FEATURES ►Smallest Encapsulated 40W Converter! ►Package Size 2.0”x 1.0”x 0.4” ►Wide 2:1 lnput Range ►Excellent Efficiency up to 92% ►Operating Temp. Range -40°C to +80°C ►Over-temperature Protection ►I/O-isolation Voltage 1500VDC ►Remote On/Off Control ►Shielded Metal Case with Isolated Baseplate ► Heatsink (Optional) ► CSA/UL/IEC/EN 60950-1 Safety Approval ►3 Years Product Warranty PRODUCT OVERVIEW The MKW40 series is a new generation of high performance dc-dc converter modules setting a new standard concerning power density. The product offers fully 40W in an encapsulated, shielded metal package with dimensions of just 2.0”x1.0”x0.4”. All models provide wide 2:1 input voltage range and precisely regulated output voltages. Advanced circuit topology provides a very high efficiency up to 92% which allows an operating temperature range of -40°C to +80°C. Further features include remote On/Off, trimmable output voltage, under-voltage shutdown as well as overload and over-temperature protection. Typical applications for these converters are battery operated equipment, instrumentation,distributed power architectures in communication and industrial electronics and many other space critical applications. Model Selection Guide Model Input Output Number Voltage Voltage (Range) VDC MKW40-12S033 MKW40-12S05 MKW40-12S12 MKW40-12S15 MKW40-12S24 MKW40-12D12 MKW40-12D15 MKW40-24S033 MKW40-24S05 MKW40-24S12 MKW40-24S15 MKW40-24S24 MKW40-24D12 MKW40-24D15 MKW40-48S033 MKW40-48S05 MKW40-48S12 MKW40-48S15 MKW40-48S24 MKW40-48D12 MKW40-48D15 12 (9 ~ 18) 24 (18 ~ 36) 48 (36 ~ 75) VDC 3.3 5 12 15 24 ±12 ±15 3.3 5 12 15 24 ±12 ±15 3.3 5 12 15 24 ±12 ±15 Output Current Input Current Reflected Over Max. capacitive Ripple Voltage Load Max. Min. @Max. Load @No Load Current Protection mA 8000 8000 3330 2670 1670 ±1670 ±1330 8000 8000 3330 2670 1670 ±1670 ±1330 8000 8000 3330 2670 1670 ±1670 ±1330 mA 0 0 0 0 0 ±145 ±110 0 0 0 0 0 ±145 ±110 0 0 0 0 0 ±145 ±110 mA(typ.) 2470 3750 3750 3700 3790 3790 3790 1220 1830 1830 1830 1850 1870 1870 610 920 910 910 920 940 940 mA(typ.) 120 160 160 150 160 70 60 75 80 85 75 85 50 45 40 50 50 50 50 65 65 mA (typ.) VDC 3.9 6.2 15 18 30 ±15 ±18 3.9 6.2 15 18 30 ±15 ±18 3.9 6.2 15 18 30 ±15 ±18 50 30 20 Toll Free: 877-646-0900 (typ.) @Max. Load μF 21000 13600 2400 1500 600 1200# 750# 21000 13600 2400 1500 600 1200# 750# 21000 13600 2400 1500 600 1200# 750# # For each output In Total Power International, Inc Efficiency www.total-power.com % 89 89 89 90 88 88 88 90 91 91 91 90 89 89 90 91 92 92 90 89 89 MKW40 SERIES Tota Total Power International, Inc. DC/DC CONVERTER 40W, Highest Power Density Input Specifications Parameter Input Surge Voltage (1 sec. max.) Start-Up Threshold Voltage Under Voltage Lockout Input Polarity Protection Power Up Remote On/Off Start Up Time Internal Filter Type Short Circuit Current Model 12V Input Models 24V Input Models 48V Input Models 12V Input Models 24V Input Models 48V Input Models 12V Input Models 24V Input Models 48V Input Models Min. -0.7 -0.7 -0.7 Typ. ------------8.3 16.5 33 Max. 25 50 100 Min. --------- Typ. --------- ----- ----- Max. ±1.0 ±2.0 ±0.5 ±0.5 ±1.0 ±5.0 Unit --9 VDC --18 --36 ------------None ----30 ms Nominal Vin and Constant Resistive Load ----30 ms All Models LC Filter (for EN55022,Class A compliance see page 8) --- (Hiccup Mode 1.5 