Data Sheet June 1999 JW050H, JW075H, JW100H, JW150H, JW175H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 175 W Features The JW-Series Power Modules use advanced, surface-mount technology and deliver high-quality, efficient, and compact dc-dc conversion. Applications Distributed power architectures Workstations Computer equipment 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: 89% typical Low output noise Constant frequency Industry-standard pinout Metal baseplate 2:1 input voltage range Overtemperature protection (100 W, 150 W, 175 W only) Remote sense Remote on/off Adjustable output voltage: 60% to 110% of VO, nom Case ground pin ISO9001 Certified manufacturing facilities Communications equipment Options Heat sinks available for extended operation Choice of remote on/off logic configuration UL* 1950 Recognized, CSA 22.2 No. 950-95 Certified, VDE 0805 (EN60950, IEC950) Licensed CE mark meets 73/23/EEC and 93/68/EEC directives * 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 JW-Series 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 175 W at a typical full-load efficiency of 89%. 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. JW050H, JW075H, JW100H, JW150H, JW175H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 175 W Data Sheet June 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: JW050H, JW075H JW100H, JW150H, JW175H Transient (100 ms; JW100H, JW150H, and JW175H 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 -- -- -- 75 80 100 Vdc Vdc V -- TC -- -40 1500 100 Vdc C Tstg -55 125 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): JW050H (See Figure 1.) JW075H (See Figure 2.) JW100H (See Figure 3.) JW150H (See Figure 4.) JW175H (See Figure 5.) Inrush Transient Input Reflected-ripple Current, Peak-to-peak (5 Hz to 20 MHz, 12 H source impedance; see Figure 20.) Input Ripple Rejection (120 Hz) Symbol VI Min 36 Typ 48 Max 75 Unit Vdc II, max II, max II, max II, max II, max i2t II -- -- -- -- -- -- -- -- -- -- -- -- -- 5 1.7 2.55 3.4 5.2 6.0 1.0 -- A A A A A A2s mAp-p -- -- 60 -- 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 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. 2 Tyco Electronics Corp. JW050H, JW075H, JW100H, JW150H, JW175H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 175 W Data Sheet June 1999 Electrical Specifications (continued) Table 2. Output Specifications Device Symbol Min Typ Max Unit Output Voltage Set Point (VI = 48 V; IO = IO, max; TC = 25 C) Parameter All VO, set 23.55 24.0 24.45 Vdc Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life. See Figure 22.) All VO 23.28 -- 24.72 Vdc Output Regulation: Line (VI = 36 V to 75 V) Load (IO = IO, min to IO, max) Temperature (TC = -40 C to +100 C) All All All -- -- -- -- -- -- 0.01 0.05 100 0.1 0.2 300 %VO %VO mV Output Ripple and Noise Voltage (See Figure 21.): RMS Peak-to-peak (5 Hz to 20 MHz) All All -- -- -- -- -- -- 150 400 mVrms mVp-p External Load Capacitance All -- 0 -- * F Output Current (At IO < IO, min, the modules may exceed output ripple specifications.) JW050H JW075H JW100H JW150H JW175H IO IO IO IO IO 0.3 0.3 0.3 0.3 0.3 -- -- -- -- -- 2.1 3.1 4.2 6.2 7.3 A A A A A Output Current-limit Inception (VO = 90% of VO, nom) JW050H JW075H JW100H JW150H JW175H IO, cli IO, cli IO, cli IO, cli IO, cli -- -- -- -- -- 2.4 3.6 4.8 7.3 8.1 2.7 4.0 5.5 8.1 9.5 A A A A A All -- -- 170 -- %IO, max JW050H JW075H JW100H JW150H JW175H -- -- -- -- -- 87.5 88.5 89.5 89.0 88.5 -- -- -- -- -- % % % % % All -- -- 500 -- kHz All All -- -- -- -- 3 300 -- -- %VO, set s All All -- -- -- -- 3 300 -- -- %VO, set s Output Short-circuit Current (VO = 250 mV) Efficiency (VI = 48 V; IO = IO, max; TC = 25 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; see