Switching Frequency
320
Isolation Voltage (Input to Output)
60 seconds
1500
Isolation Resistance
500VDC
1000
Isolation Capacitance
100kHz, 1V
KHz
VDC
MΩ
1500
Maximum Capacitive Load
pF
See Table
ENVIRONMENTAL SPECIFICATIONS
Operating Temperature (W/O Heatsink)
(see derating curves on page 5)
Operating Temperature (W/ Heatsink)
(see derating curves on page 5)
Thermal Impedance (W/O Heatsink)
Thermal Impedance (W/ Heatsink)
Natural air convection (20LFM)
Nominal Vin and full load
Natural air convection (20LFM)
Nominal Vin and full load
DHWXXS3.3-26
DHW24S5-40, DHW48S5-40,
DHW48S12-40, DHW48S15-40
DHW24S12-40, DHW24S15-40
DHW24D12-40, DHW24D15-40,
DHW48D12-40, DHW48D15-40
DHWXXS3.3-26
DHW24S5-40, DHW48S5-40,
DHW48S12-40, DHW48S15-40
DHW24S12-40, DHW24S15-40
DHW24D12-40, DHW24D15-40,
DHW48D12-40, DHW48D15-40
-40
+66
-40
+51
-40
+45
-40
+40
-40
+73
-40
+61
-40
+57
°C
°C
+52
Natural convection (20LFM)
12.0
100LFM convection
10.0
200LFM convection
9.0
400LFM convection
5.4
Natural convection (20LFM)
8.0
100LFM convection
4.5
200LFM convection
6.0
400LFM convection
3.0
Case Temperature
°C/W
°C/W
+105
Storage Temperature
-50
°C
95
% RH
Humidity (non-condensing)
RFI
°C
+125
Six-sided shielded metal case
Cooling
Natural convection is about 20LFM and is not still air (0LFM)
Lead Temperature
1.5mm from case for 10 seconds
MTBF (calculated)
MIL-HDBK-217F at 25°C, Ground Benign
natural convection
260
328,000
°C
hours
PHYSICAL SPECIFICATIONS
Weight
1.06oz (30g)
Dimensions (L x W x H)
2.0 x 1.0 x 0.43 inches (50.8 x 25.4 x 11 mm)
Case Material
Aluminum alloy, black anodized coating
Base Material
FR4 PCB (flammability to UL 94V-0 rated)
Potting Material
Epoxy (UL94-V0)
Pin Material
Copper alloy with gold plate over nickel underplate
Heatsink (optional)
See page 8
SAFETY
Safety Approvals (pending)
10/31/2012
UL/cUL 60950-1 recognition (CSA certificate), IEC/EN 60950-1 (CB-scheme)
Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 3 of 12
DHW40 Series
Single & Dual Outputs
4:1 Ultra Wide Input Ranges
40 Watt DC/DC Power Converters
Rev. A
MODEL SELECTION TABLE
SINGLE OUTPUT MODELS
Model Number Input Voltage
Output
Voltage
DHW24S3.3-26
Output Current
Input Current
Output
Power
Efficiency
Maximum
Capacitive Load
3.9 VDC
26.4W
89%
21000µF
6.2 VDC
40W
90%
13600µF
1.87A
15 VDC
40W
89%
2400µF
105mA
1.87A
18 VDC
40W
89%
1500µF
8A
55mA
620mA
3.9 VDC
26.4W
89%
21000µF
8A
55mA
930mA
6.2 VDC
40W
90%
13600µF
930mA
15 VDC
40W
90%
2400µF
930mA
18 VDC
40W
90%
1500µF
Output
Power
Efficiency
Maximum (1)
Capacitive Load
±15 VDC
40W
88%
1200µF*
±18 VDC
40W
88%
750µF*
±15 VDC
40W
88%
1200µF*
±18 VDC
40W
88%
750µF*
Min
Max
3.3 VDC
0mA
8A
90mA
1.24A
24 VDC
5 VDC
0mA
8A
90mA
1.85A
(9 – 36 VDC)
12 VDC
0mA
3.33A
95mA
DHW24S15-40
15 VDC
0mA
2.67A
DHW48S3.3-26
3.3 VDC
0mA
48 VDC
5 VDC
0mA
(18 – 75 VDC)
12 VDC
0mA
3.33A
60mA
15 VDC
0mA
2.67A
65mA
DHW24S5-40
DHW24S12-40
DHW48S5-40
DHW48S12-40
DHW48S15-40
No Load Max Load
Reflected Ripple Over Voltage
Current (Typ)
Protection
30mA
20mA
DUAL OUTPUT MODELS
Model Number Input Voltage
Output
Voltage
Output Current
Min
Max
Input Current
Reflected Ripple Over Voltage
Protection
No Load Max Load Current (Typ)
24 VDC
±12 VDC ±145mA ±1.67A
DHW24D15-40
(9 – 36 VDC)
