FLVOTEK MV10H DC/DC power supply

FAVOTEK MV10H Wide Voltage Isolated DC/DC Converter

Introduction: When you encounter the replacement value of the discontinued DC/DC module - MV10H

In the maintenance and upgrade of industrial control systems, measuring instruments, wireless network equipment, and telecommunications infrastructure, one of the most common thorny issues that engineers face is the sudden announcement of the discontinuation (EOL) of a critical DC/DC power module. Especially for modules that use non-standard pin arrangements, special output voltages, or wide input ranges (such as Woodward's isolated power supply, Vicor or Murata's old models), once the power supply is cut off, the cost of retrofitting the entire system may sharply increase. At this point, finding a substitute with electrical parameter compatibility, packaging standards, stable supply, and complete protection functions has become the top priority for hardware engineers and maintenance teams.

The MV10H series 10W DC/DC converter launched by FAVOTEK is an ideal solution designed to meet such demands. It adopts industry standard DIP 2 "× 1" metal packaging, providing a 2:1 wide input voltage range (5V/12V/24V/48V nominal input), single or dual output (3.3V to ± 24V), and has 1.5kV DC isolation, remote switch control, output voltage fine-tuning, and comprehensive electrical protection functions. This article will provide an in-depth analysis of the technical specifications, application circuit design, EMC rectification methods, and how to seamlessly replace discontinued modules of the MV10H series from an engineering perspective.

Product Overview and Selection Comparison Table

2.1 Overview of Core Features

Output power: 10 W (naturally air-cooled, no additional heat sink required)

Wide input range: 2:1, for example, 9-18 VDC (corresponding to 12V nominal input), 18-36 VDC (24V), 36-75 VDC (48V), etc

Isolation voltage: 1.5 kVDC (input to output, 1 minute)

Working temperature: -40 ℃ to+85 ℃ (refer to the derating curve)

Efficiency: up to 88% (typical value 83%~88%)

Output regulation: Output voltage accuracy ± 1% (typical), linear adjustment rate ± 0.5%, load adjustment rate ± 1% (main output)

Ripple and noise: ≤ 100 mVp-p (20 MHz bandwidth)

Protection functions: undervoltage shutdown, overcurrent protection (110%~190% Iout), short circuit protection (continuous, self recovering)

Remote switch: positive logic (hanging or high level=on, connected to low level=off)

Output voltage fine adjustment: ± 10% range

Safety certification: Complies with IEC/EN/UL 62368-1, EMC meets CISPR32/EN55032 Class B (requires external circuit)

MTBF:>1 million hours (MIL-HDBK-217F, 25 ℃)

2.2 Complete Model and Output Capability

The MV10H series covers the most commonly used voltage combinations in industrial control. The following table summarizes the main models and their output current and capacitive load capacity (engineers need to pay special attention to capacitive loads when replacing them, as excessive external capacitors may cause startup failure):

Model input nominal (range) output voltage output current (mA) typical efficiency maximum capacitive load

