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| Data Sheet July 1999 JW050A, JW075A, JW100A, JW150A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 150 W Features s Small size: 61.0 mm x 57.9 mm x 12.7 mm (2.40 in. x 2.28 in. x 0.50 in.) High power density High efficiency: 84% typical Low output noise Constant frequency Industry-standard pinout Metal baseplate 2:1 input voltage range Overtemperature protection (100 W and 150 W only) Overcurrent and overvoltage protection Remote sense Remote on/off Adjustable output voltage: 60% to 110% of VO, nom Case ground pin ISO9001 Certified manufacturing facilities s s s s s s s s s s s The JW050A, JW075A, JW100A, and JW150A Power Modules use advanced, surface-mount technology and deliver highquality, efficient, and compact dc-dc conversion. Applications s s s s s s s s Distributed power architectures Workstations Computer equipment Communications equipment UL* 1950 Recognized, CSA C22.2 No. 950-95 Certified, and VDE 0805 (EN60950, IEC950) Licensed CE mark meets 73/23/EEC and 93/68/EEC directives s Options s s Heat sinks available for extended operation Choice of remote on/off logic configuration * UL is a registered trademark of Underwriters Laboratories, Inc. CSA is a registered trademark of Canadian Standards Assn. 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.) Description The JW050A, JW075A, JW100A, and JW150A Power Modules are dc-dc converters that operate over an input voltage range of 36 Vdc to 75 Vdc and provide a precisely regulated dc output. The outputs are fully isolated from the inputs, allowing versatile polarity configurations and grounding connections. The modules have maximum power ratings from 50 W to 150 W at a typical full-load efficiency of 84%. The sealed modules offer a metal baseplate for excellent thermal performance. Threaded-through holes are provided to allow easy mounting or addition of a heat sink for high-temperature applications. The standard feature set includes remote sensing, output trim, and remote on/off for convenient flexibility in distributed power applications. JW050A, JW075A, JW100A, JW150A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1999 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: Continuous: JW050A, JW075A JW100A, JW150A Transient (100 ms; JW100A, JW150A only) I/O Isolation Voltage (for 1 minute) Operating Case Temperature (See Thermal Considerations section.) Storage Temperature Symbol Min Max Unit VI VI VI, trans -- TC Tstg -- -- -- -- -40 -55 75 80 100 1500 100 125 Vdc Vdc V Vdc C 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 75 V; IO = IO, max): JW050A (See Figure 1.) JW075A (See Figure 2.) JW100A (See Figure 3.) JW150A (See Figure 4.) Inrush Transient Input Reflected-ripple Current, Peak-to-peak (5 Hz to 20 MHz, 12 H source impedance; see Figure 17.) Input Ripple Rejection (120 Hz) 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 20 A (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. Symbol VI Min 36 Typ 48 Max 75 Unit Vdc II, max II, max II, max II, max i2t II -- -- -- -- -- -- -- -- -- -- -- 5 1.7 2.6 3.5 5.2 1.0 -- A A A A A2s mAp-p -- -- 60 -- dB 2 Tyco Electronics Corp Data Sheet July 1999 JW050A, JW075A, JW100A, JW150A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 150 W Electrical Specifications (continued) Table 2. Output Specifications Parameter Output Voltage Set Point (VI = 48 V; IO = IO, max; TC = 25 C) Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life. See Figure 19.) Output Regulation: Line (VI = 36 V to 75 V) Load (IO = IO, min to IO, max) Temperature (TC = -40 C to +100 C) Output Ripple and Noise Voltage (See Figure 18.): RMS Peak-to-peak (5 Hz to 20 MHz) External Load Capacitance Output Current (At IO < IO, min, the modules may exceed output ripple specifications.) Output Current-limit Inception (VO = 90% of VO, nom) Device All All Symbol