MPW1000 Series 25-30W, Wide Input Range, Single & Dual Output DC/DC Converters Key Features y y y y y y y y y y y y Efficiency up to 89% 1500VDC Isolation MTBF > 1,000,000 Hours CSA1950 Safety Approval Complies with EN55022 Class A Six-Sided Shielding Remote On/Off Control Over Voltage Protection Over Temperature Protection Output Trim Low Profile: 0.37"(9.3mm) Soft Start Minmax's MPW1000-Series power modules are low-profile dc-dc converters that operate over input voltage ranges of 9-18VDC, 18-36VDC and 36-75VDC which provide precisely regulated output voltages of 3.3V, 5V, 12V, 15V, {12V and {15VDC, specially addressing OVP OTP Protection Protection 2:1 1500 VDC Wide Range I/O Isolation High Power Density data communication equipments, mobile battery driven equipments, distributed power systems, telecommunication equipments, mixed More Power Remote on/off analog/digital subsystems, process/machine control equipments, computer peripheral systems and industrial robot systems. Packing up to 30W of power into a 2x1.6x0.37inch package, with efficiencies as high as 89%, the MPW1000 includes continuous short circuit protection, overvoltage protection, over temperature protection, EMI output trim function, remote on/off, six-sided shielded case and EN55022 Class A conducted noise compliance minimize design-in time, cost and EN55022 Low Profile eliminate the need for external filtering. Block Diagram Single Output +Vin Dual Output +Vo LC Filter +Vin +Vo LC Filter Com. -Vo -Vo -Vin On/Off 1 OVP OTP PWM OVP OTP OVP OVP -Vin Isolation Ref.Amp Trim On/Off MINMAX PWM Isolation Ref.Amp Trim REV:0 2005/04 MPW1000 Series Model Selection Guide Model Number MPW1021 MPW1022 MPW1023 MPW1024 MPW1026 MPW1027 MPW1031 MPW1032 MPW1033 MPW1034 MPW1036 MPW1037 MPW1041 MPW1042 MPW1043 MPW1044 MPW1046 MPW1047 Input Voltage Output Voltage VDC VDC 3.3 5 12 15 {12 {15 3.3 5 12 15 {12 {15 3.3 5 12 15 {12 {15 12 ( 9 ~ 18 ) 24 ( 18 ~ 36 ) 48 ( 36 ~ 75 ) Output Current Max. mA 5500 5000 2500 2000 {1250 {1000 5500 5000 2500 2000 {1250 {1000 5500 5000 2500 2000 {1250 {1000 Min. mA 400 350 166 133 {83 {65 400 350 166 133 {83 {65 400 350 166 133 {83 {65 Input Current @Max. Load @No Load mA (Typ.) mA (Typ.) 1867 2480 2841 40 2841 2841 2841 922 1225 1404 20 1404 1404 1404 461 613 702 10 702 702 702 Absolute Maximum Ratings Parameter 12VDC Input Models Input Surge Voltage 24VDC Input Models ( 1000 mS ) 48VDC Input Models Lead Temperature (1.5mm from case for 10 Sec.) Internal Power Dissipation Reflected Ripple Current Over Voltage Protection mA (Typ.) VDC 3.9 6.8 15 18 {15 {18 3.9 6.8 15 18 {15 {18 3.9 6.8 15 18 {15 {18 100 50 25 Efficiency @Max. Load % (Typ.) 81 84 88 88 88 88 82 85 89 89 89 89 82 85 89 89 89 89 Notes : Min. -0.7 -0.7 -0.7 ----- Max. 25 50 100 260 5500 Unit VDC VDC VDC ] mW Exceeding the absolute maximum ratings of the unit could cause damage. These are not continuous operating ratings. 1. Specifications typical at Ta=+25], resistive load, nominal input voltage, 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 0-20 MHz. 4. These power converters require a minimum output loading to maintain specified regulation. Environmental Specifications Parameter Operating Temperature Operating Temperature Storage Temperature Humidity Cooling RFI Conducted EMI REV:0 2005/04 Conditions Ambient Case Min. Max. -40 +50 -40 +105 -50 +125 --95 Free-Air Convection Six-Sided Shielded, Metal Case EN55022 Class A Unit ] ] ] % MINMAX 5. Operation under no-load conditions will not damage these modules; however, they may not meet all specifications listed. 