Data Sheet November 2000 JAHW050F-S and JAHW075F-S Power Modules; dc-dc Converters: 36 Vdc to 75 Vdc Input, 3.3 Vdc Output; 50 W to 75 W Features The JAHW-S Series Power Modules offer a surface-mount package, high efficiency, and high reliability. Applications Surface-mount, open-frame package with industrystandard pin pattern Low profile: 10.16 mm (0.40 in.) Small size: 54.36 mm x 57.40 mm x 10.16 mm (2.14 in. x 2.26 in. x 0.40 in.) High power density Very high efficiency: 89% typical Low output noise Constant frequency 2:1 input voltage range Overcurrent protection Remote sense Adjustable output voltage Output overvoltage protection Distributed power architectures Remote on/off Computer equipment Overtemperature protection Communications equipment ISO* 9001 Certified manufacturing facilities Meets the voltage isolation requirements for ETSI 300-321-2 and complies with and is Licensed for Basic Insulation rating per EN60950 (-SB version only) Options Choice of remote on/off logic configuration Basic Insulation (-SB version only) UL1950 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** Description The JAHW050F-S and JAHW075F-S Power Modules are surface-mount 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 75 W at a typical full-load efficiency of 89%. The open frame modules offer excellent thermal performance. The standard feature set includes remote sensing, output trim, and remote on/off for convenient flexibility in distributed power applications. * ISO is a registered trademark of the International Organization for Standardization. UL is a registered trademark of Underwriters Laboratories, Inc. CSA is a registered trademark of Canadian Standards Association. VDE is a trademark of Verband Deutscher Elektrotechniker e.V. ** 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.) JAHW050F-S and JAHW075F-S Power Modules; dc-dc Converters: 36 Vdc to 75 Vdc Input, 3.3 Vdc Output; 50 W to 75 W Data Sheet November 2000 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 Symbol Min Max Unit VI VI, trans -- -- 80 100 Vdc V Operating Ambient Temperature (See Thermal Considerations section.) TA -40 100 C Storage Temperature Tstg -55 125 C I/O Isolation Voltage (for 1 minute) -- -- 1500 Vdc Input Voltage: Continuous Transient (100 ms) Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Table 1. Input Specifications Parameter Symbol Min Typ Max Unit VI 36 48 75 Vdc II, max II, max -- -- -- -- 1.2 1.8 A A II, max II, max -- -- -- -- 1.0 1.5 A A Inrush Transient i2t -- -- 1.0 A2s Input Reflected-ripple Current, Peak-to-peak (5 Hz to 20 MHz, 12 H source impedance; see Figure 12.) II -- 5 -- mAp-p Input Ripple Rejection (120 Hz) -- -- 60 -- dB Operating Input Voltage Maximum Input Current: VI = 0 V to 75 V; IO = IO, max; see Figures 1--2: JAHW050F-S JAHW075F-S VI = 36 V to 75 V; IO = IO, max: JAHW050F-S JAHW075F-S Fusing Considerations An input line fuse (normal-blow) of an appropriate rating is provided for safety and system protection. A further input lines fuse may always be used for additional safety and system protection. 2 Tyco Electronics Corp. Data Sheet November 2000 JAHW050F-S and JAHW075F-S Power Modules; dc-dc Converters: 36 Vdc to 75 Vdc Input, 3.3 Vdc Output; 50 W to 75 W Electrical Specifications (continued) Table 2. Output Specifications Parameter Device Symbol Min Typ Max Unit Output Voltage Set Point (VI = 48 V; IO = IO, max; TA = 25 C) All VO, set 3.25 3.3 3.35 Vdc Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life. See Figure 14.) All VO 3.20 -- 3.40 Vdc Output Regulation: Line (VI = 36 V to 75 V) Load (IO = IO, min to IO, max) Temperature (TA = -40 C to +100 C) All All All -- -- -- -- -- -- 0.01 0.05 15 0.1 0.2 50 %VO %VO mV Output Ripple and Noise Voltage (See Figure 13.): RMS Peak-to-peak (5 Hz to 20 MHz) All All -- -- -- -- -- -- 50 100 mVrms mVp-p External Load Capacitance All -- 0 -- * F Output Current (At IO < IO, min, the modules may exceed output ripple specifications.) JAHW050F-S JAHW075F-S IO IO 0.5 0.5 -- -- 10 15 A A Output Current-limit Inception (VO = 90% of VO, nom) JAHW050F-S JAHW075F-S IO, cli IO, cli -- -- 12 18 16.0 21.9 A A Output Short-circuit Current (VO = 250 mV) All -- 0 -- 35 A Efficiency (VI = 48 V; IO = IO, max; TA = 70 C) JAHW050F-S JAHW075F-S -- -- 88.0 88.6 -- -- % % All -- -- 350 -- kHz All All -- -- -- -- 6 200 -- -- %VO, set s All All -- -- -- -- 5 200 -- -- %VO, set s Switching Frequency