VO, set VO Min 4.92 4.85 Typ 5.0 -- Max 5.08 5.15 Unit Vdc Vdc All All All -- -- -- -- -- -- 0.01 0.05 15 0.1 0.2 50 %VO %VO mV All All All JW050A JW075A JW100A JW150A JW050A JW075A JW100A JW150A All JW050A JW075A JW100A JW150A All -- -- -- IO IO IO IO IO, cli IO, cli IO, cli IO, cli -- -- -- -- 0 0.5 0.5 0.5 0.5 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- 12.0 18.0 23.0 34.5 170 84 84 84 84 500 40 150 * 10 15 20 30 14 21 26 39 -- -- -- -- -- -- mVrms mVp-p F A A A A A A A A %IO, max % % % % kHz Output Short-circuit Current (VO = 250 mV) Efficiency (VI = 48 V; IO = IO, max; TC = 70 C) Switching Frequency Dynamic Response (IO/t = 1 A/10 s, VI = 48 V, TC = 25 C; tested with a 10 F aluminum and a 1.0 F ceramic capacitor across the load): Load Change from IO = 50% to 75% of IO, max: Peak Deviation Settling Time (VO < 10% of peak deviation) Load Change from IO = 50% to 25% of IO, max: Peak Deviation Settling Time (VO < 10% of peak deviation) All All All All -- -- -- -- -- -- -- -- 2 300 2 300 -- -- -- -- %VO, set s %VO, set s * Consult your sales representative or the factory. These are manufacturing test limits. In some situations, results may differ. Tyco Electronics Corp 3 JW050A, JW075A, JW100A, JW150A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1999 Electrical Specifications (continued) Table 3. Isolation Specifications Parameter Isolation Capacitance Isolation Resistance Min -- 10 Typ 2500 -- Max -- -- Unit pF M General Specifications Parameter Calculated MTBF (IO = 80% of IO, max; TC = 40 C) Weight Min -- Typ 2,600,000 -- Max 100 (3.5) Unit hr. g (oz.) Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See Feature Descriptions for additional information. Parameter Remote On/Off Signal Interface (VI = 0 V to 75 V; open collector or equivalent compatible; signal referenced to VI(-) terminal; see Figure 20 and Feature Descriptions.): JWxxxA1 Preferred Logic: Logic Low--Module On Logic High--Module Off JWxxxA Optional Logic: Logic Low--Module Off Logic High--Module On Logic Low: At Ion/off = 1.0 mA At Von/off = 0.0 V Logic High: At Ion/off = 0.0 A Leakage Current Turn-on Time (See Figure 16.) (IO = 80% of IO, max; VO within 1% of steady state) Output Voltage Adjustment (See Feature Descriptions.): Output Voltage Remote-sense Range Output Voltage Set-point Adjustment Range (trim) Output Overvoltage Protection Overtemperature Protection (shutdown) (100 W and 150 W only; see Feature Descriptions.) * These are manufacturing test limits. In some situations, results may differ. Symbol Min Typ Max Unit Von/off Ion/off Von/off Ion/off -- 0 -- -- -- -- -- -- -- -- 20 1.2 1.0 15 50 35 V mA V A ms -- -- VO, clamp TC -- 60 5.9* -- -- -- -- 105 0.5 110 7.0* -- V %VO, nom V C 4 Tyco Electronics Corp Data Sheet July 1999 JW050A, JW075A, JW100A, JW150A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 150 W Characteristic Curves The following figures provide typical characteristics for the power modules. The figures are identical for both on/off configurations. 2.0 4.0 3.5 INPUT CURRENT, II (A) 1.5 INPUT CURRENT, II (A) 0 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 INPUT VOLTAGE, VI (V) 8-1159 (C) 3.0 2.5 2.0 1.5 1.0 0.5 1.0 0.5 0.0 0.0 0 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 INPUT VOLTAGE, VI (V) 8-1160 (C) Figure 1. Typical JW050A Input Characteristics at Room Temperature Figure 3. Typical JW100A Input Characteristics at Room Temperature 3.0 2.5 INPUT CURRENT, II (A) 6 5 INPUT CURRENT, II (A) 2.0 1.5 1.0 0.5 0.0 0 10 20 30 40 50 60 70 80 INPUT VOLTAGE, VI (V) 8-1131 (C) 4 3 2 1 0 0 10 20 30 40 50 60 70 80 INPUT VOLTAGE, VI (V) 8-1137 (C) Figure 2. Typical JW075A Input Characteristics at Room Temperature Figure 4. Typical JW150A Input Characteristics at Room Temperature Tyco Electronics Corp 5 JW050A, JW075A, JW100A, JW150A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1999 Characteristic