6. All DC/DC converters should be externally fused at the front end for protection. 7. Other input and output voltage may be available, please contact factory. 8. Specifications subject to change without notice. 2 MPW1000 Series Input Specifications Parameter Start Voltage Under Voltage Shutdown Model Min. 12V Input Models 8.6 8.8 9 24V Input Models 17 17.5 18 Max. 48V Input Models 34 35 36 12V Input Models 8.1 8.3 8.5 24V Input Models 16 16.5 17 34 48V Input Models Reverse Polarity Input Current Short Circuit Input Power Typ. All Models Unit VDC 32 33 --- --- 2 A --- --- 4500 mW Input Filter Pi Filter Output Specifications Parameter Conditions Min. Typ. Max. Unit --- {0.5 {1.0 % Dual Output, Balanced Loads --- {0.5 {2.0 % Line Regulation Vin=Min. to Max. --- {0.1 {0.3 % Load Regulation Io=10% to 100% --- {0.1 {0.5 % --- 55 80 mV P-P Output Voltage Accuracy Output Voltage Balance Ripple & Noise (20MHz) --- --- 100 mV P-P Ripple & Noise (20MHz) Ripple & Noise (20MHz) --- --- 10 mV rms Over Power Protection 110 --- 160 % --- 150 300 uS --- {2 {4 % --- {0.01 {0.02 %/] Transient Recovery Time Transient Response Deviation Over Line, Load & Temp. 25% Load Step Change Temperature Coefficient Output Short Circuit Continuous General Specifications Parameter Conditions Min. Typ. Max. Unit Isolation Voltage Rated 60 Seconds 1500 --- --- VDC Isolation Voltage Test Flash Tested for 1 Second 1650 --- --- VDC Isolation Resistance 500VDC 1000 --- --- M[ Isolation Capacitance 100KHz,1V --- 1200 1500 pF 290 330 360 KHz Switching Frequency Over Temperature Protection MTBF Case Temperature, automatic recovery 107 112 117 ] MIL-HDBK-217F @ 25], Ground Benign 1000 --- --- K Hours Conditions Min. Typ. Max. Remote On/Off Control Parameter Supply On 2.5 to 100VDC or Open Circuit Supply Off -1 Device Standby Input Current Unit VDC --- 1 VDC mA --- 2 5 Control Input Current ( on ) Vin -RC = 5.0V --- --- 5 uA Control Input Current ( off ) Vin -RC = 0V --- --- -100 uA Control Common 3 Referenced to Negative Input MINMAX REV:0 2005/04 MPW1000 Series Capacitive Load Models by Vout Maximum Capacitive Load 3.3V 5V 12V 15V {12V # {15V # Unit 10000 10000 1000 1000 330 330 uF # For each output Input Fuse Selection Guide 12V Input Models 6000mA Slow - Blow Type 24V Input Models 48V Input Models 3000mA Slow - Blow Type 1500mA Slow - Blow Type Output Voltage Trim Parameter Trim Up / Down Range Conditions Min. Typ. Max. Unit % of nominal output voltage {9.0 {10.0 {11.0 % Input Voltage Transient Rating 150 140 130 120 48VDC Input Models 110 Vin ( VDC ) 100 90 80 70 24VDC Input Models 60 50 12VDC Input Models 40 30 20 10 0 10uS REV:0 2005/04 100uS 1mS MINMAX 10mS 100mS 4 MPW1000 Series 90 90 Efficiency (%) 100 Efficiency (%) 100 80 70 80 70 60 60 50 Low Nom 50 High Low Nom Efficiency vs Input Voltage ( Dual Output ) 100 100 90 90 80 80 Efficiency (%) Efficiency (%) Efficiency vs Input Voltage ( Single Output ) 70 60 70 60 50 50 40 40 30 10 20 40 High Input Voltage (V) Input Voltage (V) 60 80 100 30 10 20 40 60 80 100 Load Current (%) Load Current (%) Efficiency vs Output Load ( Single Output ) Efficiency vs Output Load ( Dual Output ) 100 400LFM Output Power (%) 80 Natural convection 60 100LFM 200LFM 40 20 0 -40 50 60 70 90 80 Ambient Temperature 100 110 ] Derating Curve 5 MINMAX REV:0 2005/04 MPW1000 Series Test Configurations Output Voltage Trim Input Reflected-Ripple Current Test Setup 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 (Radj) between the Trim and +Vout or -Vout terminals. By adjusting Radj, the