Data Sheet July 2000 MW005AJ, MW005AJ4 Power Modules: 36 Vdc to 72 Vdc Input; 5 W Features The MW005AJ-Series Power Modules use advanced, surfacemount technology and deliver high-quality, compact, dc-dc conversion at an economical price. Applications Distributed power architectures Communication equipment Computer equipment Private branch exchange (PBX) Small size: 50.8 mm x 27.9 mm x 11.7 mm (2.00 in. x 1.10 in. x 0.46 in.) Output current limiting; unlimited duration Output overvoltage protection Input-to-output isolation Operating ambient temperature range: -40 C to + 85 C High reliability UL* 1950 Recognized, CSA C22.2 No. 950-95 Certified, VDE 0805 (EN60950, IEC950) Licensed CE mark meets 73/23/EEC and 93/68/EEC directives Within FCC Class A Radiated Limits Options Metal case with ground pin Tighter regulation for 5 V output voltage Long pins: 5.84 mm 0.51 mm (0.230 in. 0.020 in.) Description The MW005AJ and MW005AJ4 Power Modules are dc-dc converters that operate over an input voltage range of 36 Vdc to 72 Vdc and provide precisely regulated dc outputs. The outputs are isolated from the input and the modules have maximum power ratings of 5 W at a typical full-load efficiency of 78% for the MW005AJ and 76% for MW005AJ4. The modules are encapsulated in nonconductive cases that mount on PC boards. In a natural convection environment, the modules are rated to operate at full load at 85 C with no heat sinking or external filtering. * UL is a registered trademark of Underwriters Laboratories, Inc. CSA is a registered trademark of Canadian Standards Association. VDE is a trademark of Verband Deutscher Elektrotechniker e.V. This product is intended for integration into end-use equipment. All the required procedures for CE marking of end-use equipment should be followed. (The CE mark is placed on selected products.) MW005AJ, MW005AJ4 Power Modules: 36 Vdc to 72 Vdc Input; 5 W Data Sheet July 2000 Absolute Maximum Ratings Stresses in excess of the absolute maximum ratings can cause permanent damage to the device. These are absolute stress ratings only. Functional operation of the device is not implied at these or any other conditions in excess of those given in the operations sections of the data sheet. Exposure to absolute maximum ratings for extended periods can adversely affect device reliability. Parameter Input Voltage I/O Isolation Voltage Operating Ambient Temperature (At 60 ft./min. natural convection) Storage Temperature Symbol VI -- TA Min -- -- -40 Max 75 500 85 Unit Vdc Vdc C Tstg -40 100 C Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Table 1. Input Specifications Parameter Operating Input Voltage Maximum Input Current (VI = 0 V to 72 V; IO = IO, max; see Figure 1.) Symbol VI II, max Min 36 -- Typ 48 -- Max 72 600 Unit Vdc mA Inrush Transient Input Reflected-ripple Current, Peak-to-peak (5 Hz to 20 MHz, 12 H source impedance; TA = 25 C; see Figure 11 and Design Considerations section.) Input Ripple Rejection (120 Hz) i2t II -- -- 0.1 20 0.2 -- A2s mAp-p -- -- 53 -- dB Fusing Considerations CAUTION: This power module is not internally fused. An input line fuse must always be used. This encapsulated power module can be used in a wide variety of applications, ranging from simple stand-alone operation to an integrated part of a sophisticated power architecture. To preserve maximum flexibility, internal fusing is not included; however, to achieve maximum safety and system protection, always use an input line fuse. The safety agencies require a normal-blow fuse with a maximum rating of 5 A in series with the input (see Safety Considerations section). Based on the information provided in this data sheet on inrush energy and maximum dc input current, the same type of fuse with a lower rating can be used. Refer to the fuse manufacturer's data for further information. 