Dynamic Response (IO/t = 1 A/10 s, VI = 48 V, TC = 25 C; tested with a 10 F tantalum 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) * Consult your sales representative or the factory. These are manufacturing test limits. In some situations, results may differ. This module does not have a tail-out feature but a hiccup mode with automatic restart, in the event of a current limit. The value given here is an instantaneous peak value and not an RMS or continuous rating. Table 3. Isolation Specifications Parameter Min Typ Max Unit Isolation Capacitance -- 2500 -- pF Isolation Resistance 10 -- -- M Tyco Electronics Corp. 3 JAHW050F-S and JAHW075F-S Power Modules; dc-dc Converters: 36 Vdc to 75 Vdc Input, 3.3 Vdc Output; 50 W to 75 W Data Sheet November 2000 General Specifications Parameter Min Calculated MTBF (IO = 80% of IO, max; TA = 20 C) Weight Typ Max 6,000,000 -- -- Unit hours 38 (1.34) 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 15 and Feature Descriptions.): JAHWxxxF1 Preferred Logic: Logic Low--Module On Logic High--Module Off JAHWxxxF 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 11.) (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 (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 -- -- 0.5 110 V %VO, nom VO, sd 4.0* -- 5.0* V TC -- 110 -- C * These are manufacturing test limits. In some situations, results may differ. Solder Ball and Cleanliness Requirements The open frame (no case or potting) power module will meet the solder ball requirements per J-STD-001B. These requirements state that solder balls must neither be loose nor violate the power module minimum electrical spacing. The cleanliness designator of the open frame power module is C00 (per J specification). 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). 4 Tyco Electronics Corp. Data Sheet November 2000 JAHW050F-S and JAHW075F-S Power Modules; dc-dc Converters: 36 Vdc to 75 Vdc Input, 3.3 Vdc Output; 50 W to 75 W Characteristic Curves 1.3 1.2 1.1 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.0 91 90 IO = 10 A IO = 5 A IO = 0.5 A VI = 36 V VI = 48 V VI = 75 V 89 EFFICIENCY, (%) INPUT CURRENT, II (A) The following figures provide typical characteristics for the power modules. The figures are identical for both on/off configurations. 88 87 86 85 84 83 82 81 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 2 3 4 INPUT VOLTAGE, VI (V) 5 6 7 8 8-2244 (F) Figure 1. Typical JAHW050F-S Input Characteristics at Room Temperature 10 8-2245 (F) Figure 3. Typical JAHW050F-S Converter Efficiency vs. Output Current at Room Temperature 2.0 90 IO = 15 A IO = 7.5 A IO = 0.75 A 1.6 1.4 1.2 1.0 0.8 0.6 0.4 89 88 EFFICIENCY, (%) 1.8 INPUT CURRENT, II (A) 9 OUTPUT CURRENT, IO (A) 87 86 85 84 VI = 36 V VI = 48 V VI = 75 V 83 82 0.2 81 0.0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 INPUT VOLTAGE, VI (V) 8-2291 (F) 80 2 3 4 5 6 7 8 9 10 11 12 13 14 15 OUTPUT CURRENT, IO (A) 8-2311 (F) Figure 2. Typical JAHW075F-S Input Characteristics at Room Temperature Tyco Electronics Corp. Figure 4. Typical JAHW075F-S Converter Efficiency vs. Output Current at Room Temperature 5 JAHW050F-S and JAHW075F-S Power Modules; dc-dc Converters: 36 Vdc to 75 Vdc Input, 3.3 Vdc Output; 50 W to 75 W OUTPUT CURRENT, IO (A) OUTPUT VOLTAGE, VO (V) (1 A/div) (100 mV/div) Characteristic Curves (continued) OUTPUT VOLTAGE, VO (V) (20 mV/div) VI = 36 V VI = 48 V VI = 75 V Data Sheet November 2000 2.5 A TIME, t (50 s/div) 8-2378 (F) Note: Tested with a 10 F tantalum and a 1.0 F ceramic capacitor across the load. TIME, t (1 s/div) 8-2293 (F) Note: See Figure 13 for test conditions. OUTPUT CURRENT, IO (A) OUTPUT VOLTAGE, VO (V) (1 A/div) (100 mV/div) Figure 5. Typical JAHW050F-S Output Ripple Voltage at Room Temperature, IO = IO, max VI = 36 V OUTPUT VOLTAGE, VO (V) (50 mV/div) Figure 7. Typical JAHW050F-S Transient Response to Step Decrease in Load from 50% to 25% of IO, max at Room Temperature and 48 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) VI = 48 V VI = 75 V 3.75 A TIME, t (100 s/div) TIME, t (2 s/div) 8-2294 (F) 8-2486 (F) Note: See Figure 13 for test conditions. Figure 6. Typical JAHW075F-S Output Ripple Voltage at Room Temperature, IO = IO, max 6 Note: Tested with a 10 F tantalum and a 1.0 F ceramic capacitor across the load. Figure 8. Typical JAHW075F-S Transient Response to Step Decrease in Load from 50% to 25% of IO, max at Room Temperature and 48 