MKW3000 Series 20W, Wide Input Range, Single & Dual Output DC/DC Converters Key Features y y y y y y y y y y Efficiency up to 89% 1500VDC Isolation MTBF > 800,000 Hours 2:1 Wide Input Range CSA1950 Safety Approval Complies with EN55022 Class A Six-Sided Shielding Remote On/Off Control Soft Start Over Voltage Protection Minmax's MKW3000 series, comprising 18 different models, has been conceived as an application specific range of DC/DC converters, specially addressing data communication equipments, mobile battery High Power Density OVP driven equipments, distributed power systems, telecommunication equipments, mixed analog/digital subsystems, process/machine control Protection equipments, computer peripheral systems and industrial robot systems. Remote on/off More Power EMI 2:1 EN55022 Wide Range Packing up to 20W of power into a 2x1x0.4 inch package, with efficiency as high as 89%, the MKW3000 has wide input ranges of 9-18VDC, 18-36VDC and 36-75VDC and is available in output voltages 1500 VDC of 3.3V, 5V, 12V, 15V, {12V and {15VDC. Other feathers include continuous short circuit protection, overvoltage protection, remote on/off, six-sided shielded case, and EN55022 Class A conducted noise compliance minimize design-in time, cost and eliminate I/O Isolation the need for external filtering. Block Diagram Single Output +Vin Dual Output +Vo LC Filter +Vin +Vo LC Filter Com. -Vo -Vo OVP -Vin On/Off 1 OVP -Vin PWM Isolation Ref.Amp On/Off MINMAX PWM Isolation Ref.Amp REV:0 2005/04 MKW3000 Series Model Selection Guide Model Number MKW3021 MKW3022 MKW3023 MKW3024 MKW3026 MKW3027 MKW3031 MKW3032 MKW3033 MKW3034 MKW3036 MKW3037 MKW3041 MKW3042 MKW3043 MKW3044 MKW3046 MKW3047 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 4000 4000 1670 1340 {835 {670 4000 4000 1670 1340 {835 {670 4000 4000 1670 1340 {835 {670 Min. mA 240 240 100 80 {50 {40 240 240 100 80 {50 {40 240 240 100 80 {50 {40 Input Current @Max. Load @No Load mA (Typ.) mA (Typ.) 1358 1984 1898 30 1903 1898 1903 671 980 938 17 941 938 941 335 490 469 10 471 469 471 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 50 30 20 Efficiency @Max. Load % (Typ.) 81 84 88 88 88 88 82 85 89 89 89 89 82 85 89 89 89 89 Notes : 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 Min. -0.7 -0.7 -0.7 ----- Max. 25 50 100 260 4,500 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. 5. Operation under no-load conditions will not damage these modules; however, they may not meet all specifications listed. 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 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. 9. To order the converter without Remote On/Off function, please add a suffix -N (e.g.MKW3021-N). 2 MKW3000 Series Input Specifications Parameter Start Voltage Under Voltage Shutdown Model Min. Typ. Max. 12V Input Models 8.6 8.8 9 18 24V Input Models 17 17.5 48V Input Models 34 35 36 12V Input Models 8.1 8.3 8.5 24V Input Models 16 16.5 17 48V Input Models 32 33 34 --- --- 2 A --- --- 3500 mW Reverse Polarity Input Current Short Circuit Input Power Unit All Models Input Filter VDC 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 --- --- 100 mV P-P --- --- 10 mV rms Over Power Protection 110 --- 160 % Transient Recovery Time --- 150 300 uS Output Voltage Accuracy Output Voltage Balance Ripple & Noise (20MHz) Ripple & Noise (20MHz) Over Line, Load & Temp. Ripple & Noise (20MHz) Transient Response Deviation 25% Load Step Change Temperature Coefficient Output Short Circuit --- {2 {4 % --- {0.01 {0.02 %/] 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 Switching Frequency MTBF 290 330 360 KHz MIL-HDBK-217F @ 25], Ground Benign 800 --- --- K Hours Conditions Min. Typ. Max. Unit Remote On/Off Control Parameter