2 Tyco Electronics Corp. MW005AJ, MW005AJ4 Power Modules: 36 Vdc to 72 Vdc Input; 5 W Data Sheet July 2000 Electrical Specifications (continued) Table 2. Output Specifications Parameter Output Voltage Set Point (VI = 48 V; IO1, IO2 = 50% IO, max; TA = 25 C) Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life; see Figures 2--4 and 13.) Output Regulation: Temperature (TA = -40 C to +85 C; see Figure 5.) Output Ripple and Noise Voltage (See Figure 12.): RMS Peak-to-peak (5 Hz to 20 MHz; see Output Ripple in the Design Considerations section for lower output noise.) Output Current (At IO < IO, min, the modules may exceed output ripple specifications.) Device MW005AJ Symbol VO1, set VO2, set VO1, set VO2, set VO1 VO2 VO1 VO2 Min 4.85 -4.85 4.90 -5.00 4.70 -4.70 4.80 -4.70 Typ 5.00 -5.00 5.00 -5.20 -- -- -- -- Max 5.15 -5.15 5.10 -5.40 5.30 -5.30 5.25 -5.80 Unit Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc All -- -- 25 -- mV All All -- -- -- -- 25 120 120 500 mVrms mVp-p MW005AJ IO1 IO2 IO1 IO2 -- -- -- -- 1.6 0.5 0.5 0.8 0.2 2.5 A A A A A MW005AJ4 MW005AJ MW005AJ4 Output Current-limit Inception (VO = 90% of VO, nom; see Figures 6--9.) All IO1, 2 0.1 0.1 0.1 0.05 -- Output Short-circuit Current (VO1, 2 = 250 mV; see Figures 6--9.) Efficiency (VI = 48 Vdc; IO = IO, max; TA = 25 C; see Figures 10 and 13.) All IO1, 2 -- 1.8 2.8 A MW005AJ MW005AJ4 75 74 78 77 -- -- % % All All -- -- -- -- 80 5.0 -- -- mV ms All All -- -- -- -- 80 5.0 -- -- mV ms Dynamic Response (Applies to VO1 and VO2 at full load; IO/t = 1 A/10 s, VI = 48 V, TA = 25 C): Load Change from IO = 50% to 75% of IO, max: Peak Deviation Settling Time (VO < 10% peak deviation) Load Change from IO = 50% to 25% of IO, max: Peak Deviation Settling Time (VO < 10% peak deviation) Tyco Electronics Corp. MW005AJ4 3 MW005AJ, MW005AJ4 Power Modules: 36 Vdc to 72 Vdc Input; 5 W Data Sheet July 2000 Electrical Specifications (continued) Table 3. Isolation Specifications Parameter Isolation Capacitance Isolation Resistance Min -- 10 Typ 1200 -- Max -- -- Unit pF M Min Typ 1,900,000 -- Max Unit hours g (oz.) General Specifications Parameter Calculated MTBF (IO = 80% of IO, max; TC = 40 C) Weight -- 28 (1.0) Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See Feature Descriptions and Design Considerations for further information. Parameter Output Overvoltage Protection (clamp) Device MW005AJ MW005AJ4 4 Symbol VO1, clamp VO2, clamp VO1, clamp VO2, clamp Min -- -- -- -- Typ Max Unit -- -- -- -- 7.0 -7.0 7.0 -8.0 V V V V Tyco Electronics Corp. MW005AJ, MW005AJ4 Power Modules: 36 Vdc to 72 Vdc Input; 5 W Data Sheet July 2000 Characteristic Curves 0.350 0.300 0.250 0.200 0.150 VO 0.100 VO 0.050 0 0 10 20 30 40 50 60 OUTPUT VOLTAGE, -VO2 (V) 5.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0 II II OUTPUT VOLTAGE, VO (V) INPUT CURRENT, II (A) 0.450 0.400 5.12 5.08 IO1 = 0.50 A 5.04 5.00 4.96 IO1 = 0.25 A 4.92 4.88 0.10 IO1 = 0.10 A 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 OUTPUT CURRENT, IO2 (A) 70 8-911(C) INPUT VOLTAGE, VI (V) 8-909(C) Figure 3. MW005AJ Typical VO2 vs. IO2 Regulation, VI = 48 V and TA = 25 C Figure 1. MW005AJ and MW005AJ4 Input Current and Output Voltage vs. Input Voltage at TA = 25 C and Full Load OUTPUT VOLTAGE, -VO2 (V) OUTPUT VOLTAGE, VO1 (V) 5.12 5.08 IO2 = 0.50 A IO2 = 0.25 A 5.04 5.00 4.96 5.4 5.3 IO2 = 0.10 A IO1 = 0.8 A 5.2 5.1 IO1 = 0.4 A IO1 = 0.1 A 5.0 4.9 0.050 4.92 4.88 0.10 5.5 0.075 0.100 0.125 0.150 0.175 0.200 OUTPUT CURRENT, IO2 (A) 8-912(C) 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 OUTPUT CURRENT, IO1 (A) 8-910(C) Figure 4. MW005AJ4 Typical VO2 vs. IO2 Regulation, VI = 48 V and TA = 25 C Figure 2. MW005AJ Typical VO1 vs. lO1 Regulation, VI = 48 V and TA = 25 C Tyco Electronics Corp. 5 MW005AJ, MW005AJ4 Power Modules: 36 Vdc to 72 Vdc Input; 5 W Data