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) Tyco Electronics Corp. Data Sheet November 2000 JAHW050F-S and JAHW075F-S Power Modules; dc-dc Converters: 36 Vdc to 75 Vdc Input, 3.3 Vdc Output; 50 W to 75 W OUTPUT VOLTAGE, VO (V) (1 V/div) OUTPUT CURRENT, IO (A) OUTPUT VOLTAGE, VO (V) (1 A/div) (10 mV/div) REMOTE ON/OFF, VON/OFF (V) Characteristic Curves (continued) 5A TIME, t (5 ms/div) TIME, t (50 s/div) 8-2296 (F) 8-2379 (F) Note: Tested with a 10 F tantalum and a 1.0 F ceramic capacitor across the load. Figure 11. Typical Start-Up from Remote On/Off; IO = IO, max OUTPUT CURRENT, IO (A) OUTPUT VOLTAGE, VO (V) (1 A/div) (100 mV/div) Figure 9. Typical JAHW050F-S Transient Response to Step Increase in Load from 50% to 75% of IO, max at Room Temperature and 48 Vdc Input. (Waveform Averaged to Eliminate Ripple Component.) Note: Tested with a 10 F tantalum and a 1.0 F ceramic capacitor across the load. TIME, t (100 s/div) 8-2295 (F) Note: Tested with a 10 F tantalum and a 1.0 F ceramic capacitor across the load. Figure 10. Typical JAHW075F-S Transient Response to Step Increase in Load from 50% to 75% of IO, max at Room Temperature and 48 Vdc Input. (Waveform Averaged to Eliminate Ripple Component.) Tyco Electronics Corp. 7 JAHW050F-S and JAHW075F-S Power Modules; dc-dc Converters: 36 Vdc to 75 Vdc Input, 3.3 Vdc Output; 50 W to 75 W Test Configurations Design Considerations Input Source Impedance TO OSCILLOSCOPE CURRENT PROBE LTEST VI(+) 12 H CS 220 F ESR < 0.1 @ 20 C, 100 kHz BATTERY 33 F ESR < 0.7 @ 100 kHz VI(-) 8-203 (F).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 12. Input Reflected-Ripple Test Setup COPPER STRIP VO(+) 1.0 F 10 F SCOPE RESISTIVE LOAD VO(-) 8-513 (F).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 13. Peak-to-Peak Output Noise Measurement Test Setup SENSE(+) VI(+) CONTACT AND DISTRIBUTION LOSSES VO(+) II IO LOAD SUPPLY VI(-) Data Sheet November 2000 VO(-) CONTACT RESISTANCE SENSE(-) 8-749 (F) 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 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 12, 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. 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., UL 1950, 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: The input source is to be provided with reinforced insulation from any other 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 pins and ground. The power module has extra-low voltage (ELV) outputs when all inputs are ELV. % Figure 14. Output Voltage and Efficiency Measurement Test Setup 8 Tyco Electronics Corp. Data Sheet November 2000 JAHW050F-S and JAHW075F-S Power Modules; dc-dc Converters: 36 Vdc to 75 Vdc Input, 3.3 Vdc Output; 50 W to 75 W Safety Considerations (continued) For input voltages exceeding -60 Vdc but -75 Vdc, these converters have been evaluated to the applicable requirements of BASIC INSULATION between secondary DC MAINS DISTRIBUTION input (classified as TNV-2 in Europe) and unearthed SELV outputs (-SB version only). Ion/off + ON/OFF Von/off - SENSE(+) VO(+) LOAD VO(-) VI(+) The input to these units is to be provided with a maximum 6 A normal-blow fuse in the ungrounded lead of the JAHW050F-S and JAHW075F-S. VI(-) SENSE(-) 8-720 (F).c Feature Descriptions Figure 15. Remote On/Off Implementation Overcurrent Protection To provide protection in an output overload condition, the unit is equipped with an internal shutdown and auto-restart mechanism. At the instance of current-limit inception, the module enters a hiccup mode of operation whereby it shuts down and automatically attempts to restart. As long as the fault persists, the module remains in this mode. The protection mechanism is such that the unit can continue in this condition until the fault is cleared. 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. 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, device 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 15). 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. With an external resistor between the TRIM and SENSE(-) pins (Radj-down), the output voltage set point (VO, adj) decreases (see Figure 16). The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. 