Hz typ.) Output Specifications Parameter Output Voltage Setting Accuracy Output Voltage Balance Line Regulation Load Regulation Load Cross Regulation (Dual Output) Minimum Load Ripple & Noise (20MHz) Ripple & Noise (20MHz) Ripple & Noise (20MHz) Transient Recovery Time Temperature Coefficient Over Load Protection Short Circuit Protection Over Voltage Protection Conditions At 50% Load and Nominal Vin Dual Output, Balanced Loads Vin=Min. to Max. Single Output Min. Load to Full Load Dual Output Asymmetrical Load 25%/100% Full Load Unit %Vnom. % % % % % No Minimum Load Requirement for Single Output Models, for dual Output Models see Table 3.3V & 5V Output Models --100 --mV P-P 12V, 15V & 24V Models --150 --mV P-P Dual Output Models --150 --mV P-P 25% Load Step Change --250 --μsec ----±0.02 %/℃ Current Limitation at 150% typ. of Iout max., Hiccup Hiccup Automatic Recovery For Shutdown Voltage see Model Selection Guide General Specifications Parameter I/O Isolation Voltage (rated) I/O Isolation Resistance I/O Isolation Capacitance Switching Frequency MTBF(calculated) Safety Approvals Conditions 60 Seconds 500 VDC 100KHz, 1V Min. Typ. Max. 1500 ----1000 --------1500 --320 --MIL-HDBK-217F@25℃, Ground Benign 328,000 ----UL/cUL 60950-1 recognition(CSA certificate), IEC/EN 60950-1(CB-scheme) Unit VDC MΩ pF KHz Hours Input Fuse 12V Input Models 8000mA Slow-Blow Type 24V Input Models 4000mA Slow-Blow Type 48V Input Models 2000mA Slow-Blow Type Remote On/Off Control Parameter Converter On Converter Off Control Input Current (on) Control Input Current (off) Control Common Standby Input Current Conditions Vctrl = 5.0V Vctrl = 0V Nominal Vin Min. Typ. 3.5V ~ 12V or Open Circuit 0V ~ 1.2V or Short Circuit --0.5 ---0.5 Referenced to Negative Input --2.5 Max. Unit ----- mA mA --- mA Max. --- Unit % Output Voltage Trim Parameter Trim Up / Down Range In Total Power International, Inc Conditions % of nominal output voltage Toll Free: 877-646-0900 Min. ±10 Typ. --- www.total-power.com MKW40 SERIES Tota Total Power International, Inc. DC/DC CONVERTER 40W, Highest Power Density Environmental Specifications Parameter Operating Ambient Temperature Range (Natural Convection, see Derating) Thermal Impedance Case Temperature Thermal Protection Storage Temperature Range Humidity (non condensing) RFI Lead Temperature (1.5mm from case for 10Sec.) Model MKW40-XXS033 MKW40-XXS05 MKW40-XXS12 MKW40-XXS15 MKW40-XXDXX Natural Convection without Heatsink Natural Convection with Heatsink 100LFM Convection without Heatsink 100LFM Convection with Heatsink 200LFM Convection without Heatsink 200LFM Convection with Heatsink 400LFM Convection without Heatsink 400LFM Convection with Heatsink Shutdown Temperature Min. -40 Max. without Heatsink with Heatsink 66 73 46 57 40 52 12.0 10.0 9.0 5.4 8.0 4.5 6.0 3.0 --- ----------------+105 110℃ typ. -50 +125 --95 Six-Sided Shielded, Metal Case --260 Output Power (%) Power Derating Curve MKW40-XXS033 Derating Curve without Heatsink MKW40-XXS033 Derating Curve with Heatsink MKW40-XXS05, MKW40-XXS12, MKW40-XXS15 Derating Curve without Heatsink MKW40-XXS05, MKW40-XXS12, MKW40-XXS15 Derating Curve with Heatsink MKW40-XXDXX Derating Curve without Heatsink MKW40-XXDXX Derating Curve with Heatsink In Total Power International, Inc Toll Free: 877-646-0900 www.total-power.com Unit ℃ ℃/W ℃/W ℃/W ℃/W ℃/W ℃/W ℃/W ℃/W ℃ ℃ % rel. H ℃ MKW40 SERIES Total Power International, Inc. Tota DC/DC CONVERTER 40W, Highest Power Density 100 100 90 90 80 80 70 70 Efficiency(%) Efficiency(%) Efficiency Curve @25℃ 60 50 40 30 9V 20 10 20 30 40 50 60 70 80 90 40 30 9V 12V 10 18V 0 50 20 12V 10 60 18V 0 100 10 20 30 100 100 90 90 80 80 70 70 60 50 40 30 9V 20 10 50 60 70 80 90 40 30 9V 12V 18V 0 100 10 20 30 90 80 80 70 70 Efficiency(%) Efficiency(%) 100 60 50 40 30 9V 20 12V 10 18V 0 50 60 60 70 80 90 100 70 80 90 60 50 40 30 9V 20 12V 10 100 % of Full Load 18V 0 10 20 30 40 50 60 70 80 90 100 % of Full Load MKW40-12D12 Efficiency vs Load Current In Total Power International, Inc 50 MKW40-12S15 Efficiency vs Load Current 90 40 40 % of Full Load 100 30 100 50 MKW40-12S12 Efficiency vs Load Current 20 90 60 % of Full Load 10 80 10 18V 0 40 70 20 12V 30 60 MKW40-12S05 Efficiency vs Load Current Efficiency(%) Efficiency(%) MKW40-12S033 Efficiency vs Load Current 20 50 % of Full Load % of Full Load 10 40 Toll Free: 877-646-0900 MKW40-12D15 Efficiency vs Load Current www.total-power.com MKW40 SERIES Total Power International, Inc. Tota DC/DC CONVERTER 40W, Highest Power Density 100 100 90 90 80 80 70 70 Efficiency(%) Efficiency(%) Efficiency Curve @25℃ 60 50 40 30 18V 20 10 20 30 40 50 60 70 80 90 40 30 18V 24V 10 36V 0 50 20 24V 10 60 36V 0 100 10 20 30 % of Full Load 90 80 80 70 70 Efficiency(%) Efficiency(%) 100 90 60 50 40 30 18V 20 10 50 60 70 80 90 40 30 18V 24V 36V 0 100 10 20 30 90 80 80 70 70 Efficiency(%) Efficiency(%) 100 60 50 40 30 18V 20 24V 10 36V 0 50 60 60 70 80 90 100 70 80 90 60 50 40 30 18V 20 24V 10 36V 0 100 % of Full Load 10 20 30 40 50 60 70 80 90 100 % of Full Load MKW40-24D12 Efficiency vs Load Current In Total Power International, Inc 50 MKW40-24S15 Efficiency vs Load Current 90 40 40 % of Full Load 100 30 100 50 MKW40-24S12 Efficiency vs Load Current 20 90 60 % of Full Load 10 80 10 36V 0 40 70 20 24V 30 60 MKW40-24S05 Efficiency vs Load Current 100 20 50 % of Full Load MKW40-24S033 Efficiency vs Load Current 10 40 Toll Free: 877-646-0900 MKW40-24D15 Efficiency vs Load Current www.total-power.com MKW40 SERIES Total Power International, Inc. Tota DC/DC CONVERTER 40W, Highest Power Density 100 100 90 90 80 80 70 70 Efficiency(%) Efficiency(%) Efficiency Curve @25℃ 60 50 40 30 36V 20 10 20 30 40 50 60 70 80 90 40 30 36V 48V 10 75V 0 50 20 48V 10 60 75V 0 100 10 20 30 % of Full Load 90 80 80 70 70 Efficiency(%) Efficiency(%) 100 90 60 50 40 30 36V 20 10 50 60 70 80 90 40 30 36V 48V 75V 0 100 10 20 30 90 80 80 70 70 Efficiency(%) Efficiency(%) 100 60 50 40 30 36V 20 48V 10 75V 0 50 60 60 70 80 90 100 70 80 90 60 50 40 30 36V 20 48V 10 75V 0 100 % of Full Load 10 20 30 40 50 60 70 80 90 100 % of Full Load MKW40-48D12 Efficiency vs Load Current In Total Power International, Inc 50 MKW40-48S15 Efficiency vs Load Current 90 40 40 % of Full Load 100 30 100 50 MKW40-48S12 Efficiency vs Load Current 20 90 60 % of Full Load 10 80 10 75V 0 40 70 20 48V 30 60 MKW40-48S05 Efficiency vs Load Current 100 20 50 % of Full Load MKW40-48S033 Efficiency vs Load Current 10 40 Toll Free: 877-646-0900 MKW40-48D15 Efficiency vs Load Current www.total-power.com Tota Total Power International, Inc. MKW40 SERIES DC/DC CONVERTER 40W, Highest Power Density Notes 1 Specifications typical at Ta=+25℃, resistive load, nominal input voltage and rated output current unless otherwise noted. 