Figures 17 and 18.): 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) * Please consult your sales representative or the factory. These are manufacturing test limits. In some situations, results may differ. Tyco Electronics Corp. 3 JW050H, JW075H, JW100H, JW150H, JW175H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 175 W Data Sheet June 1999 Electrical Specifications (continued) Table 3. Isolation Specifications Parameter Isolation Capacitance Isolation Resistance Min -- 10 Typ 2500 -- Max -- -- Unit pF M Min Typ 2,600,000 -- Max Unit hours g (oz.) General Specifications Parameter Calculated MTBF (IO = 80% of IO, max; TC = 40 C) Weight -- 100 (3.5) 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 23 and Feature Descriptions.): JWxxxH1 Preferred Logic: Logic Low--Module On Logic High--Module Off JWxxxH 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 19.) (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 Shutdown (100 W, 150 W and 175W only; see Feature Descriptions.) Symbol Min Typ Max Unit Von/off Ion/off 0 -- -- -- 1.2 1.0 V mA Von/off Ion/off -- -- -- -- -- -- 20 15 50 35 V A ms -- -- -- 60 26.5* -- -- -- -- 105 0.5 110 33.0* -- V %VO, nom V C VO, clamp TC * These are manufacturing test limits. In some situations, results may differ. 4 Tyco Electronics Corp. JW050H, JW075H, JW100H, JW150H, JW175H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 175 W Data Sheet June 1999 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 INPUT CURRENT, II (A) INPUT CURRENT, II (A) 3.5 1.5 1.0 0.5 3.0 2.5 2.0 1.5 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 0 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 INPUT VOLTAGE, VI (V) INPUT VOLTAGE, VI (V) 8-1159 (C) 8-1160 (C) Figure 3. Typical JW100H Input Characteristics at Room Temperature 3.0 6 2.5 5 INPUT CURRENT, II (A) INPUT CURRENT, II (A) Figure 1. Typical JW050H Input Characteristics at Room Temperature 2.0 1.5 1.0 0.5 4 3 2 1 0.0 0 10 20 30 40 50 60 70 80 INPUT VOLTAGE, VI (V) 0 10 20 30 40 50 60 70 80 INPUT VOLTAGE, VI (A) 8-1131 (C) Figure 2. Typical JW075H Input Characteristics at Room Temperature Tyco Electronics Corp. 0 8-1142 (C) Figure 4. Typical JW150H Input Characteristics at Room Temperature 5 JW050H, JW075H, JW100H, JW150H, JW175H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 175 W Data Sheet June 1999 Characteristic Curves (continued) 25 6 OUTPUT VOLTAGE, VO (V) IO = 7.29 A INPUT CURRENT, II (A) 5 4 3 IO = 3.60 A 2 IO = 0.73 A 1 0 0 10 20 30 40 50 60 70 20 15 10 5 0 80 0 INPUT VOLTAGE, VI (V) 1 2 3 4 Figure 5. Typical JW175H Input Characteristics at Room Temperature 8-1287 (C) Figure 7. Typical JW075H Output Characteristics at Room Temperature 20 OUTPUT VOLTAGE, VO (V) OUTPUT VOLTAGE, VO (V) 25 15 10 5 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 OUTPUT CURRENT, IO (A) 25 24 22 20 18 16 14 12 10 8 6 4 2 0 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 OUTPUT CURRENT, IO (A) 8-1286 (C) Figure 6. Typical JW050H Output Characteristics at Room Temperature 6 6 OUTPUT CURRENT, IO (A) 8-2530 (C) 0 0.0 5 8-1288 (C) Figure 8. Typical JW100H Output Characteristics at Room Temperature Tyco Electronics Corp. JW050H, JW075H, JW100H, JW150H, JW175H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 175 W Data Sheet June 1999 Characteristic Curves (continued) 89 25 VI = 36 V 87 20 EFFICIENCY, (%) OUTPUT VOLTAGE, VO (V) 88 15 10 86 VI = 54 V 85 84 83 VI = 75 V 82 5 81 0 79 0.6 80 0 1 2 3 4 5 6 7 8 9 10 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 OUTPUT CURRENT, IO (A) OUTPUT CURRENT, IO (A) 8-1289 (C) Figure 9. Typical JW150H Output Characteristics at Room Temperature 8-1290 (C).A Figure 11. Typical JW050H