Rev A MM Series Single and Dual Output 2:1 Input Voltage Range 25~30 Watt DC/DC Converter FEATURES ● Soft Start ● Output Trim ● 1500VDC Isolation ● 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) ● CSA60950-1 Safety Approval ● 2:1 Wide Input Voltage Range ● Complies with EN55022 Class A ● Short Circuit, Over Voltage, and Over Temperature Protected DESCRIPTION The MM 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 9-18VDC, 18-36VDC, and 36-75VDC. 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 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. SPECIFICATIONS: MM 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) 12V nominal input models 9 12 18 VDC Input Voltage Range 24V nominal input models 18 24 36 VDC 48V nominal input models 36 48 75 VDC 12V nominal input models 8.6 8.8 9 VDC Start Voltage 24V nominal input models 17 17.5 18 VDC 48V nominal input models 34 35 36 VDC 12V nominal input models 8.1 8.3 8.5 VDC Under Voltage Shutdown 24V nominal input models 16 16.5 17 VDC 48V nominal input models 32 33 34 VDC Reverse Polarity Input Current All models 2 A Short Circuit Input Power 4500 mW 12V nominal input models -0.7 25 VDC Input Surge Voltage 24V nominal input models -0.7 50 VDC 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 Output, Balanced Loads ±0.5 ±2.0 % Output Trim ±10 % Load Regulation Io = 10% to 100% ±0.1 ±0.5 % Line Regulation Vin = min. to max. ±0.1 ±0.3 % 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 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 MM Series Single and Dual Output 2:1 Input Voltage Range 25~30 Watt DC/DC Converter Rev A SPECIFICATION PROTECTION Over Power Protection Short Circuit Protection TEST CONDITIONS Min 110 12V nominal input models 24V nominal input models 48V nominal input models Input Fuse Recommendation 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 290 1500 1650 1000 60 seconds Flash Test for 1 second 500VDC 100KHz, 1V Nom Max Unit 160 Continuous 6000mA slow-blow type 3000mA slow-blow type 1500mA slow-blow type See Rating Chart 330 360 1200 1500 5,500 See Rating Chart % KHz VDC VDC MΩ pF mW -40 -40 -50 107 Case Temperature, automatic 1.5mm from case for 10 seconds MIL-HDBK-217F @ 25°C, Ground Benign +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 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) Dimensions (L x W x H) Case Material Flammability Heatsink material Heatsink finish OUTPUT VOLTAGE / CURRENT RATING CHART SINGLE OUTPUT MODELS Model Number MM12S3.3-5500 MM12S5-5000 MM12S12-2500 MM12S15-2000 MM24S3.3-5500 MM24S5-5000 MM24S12-2500 MM24S15-2000 MM48S3.3-5500 MM48S5-5000 MM48S12-2500 MM48S15-2000 Model Number MM12D12-1250 MM12D15-1000 MM24D12-1250 MM24D15-1000 MM48D12-1250 MM48D15-1000 Input Voltage Output Current Input Current Reflected Efficiency (Typ) Min Max No Load Max Load Ripple Current 400 mA 5500 mA 1867 mA 81% 350 mA 5000 mA 2480 mA 84% 40 mA 100 mA 166 mA 2500 mA 2841 mA 88% 133 mA 2000 mA 2841 mA 88% 300 mA 5500 mA 922 mA 82% 300 mA 5000 mA 1225 mA 85% 20 mA 50 mA 300 mA 2500 mA 1404 mA 89% 125 mA 2000 mA 1404 mA 89% 300 mA 5500 mA 461 mA 82% 300 mA 5000 mA 613 mA 85% 10 mA 25 mA 300 mA 2500 mA 702 mA 89% 125 mA 2000 mA 702 mA 89% Output Voltage 3.3 VDC 5 VDC 12 VDC 15 VDC 3.3 VDC 24 VDC 5 VDC (18 ~ 36 VDC) 12 VDC 15 VDC 3.3 VDC 48 VDC 5 VDC (36 ~ 75 VDC) 12 VDC 15 VDC 12 VDC (9 ~ 18 VDC) DUAL OUTPUT MODELS Output Current Input Current Output Input Voltage Voltage ±12 VDC ±15 VDC ±12 VDC 24 VDC (18 ~ 36 VDC) ±15 VDC ±12 VDC 48 VDC (36 ~ 75 VDC) ±15 VDC 12 VDC (9 ~ 18 VDC) Min Max ±83 ±65 ±83 ±65 ±83 ±65 ±1250 ±1000 ±1250 ±1000 ±1250 ±1000 Reflected Efficiency (Typ) No Load Max Load Ripple Current 40mA 40mA 20mA 20mA 10mA 10mA 2841 mA 2841 mA 1404 mA 1404 mA 702 mA 702 mA 100mA 50mA 25mA # For each output Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 88% 88% 89% 89% 89% 89% Over Voltage Maximum Protection Capacitive Load 3.9 VDC 6.8 VDC 15 VDC 18 VDC 3.9 VDC 6.8 VDC 15 VDC 18 VDC 3.9 VDC 6.8 VDC 15 VDC 18 VDC Over Voltage Protection ±15 VDC ±18 VDC ±15 VDC ±18 VDC ±15 VDC ±18 VDC 470 μF 470 μF 470 μF 470 μF 470 μF 470 μF 470 μF 470 μF 470 μF 470 μF 470 μF 470 μF Maximum Capacitive Load 220 μF # 220 μF # 220 μF # 220 μF # 220 μF # 220 μF # MM Series Single and Dual Output 2:1 Input Voltage Range 25~30 Watt DC/DC Converter Rev A 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 MM 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. Heat-sink is optional, please