2 Transient recovery time is measured to within 1% error band for a step change in output load of 75% to 100%. 3 Ripple & Noise measurement bandwidth is 20 MHz, measured with a 1μF M/C and a 10μF T/C. 4 All DC/DC converters should be externally fused at the front end for protection. 5 Other input and output voltage may be available, please contact factory. 6 To order the converter with heatsink, please add a suffix –HS (e.g.MKW40-12S05-HS) to order code. 7 To order the converter without Remote On/Off function, please add a suffix -N (e.g.MKW40-12S05-N) to order code. 8 That “natural convection” is about 20LFM but is not equal to still air (0 LFM). 9 Specifications are subject to change without notice. Package Specifications Mechanical Dimensions Pin Connections 1 1.00 [ 0.04] 2 3.6 [0.14] Bottom View 50.8 [2.00] 3 5.08 [0.20] 45.72 [1.80] 10.16 [0.40] 5 Single Output Dual Output 1 +Vin +Vin 2 -Vin -Vin 3 Remote On/Off Remote On/Off 4 +Vout +Vout 5 -Vout Common 6 Trim -Vout ►All 1.1 [0.04] 6 Pin 4 dimensions in mm (inches) ►Tolerance: X.X±0.25 (X.XX±0.01) X.XX±0.13 ( X.XXX±0.005) 10.16 [0.40] 10.16 [0.40] 2.54 [0.10] 5.5 [0.22] 11.0 [0.43] ►Pin diameter 1.0 ±0.05 (0.04±0.002) 25.4 [1.00] Physical Characteristics Case Size : 50.8x25.4x11mm (2.0x1.0x0.43 inches) Case Material : Aluminium Alloy, Black Anodized Coating Base Material : FR4 PCB (flammability to UL 94V-0 rated) Pin Material : Copper Alloy with Gold Plate Over Nickel Subplate Weight : 30g Heatsink (Option –HS) 23.0 [0.91] Physical Characteristics Heatsink Material : Aluminum Finish : Black Anodized Coating Weight : 9g 18.0 [0.71]Max ►The 31.0 [1.22]Max advantages of adding a heatsink are: 1. To help heat dissipation and increase the stability Heat-sink Thermal pad and reliability of DC/DC converters at high operating temperature atmosphere. Clamp Converter 2. To upgrade the operating temperature of DC/DC converters, please refer to Derating Curve. In Total Power International, Inc Toll Free: 877-646-0900 www.total-power.com MKW40 SERIES Tota Total Power International, Inc. DC/DC CONVERTER 40W, Highest Power Density EMI-Filter to meet EN 55022, class A; FCC part 15 ,level A Conducted and radiated emissions EN55022 Class A Part No. C1 C2 & C3 MKW40-12SXX 10μF/25V 1812 MLCC 1000pF/2KV 1808 MLCC MKW40-24SXX 4.7μF/50V 1812 MLCC 1000pF/2KV 1808 MLCC MKW40-48SXX 2.2μF/100V 1812 MLCC 1000pF/2KV 1808 MLCC Part No. C1 C2 & C4 MKW40-12DXX 10μF/25V 1812 MLCC 1000pF/2KV 1808 MLCC MKW40-24DXX 4.7μF/50V 1812 MLCC 1000pF/2KV 1808 MLCC MKW40-48DXX 2.2μF/100V 1812 MLCC 1000pF/2KV 1808 MLCC External Output Trimming Output can be externally trimmed by using the method shown below MKW40-XXS033 Trim Table Trim down 1 2 Vout= Vox0.99 Vox0.98 Rd= 63.59 30.28 3 Vox0.97 18.19 4 Vox0.96 11.95 5 Vox0.95 8.13 6 Vox0.94 5.56 7 Vox0.93 3.70 8 Vox0.92 2.31 9 Vox0.91 1.21 10 Vox0.90 0.34 % Volts KOhms Trim up 1 Vout= Vox1.01 Ru= 70.50 MKW40-XXS05 Trim Table Trim down 1 Vout= Vox0.99 Rd= 45.53 2 Vox1.02 29.28 3 Vox1.03 16.87 4 Vox1.04 10.90 5 Vox1.05 7.38 6 Vox1.06 5.06 7 Vox1.07 3.42 8 Vox1.08 2.20 9 Vox1.09 1.25 10 Vox1.10 0.49 % Volts KOhms 2 Vox0.98 20.61 3 Vox0.97 12.31 4 Vox0.96 8.15 5 Vox0.95 5.66 6 Vox0.94 4.00 7 Vox0.93 2.81 8 Vox0.92 1.92 9 Vox0.91 1.23 10 Vox0.90 0.68 % Volts KOhms Trim up 1 