Curves (continued) 6 OUTPUT VOLTAGE, VO (V) 6 OUTPUT VOLTAGE, VO (V) 5 4 3 2 1 0 0 1 2 3 4 5 6 7 8 9 10 11 12 5 4 3 2 1 0 0 2 4 6 8 10 12 14 16 18 20 22 24 26 OUTPUT CURRENT, IO (A) 8-1165 (C) OUTPUT CURRENT, IO (A) 8-1167 (C) Figure 5. Typical JW050A Output Characteristics at Room Temperature Figure 7. Typical JW100A Output Characteristics at Room Temperature 6 6 OUTPUT VOLTAGE, VO (V) 4 3 2 1 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1718 OUTPUT CURRENT, IO (A) 8-1134 (C) OUTPUT VOLTAGE, VO (V) 5 5 4 3 2 1 0 0 5 10 15 20 25 30 35 40 OUTPUT CURRENT, IO (A) 8-1140 (C) Figure 6. Typical JW075A Output Characteristics at Room Temperature Figure 8. Typical JW150A Output Characteristics at Room Temperature 6 Tyco Electronics Corp Data Sheet July 1999 JW050A, JW075A, JW100A, JW150A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 150 W Characteristic Curves (continued) 85 84 83 (%) 86 85 84 VI = 36 V VI = 54 V VI = 72 V (%) 82 81 80 79 78 77 76 0 1 2 83 82 81 80 79 78 77 76 VI = 36 V VI = 54 V VI = 72 V EFFICIENCY, 3 4 5 6 7 8 9 10 EFFICIENCY, 0 2 4 6 8 10 12 14 16 18 20 OUTPUT CURRENT, IO (A) 8-1161 (C) OUTPUT CURRENT, IO (A) 8-1163 (C) Figure 9. Typical JW050A Converter Efficiency vs. Output Current at Room Temperature Figure 11. Typical JW100A Converter Efficiency vs. Output Current at Room Temperature 88 86 84 (%) (%) 82 80 VI = 36 V 78 76 74 72 70 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 OUTPUT CURRENT, IO (A) 8-1132 (C) VI = 54 V VI = 72 V 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 0 5 10 EFFICIENCY, EFFICIENCY, VI = 36 V VI = 54 V VI = 72 V 15 20 25 30 OUTPUT CURRENT, IO (A) 8-1138 (C) Figure 10. Typical JW075A Converter Efficiency vs. Output Current at Room Temperature Figure 12. Typical JW150A Converter Efficiency vs. Output Current at Room Temperature Tyco Electronics Corp 7 JW050A, JW075A, JW100A, JW150A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1999 Characteristic Curves (continued) OUTPUT VOLTAGE, VO (V) (100 mV/div) OUTPUT CURRENT, IO (A) (5 A/div) OUTPUT VOLTAGE, VO (V) (20 mV/div) TIME, t (100 s/div) 8-2058 (C) TIME, t (1 s/div) 8-2014 (C) Note: Tested with a 10 F aluminum and a 1.0 F ceramic capacitor across the load. Figure 13. Typical JW150A Output Ripple Voltage at Room Temperature, 48 V Input, IO = Full Load Figure 15. Typical JW150A Transient Response to Step Increase in Load from 50% to 75% of Full Load at Room Temperature and 48 V Input (Waveform Averaged to Eliminate Ripple Component.) OUTPUT VOLTAGE, VO (V) (100 mV/div) REMOTE ON/OFF PIN, VON/OFF (V) TIME, t (100 s/div) 8-2057 (C) 0 OUTPUT CURRENT, IO (A) (5 A/div) OUTPUT VOLTAGE, VO (V) (1 V/div) 0 TIME, t (2 ms/div) 8-1143 (C).b Note: Tested with a 10 F aluminum and a 1.0 F ceramic capacitor across the load. Figure 14. Typical JW150A Transient Response to Step Decrease in Load from 50% to 25% of Full Load at Room Temperature and 48 V Input (Waveform Averaged to Eliminate Ripple Component.) 8 Note: Tested with a 10 F aluminum and a 1.0 F ceramic capacitor across the load. Figure 16. Typical Start-Up from Remote On/Off JW150A1; IO = IO, max Tyco Electronics Corp Data Sheet July 1999 JW050A, JW075A, JW100A, JW150A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 150 W Test Configurations SENSE(+) TO OSCILLOSCOPE LTEST 12 H CS 220 F ESR < 0.1 33 F @ 20 C, 100 kHz ESR < 0.7 @ 100 kHz VI(-) CURRENT PROBE VI(+) CONTACT AND DISTRIBUTION LOSSES VI(+) II SUPPLY VI(-) CONTACT RESISTANCE VO(+) IO LOAD VO(-) BATTERY SENSE(-) 8-749 (C) 8-203 (C).l Note: All measurements are taken at the module terminals. When socketing, place Kelvin connections at module terminals to avoid measurement errors due to socket contact resistance. Note: Measure input reflected-ripple current with a simulated source inductance (LTEST) of 12 H. Capacitor CS offsets possible battery impedance. Measure current as shown above. [ VO(+) - V O (-) ] I O = ----------------------------------------------- x 100 [ V I (+) - V I (-) ] I I - % Figure 17. Input Reflected-Ripple Test Setup Figure 19. Output Voltage and Efficiency Measurement Test Setup COPPER STRIP VO(+) 1.0 F VO(-) 10 F SCOPE RESISTIVE LOAD Design Considerations Input Source Impedance 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. For the test configuration in Figure 17, a 33 F electrolytic capacitor (ESR < 0.7 at 100 kHz) mounted close to the power module helps ensure stability of the unit. For other highly inductive source impedances, consult the factory for further application guidelines. 8-513 (C).d Note: Use a 1.0 F ceramic capacitor and a 10 F aluminum or tantalum capacitor. Scope measurement should be made using a BNC socket. Position the load between 51 mm and 76 mm (2 in. and 3 in.) from the module. Figure 18. Peak-to-Peak Output Noise Measurement Test Setup Tyco Electronics Corp 9 JW050A, JW075A, JW100A, JW150A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1999 Safety Considerations 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., UL1950, CSA C22.2 No. 950-95, and VDE 0805 (EN60950, IEC950). 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: s Remote On/Off Two remote on/off options are available. Positive logic remote on/off turns the module on during a logic-high voltage on the ON/OFF pin, and off during a logic low. Negative logic remote on/off turns the module off during a logic high and on during a logic low. Negative logic (code suffix "1") is the factory-preferred configuration. 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 VI(-) terminal (Von/off). The switch can be an open collector or equivalent (see Figure 20). A logic low is Von/off = 0 V to 1.2 V. The maximum Ion/off during a logic low is 1 mA. The switch should maintain a logic-low voltage while sinking 1 mA. During a logic high, the maximum Von/off generated by the power module is 15 V. The maximum allowable leakage current of the switch at Von/off = 15 V is 50 A. If not using the remote on/off feature, do one of the following: s For negative logic, short ON/OFF pin to VI(-). s For positive logic, leave ON/OFF pin open. Ion/off ON/OFF Von/off The input source is to be provided with reinforced insulation from any 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. s s s 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 20 A normal-blow fuse in the ungrounded lead. Feature Descriptions 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. Figure 20. Remote On/Off Implementation 10 + SENSE(+) VO(+) LOAD VI(+) VI(-) VO(-) SENSE(-) - 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 pin and ground. 8-720 (C).c Tyco Electronics Corp Data Sheet July 1999 JW050A, JW075A, JW100A, JW150A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 150 W Output Voltage Set-Point Adjustment (Trim) Output voltage trim allows the user to increase or decrease the output voltage set point of a module. This is accomplished by connecting an external resistor between the TRIM pin and either the SENSE(+) or SENSE(-) pins. The trim resistor should be positioned close to the module. If not using the trim feature, leave the TRIM pin open. With an external resistor between the TRIM and SENSE(-) pins (Radj-down), the output voltage set point (VO, adj) decreases (see Figure 22). The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. 