±15 VDC ±110mA ±1.33A
65mA
1.89A
DHW48D12-40
48 VDC
±12 VDC ±145mA ±1.67A
45mA
950mA
DHW24D12-40
DHW48D15-40
65mA
1.89A
30mA
(18 – 75 VDC) ±15 VDC ±110mA ±1.33A
20mA
45mA
950mA
NOTES
1. “*” for each output
2. Transient recovery time is measured to within 1% error band for a step change in output load from 75% to 100%.
3. All DC/DC converters should be externally fused at the front end for protection.
4. To order the converter with a heatsink, please add the suffix “HS” to the model number. (Ex: DHW24S12-40HS)
5. To order the converter without Remote on/off control, please add the suffix “N” to the model number. (Ex: DHW24S12-40N)
Due to advances in technology, specifications subject to change without notice.
EMI-FILTER TO MEET EN55022, CLASS A; FCC PART 15, LEVEL A
Conducted and Radiated Emissions EN55022 Class A
Part No
DHW24SXX-40
DHW48SXX-40
Part No
DHW24DXX-40
DHW48DXX-40
C1
4.7µF/50V 1812 MLCC
2.2µF/100V 1812 MLCC
C1
4.7µF/50V 1812 MLCC
2.2µF/100V 1812 MLCC
C2, C3
1000pF/2KV 1808 MLCC
1000pF/2KV 1808 MLCC
C2, C4
1000pF/2KV 1808 MLCC
1000pF/2KV 1808 MLCC
10/31/2012
Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 4 of 12
DHW40 Series
Single & Dual Outputs
4:1 Ultra Wide Input Ranges
40 Watt DC/DC Power Converters
Rev. A
POWER DERATING CURVES
DHW24S3.3-26, DHW48S3.3-26
Derating Curve without Heatsink
DHW24S3.3-26, DHW48S3.3-26
Derating Curve with Heatsink
DHW24S5-40, DHW48S5-40, DHW48S12-40, DHW48S15-40
Derating Curve without Heatsink
DHW24S5-40, DHW48S5-40, DHW48S12-40, DHW48S15-40
Derating Curve with Heatsink
DHW24S12-40, DHW24S15-40
Derating Curve without Heatsink
DHW24S12-40, DHW24S15-40
Derating Curve with Heatsink
DHW24D12-40, DHW24D15-40, DHW48D12-40, DHW48D15-40
Derating Curve without Heatsink
DHW24D12-40, DHW24D15-40, DHW48D12-40, DHW48D15-40
Derating Curve with Heatsink
10/31/2012
Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 5 of 12
DHW40 Series
Single & Dual Outputs
4:1 Ultra Wide Input Ranges
40 Watt DC/DC Power Converters
Rev. A
EFFICIENCY CURVES @ 25°C (24VDC INPUT MODELS)
10/31/2012
DHW24S3.3-26 Efficiency vs Load Current
DHW24S5-40 Efficiency vs Load Current
DHW24S12-40 Efficiency vs Load Current
DHW24S15-40 Efficiency vs Load Current
DHW24D12-40 Efficiency vs Load Current
DHW24D15-40 Efficiency vs Load Current
Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 6 of 12
DHW40 Series
Single & Dual Outputs
4:1 Ultra Wide Input Ranges
40 Watt DC/DC Power Converters
Rev. A
EFFICIENCY CURVES @ 25°C (48VDC INPUT MODELS)
10/31/2012
DHW48S3.3-26 Efficiency vs Load Current
DHW48S5-40 Efficiency vs Load Current
DHW48S12-40 Efficiency vs Load Current
DHW48S15-40 Efficiency vs Load Current
DHW48D12-40 Efficiency vs Load Current
DHW48D15-40 Efficiency vs Load Current
Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 7 of 12
Rev. A
DHW40 Series
Single & Dual Outputs
4:1 Ultra Wide Input Ranges
40 Watt DC/DC Power Converters
MECHANICAL DRAWING
10/31/2012
Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 8 of 12
DHW40 Series
Single & Dual Outputs
4:1 Ultra Wide Input Ranges
40 Watt DC/DC Power Converters
Rev. A
EXTERNAL OUTPUT TRIM
Output can be externally trimmed by using the method shown below
DHWXXS3.3-26 TRIM TABLE
DHWXXS5-40 TRIM TABLE
Trim
Trimup
Rup
Trimdown
Rdown
Trim
Trimup
Rup
Trimdown
Rdown
1%
3.333V
70.50kΩ
3.267V
63.59kΩ
1%
5.050V
36.57kΩ
4.950V
45.53kΩ
2%
3.366V
29.28kΩ
3.234V
30.28kΩ
2%
5.100V
16.58kΩ
4.900V
20.61kΩ
3%
3.399V
16.87kΩ
3.201V
18.19kΩ
3%
5.150V
9.92kΩ
4.850V
12.31kΩ
4%
3.432V
10.90kΩ
3.168V
11.95kΩ
4%
5.200V
6.59kΩ
4.800V
8.15kΩ
5%
3.465V
7.38kΩ
3.135V
8.13kΩ
5%
5.250V
4.59kΩ
4.750V
5.66kΩ
6%
3.498V
5.06kΩ
3.102V
5.56kΩ
6%
5.300V
3.25kΩ
4.700V
4.00kΩ
7%
3.531V
3.42kΩ
3.069V
3.70kΩ
7%
5.350V
2.30kΩ
4.650V