Sheet July 2000 6 OUTPUT VOLTAGE, -VO2 (V) NORMALIZED OUTPUT VOLTAGE SET POINT Characteristic Curves (continued) 1.003 1.002 1.001 1.000 0.999 0.998 VO, set = VO, setmin 0.997 5 4 IO1 = 0.50 A IO1 = 0.25 A IO1 = 0.10 A 3 2 1 0 0 VO, set = VO, setnom 0.2 0.4 0.996 0.8 1.0 1.2 1.4 1.6 1.8 2.0 OUTPUT CURRENT, IO2 (A) VO, set = VO, setmax 0.995 0.6 8-914(C) 0.994 -40 -20 0 20 40 60 80 AMBIENT TEMPERATURE, TA (C) Figure 7. MW005AJ Typical -VO2 vs. IO2 Output Characteristics, VI = 48 V and TA = 25 C 8-913(C) OUTPUT VOLTAGE, VO1 (V) 6 5 4 IO2 = 0.50 A IO2 = 0.25 A IO2 = 0.10 A 3 6 OUTPUT VOLTAGE, VO1 (V) Figure 5. MW005AJ and MW005AJ4 Output Voltage Set Point vs. Ambient Temperature at VI = 48 V and Full Load 5 4 IO2 = 0.20 A IO2 = 0.10 A IO2 = 0.05 A 3 2 1 0 0 2 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 OUTPUT CURRENT, IO1 (A) 8-915(C) 1 0 0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 Figure 8. MW005AJ4 Typical VO1 vs. IO1 Output Characteristics, VI = 48 V and TA = 25 C OUTPUT CURRENT, IO1 (A) 8-916(C) Figure 6. MW005AJ Typical VO1 vs. IO1 Output Characteristics, VI = 48 V and TA = 25 C 6 Tyco Electronics Corp. MW005AJ, MW005AJ4 Power Modules: 36 Vdc to 72 Vdc Input; 5 W Data Sheet July 2000 Characteristic Curves (continued) 82 (%) 5 EFFICIENCY, OUTPUT VOLTAGE, -VO2 (V) 6 4 IO2 = 0.8 A IO2 = 0.4 A IO2 = 0.1 A 3 78 74 MW005AJ4 70 MW005AJ 66 2 62 1.0 1 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 OUTPUT POWER, PO (W) 0 0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 8-917(C) OUTPUT CURRENT, IO2 (V) 8-918(C) Figure 9. MW005AJ4 Typical -VO2 vs. IO2 Output Characteristics, VI = 48 V and TA = 25 C Tyco Electronics Corp. Figure 10. MW005AJ and MW005AJ4 Typical Efficiency vs. Output Power, VI = 48 V and TA = 25 C 7 MW005AJ, MW005AJ4 Power Modules: 36 Vdc to 72 Vdc Input; 5 W Data Sheet July 2000 Test Configurations CONTACT AND DISTRIBUTION LOSSES VI(+) TO OSCILLOSCOPE LTEST IO II CURRENT PROBE VO1 SUPPLY LOAD V I (+) 12 H BATTERY VI(-) 8-863(C).a V I (-) Note: Take all measurements at the module terminals. When socketing, place Kelvin connections at module terminals to avoid measurement errors due to socket contact resistance. 2 8-489(C) Note: Input reflected-ripple current is measured with a simulated source impedance of 12 H. Capacitor Cs offsets possible battery impedance. Current is measured at the input of the module. Figure 11. Input Reflected-Ripple Test Setup VO1(+) SCOPE RLOAD1 COM SCOPE RLOAD2 VO2(-) 8-808(C) Note: Use a 0.1 F ceramic capacitor. Scope measurement should be made by using a BNC socket. Position the load between 50 mm and 75 mm (2 in. and 3 in.) from the module. Figure 12. Output Noise Measurement Test Setup 8 = [ V Oj ( + ) - V com ] I Oj j=1 ----------------------------------------------------[ V I ( + ) + ( -V I ( - ) ) ] I I - x 100 % Figure 13. Output Voltage and Efficiency Measurement Test Setup Design Considerations COPPER STRIP 0.1 F VO2 CONTACT RESISTANCE CS 220 F IMPEDANCE < 0.1 @ 20 C, 100 kHz 0.1 F LOAD COM Output Ripple If lower output ripples are needed, external L-C filters across the module output terminals are recommended. A 3.9 H, 50 m inductor and a 47 F capacitor with its impedance less than 1.5 at 100 kHz will reduce the output ripple by at least 50%. Input or Output Voltage Reversal CAUTION: Applying a reverse voltage across the module input or output can damage the module. Tyco Electronics Corp. Data Sheet July 2000 MW005AJ, MW005AJ4 Power Modules: 36 Vdc to 72 Vdc Input; 5 W Safety Considerations Feature Descriptions For safety-agency approval of the system in which the power module is used, the power module must be installed in compliance with the spacing and separation requirements of the end-use safety agency standard, i.e., UL 1950, CSA C22.2 No. 950-95, and VDE 0805 (EN60950, IEC950). Output Overvoltage