Supply On 2.5 to 100VDC or Open Circuit Supply Off Standby Input Current Control Input Current ( on ) Vin-RC = 5.0V Control Input Current ( off ) Vin-RC = 0V Control Common 3 0 --- 1 VDC --- 2 5 mA --- --- 5 uA --- --- -100 uA Referenced to Negative Input MINMAX REV:0 2005/04 MKW3000 Series Capacitive Load Models by Vout 3.3V 5V 12V 15V {12V # {15V # Unit Maximum Capacitive Load 6800 6800 680 680 270 270 uF # For each output Input Fuse Selection Guide 12V Input Models 24V Input Models 48V Input Models 4000mA Slow - Blow Type 2000mA Slow - Blow Type 1000mA Slow - Blow Type Input Voltage Transient Rating 150 140 130 120 48VDC Input Models 110 Vin ( VDC ) 100 90 80 70 24VDC Input Models 60 50 40 12VDC Input Models 30 20 10 0 10uS REV:0 2005/04 100uS 1mS MINMAX 10mS 100mS 4 100 100 90 90 Efficiency (%) Efficiency (%) MKW3000 Series 80 70 60 80 70 60 50 Low Nom 50 High Low Nom Input Voltage (V) Efficiency vs Input Voltage ( Dual Output ) 90 90 80 80 70 70 Efficiency (%) Efficiency (%) Efficiency vs Input Voltage ( Single Output ) 60 50 60 50 40 40 30 30 20 10 20 40 High Input Voltage (V) 60 80 100 20 Load Current (%) 10 20 40 60 80 100 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 80 Ambient Temperature 90 100 110 ] Derating Curve 5 MINMAX REV:0 2005/04 MKW3000 Series Test Configurations Overcurrent Protection Input Reflected-Ripple Current Test Setup 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 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. To Oscilloscope + + Battery +Vin Lin Cin -Vin 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. +Out DC / DC Converter Current Probe Overvoltage Protection Load -Out Peak-to-Peak Output Noise Measurement Test Input Source Impedance 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. 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. +Vin +Out Single Output DC / DC Converter Copper Strip Cout -Vin -Out +Vin +Out Com. -Vin -Out 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 22uF for the 12V input devices and a 6.8uF for the 24V and 48V devices. Resistive Load Copper Strip Cout Dual Output DC / DC Converter Scope Cout + Scope Resistive Load DC Power Source Scope - +Vin + +Out DC / DC Converter Load Cin -Vin -Out 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 -0V to 1.0V. A logic high is 2.5V to 100V. The maximum sink current at on/off terminal during a logic low is -100 uA. The maximum allowable leakage current of the switch at on/off terminal (2.5 to 100V) is 5uA. REV:0 2005/04 MINMAX 6 MKW3000 Series 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 Load Cout Load -Out Maximum Capacitive Load The MKW3000 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 270uF maximum capacitive load for dual outputs, 680uF capacitive load for 12V & 15V outputs and 6800uF capacitive load for 3.3V & 5V outputs. 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 105C. The derating curves are determined from measurements obtained in an experimental apparatus. Position of air velocity probe and thermocouple 15mm / 0.6in 7 50mm / 2in Air Flow DUT MINMAX REV:0 2005/04 MKW3000 Series Mechanical Dimensions 5 6 Dual Output 15.2 [0.60] 2 Side 1.00[ Bottom 1 0.039] 4 20.30 [0.800] 3 Single Output 2.5 [0.1] 50.8 [2.00] 10.20 [0.402] 10.20 [0.402] Connecting Pin Patterns Top View ( 2.54 mm / 0.1 inch grids ) 10.2 [0.40] 5.08 [0.200] 25.4 [1.00] Tolerance Pin 6.0 [0.24] 10.2 [0.40] 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 3 +Vout +Vout 4 No Pin Common 5 -Vout -Vout 6 Remote On/Off Remote On/Off 50.8*25.4*10.2 mm Case Size : Case Material : Metal With Non-Conductive Baseplate Weight : 30g Flammability : UL94V-0 2.0*1.0*0.4 inches The MKW3000 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