100 Radj-down = --------- - 2 k % The test results for this configuration are displayed in Figure 23. This figure applies to all output voltages. With an external resistor connected between the TRIM and SENSE(+) pins (Radj-up), the output voltage set point (VO, adj) increases (see Figure 24). The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. ( 100 + % ) ( 100 + 2% ) Radj-up = VO -- - k ------------------------------------- --------------------------------- % 1.225% The test results for this configuration are displayed in Figure 25. The voltage between the VO(+) and VO(-) terminals must not exceed the minimum value of the output overvoltage protection. This limit includes any increase in voltage due to remote-sense compensation and output voltage set-point adjustment (trim). See Figure 21. Although the output voltage can be increased by both the remote sense and by the trim, the maximum increase for the output voltage is not the sum of both. The maximum increase is the larger of either the remote sense or the trim. Consult the factory if you need to increase the output voltage more than the above limitation. The amount of power delivered by the module is defined as the voltage at the output terminals multiplied by the output current. When using remote sense and trim, the output voltage of the module can be increased, which at the same output current would increase the power output of the module. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power. 11 Feature Descriptions (continued) Remote Sense Remote sense minimizes the effects of distribution losses by regulating the voltage at the remote-sense connections. The voltage between the remote-sense pins and the output terminals must not exceed the output voltage sense range given in the Feature Specifications table, i.e.: [VO(+) - VO(-)] - [SENSE(+) - SENSE(-)] 0.5 V The voltage between the VO(+) and VO(-) terminals must not exceed the minimum value of the output overvoltage protection. This limit includes any increase in voltage due to remote-sense compensation and output voltage set-point adjustment (trim). See Figure 21. If not using the remote-sense feature to regulate the output at the point of load, then connect SENSE(+) to VO(+) and SENSE(-) to VO(-) at the module. Although the output voltage can be increased by both the remote sense and by the trim, the maximum increase for the output voltage is not the sum of both. The maximum increase is the larger of either the remote sense or the trim. Consult the factory if you need to increase the output voltage more than the above limitation. The amount of power delivered by the module is defined as the voltage at the output terminals multiplied by the output current. When using remote sense and trim, the output voltage of the module can be increased, which at the same output current would increase the power output of the module. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power. SENSE(+) SENSE(-) VI(+) SUPPLY II VI(-) CONTACT RESISTANCE VO(-) CONTACT AND DISTRIBUTION LOSSES 8-651 (C).m VO(+) IO LOAD Figure 21. Effective Circuit Configuration for Single-Module Remote-Sense Operation Tyco Electronics Corp JW050A, JW075A, JW100A, JW150A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1999 Feature Descriptions (continued) 10M ADJUSTMENT RESISTOR VALUE () Output Voltage Set-Point Adjustment (Trim) (continued) VI(+) ON/OFF CASE VI(-) VO(+) SENSE(+) TRIM Radj-down SENSE(-) VO(-) 8-748 (C).b 1M RLOAD 100k 10k 0 2 4 6 8 10 Figure 22. Circuit Configuration to Decrease Output Voltage % CHANGE IN OUTPUT VOLTAGE (%) 8-880 (C).a Figure 25. Resistor Selection for Increased Output Voltage 1M ADJUSTMENT RESISTOR VALUE () Output Overvoltage Protection 100k 10k 1k The output overvoltage clamp consists of control circuitry, 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. Overtemperature Protection 100 0 10 20 30 40 8-879 (C) % CHANGE IN OUTPUT VOLTAGE (%) Figure 23. Resistor Selection for Decreased Output Voltage The 100 W and 150 W modules feature an overtemperature protection circuit to safeguard against thermal damage. The circuit shuts down the module when the maximum case temperature is exceeded. The module restarts automatically after cooling. VI(+) ON/OFF CASE VI(-) VO(+) SENSE(+) Radj-up TRIM SENSE(-) VO(-) 8-715 (C).b RLOAD Figure 24. Circuit Configuration to