2.81kΩ
8%
3.564V
2.20kΩ
3.036V
2.31kΩ
8%
5.400V
1.59kΩ
4.600V
1.92kΩ
9%
3.597V
1.25kΩ
3.003V
1.21kΩ
9%
5.450V
1.03kΩ
4.550V
1.23kΩ
10%
3.630V
0.49kΩ
2.970V
0.34kΩ
10%
5.500V
0.59kΩ
4.500V
0.68kΩ
DHWXXS12-40 TRIM TABLE
DHWXXS15-40 TRIM TABLE
Trim
Trimup
Rup
Trimdown
Rdown
Trim
Trimup
Rup
Trimdown
Rdown
1%
12.120V
368.92kΩ
11.880V
394.50kΩ
1%
15.150V
392.98kΩ
14.850V
572.67kΩ
2%
12.240V
161.92kΩ
11.760V
179.74kΩ
2%
15.300V
182.12kΩ
14.700V
248.63kΩ
3%
12.360V
94.97kΩ
11.640V
106.08kΩ
3%
15.450V
108.73kΩ
14.550V
145.60kΩ
4%
12.480V
61.86kΩ
11.520V
68.86kΩ
4%
15.600V
71.43kΩ
14.400V
94.97kΩ
5%
12.600V
42.12kΩ
11.400V
46.39kΩ
5%
15.750V
48.85kΩ
14.250V
64.87kΩ
6%
12.720V
29.00kΩ
11.280V
31.36kΩ
6%
15.900V
33.71kΩ
14.100V
44.92kΩ
7%
12.840V
19.66kΩ
11.160V
20.60kΩ
7%
16.050V
22.86kΩ
13.950V
30.72kΩ
8%
12.960V
12.66kΩ
11.040V
12.51kΩ
8%
16.200V
14.69kΩ
13.800V
20.10kΩ
9%
13.080V
7.23kΩ
10.920V
6.21kΩ
9%
16.350V
8.33kΩ
13.650V
11.86kΩ
10%
13.200V
2.89kΩ
10.800V
1.17kΩ
10%
16.500V
3.23kΩ
13.500V
5.28kΩ
10/31/2012
Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 9 of 12
Rev. A
DHW40 Series
Single & Dual Outputs
4:1 Ultra Wide Input Ranges
40 Watt DC/DC Power Converters
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 100 KHz)
to simulate source impedance. Capacitor Cin offsets possible battery impedance.
Current ripple is measured at the input terminals of the module. Measurement bandwidth is 0-500 KHz.
Peak-to-Peak Output Noise Measurement Test
Use a 1µF ceramic capacitor and a 10µF tantalum 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.
DESIGN & FEATURE CONSIDERATIONS
Remote On/Off
Positive logic remote on/off turns the module on during a logic high voltage on the remote on/off pin and off during
a logic low. To turn the 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 0V to 1.2V. A
logic high is 4.7V to 12V. The maximum sink current at on/off terminal (Pin 3) during a logic low is -100µA. The
maximum allowable leakage current of a switch connected to the on/off terminal (Pin 3) at logic high (2.5V to
100V) is 5µA.
Over Current Protection
To provide protection in a fault (output overload) condition, the unit is equipped with internal current limiting
circuitry and can endure overload for an unlimited duration.
Over Voltage Protection
The output over voltage clamp consists of control circuitry which is independent of 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 output over voltage. The OVP level
can be found in the model selection table.
10/31/2012
Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 10 of 12
Rev. A
DHW40 Series
Single & Dual Outputs
4:1 Ultra Wide Input Ranges
40 Watt DC/DC Power Converters
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.
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 10µF for the 24V and 48V
devices.
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.
Maximum Capacitive Load
The DHW40 series has a limitation of maximum connected capacitance on the output. The power module may be
operated in current limiting mode during start-up, affecting the ramp-up and the start-up time. The maximum
capacitance can be found in the model selection table.
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 a test setup.
10/31/2012
Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 11 of 12
Rev. A
DHW40 Series
Single & Dual Outputs
4:1 Ultra Wide Input Ranges
40 Watt DC/DC Power Converters
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:
10/31/2012
(603)778-2300
(888)597-9255
(603)778-9797
[email protected]
www.wallindustries.com
5 Watson Brook Rd.
Exeter, NH 03833
Wall Industries, Inc. 37 Industrial Drive Exeter, NH 03833
603-778-2300 www.wallindustries.com Fax 603-778-9797
Page 12 of 12