MV10H-0505 5V (4.5~9V) 5V 2000 85% 470 µF

MV10H-0512 5V 12V 834 83% 470 µF

MV10H-0515 5V 15V 667 84% 330 µF

MV10H-0524 5V 24V 417 83% 100 µF

MV10H-0505D 5V ±5V ±1000 78% 1000 µF

MV10H-0512D 5V ±12V ±417 83% 470 µF

MV10H-0515D 5V ±15V ±334 84% 330 µF

MV10H-0524D 5V ±24V ±209 83% 100 µF

MV10H-1205 12V (9~18V) 5V 2000 83% 2200 µF

MV10H-1212 12V 12V 834 85% 470 µF

MV10H-1215 12V 15V 667 86% 330 µF

MV10H-1224 12V 24V 416 86% 100 µF

MV10H-1215D 12V ±15V ±334 86% 330 µF

MV10H-2405 24V (18~36V) 5V 2000 83% 2200 µF

MV10H-2412 24V 12V 834 87% 470 µF

MV10H-2415 24V 15V 667 88% 330 µF

MV10H-2424 24V 24V 416 88% 100 µF

MV10H-4803 48V (36~75V) 3.3V 2400 79% 2200 µF

MV10H-4805 48V 5V 2000 83% 2200 µF

MV10H-4812 48V 12V 834 87% 470 µF

MV10H-4815 48V 15V 667 87% 330 µF

MV10H-4824 48V 24V 416 88% 100 µF

Replacement reminder: When the output voltage or current of the original module (such as discontinued Woodhead, Lambda, RECOM, etc.) is similar, priority should be given to selecting models with equivalent capacitive load capacity in MV10H. If a large number of electrolytic capacitors (e.g.>500 µ F) have been connected in parallel at the output of the original system, it is necessary to reduce external capacitors or add soft start circuits.

In depth interpretation of electrical specifications - the top ten parameters that engineers are most concerned about

3.1 Input voltage surge and starting voltage

The input voltage surge allowed by MV10H (lasting ≤ 1 second) is much higher than the normal operating range:

5V input model: Maximum 16 VDC

12V input model: maximum 25 VDC

24V input model: maximum 50 VDC

48V input model: maximum 100 VDC

This provides valuable tolerance for industrial sites with power transients, such as contactor action and motor start stop. The starting voltage threshold has been carefully designed to avoid frequent on/off during slight voltage drops.

3.2 Output voltage accuracy and load adjustment

Accuracy: Under any load (0%~100%), the output voltage error is typically ± 1%, with a maximum of ± 3%. For analog circuits with strict requirements (such as supplying ± 15V to operational amplifiers), an initial accuracy of 1% is sufficient and does not require additional calibration.

Linear adjustment rate: ± 0.5% (input voltage changes from minimum to maximum). For example, for MV10H-2415 with 24V input, the input jumps from 18V to 36V, and the output change at 15V does not exceed 75 mV.

Load adjustment rate: ± 1% for main output, ± 1.5% for auxiliary output (negative pressure or second channel of dual module). If the dual output is unbalanced (such as+15V with 80% load, -15V with 20% load), the cross adjustment rate is typically ± 5%. Therefore, in applications that require extremely high symmetry, such as precision bipolar ADC drivers, it is recommended to balance positive and negative loads as much as possible.

3.3 Ripple and Noise

Measured at a bandwidth of 20 MHz, the typical ripple is 40 mVp-p, with a maximum of 100 mVp-p. In practical applications, this series adopts PWM control, with a switching frequency of 312.5 kHz at full load, much higher than the audible frequency of the human ear and easy to filter. Attention: When measuring ripple, it is necessary to use a ground loop (attached to the probe), otherwise high-frequency radiation noise may be introduced, and the reading may reach up to 200 mV.

3.4 Dynamic load response

When the load steps from 25% to 75% (or reverse), the peak deviation of the output voltage is typically ± 3%, and the recovery time is about 300 µ s (maximum 500 µ s). This means that MV10H can cope with sudden changes in current from sleep to full speed operation of digital circuits (FPGA, DSP) without causing system reset.

3.5 Protection Function: Undervoltage, Overcurrent, Short Circuit

Protection type action threshold behavior

Input undervoltage shutdown 5V input:<3.5V; 12V input:<6.5V; 24V input:<15.5V; 48V input:<30V Module shutdown, self recovery after voltage recovery

Overcurrent protection 110%~190% rated output current limit or hiccup mode

Short circuit protection output terminal directly short circuited continuously without damage, automatically restored after removing the short circuit

These protections are crucial for replacing old modules - many early DC/DC modules did not have complete short-circuit protection, which could burn out the module or even cause a fire in case of a subsequent fault. The "automatic recovery" feature of MV10H significantly reduces on-site maintenance costs.