Vout= Vox1.01 Ru= 36.57 MKW40-XXS12 Trim Table Trim down 1 Vout= Vox0.99 Rd= 394.50 2 Vox1.02 16.58 3 Vox1.03 9.92 4 Vox1.04 6.59 5 Vox1.05 4.59 6 Vox1.06 3.25 7 Vox1.07 2.30 8 Vox1.08 1.59 9 Vox1.09 1.03 10 Vox1.10 0.59 % Volts KOhms 2 Vox0.98 179.74 3 Vox0.97 106.08 4 Vox0.96 68.86 5 Vox0.95 46.39 6 Vox0.94 31.36 7 Vox0.93 20.60 8 Vox0.92 12.51 9 Vox0.91 6.21 10 Vox0.90 1.17 % Volts KOhms Trim up 1 Vout= Vox1.01 Ru= 368.92 MKW40-XXS15 Trim Table Trim down 1 Vout= Vox0.99 Rd= 572.67 2 Vox1.02 161.92 3 Vox1.03 94.97 4 Vox1.04 61.86 5 Vox1.05 42.12 6 Vox1.06 29.00 7 Vox1.07 19.66 8 Vox1.08 12.66 9 Vox1.09 7.23 10 Vox1.10 2.89 % Volts KOhms 2 Vox0.98 248.63 3 Vox0.97 145.60 4 Vox0.96 94.97 5 Vox0.95 64.87 6 Vox0.94 44.92 7 Vox0.93 30.72 8 Vox0.92 20.10 9 Vox0.91 11.86 10 Vox0.90 5.28 % Volts KOhms 2 Vox1.02 182.12 3 Vox1.03 108.73 4 Vox1.04 71.43 5 Vox1.05 48.85 6 Vox1.06 33.71 7 Vox1.07 22.86 8 Vox1.08 14.69 9 Vox1.09 8.33 10 Vox1.10 3.23 % Volts KOhms Trim up Vout= Ru= 1 Vox1.01 392.98 In Total Power International, Inc Toll Free: 877-646-0900 www.total-power.com MKW40 SERIES Total Power International, Inc. Tota DC/DC CONVERTER 40W, Highest Power Density Test Setup Input Reflected-Ripple Current Test Setup Input reflected-ripple current is measured with a 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. To Oscilloscope + + Battery +Vin Lin DC / DC Converter Current Probe Cin +Out -Vin Load -Out 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 0-20 MHz. Position the load between 50 mm and 75 mm from the DC/DC Converter. +Vin +Out Copper Strip Single Output DC / DC Converter -Vin Cout -Out Resistive Load Scope Copper Strip +Vin +Out Copper Strip Dual Output DC / DC Converter Com. Copper Strip -Vin -Out Scope Cout Cout Resistive Load Scope Copper Strip Technical Notes 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 0V to 1.2V. A logic high is 3.5V to 12V. The maximum sink current at the on/off terminal (Pin 3) during a logic low is -100μA. Overcurrent Protection To provide hiccup mode protection in a fault (output overload) condition, the unit is equipped with internal current limiting circuitry and can endure overload for an unlimited duration. Overvoltage Protection The output overvoltage 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 overvoltage. The OVP level can be found in the output data. 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 < 1.0 Ω at 100 KHz) capacitor of a 33μF for the 12V input devices and a 10μF for the 24V and 48V devices. + DC Power Source +Vin + +Out DC / DC Converter Load Cin - -Vin -Out Output Ripple Reduction A good quality low ESR capacitor placed as close as practicable 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 - +Out Single Output DC / DC Converter DC Power Source -Vin + Cout +Vin DC Power Source Load -Out - +Out Dual Output Com. DC / DC Converter -Vin -Out Cout Load Load Cout Maximum Capacitive Load The MKW40 series has 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. The maximum capacitance can be found in the data sheet. 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℃. The derating curves are determined from measurements obtained in a test setup. Position of air velocity probe and thermocouple 50mm / 2in 15mm / 0.6in In Total Power International, Inc Air Flow DUT Toll Free: 877-646-0900 www.total-power.com