Converter Efficiency vs. Output Current at Room Temperature OUTPUT VOLTAGE, VO (V) 25 20 VI = 75 V VI = 54 V 15 VI = 36 V 10 5 0 0 1 2 3 4 5 6 7 8 9 OUTPUT CURRENT, IO (A) 8-2529 (C) Figure 10. Typical JW175H Output Characteristics at Room Temperature Tyco Electronics Corp. 8-1291 (C) Figure 12. Typical JW075H Converter Efficiency vs. Output Current at Room Temperature 7 JW050H, JW075H, JW100H, JW150H, JW175H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 175 W Data Sheet June 1999 Characteristic Curves (continued) 90 89 90.5 90.0 VI = 36 V 89.5 VI = 54 V EFFICIENCY, (%) EFFICIENCY, (%) 87 85 83 81 VI = 75 V 79 VI = 36 V VI = 54 V VI = 75 V 89.0 88.5 88.0 87.5 87.0 86.5 86.0 77 85.5 85.0 75 0.0 0.4 0.8 1.2 1.6 2.0 2.4 2.8 3.2 0 3.6 4.0 4.2 1 2 3 4 5 6 7 8 OUTPUT CURRENT, IO (A) OUTPUT CURRENT, IO (A) 8-2528 (C) 8-1292 (C) Figure 13. Typical JW100H Converter Efficiency vs. Output Current at Room Temperature Figure 15. Typical JW175H Converter Efficiency vs. Output Current at Room Temperature 90 89 VI = 36 V VI = 54 V 87 OUTPUT VOLTAGE, VO (V) (100 mV/div) EFFICIENCY, (%) 88 86 85 VI = 75 V 84 83 82 81 80 0 1 2 3 4 5 6 OUTPUT CURRENT, IO (A) 8-1293 (C) Figure 14. Typical JW150H Converter Efficiency vs. Output Current at Room Temperature TIME, t (1 s/div) 8-2017 (C) Figure 16. Typical JW150H Output Ripple Voltage at Room Temperature, 48 V Input, IO = Full Load 8 Tyco Electronics Corp. Data Sheet June 1999 JW050H, JW075H, JW100H, JW150H, JW175H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 175 W OUTPUT CURRENT, IO (V) (1 A/div) OUTPUT VOLTAGE, VO (V) (10 V/div) REMOTE ON/OFF VOLTAGE, VON/OFF (V) OUTPUT VOLTAGE, VO (V) (500 mV/div) Characteristic Curves (continued) 0V 0V TIME, t (5 ms/div) TIME, t (50 s/div) 8-2019 (C) 8-1266 (C).d Note: Tested with a 10 F aluminum and a 1.0 F ceramic capacitor across the load. Figure 17. Typical JW150H 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.) Figure 19. Typical Start-Up from Remote On/Off JW150H1; IO = IO, max OUTPUT CURRENT, IO (V) (1 A/div) OUTPUT VOLTAGE, VO (V) (500 mV/div) Note: Tested with a 10 F aluminum and a 1.0 F ceramic capacitor across the load. TIME, t (50 s/div) 8-2018 (C) Note: Tested with a 10 F aluminum and a 1.0 F ceramic capacitor across the load. Figure 18. Typical JW150H 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.) Tyco Electronics Corp. 9 JW050H, JW075H, JW100H, JW150H, JW175H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 175 W Data Sheet June 1999 Test Configurations SENSE(+) TO OSCILLOSCOPE VI(+) LTEST CURRENT PROBE VO(+) IO II V I (+) CONTACT AND DISTRIBUTION LOSSES LOAD SUPPLY 12 H BATTERY VI(-) CS 220 F ESR < 0.1 33 F @ 20 C, 100 kHz ESR < 0.7 @ 100 kHz CONTACT RESISTANCE V I (-) 8-203 (C).l 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. Figure 20. Input Reflected-Ripple Test Setup COPPER STRIP VO(-) SENSE(-) 8-749 (C) 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. [ V O (+) - V O (-) ] I O = ------------------------------------------------ x 100 [ V I (+) - V I (-) ] I I % Figure 22. Output Voltage and Efficiency Measurement Test Setup Design Considerations V O (+) 1.0 F 10 F SCOPE RESISTIVE LOAD V O (-) 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 21. Peak-to-Peak Output Noise Measurement Test Setup 10 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 20, 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. Tyco Electronics Corp. Data Sheet June 1999 JW050H, JW075H, JW100H, JW150H, JW175H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 175 W Safety Considerations Remote On/Off 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). 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. 