DMW Ultra Wide Series Single and Dual Output 4:1 Ultra Wide Input Voltage Range Up to 15.3 Watts DC/DC Converters Rev C FEATURES ● 1500VDC Isolation ● Six-Sided Shielding ● Efficiency up to 86% ● MTBF > 700,000 Hours ● Internal SMT Construction ● 4:1 Ultra Wide Input Range ● UL 94V-0 Package Material ● UL60950-1 Safety Approval ● Complies with EN55022 Class A ● Positive Remote On/Off Control (Optional) DESCRIPTION The DMW series of DC/DC converters provide up to 15 watts in a 2 x 1 x 0.4 inch package. These converters operate over 4:1 wide input voltage ranges of 9-36VDC and 18-75VDC. This series also has single and dual output models available. These converters feature efficiency up to 86%, positive remote ON/OFF (optional), six-sided shielding, 1500VDC isolation, and short circuit protection. This series is ideal for data communication equipment, mobile battery driven equipment, process/machine control equipment, telecommunication equipment, computer peripheral systems, distributed power systems, mixed analog/digital subsystems, and industrial robot systems. The EN55022 Class A conducted noise compliance minimizes design time, cost, and eliminates the need for external filter components. SPECIFICATIONS: DMW Ultra Wide 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 INPUT (Vin) Operating Voltage Range Start Voltage Under Voltage Shutdown TEST CONDITIONS Min Nom Max Unit 24V nominal input models 48V nominal input models 24V nominal input models 48V nominal input models 24V nominal input models 48V nominal input models 9 18 8 15 7 13 24 48 8.5 17 8 15 24V nominal input models 48V nominal input models -0.7 -0.7 36 75 9 18 8.5 17 1 3500 50 100 VDC VDC VDC VDC VDC VDC A mW VDC VDC Reverse Polarity Input Current Short Circuit Input Power Input Surge Voltage (1000ms) Input Filter OUTPUT (Vo) Output Voltage Range Output Voltage Accuracy Output Voltage Balance Load Regulation Line Regulation Output Power Output Current Range Ripple & Noise (peak to peak) Ripple & Noise (peak to peak) Ripple & Noise Transient Recovery Time (See Note 1) Transient Response Deviation POSITIVE REMOTE ON/OFF (See Note 5) Supply On Supply Off Standby Input Current Control Input Current (On) Control Input Current (Off) Control Common PROTECTION Over Power Protection Short Circuit Protection Input Fuse Recommendation GENERAL Efficiency Switching Frequency Isolation Voltage Rated Isolation Voltage Test Isolation Resistance Isolation Capacitance Internal Power Dissipation ENVIRONMENTAL Operating Temperature (Ambient) Operating Temperature (Case) Storage Temperature Lead Temperature Humidity Cooling RFI Temperature Coefficient MTBF Conducted EMI PHYSICAL Weight Dimensions Case Material Flammability 02/24/2010 Pi Filter See Table ±1.0 ±2.0 ±0.5 ±2.0 ±0.5 ±1.0 ±0.1 ±0.5 15 See Table 55 80 100 15 300 500 ±2 ±4 Dual Output, Balanced Loads Io = 10% to 100% Vin = min. to max. 20MHz bandwidth Over Line, Load, and Temperature 25% load step change 25% load step change -0.7 Vin – RC = 5.0V Vin – RC = 0V 290 1500 1650 1000 % See Table 330 400 1200 -40 -40 -50 MIL-HDBK-217F @ 25°C, Ground Benign VDC mA mA mA Continuous 2500mA Slow-Blow Type 1250mA Slow-Blow Type 24V nominal input models 48V nominal input models 1.5mm from case for 10 seconds mVpk-pk mVpk-pk mVrms μs % 2.5 to 5.5VDC or Open Circuit 0.8 10 50 -1 Referenced to negative input 120 60 seconds Flash Test for 1 second 500VDC 100KHz, 1V % % % % W 1500 5,000 KHz VDC VDC MΩ pF mW +60 °C +100 °C +125 °C 260 °C 95 % Free air