Increase Output Voltage 12 Tyco Electronics Corp Data Sheet July 1999 JW050A, JW075A, JW100A, JW150A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 150 W Heat Transfer Without Heat Sinks Increasing airflow over the module enhances the heat transfer via convection. Figure 27 shows the maximum power that can be dissipated by the module without exceeding the maximum case temperature versus local ambient temperature (TA) for natural convection through 4 m/s (800 ft./min.). Note that the natural convection condition was measured at 0.05 m/s to 0.1 m/s (10 ft./min. to 20 ft./min.); however, systems in which these power modules may be used typically generate natural convection airflow rates of 0.3 m/s (60 ft./min.) due to other heat dissipating components in the system. The use of Figure 27 is shown in the following example. Example Thermal Considerations Introduction The power modules operate in a variety of thermal environments; however, sufficient cooling should be provided to help ensure reliable operation of the unit. Heat-dissipating components inside the unit are thermally coupled to the case. Heat is removed by conduction, convection, and radiation to the surrounding environment. Proper cooling can be verified by measuring the case temperature. Peak temperature (TC) occurs at the position indicated in Figure 26. 38.0 (1.50) MEASURE CASE TEMPERATURE HERE 7.6 (0.3) VI (+) VO (+) What is the minimum airflow necessary for a JW100A operating at VI = 54 V, an output current of 20 A, and a maximum ambient temperature of 40 C? Solution Given: VI = 54 V IO = 20 A TA = 40 C Determine PD (Use Figure 30.): 8-716 (C).f ON/OFF + SEN TRIM CASE - SEN VO (-) VI (-) Note: Top view, pin locations are for reference only. Measurements shown in millimeters and (inches). PD = 17 W Determine airflow (v) (Use Figure 27.): v = 2.0 m/s (400 ft./min.) 35 POWER DISSIPATION, PD (W) Figure 26. Case Temperature Measurement Location The temperature at this location should not exceed 100 C. The output power of the module should not exceed the rated power for the module as listed in the Ordering Information table. Although the maximum case temperature of the power modules is 100 C, you can limit this temperature to a lower value for extremely high reliability. For additional information on these modules, refer to the Thermal Management JC-, JFC-, JW-, and JFWSeries 50 W to 150 W Board-Mounted Power Modules Technical Note (TN97-008EPS). 30 25 20 15 10 5 0 0 10 20 30 40 50 60 0.1 m/s (NAT. CONV.) (20 ft./min.) 4.0 m/s (800 ft./min.) 3.5 m/s (700 ft./min.) 3.0 m/s (600 ft./min.) 2.5 m/s (500 ft./min.) 2.0 m/s (400 ft./min.) 1.5 m/s (300 ft./min.) 1.0 m/s (200 ft./min.) 0.5 m/s (100 ft./min.) 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (C) 8-1150 (C).a Figure 27. Forced Convection Power Derating with No Heat Sink; Either Orientation Tyco Electronics Corp 13 JW050A, JW075A, JW100A, JW150A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1999 Thermal Considerations (continued) 20 POWER DISSIPATION, PD (W) Heat Transfer Without Heat Sinks (continued) 12 11 POWER DISSIPATION, PD (W) 18 16 14 12 10 8 6 4 2 0 0 2 4 6 8 10 12 14 16 18 20 OUTPUT CURRENT, IO (A) 8-1184 (C) 10 9 8 7 6 5 4 3 2 1 0 0 1 2 3 4 5 6 7 8 9 10 OUTPUT CURRENT, IO (A) 8-1182 (C) VI = 72 V VI = 54 V VI = 36 V VI = 72 V VI = 54 V VI = 36 V Figure 30. JW100A Power Dissipation vs. Output Current Figure 28. JW050A Power Dissipation vs. Output Current POWER DISSIPATION, PD (W) 45 40 35 30 25 20 15 10 5 0 0 5 10 15 20 25 30 OUTPUT CURRENT, IO (A) 8-1185 (C) 20 POWER DISSIPATION, PD (W) 18 16 14 12 10 8 6 4 2 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 OUTPUT CURRENT, IO (A) 8-1183 (C) VI = 72 V VI = 36 V VI = 54 V VI = 72 V VI = 54 V VI = 36 V Figure 31. JW150A Power Dissipation vs. Output Current Figure 29. JW075A Power Dissipation vs. Output Current 14 Tyco Electronics