Remote switch and output voltage fine-tuning - flexible power management

4.1 Remote On/Off

Pin 1 (Ctrl) supports positive logic control:

High level (floating or>2.7V): The module is working normally.

Low level (<1.2V or grounded): The module is turned off, the output is zero, and the input static current drops to microampere level.

This function can be used for system power on timing control, low-power standby, or fault interlock protection. In actual replacement design, if the original module does not have a remote switch, the Ctrl pin can be left hanging (pulled up internally), and the module defaults to normally open.

4.2 Output Trim

The MV10H single output model allows the output voltage to be adjusted within ± 10% of the rated value (some models support it, please refer to the detailed manual for details). Connect the Trim pin to+Vout or GND through an external resistor to achieve boost or buck. Formula (typical):

Increase output voltage: Connect a resistor between TRIM and GND

Reduce output voltage: Connect a resistor between TRIM and+VOUT

The fine-tuning function can be used to compensate for long line voltage drop or adapt to non-standard voltage devices (such as fine-tuning 5V to 5.5V for USB charging ports). However, it should be noted that the output power is still limited by 10W after fine-tuning, and the current must be reduced accordingly.

Application Circuit and EMC Design - Practical Methods Using EN55032 Class B

5.1 Basic Application Circuit (Reducing Ripple)

Although the output ripple of MV10H itself is already low, for sensitive loads such as high-precision ADCs and RF circuits, it is recommended to use the typical external circuit shown in Figure 1: parallel 100 µ F electrolytic capacitor (CIN) on the input side and parallel 10 µ F capacitor (COUP) on the output side. The capacitor should be placed near the module pins and connected in parallel with a small capacity ceramic capacitor (0.1 µ F) to suppress high-frequency spikes.

text

Vin  ----[CIN]----+----[MV10H Vin]        [MV10H Vout]----+----[COUT]---- Vout+

|                                          |

GND ------------------------------------- GND

Attention: Excessive output capacitance (exceeding the "Max. Capacitive Load" value in the specification) may cause slow voltage ramp up or trigger short-circuit protection during startup. If a large capacitor must be used, a PTC thermistor can be connected in series or a soft start circuit can be used.

5.2 EMC Enhancement Solution - Meets EN55032 Class B Industrial Standard

Many export devices require conduction and radiation emissions to meet Class B limits. MV10H can meet Class A without external circuits, but can easily pass Class B through the following recommended circuits (see PDF Table 2):

Input voltage MOV L (common mode choke) C1, C2, C4 CY1, CY2

5V -4.7 µ H (differential mode) 4.7 µ F+2200 µ F+4.7 µ F 1 nF/2 kV

12V 200V 470 µ H common mode 4.7 µ F+330 µ F+1 µ F+330 µ F 1 nF/2 kV

24V 200V 4.7 mH common mode 680 µ F+1 µ F+330 µ F+4.7 µ F 1 nF/2 kV

48V 140V 4.7 mH common mode 680 µ F+1 µ F+330 µ F+4.7 µ F 1 nF/2 kV

Design points:

MOV: Varistors are used to suppress input surges.

Common mode choke (LCM): Select the appropriate inductance (470 µ H~4.7 mH) and ensure that the rated current is not less than the maximum input current.

Y capacitors (CY1, CY2): connected from the input/output terminal to the chassis ground (PGND), can effectively filter out common mode noise. The withstand voltage needs to be above 2 kV.

Fuse: The input terminal should be connected in series with a slow melting fuse that meets UL certification, with a rated current equal to the maximum input current multiplied by 1.5 times.

Engineering experience: Many replacement projects did not consider EMI filtering for the original power module, resulting in excessive overall radiation. Using MV10H in conjunction with the recommended circuit not only improves conversion efficiency, but also passes certification testing in one go.