convection Six-sided shielding, metal case ±0.01 ±0.02 %/°C 700,000 hours EN55022 Class A 1.13oz (32g) 2.0 x 1.0 x 0.4 inches (50.8 x 25.4 x 10.2 mm) Metal with non-conductive baseplate UL94V-0 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 1 of 6 DMW Ultra Wide Series Single and Dual Output 4:1 Ultra Wide Input Voltage Range Up to 15.3 Watts DC/DC Converters Rev C MODEL SELECTION TABLE Model Number Input Voltage DMW24S3.3-3000 Output Voltage 3.3 VDC Output Current Min Max 300mA 3000mA Input Current Reflected No Load Max Load Ripple Current 528mA Output Power Efficiency (Typ) Max Capacitive Load 470μF 9.9W 78% 5 VDC 300mA 3000mA 762mA 15W 82% 470μF 5.1 VDC 300mA 3000mA 735mA 15.3W 81% 470μF 12 VDC 125mA 1250mA 15W 85% 470μF 15 VDC 100mA 1000mA 15W 86% 470μF DMW24D5-1500 ±5 VDC ±150mA ±1500mA 735mA 15W 81% 220μF DMW24D12-625 ±12 VDC ±62.5mA ±625mA 726mA 15W 85% 220μF DMW24D15-500 ±15 VDC ±50mA ±500mA 787mA 15W 86% 220μF DMW48S3.3-3000 3.3 VDC 300mA 3000mA 26mA 9.9W 78% 470μF 5 VDC 300mA 3000mA 381mA 15W 82% 470μF 5.1 VDC 300mA 3000mA 368mA 15.3W 81% 470μF 12 VDC 125mA 1250mA 363mA 15W 85% 470μF 15 VDC 100mA 1000mA 15W 86% 470μF DMW48D5-1500 ±5 VDC ±150mA ±1500mA 368mA 15W 81% 220μF DMW48D12-625 ±12 VDC ±62.5mA ±625mA 363mA 15W 85% 220μF DMW48D15-500 ±15 VDC ±50mA ±500mA 393mA 15W 86% 220μF DMW24S5-3000 DMW24S5.1-3000 DMW24S12-1250 DMW24S15-1000 24 VDC (9 ~ 36 VDC) DMW48S5-3000 DMW48S5.1-3000 DMW48S12-1250 DMW48S15-1000 48 VDC (18 ~ 75 VDC) 25mA (typ) 15mA (typ) 726mA 40mA (typ) 771mA 30mA (typ) 386mA 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 DMW series requires a minimum output load to maintain specified regulations. Operation under no-load condition 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. Only positive control logic remote On/Off is available. To order the converter with positive remote on/off add the suffix “RC” to the part number. 6. To order the converter with EN55022 Class A function, please add the suffix “A” to the part number. 7. To order the converter with a heatsink please add the suffix “HS” to the part number. BLOCK DIAGRAMS Single Output Dual Output +Vo LC Filter +Vin +Vin +Vo LC Filter Com. -Vo PWM -Vin Isolation -Vo Ref.Amp -Vin PWM Isolation Ref.Amp INPUT VOLTAGE TRANSIENT RATING 130 125 120 115 48VDC Input Models 110 100 ~ Vin (VDC) 105 80 75 70 65 24VDC Input Models 60 55 50 45 40 10µs 02/24/2010 100µs 1ms 10ms 100ms Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 2 of 6 DMW Ultra Wide Series Single and Dual Output 4:1 Ultra Wide Input Voltage Range Up to 15.3 Watts DC/DC Converters Rev C Efficiency vs Input Voltage (Dual Output) 100 100 90 90 Efficiency (%) Efficiency (%) Efficiency vs Input Voltage (Single Output) 80 70 60 80 70 60 50 Low 50 Nom Low High Nom Input Voltage (V) Efficiency vs Output Load (Dual Output) 90 90 80 80 70 70 Efficiency (%) Efficiency (%) Efficiency vs Output Load (Single Output) 60 60 50 50 40 40 30 30 10 20 40 60 80 40 100 400LFM 400LFM 100LFM 200LFM Output Power (%) 80 Natural Convection 200LFM Natural Convection 60 40 20 20 ~ ~ 0 50 60 70 80 90 100 110 -40 50 Ambient Temperature (°C) 02/24/2010 100 80 60 Derating Curve with Heatsink 40 -40 20 Derating Curve without Heatsink 80 0 10 Load Current (%) 100LFM 60 100 Load Current (%) 100 Output Power (%) High Input Voltage (V) Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 60 70 80 90 100 110 Ambient Temperature (°C) Page 3 of 6 DMW Ultra Wide Series Single and Dual Output 4:1 Ultra Wide Input Voltage Range