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 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. 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. 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. 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 23). 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: For negative logic, short ON/OFF pin to VI(-). For positive logic, leave ON/OFF pin open. Ion/off + ON/OFF Von/off SENSE(+) - VO(+) LOAD VI(+) VI(-) VO(-) SENSE(-) 8-720 (C).c Feature Descriptions Figure 23. Remote On/Off Implementation 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. Tyco Electronics Corp. 11 JW050H, JW075H, JW100H, JW150H, JW175H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 175 W Data Sheet June 1999 Feature Descriptions (continued) SENSE(-) pins. The TRIM resistor should be positioned close to the module. Remote Sense If not using the trim feature, leave the TRIM pin open. 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.: With an external resistor between the TRIM and SENSE(-) pins (Radj-down), the output voltage set point (VO, adj) decreases (see Figure 25). The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. [VO(+) - VO(-)] - [SENSE(+) - SENSE(-)] 0.5 V The voltage between the VO(+) and VO(-) terminals must not exceed 26.4 V. This limit includes any increase in voltage due to remote-sense compensation and output voltage set-point adjustment (trim). See Figure 24. 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(-) SUPPLY VI(+) VO(+) VI(-) VO(-) IO II CONTACT RESISTANCE LOAD CONTACT AND DISTRIBUTION LOSSES 8-651 (C).m Figure 24. Effective Circuit Configuration for Single-Module Remote-Sense Operation 100 R adj-down = ---------- - 2 k % The test results for this configuration are displayed in Figure 26. 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 27). The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. O ( 100 + % ) ( 100 + 2% ) R adj-up = V - - k ------------------------------------% 1.225% - --------------------------------The test results for this configuration are displayed in Figure 28. The voltage between the VO(+) and VO(-) terminals must not exceed 26.4 V. This limit includes any increase in voltage due to remote-sense compensation and output voltage set-point adjustment (trim). See Figure 24. 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. 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 12 Tyco Electronics Corp. JW050H, JW075H, JW100H, JW150H, JW175H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 175 W Data Sheet June 1999 ADJUSTMENT RESISTOR VALUE () Feature Descriptions (continued) Output Voltage Set-Point Adjustment (Trim) (continued) VI(+) ON/OFF CASE VO(+) SENSE(+) RLOAD TRIM Radj-down VI(-) SENSE(-) 100M 10M 1M 100k 0 VO(-) 8-748 (C).b 4 6 8 10 % CHANGE IN OUTPUT VOLTAGE (%) 8-2093 (C) Figure 25. Circuit Configuration to Decrease Output Voltage Figure 28. Resistor Selection for Increased Output Voltage Output Overvoltage Protection 1M ADJUSTMENT RESISTOR VALUE () 2 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. 100k 10k Overtemperature Protection 1k 100 0 10 20 30 40 % CHANGE IN OUTPUT VOLTAGE (%) 8-879 (C) Figure 26. Resistor Selection for Decreased Output Voltage VI(+) ON/OFF The 100 W, 150 W and175 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. VO(+) SENSE(+) Radj-up CASE VI(-) TRIM RLOAD SENSE(-) VO(-) 8-715 (C).b Figure 27. Circuit Configuration to Increase Output Voltage Tyco Electronics Corp. 13 JW050H, JW075H, JW100H, JW150H, JW175H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 175 W Data Sheet June 1999 Thermal Considerations Heat Transfer Without Heat Sinks Introduction Increasing airflow over the module enhances the heat transfer via convection. Figure 30 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.). 