Corp Data Sheet July 1999 JW050A, JW075A, JW100A, JW150A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 150 W These measured resistances are from heat transfer from the sides and bottom of the module as well as the top side with the attached heat sink; therefore, the case-to-ambient thermal resistances shown are generally lower than the resistance of the heat sink by itself. The module used to collect the data in Figure 32 had a thermal-conductive dry pad between the case and the heat sink to minimize contact resistance. The use of Figure 32 is shown in the following example. Example If an 85 C case temperature is desired, what is the minimum airflow necessary? Assume the JW100A module is operating at VI = 54 V and an output current of 20 A, maximum ambient air temperature of 40 C, and the heat sink is 1/2 inch. Solution Given: VI = 54 V IO = 20 A TA = 40 C TC = 85 C Heat sink = 1/2 in. Determine PD by using Figure 30: PD = 17 W Then solve the following equation: ) ca = ( TC - TA ----------------------PD 1 1/2 IN. HEAT SINK 1 IN. HEAT SINK 1/2 IN. HEAT SINK 1/4 IN. HEAT SINK NO HEAT SINK Thermal Considerations (continued) Heat Transfer with Heat Sinks The power modules have through-threaded, M3 x 0.5 mounting holes, which enable heat sinks or cold plates to attach to the module. The mounting torque must not exceed 0.56 N-m (5 in.-lb.). For a screw attachment from the pin side, the recommended hole size on the customer's PWB around the mounting holes is 0.130 0.005 inches. If a larger hole is used, the mounting torque from the pin side must not exceed 0.25 N-m (2.2 in.-lb.). Thermal derating with heat sinks is expressed by using the overall thermal resistance of the module. Total module thermal resistance (ca) is defined as the maximum case temperature rise (TC, max) divided by the module power dissipation (PD): ) ca = TC, max = ( TC - TA -----------------------------------------PD PD The location to measure case temperature (TC) is shown in Figure 26. Case-to-ambient thermal resistance vs. airflow is shown, for various heat sink configurations and heights, in Figure 32. These curves were obtained by experimental testing of heat sinks, which are offered in the product catalog. 8 CASE-TO-AMBIENT THERMAL RESISTANCE, CA (C/W) 7 6 5 4 3 2 1 0 0 0.5 (100) 1.0 (200) 1.5 (300) ca = ( 85 - 40 ) ----------------------17 ca = 2.6 C/W Use Figure 32 to determine air velocity for the 1/2 inch heat sink. The minimum airflow necessary for the JW100A module is 1.3 m/s (260 ft./min.). 2.0 (400) 2.5 (500) 3.0 (600) 8-1153 (C) AIR VELOCITY, m/s (ft./min.) Figure 32. Case-to-Ambient Thermal Resistance Curves; Either Orientation Tyco Electronics Corp 15 JW050A, JW075A, JW100A, JW150A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1999 Thermal Considerations (continued) Custom Heat Sinks A more detailed model can be used to determine the required thermal resistance of a heat sink to provide necessary cooling. The total module resistance can be separated into a resistance from case-to-sink (cs) and sink-to-ambient (sa) shown below (Figure 33). Solder, Cleaning, and Drying Considerations Post solder cleaning is usually the final circuit-board assembly process prior to electrical testing. The result of inadequate circuit-board cleaning and drying can affect both the reliability of a power module and the testability of the finished circuit-board assembly. For guidance on appropriate soldering, cleaning, and drying procedures, refer to the Board-Mounted Power Modules Soldering and Cleaning Application Note (AP97-021EPS). PD TC cs TS sa TA 8-1304 (C) EMC Considerations For assistance with designing for EMC compliance, please refer to the FLTR100V10 data sheet (DS98-152EPS). Figure 33. Resistance from Case-to-Sink and Sink-to-Ambient For a managed interface using thermal grease or foils, a value of cs = 0.1 C/W to 0.3 C/W is typical. The solution for heat sink resistance is: sa = ------------------------ - cs This equation assumes that all dissipated power must be shed by the heat sink. Depending on the userdefined application environment, a more accurate model, including heat transfer from the sides and bottom of the module, can be used. This equation provides a conservative estimate for such instances. ( TC - TA ) PD Layout Considerations Copper paths must not be routed beneath the power module mounting inserts. For additional layout guidelines, refer to the FLTR100V10 data sheet (DS98-152EPS). 