output voltage can be change by {10% of the nominal output voltage. Input reflected-ripple current is measured with a inductor Lin (4.7uH) and Cin (220uF, ESR < 1.0[ 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. +Vin +Out -Vin -Out Trim Down To Oscilloscope + + Battery +Vin Lin DC / DC Converter Current Probe Cin +Out -Vin Trim Up Enable Load Use a Cout 1.0uF 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. +Out Single Output DC / DC Converter -Vin Scope (33*Vout)- (30*Vadj) Vadj - Vout Radj-up = Connecting the external resistor (Radj-down) between the Trim and +Vout pins decreases the output voltage set point as defined in the following equation: Copper Strip Cout Trim Up/Down A 10K, 1 or 10 Turn trimpot is usually specified for continuous trimming. Trim pin may be safely left floating if it is not used. Connecting the external resistor (Radj-up) between the Trim and -Vout pins increases the output voltage to set the point as defined in the following equation: -Out Peak-to-Peak Output Noise Measurement Test +Vin Trim 10K Resistive Load Radj-down = -Out (36.667*Vadj) - (33*Vout) Vout-Vadj Vout : Nominal Output Voltage +Vin +Out Dual Output DC / DC Converter Com. -Vin -Out Vadj : Adjusted Output Voltage Copper Strip Cout Scope Cout Scope Units : VDC/ K[ Resistive Load Overcurrent 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. 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 -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 -100 uA. The maximum allowable leakage current of a switch connected to the on/off terminal (Pin 4) at logic hight (2.5V to 100V) is 5uA. REV:0 2005/04 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. MINMAX 6 MPW1000 Series Input Source Impedance Thermal Considerations 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. 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 105C. The derating curves are determined from measurements obtained in an experimental apparatus. 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[ at 100 KHz) capacitor of a 33uF for the 12V input devices and a 10uF for the 24V and 48V devices. Position of air velocity probe and thermocouple 15mm / 0.6in + DC Power Source +Vin + 50mm / 2in Air Flow DUT +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 4.7uF capacitors at the output. + +Vin +Out Single Output DC / DC Converter DC Power Source Cout - -Vin -Out + +Vin +Out Dual Output DC / DC Com. Converter DC Power Source - -Vin -Out Load Cout Load Maximum Capacitive Load The MPW1000 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. For optimum performance we recommend 330uF maximum capacitive load for dual outputs, 1000uF capacitive load for 12V & 15V outputs and 10000uF capacitive load for 3.3V & 5V outputs. The maximum capacitance can be found in the data sheet. 7 MINMAX REV:0 2005/04 MPW1000 Series Mechanical Dimensions Connecting Pin Patterns Bottom View ( 2.54 mm / 0.1 inch grids ) Single Output 40.6 [1.60] 5.0 [0.20] 10.20 [0.402] 10.20 [0.402] 10.20 [0.402] 7 9.3[0.37] 8 Side Dual Output 1.00[ 0.039] Bottom 50.8 [2.00] 6 45.70 [1.801] 5 6.0 [0.24] 5.10 [0.201] Tolerance Pin 2 4 7.6 [0.30] 2.5 [0.10] 1 Millimeters Inches X.X{0.25 X.XX{0.01 X.XX{0.13 {0.05 X.XXX{0.005 {0.002 Pin Connections Physical Characteristics 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 50.8*40.6*9.3 mm Case Size : Case Material : Metal With Non-Conductive Baseplate Weight : 48g Flammability : UL94V-0 2.0*1.6*0.37 inches The MPW1000 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. REV:0 2005/04 MINMAX 8