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 29. 38.0 (1.50) MEASURE CASE TEMPERATURE HERE 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 30 is shown in the following example. Example 7.6 (0.3) VI (+) ON/OFF What is the minimum airflow necessary for a JW100H operating at VI = 54 V, an output current of 4.2 A, and a maximum ambient temperature of 40 C? VO (+) + SEN Solution TRIM CASE - SEN VI (-) VO (-) Given: VI = 54 V IO = 4.2 A TA = 40 C Determine PD (Use Figure 33): 8-716 (C).f Note: Top view, pin locations are for reference only. Measurements shown in millimeters and (inches). PD = 12 W Determine airflow (v) (Use Figure 30): Figure 29. Case Temperature Measurement Location v = 1.0 m/s (200 ft./min.) 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). POWER DISSIPATION, PD (W) 35 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. 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.) 30 25 20 15 10 5 0.1 m/s (NAT. CONV.) (20 ft./min.) 0 0 10 20 30 40 50 60 70 90 100 80 LOCAL AMBIENT TEMPERATURE, TA (C) 8-1150 (C).a Figure 30. Forced Convection Power Derating with No Heat Sink; Either Orientation 14 Tyco Electronics Corp. JW050H, JW075H, JW100H, JW150H, JW175H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 175 W Data Sheet June 1999 Heat Transfer Without Heat Sinks (continued) 10 POWER DISSIPATION, PD (W) 9 VI = 72 V 8 7 VI = 54 V 6 5 VI = 36 V 4 POWER DISSIPATION, PD (W) Thermal Considerations (continued) 3 14 13 12 11 10 9 VI = 54 V 8 7 6 5 4 3 2 1 0 0.0 0.4 0.8 1.2 2 VI = 72 V VI = 36 V 1.6 2.0 2.4 2.8 3.2 3.6 4.0 4.2 OUTPUT CURRENT, IO (A) 8-1297 (C) 1 0 0.0 0.5 1.5 1.0 2.0 Figure 33. JW100H Power Dissipation vs. Output Current OUTPUT CURRENT, IO (A) 8-1295 (C) Figure 31. JW050H Power Dissipation vs. Output Current POWER DISSIPATION, PD (W) 25 POWER DISSIPATION, PD (W) 14 12 VI = 72 V 10 VI = 54 V 8 6 20 VI = 72 V 15 VI = 54 V 10 VI = 36 V 5 VI = 36 V 0 4 0 2 0 0.0 1 2 3 4 5 6 OUTPUT CURRENT, IO (A) 8-1298 (C) 0.5 1.0 1.5 2.0 2.5 3.0 OUTPUT CURRENT, IO (A) Figure 34. JW150H Power Dissipation vs. Output Current 8-1296 (C) Figure 32. JW075H Power Dissipation vs. Output Current Tyco Electronics Corp. 15 JW050H, JW075H, JW100H, JW150H, JW175H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 175 W Data Sheet June 1999 Thermal Considerations (continued) POWER DISSIPATION, PD (W) 30 25 VI = 72 V VI = 54 V VI = 36 V 20 15 10 CASE-TO-AMBIENT THERMAL RESISTANCE, CA (C/W) 8 Heat Transfer Without Heat Sinks (continued) 7 1 1/2 IN. HEAT SINK 1 IN. HEAT SINK 1/2 IN. HEAT SINK 1/4 IN. HEAT SINK NO HEAT SINK 6 5 4 3 2 1 0 0 5 0.5 (100) 1.0 (200) 1.5 (300) 2.0 (400) 2.5 (500) 3.0 (600) AIR VELOCITY MEASURED IN m/s (ft./min.) 8-1153 (C) 0 0 1 2 3 4 5 6 7 OUTPUT CURRENT, IO (A) Figure 36. Case-to-Ambient Thermal Resistance Curves; Either Orientation 8-2655 (C) Figure 35. JW175H Power Dissipation vs. Output Current 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/lbs.). 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): (TC - TA) C, max ca = T = ------------------------------------------PD PD The location to measure case temperature (TC) is shown in Figure 29. Case-to-ambient thermal resistance vs. airflow is shown, for various heat sink configurations and heights, in Figure 36. These curves were obtained by experimental testing of heat sinks, which are offered in the product catalog. 