consult factory for ordering details. Due to advances in technology, specifications subject to change without notice. BLOCK DIAGRAMS Single Output +Vin Dual Output +Vo LC Filter +Vin +Vo LC Filter Com. -Vo OVP OTP -Vo OVP OTP OVP -Vin OVP -Vin PWM On/Off Isolation Ref.Amp On/Off Trim PWM Isolation Ref.Amp Trim INPUT VOLTAGE TRANSIENT RATING 150 140 130 48VDC Input Models 120 110 Vin ( VDC ) 100 90 80 24VDC Input Models 70 60 50 12VDC Input Models 40 30 20 10 0 10uS 100uS 1mS 10mS Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 100mS MM Series Single and Dual Output 2:1 Input Voltage Range 25~30 Watt DC/DC Converter Rev A DERATING CURVES & EFFICIENCY GRAPHS Efficiency vs Input Voltage (Single Output) Efficiency vs Input Voltage (Dual Output) 100 100 90 Efficiency (%) Efficiency (%) 90 80 70 80 70 60 60 50 Low Nom 50 High Low Nom Input Voltage (V) Input Voltage (V) Efficiency vs Output Load (Single Output) Efficiency vs Output Load (Dual Output) 100 100 90 90 80 80 Efficiency (%) Efficiency (%) High 70 60 50 70 60 50 40 40 30 10 20 40 60 80 30 100 10 20 40 80 60 Load Current (%) Load Current (%) Derating Curve without Heatsink Derating Curve with Heatsink 100 100 100 400LFM 400LFM 80 Natural convection 100LFM Output Power (%) Output Power (%) 80 60 Natural convection 200LFM 40 200LFM 60 100LFM 40 20 20 0 ~ ¡ã 0 -40 50 60 70 80 90 100 110 ~ -40 50 60 Ambient Temperature (°C) Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 70 80 Ambient Temperature (°C) 90 100 110 MM Series Single and Dual Output 2:1 Input Voltage Range 25~30 Watt DC/DC Converter Rev A MECHANICAL DRAWINGS Standard With Heatsink Unit: mm [inches] 40.6 [1.60] 7 9.3[0.37] 8 16.3[0.64]Max Side 0.039] Bottom 50.8 [2.00] 6 45.70 [1.801] 5 6.0 [0.24] 5.0 [0.20] 23.0[0.91] 10.20 [0.402] 10.20 [0.402] 10.20 [0.402] 55.32[2.18]Max 1.00[ Heat-sink 1 2 Thermal pad 4 Clamp Converter 2.5 [0.10] 7.6 [0.30] 5.10 [0.201] 1. Tolerance: X.X±0.25 [X.XX±0.01] X.XX±0.13 [X.XXX±0.005] 2. Pin: ±0.05 [±0.002] Advantages of adding a Heatsink: PIN CONNECTIONS PIN SINGLE OUTPUT DUAL OUTPUT 1 +Vin +Vin 2 -Vin -Vin 4 Remote ON/OFF Remote ON/OFF 5 No Pin +Vout 6 +Vout Common 7 -Vout -Vout 8 Trim Trim 1. To help heat dissipation and increase the stability and reliability of the DC/DC converter at high operating temperature 2. To upgrade the operating temperature of the DC/DC converter. Please refer to the Derating Curve. The MM Series converter is encapsulated in a low thermal resistance molding compound that has excellent resistance/electrical characteristics over a wide temperature range or in high humidity environments. The encapsulant and unit case are both rated to UL 94V-0 flammability specifications. Leads are tin plated for improved solderability. Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 MM Series Single and Dual Output 2:1 Input Voltage Range 25~30 Watt DC/DC Converter Rev A DESIGN & FEATURE CONSIDERATONS 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 10K -Out Trim Up Enable Trim Up/Down 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: 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 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. Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 MM Series Single and Dual Output 2:1 Input Voltage Range 25~30 Watt DC/DC Converter Rev A 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 12V input models and a 10μF for the 24V and 48V input models. + +Vin + DC Power Source +Out DC / DC Converter Load Cin - -Vin -Out Maximum Capacitive Load The MM 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. To Oscilloscope + + Battery +Vin Lin Cin Current Probe +Out DC / DC Converter -Vin Load -Out Capacitor Cin offsets possible battery impedance. Current ripple is measured at the input terminals of the module. Measurement bandwidth is 0 ~ 500KHz. 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 Single Output DC / DC Converter -Vin Copper Strip Cout -Out +Vin Resistive Scope Load +Out Copper Strip Cout Dual Output DC / DC Converter Com. -Vin -Out Resistive Load Cout Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Scope Scope MM Series Single and Dual Output 2:1 Input Voltage Range 25~30 Watt DC/DC Converter Rev A 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 Com. DC / DC 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 50mm / 2in 15mm / 0.6in Air Flow DUT 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, 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