MKW2500 Series 15W, Wide Input Range, Single & Dual Output DC/DC Converters Key Features y y y y y y y y y y Efficiency up to 86% 1500VDC Isolation MTBF > 700,000 Hours 2:1 Wide Input Range CSA1950 Safety Approval Complies with EN55022 Class A Six-Sided Shielding Remote On/Off Control UL 94V-0 Package Material Internal SMD Construction Minmax's MKW2500 series, comprising 21 different models, has been conceived as an application specific range of DC/DC converters, specially addressing data communication equipments, mobile battery 2:1 High Power Density Wide Range More Power driven equipments, distributed power systems, telecommunication equipments, mixed analog/digital subsystems, process/machine control equipments, computer peripheral systems and industrial robot systems. Packing up to 15W of power into a 2x1x0.4 inch package, with efficiency as high as 86%, the MKW2500 has wide input ranges of 9-18VDC, 18-36VDC and 36-75VDC which is available in output 1500 VDC voltages of 3.3V, 5V, 5.1V, 12V, 15V, {12V and {15VDC. Other feathers include continuous short circuit protection, remote on/off, six-sided shielded case and EN55022 Class A conducted noise I/O Isolation compliance minimize design-in time, cost and eliminate the need for EMI EN55022 Remote on/off external filtering. Block Diagram Single Output +Vin Dual Output +Vo LC Filter +Vin +Vo LC Filter Com. -Vo -Vin 1 PWM Isolation Ref.Amp -Vo -Vin MINMAX PWM Isolation Ref.Amp REV:0 2005/04 MKW2500 Series Model Selection Guide Model Number MKW2521 MKW2522 MKW2523 MKW2524 MKW2526 MKW2527 MKW2529 MKW2531 MKW2532 MKW2533 MKW2534 MKW2536 MKW2537 MKW2539 MKW2541 MKW2542 MKW2543 MKW2544 MKW2546 MKW2547 MKW2549 Input Voltage Output Voltage VDC VDC 3.3 5 12 15 {12 {15 5.1 3.3 5 12 15 {12 {15 5.1 3.3 5 12 15 {12 {15 5.1 12 ( 9 ~ 18 ) 24 ( 18 ~ 36 ) 48 ( 36 ~ 75 ) Output Current Max. mA 3000 3000 1250 1000 {625 {500 3000 3000 3000 1250 1000 {625 {500 3000 3000 3000 1250 1000 {625 {500 3000 Min. mA 300 300 125 100 {62.5 {50 300 300 300 125 100 {62.5 {50 300 300 300 125 100 {62.5 {50 300 @Max. Load @No Load mA (Typ.) mA (Typ.) 1057 1524 1452 1452 1452 1452 1574 528 762 726 726 726 726 787 264 381 363 363 363 363 393 Reflected Ripple Current mA (Typ.) 30 50 20 40 10 30 Efficiency @Max. Load % (Typ.) 78 82 86 86 86 86 81 78 82 86 86 86 86 81 78 82 86 86 86 86 81 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 Input Current Min. -0.7 -0.7 -0.7 ----- Max. 25 50 100 260 5,000 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. 6. All DC/DC converters should be externally fused at the front end for protection. Environmental Specifications Parameter Operating Temperature Operating Temperature Storage Temperature Humidity Cooling RFI Conducted EMI REV:0 2005/04 Conditions Ambient Case Min. Max. -40 +60 -40 +100 -50 +125 --95 Free-Air Convection Six-Sided Shielded, Metal Case EN55022 Class A Unit ] ] ] % MINMAX 7. Other input and output voltage may be available, please contact factory. 8. To order the converter with Remote On/Off function, please add a suffix -RC (e.g. MKW2521-RC). 9. To order the converter with EN55022 Class A function, please add a suffix A (e.g. MKW2521A). 10. Specifications subject to change without notice. 