16 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 36 had a thermal-conductive dry pad between the case and the heat sink to minimize contact resistance. The use of Figure 36 is shown in the following example. Example If an 85 C case temperature is desired, what is the minimum airflow necessary? Assume the JW100H module is operating at VI = 54 V and an output current of 4.2 A, maximum ambient air temperature of 40 C, and the heat sink is 1/2 in. Solution Given: VI = 54 V IO = 4.2 A TA = 40 C TC = 85 C Heat sink = 1/2 in. Determine PD by using Figure 33: PD = 12 W Tyco Electronics Corp. JW050H, JW075H, JW100H, JW150H, JW175H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 175 W Data Sheet June 1999 Thermal Considerations (continued) Solder, Cleaning, and Drying Considerations Heat Transfer with Heat Sinks 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). Then solve the following equation: TC - TA) ca = (----------------------PD 85 - 40 ) ca = (----------------------12 ca = 3.75 C/W Use Figure 36 to determine air velocity for the 1/2 inch heat sink. The minimum airflow necessary for the JW100H module is 0.6 m/s (125 ft./min.). 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 37). PD TC TS cs TA EMC Considerations For assistance with designing for EMC compliance, please refer to the FLTR100V10 data sheet (DS98-152EPS). 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). sa 8-1304 (C) Figure 37. 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: (TC - TA) sa = ------------------------- - cs PD 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. Tyco Electronics Corp. 17 JW050H, JW075H, JW100H, JW150H, JW175H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 175 W Data Sheet June 1999 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) 1.02 (0.040) DIA SOLDER-PLATED BRASS 7 PLACES 5.1 (0.20) MIN 2.06 (0.081) DIA SOLDER-PLATED BRASS 2 PLACES (-OUTPUT AND +OUTPUT) Bottom View MOUNTING INSERTS M3 x 0.5 THROUGH 4 PLACES 12.7 (0.50) 5.1 (0.20) 10.16 (0.400) 50.8 (2.00) 25.40 (1.000) 35.56 (1.400) VI (-) VO (-) CASE -SEN TRIM ON/OFF VI (+) +SEN 48.26 (1.900) 10.16 (0.400) 17.78 (0.700) 25.40 (1.000) 35.56 (1.400) VO (+) TERMINALS 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. 18 Tyco Electronics Corp. JW050H, JW075H, JW100H, JW150H, JW175H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 175 W Data Sheet June 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 (+) 35.56 (1.400) 50.8 (2.00) ON/OFF 48.26 (1.900) VO (+) 35.56 (1.400) +SEN 25.40 (1.000) TRIM 25.40 (1.000) 10.16 (0.400) CASE -SEN VI (-) VO (-) 61.0 (2.40) MAX 17.78 10.16 (0.700) (0.400) 5.1 (0.20) 12.7 (0.50) MOUNTING INSERTS MODULE OUTLINE 8-1945 (C).a Ordering Information Input Voltage 48 V 48 V 48 V 48 V 48 V 48 V 48 V 48 V 48 V 48 V Tyco Electronics Corp. Output Voltage 24.0 V 24.0 V 24.0 V 24.0 V 24.0 V 24.0 V 24.0 V 24.0 V 24.0 V 24.0 V Output Power 50 W 75 W 100 W 150 W 175 W 50 W 75 W 100 W 150 W 175W Remote On/Off Logic negative negative negative negative negative positive positive positive positive positive Device Code JW050H1 JW075H1 JW100H1 JW150H1 JW175H1 JW050H JW075H JW100H JW150H JW175H Comcode 107430258 107477283 107430282 107253197 108180720 107477358 107430266 107477572 107477432 TBD 19 JW050H, JW075H, JW100H, JW150H, JW175H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 175 W Data Sheet June 1999 Ordering Information (continued) Table 4. Device Accessories Accessory Comcode 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) 407243989 407243997 407244706 407244714 407244722 407244730 407244748 407244755 Dimensions are in millimeters and (inches). 1/4 IN. 1/4 IN. 1/2 IN. 1/2 IN. 1 IN. 1 IN. 61 (2.4) 57.9 (2.28) 1 1/2 IN. 1 1/2 IN. 57.9 (2.28) 61 (2.4) D000-c.cvs D000-d.cvs Figure 38. Longitudinal Heat Sink Figure 39. Transverse Heat Sink 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. June 1999 DS99-117EPS (Replaces DS98-093EPS) Printed on Recycled Paper