Thermal design and derating curve

6.1 Operating temperature range

MV10H can operate at full load in ambient temperatures ranging from -40 ℃ to+85 ℃, provided that the derating curve is met (see PDF derating diagram). Typical derating requirements:

Below+55 ℃: capable of outputting 100% rated power.

+55 ℃ to+85 ℃: For every 1 ℃ increase, the output power linearly decreases to 50% (at 85 ℃).

It is not recommended to use above+85 ℃.

6.2 Suggestions for heat dissipation installation

Due to the use of 2 "× 1" metal aluminum shell packaging, the thermal pad has good contact with the outer shell. In a sealed computer case, it is recommended to:

Apply thermal grease or install thermal pads between the bottom of the module and the metal casing.

Avoid stacking thermal sensitive components around the module.

For high current models with 48V input and 3.3V output (such as MV10H-4803, output 2.4A), more attention should be paid to heat dissipation, and small heat sinks can be installed.

Mechanical dimensions and pin definitions

The packaging of MV10H is standard DIP 24 (but the actual number of pins is 6 or 5, depending on the single/dual output), with dimensions of 50.8 mm x 25.4 mm x 12 mm (length x width x height) and pin spacing of 2.54 mm (0.1 inch), compatible with the vast majority of existing DIP sockets and PCB hole positions.

Pin Function Table

Pin number Single output model Dual output model

1 Ctrl Ctrl

2 GND (input ground) GND (input ground)

3 Vin (positive input) Vin (positive input)

4 +Vout +Vout

5 Pin less COM (Common Ground)

6 No Pin Out

Pin verification during replacement: If the original module uses SIP or different pin sorting, an adapter board may need to be made. But the 2 "× 1" DIP package of MV10H is one of the most universal sizes, which can directly replace most industry standards (such as ISO9000 series compatible modules).

Practical case: How to replace a discontinued 10W isolated power supply with MV10H

Scene reproduction

A certain factory's imported PCB drilling machine uses Lambda PXD10-24D15 (24V input, ± 15V/0.33A output, DIP package) on its control board. This module has been discontinued and the original model cannot be found on the market. Alternative requirements: 1.5kV isolation, equivalent efficiency, pins as close as possible, working environment temperature of 50 ℃ and vibration.

Replacement steps

Electrical parameter matching: ± 15V, 10W ->MV10H-2415D (24V input, ± 15V output, 334 mA, efficiency 86%, pin definition completely consistent).

Pin compatibility check: The original module is a 6-pin DIP with a spacing of 2.54mm, and the MV10H pin position is the same, so there is no need to change the PCB.

Capacitive load: The output end of the original board already has 100 µ F electrolysis (each output to ground). MV10H-2415D allows a maximum capacitive load of 330 µ F, meeting the requirements.

EMC modification: The original system had no input filter, and the conducted emission occasionally exceeded the standard. The new design incorporates a common mode choke (470 µ H) and two Y capacitors, successfully passing EN55032 Class B.

Long term reliability: MTBF>1 million hours, far higher than the original module's 500000 hours, and comes with a 3-year warranty.

After replacement testing: The measured errors of ± 15V output at full load are+1.2% and -1.8%, respectively, with a ripple of 35 mVp-p. The dynamic response meets the requirements of spindle motor control.

Common troubleshooting and precautions

Possible causes and solutions for the fault phenomenon

No output input voltage below the start-up threshold when powered on; Ctrl grounding measurement input voltage; Disconnect the Ctrl pin (floating)

Low output voltage and heavy load (exceeding 10W); Significant input line loss reduces load; Bold input wire or increase input voltage

The output ripple is large and the output capacitance does not meet the recommended value; Measurement method error: adding 10 µ F+0.1 µ F ceramic capacitor; Use ground wire loop probe

Intermittent shutdown of overcurrent or overheating protection triggered by the module to check if the load is short circuited; Improve heat dissipation and view the derating curve

Radiation exceeds the standard without using common mode choke and Y capacitor. Refer to Table 2 and add EMI filter