Up to 15.3 Watts DC/DC Converters Rev C MECHANICAL DRAWING STANDARD WITH HEATSINK Unit: inches (mm) Unit: inches (mm) 0.402 (10.20) 0.1 (2.5) 0.91 (23.0) 0.402 (10.20) 4 5 0.14 (3.5) x 4 2 Side 2.00 (50.8) 0.800 ( 20.30) Bottom 1 Ø 0.039 ( Ø1.00) 3 6 0.68 (17.2) max 0.60 ( 15.2) 1.22 (31.0) max Heatsink Thermal Pad 0.200 (50.8) Clamp 0.40 (10.2) Converter 0.40 (10.2) 0.24 (6.0) 1.00 (25.4) 1. Tolerance: X.XX±0.01 (X.X±0.25) X.XXX±0.005 (X.XX±0.13) Heatsink Specifications 2. Pin: ±0.002 (±0.05) Heatsink Material: Aluminum 1. Tolerance: X.XX±0.01 (X.X±0.25) X.XXX±0.005 (X.XX±0.13) 2. Pin: ±0.002 (±0.05) Finish: Anodic treatment (black) Weight: 0.07oz (2g) PIN CONNECTIONS Pin Single Output Dual Output 1 +Vin +Vin The Advantages of adding a Heatsink: 2 -Vin -Vin 3 +Vout +Vout 1. To help heat dissipation and increase the stability and reliability of DC/DC converters at high operating temperature atmosphere. 4 No Pin Common 5 -Vout -Vout 6 2. To upgrade the operating temperature of DC/DC converters, please refer to the Derating Curve. *Positive Remote ON/OFF (Optional) *Add the suffix “RC” to the part number for Remote On/Off option The DMW 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. 02/24/2010 Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Page 4 of 6 DMW Ultra Wide Series Single and Dual Output 4:1 Ultra Wide Input Voltage Range Up to 15.3 Watts DC/DC Converters Rev C 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 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 -0.7V to 0.8V. A logic high is 2.5V to 5.5V. The maximum sink current at on/off terminal during a logic low is -1mA. The maximum allowable leakage current of the switch at on/off terminal (2.5 to 5.5V) is 50µA. 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. 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 6.8µF for the 24V and 48V input devices. + +Vin +Out + DC Power Source DC / DC Converter Load Cin -Vin - -Out Maximum Capacitive Load The DMW 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 220µF maximum capacitive load for dual outputs and 470µF capacitive load for single outputs. The maximum capacitance can be found in the Model Selection Guide. 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 0-500 KHz. To Oscilloscope + Battery + +Vin Lin Cin Current Probe +Out DC / DC Converter -Vin Load -Out Peak-to-Peak Output Noise Measurement Test Use a Cout 0.47µF ceramic capacitor. Scope measurement should be made by using a BNC socket; measurement bandwidth is 0-20 MHz. Position the load between 50 mm and 75 mm from the DC/DC converter. +Vin +Out Single Output DC / DC Converter -Vin 02/24/2010 Copper Strip Cout -Out Copper Strip +Vin Resistive Scope Load +Out Copper Strip Cout Dual Output DC / DC Converter Com. Copper Strip -Vin -Out Copper Strip Cout Wall Industries, Inc. 5 Watson Brook Road Exeter, NH 03833 603-778-2300 www.wallindustries.com Fax 603-778-9797 Scope Resistive Load Scope Page 5 of 6 DMW Ultra Wide Series Single and Dual Output 4:1 Ultra Wide Input Voltage Range Up to 15.3 Watts DC/DC Converters Rev C 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 - + -Vin +Vin Cout Load -Out +Out Dual Output DC / DC Com. Converter DC Power Source - +Out -Vin Cout Load Load Cout -Out 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 100°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 ISO9001-2008 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: 02/24/2010 (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 6 of 6