2 MKW2500 Series Input Specifications Parameter Start Voltage Under Voltage Shutdown Model Min. Typ. Max. 12V Input Models 8 8.5 9 24V Input Models 15 17 18 48V Input Models 30 33 36 12V Input Models 7 8 8.5 24V Input Models 13 15 17 48V Input Models 25 29 34 --- --- 1 A --- --- 3500 mW Reverse Polarity Input Current Short Circuit Input Power All Models Input Filter Unit VDC Pi Filter Output Specifications Parameter Conditions Min. Typ. Max. Unit --- {1.0 {2.0 % Dual Output, Balanced Loads --- {0.5 {2.0 % Line Regulation Vin=Min. to Max. --- {0.1 {0.5 % Load Regulation Io=10% to 100% --- {0.5 {1.0 % --- 55 80 mV P-P --- --- 100 mV P-P --- --- 15 mV rms Over Power Protection 120 --- --- % Transient Recovery Time --- 300 500 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 290 330 400 KHz MIL-HDBK-217F @ 25], Ground Benign 700 --- --- K Hours Conditions Min. Typ. Max. Unit Remote On/Off Control Parameter Supply On 2.5 to 5.5VDC or Open Circuit Supply Off -0.7 --- 0.8 VDC Standby Input Current --- --- 10 mA --- --- 50 uA --- --- -1 mA Control Input Current ( on ) Vin-RC=5.0V Control Input Current ( off ) Vin-RC=0V Control Common 3 Referenced to Negative Input MINMAX REV:0 2005/04 MKW2500 Series Capacitive Load Models by Vout Maximum Capacitive Load 3.3V 5V 5.1V 12V 15V {12V # {15V # Unit 470 470 470 470 470 220 220 uF # For each output Input Fuse Selection Guide 12V Input Models 24V Input Models 48V Input Models 2500mA Slow - Blow Type 1250mA Slow - Blow Type 750mA Slow - Blow Type Input Voltage Transient Rating 150 140 130 120 48VDC Input Models 110 Vin ( VDC ) 100 90 80 24VDC Input Models 70 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 (%) MKW2500 Series 80 70 60 80 70 60 50 50 Low Nom High Low Nom Input Voltage (V) Input Voltage (V) Efficiency vs Input Voltage ( Single Output ) Efficiency vs Input Voltage ( Dual Output ) 90 100 80 90 80 Efficiency (%) 70 Efficiency (%) High 60 50 70 60 50 40 30 40 10 40 20 60 80 30 100 Load Current (%) 20 40 60 80 100 Load Current (%) Efficiency vs Output Load ( Single Output ) 100 Efficiency vs Output Load ( Dual Output ) 400LFM 100LFM 80 Output Power (%) 10 200LFM Natural convection 60 40 20 0 -40 50 60 70 90 80 Ambient Temperature 100 110 ] Derating Curve 5 MINMAX REV:0 2005/04 MKW2500 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 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. +Out DC / DC Converter Current Probe Input Source Impedance Load -Out Peak-to-Peak Output Noise Measurement Test Use a Cout 0.47uF 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. 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. + +Vin +Out Single Output DC / DC Converter Copper Strip Cout -Vin -Out +Vin +Out Dual Output DC / DC Converter Com. -Vin -Out DC Power Source Resistive Scope Load - +Vin + +Out DC / DC Converter Load Cin -Vin -Out Copper Strip Cout Scope Cout Scope Resistive Load 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 -1 mA. The maximum allowable leakage current of the switch at on/off terminal (2.5 to 5.5V) is 50uA. REV:0 2005/04 MINMAX 6 MKW2500 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 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 -Out Maximum Capacitive Load The MKW2500 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 220uF maximum capacitive load for dual outputs and 470uF capacitive load for single 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 100C. 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 MKW2500 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 -Vout -Vout 5 6 50.8*25.4*10.2 mm Case Size : Case Material : Metal With Non-Conductive Baseplate Weight : 32g Flammability : UL94V-0 2.0*1.0*0.4 inches Remote On/Off (Optional) The MKW2500 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