Protection If the input source is non-SELV (ELV or a hazardous voltage greater than 60 Vdc and less than or equal to 75 Vdc), for the module's output to be considered meeting the requirements of safety extra-low voltage (SELV), all of the following must be true: The input source is to be provided with reinforced insulation from any other hazardous voltages, including the ac mains. One VI pin and one VO pin are to be grounded or both the input and output pins are to be kept floating. The input pins of the module are not operator accessible. Another SELV reliability test is conducted on the whole system, as required by the safety agencies, on the combination of supply source and the subject module to verify that under a single fault, hazardous voltages do not appear at the module's output. 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 (see Feature Specifications table). This provides a redundant voltage-control that reduces the risk of output overvoltage. 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. If the output voltage is pulled very low during a severe fault, the current-limit circuit can exhibit either foldback or tailout characteristics (output-current decrease or increase). The unit operates normally once the output current is brought back into its specified range. Note: Do not ground either of the input pins of the module without grounding one of the output pins. This may allow a non-SELV voltage to appear between the output pins and ground. The power module has extra-low voltage (ELV) outputs when all inputs are ELV. The input to these units is to be provided with a maximum 5 A normal-blow fuse in the ungrounded lead. Tyco Electronics Corp. 9 MW005AJ, MW005AJ4 Power Modules: 36 Vdc to 72 Vdc Input; 5 W Data Sheet July 2000 Outline Diagram Dimensions are in millimeters and (inches). Copper paths must not be routed beneath the power module standoffs. Tolerances: x.x 0.5 mm (0.02 in.), x.xx 0.25 mm (0.010 in.) Top View - IN Lucent - 5V MW005AJ DC-DC Power Module IN:DC 48V, 0.13A + COM 27.9 (1.10) MAX OUT:DC 5V, 0.5A OUT:DC -5V, 0.5A MADE IN USA + 5V R U.S. Patent 4903182 TUV Rheinland 50.8 (2.00) MAX Side View 11.7 (0.46) MAX 0.51 (0.020) 0.79 (0.031) DIA ROUND PIN (TYP) 2.8 (0.11) Bottom View 2.54 (0.100) 12.70 (0.500) 5.08 (0.200) 11.4 (0.45) 7.62 (0.300) 15.2 (0.60) 20.32 (0.800) 8-356(C).e 10 Tyco Electronics Corp. MW005AJ, MW005AJ4 Power Modules: 36 Vdc to 72 Vdc Input; 5 W Data Sheet July 2000 Recommended Hole Pattern Component-side footprint. Dimensions are in millimeters and (inches). MODULE OUTLINE 2.54 (0.100) 12.70 (0.500) 5.08 (0.200) 11.4 (0.45) 7.62 (0.300) 15.2 (0.60) 20.32 (0.800) 8-356(C).e Ordering Information Please contact your Account Manager or Application Engineer for pricing and availability of options. Tighter regulation for +5 V output voltage is optional and is designated by suffix "4" in the device code name. Input Voltage 36 V to 72 V 36 V to 72 V Tyco Electronics Corp. Output Voltage 5.0 V +5.0 V, -5.2 V Output Power 5W 5W Device Code MW005AJ MW005AJ4 Comcode 106778558 107003329 11 MW005AJ, MW005AJ4 Power Modules: 36 Vdc to 72 Vdc Input; 5 W Data Sheet July 2000 Tyco Electronics Power Systems, Inc. 3000 Skyline Drive, Mesquite, TX 75149, USA +1-800-526-7819 FAX: +1-888-315-5182 (Outside U.S.A.: +1-972-284-2626, FAX: +1-972-284-2900) http://power.tycoelectronics.com Tyco Electronics Corporation reserves the right to make changes to the product(s) or information contained herein without notice. No liability is assumed as a result of their use or application. No rights under any patent accompany the sale of any such product(s) or information. (c) 2001 Tyco Electronics Corporation, Harrisburg, PA. All International Rights Reserved. Printed in U.S.A. July 2000 DS98-312EPS (Replaces DS93-133EPS) Printed on Recycled Paper