16 Tyco Electronics Corp Data Sheet July 1999 JW050A, JW075A, JW100A, JW150A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 150 W Outline Diagram Dimensions are in millimeters and (inches). Tolerances: x.x mm 0.5 mm (x.xx in. 0.02 in.) x.xx mm 0.25 mm (x.xxx in. 0.010 in.) Top View 57.9 (2.28) MAX 61.0 (2.40) MAX Side View SIDE LABEL* 12.70 0.5 (0.500 0.020) 5.1 (0.20) MIN 1.02 (0.040) DIA SOLDER-PLATED BRASS, 7 PLACES 2.06 (0.081) DIA SOLDER-PLATED BRASS, 2 PLACES (-OUTPUT AND +OUTPUT) Bottom View 12.7 (0.50) 5.1 (0.20) VI (-) CASE VO (-) MOUNTING INSERTS M3 x 0.5 THROUGH, 4 PLACES 10.16 (0.400) 50.8 (2.00) 25.40 (1.000) 10.16 (0.400) -SEN TRIM 17.78 (0.700) 25.40 (1.000) 35.56 (1.400) 35.56 (1.400) ON/OFF +SEN VI (+) 48.26 (1.900) VO (+) 4.8 (0.19) 48.3 (1.90) 8-1945 (C).a * Side label includes Tyco name, product designation, safety agency markings, input/output voltage and current ratings, and bar code. Tyco Electronics Corp 17 JW050A, JW075A, JW100A, JW150A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1999 Recommended Hole Pattern Component-side footprint. Dimensions are in millimeters and (inches). 57.9 (2.28) MAX 4.8 (0.19) 48.3 (1.90) VI (+) 48.26 (1.900) VO (+) 35.56 (1.400) 50.8 (2.00) 25.40 (1.000) 10.16 (0.400) ON/OFF +SEN TRIM 35.56 (1.400) 25.40 (1.000) 17.78 10.16 (0.700) (0.400) 61.0 (2.40) MAX CASE -SEN VI (-) VO (-) 5.1 (0.20) 12.7 (0.50) MODULE OUTLINE 8-1945 (C).a MOUNTING INSERTS Ordering Information Table 4. Device Codes Input Voltage 48 V 48 V 48 V 48 V 48 V 48 V 48 V 48 V Output Voltage 5.0 V 5.0 V 5.0 V 5.0 V 5.0 V 5.0 V 5.0 V 5.0 V Output Power 50 W 75 W 100 W 150 W 50 W 75 W 100 W 150 W Remote On/Off Logic Negative Negative Negative Negative Positive Positive Positive Positive Device Code JW050A1 JW075A1 JW100A1 JW150A1 JW050A JW075A JW100A JW150A Comcode 107361370 107071581 107361404 107361453 107304792 107361388 107002750 107361446 18 Tyco Electronics Corp Data Sheet July 1999 JW050A, JW075A, JW100A, JW150A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 150 W Ordering Information (continued) Table 5. Device Accessories Accessory 1/4 in. transverse kit (heat sink, thermal pad, and screws) 1/4 in. longitudinal kit (heat sink, thermal pad, and screws) 1/2 in. transverse kit (heat sink, thermal pad, and screws) 1/2 in. longitudinal kit (heat sink, thermal pad, and screws) 1 in. transverse kit (heat sink, thermal pad, and screws) 1 in. longitudinal kit (heat sink, thermal pad, and screws) 1 1/2 in. transverse kit (heat sink, thermal pad, and screws) 1 1/2 in. longitudinal kit (heat sink, thermal pad, and screws) Dimensions are in millimeters and (inches). Comcode 407243989 407243997 407244706 407244714 407244722 407244730 407244748 407244755 1/4 IN. 1/4 IN. 1/2 IN. 1/2 IN. 1 IN. 61 (2.4) 1 IN. 57.9 (2.28) 1 1/2 IN. 57.9 (2.28) 1 1/2 IN. 61 (2.4) D000-c.cvs D000-d.cvs Figure 34. Longitudinal Heat Sink Figure 35. Transverse Heat Sink Tyco Electronics Corp 19 JW050A, JW075A, JW100A, JW150A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1999 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.tycoeleectronics.com Tyco Electronics Corportation 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 1999 DS99-284EPS (Replaces DS98-088EPS) Printed on Recycled Paper |
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