1000 R adj-down = ------------- - 11 k % With an external resistor connected between the TRIM and SENSE(+) pins (Radj-up), the output voltage set point (VO, adj) increases (see Figure 17). The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. R adj-up % ( V O, nom ) ( 1 + ------ - ) - 1.225 100 = -------------------------------------------------------------------------- 1000 - 11 k 1.225% If not using the remote on/off feature, do one of the following to turn the unit on: For negative logic, short ON/OFF pin to VI(-). For positive logic, leave ON/OFF pin open. Tyco Electronics Corp. 9 JAHW050F-S and JAHW075F-S Power Modules; dc-dc Converters: 36 Vdc to 75 Vdc Input, 3.3 Vdc Output; 50 W to 75 W Data Sheet November 2000 Feature Descriptions (continued) VO(+) VI(+) Output Voltage Set-Point Adjustment (Trim) (continued) ON/OFF Radj-up The voltage between the VO(+) and VO(-) terminals must not exceed the minimum output overvoltage shutdown value indicated in the Feature Specifications table. This limit includes any increase in voltage due to remote-sense compensation and output voltage setpoint adjustment (trim) (see Figure 18). 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. VI(+) ON/OFF CASE VO(+) SENSE(+) TRIM SENSE(+) RLOAD CASE VI(-) TRIM RLOAD SENSE(-) VO(-) 8-715 (F).b Figure 17. Circuit Configuration to Increase Output Voltage 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 output overvoltage shutdown value indicated in the Feature Specifications table. This limit includes any increase in voltage due to remote-sense compensation and output voltage setpoint adjustment (trim) (see Figure 18). 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. Radj-down VI(-) SENSE(-) VO(-) 8-748 (F).b Figure 16. Circuit Configuration to Decrease Output Voltage 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. 10 Tyco Electronics Corp. Data Sheet November 2000 JAHW050F-S and JAHW075F-S Power Modules; dc-dc Converters: 36 Vdc to 75 Vdc Input, 3.3 Vdc Output; 50 W to 75 W Feature Descriptions (continued) The thermal data presented is based on measurements taken in a wind tunnel. Note that the orientation of the module with respect to airflow affects thermal performance. Remote Sense (continued) Two orientations are shown in Figures 20 and 21. SENSE(+) SENSE(-) SUPPLY VI(+) VO(+) VI(-) VO(-) IO II CONTACT RESISTANCE LOAD 203.2 (8.0) AIRFLOW CONTACT AND DISTRIBUTION LOSSES 8-651 (F).m Figure 18. Effective Circuit Configuration for Single-Module Remote-Sense Operation Output Overvoltage Protection To provide protection in an output overvoltage condition, the unit is equipped with circuitry that moonitors the voltage on the output terminals. If the voltage on the output terminals exceed the overvoltage protection threshold, the module enters a hiccup mode of operation whereby it shuts down and automatically attempts to restart. As long as the fault persists, the module remains in this mode. 25.4 (1.0) POWER MODULE AIR VELOCITY AND AMBIENT TEMPERATURE MEASURED HERE 76.2 (3.0) 8-1199 (F).f Note: Dimensions are in millimeters and (inches). Figure 19. Thermal Test Setup The protection mechanism is such that the unit can continue in this condition until the fault is cleared. Overtemperature Protection To provide protection in a overtemperature condition, the unit is equipped with an overtemperature circuit. In the event of such a fault, the module enters into a hiccup mode of operation whereby it shuts down and automatically attempts to restart. As long as the fault persists, the module remains in this mde. The protection mechanism is such that the unit can continue in this condition until the fault is cleared. AIRFLOW 8-3019 (F) Thermal Considerations Figure 20. Best Orientation (Top View) 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 is removed by convection, and radiation to the surrounding environment. Tyco Electronics Corp. 11 JAHW050F-S and JAHW075F-S Power Modules; dc-dc Converters: 36 Vdc to 75 Vdc Input, 3.3 Vdc Output; 50 W to 75 W Thermal Considerations (continued) Data Sheet November 2000 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. Introduction (continued) Although the maximum temperature of the power modules is 100 C, you can limit this temperature to a lower value for extremely high reliability. Heat Transfer AIRFLOW 8-3020 (F) Figure 21. Worst Orientation (Top View) Proper cooling can be verified by measuring the temperature. Peak temperature (TC) occurs at the position indicated in Figure 22. Increasing airflow over the module enhances the heat transfer via convection. Figures 23 and 25 show the maximum power that can be dissipated by the JAHW050F-S module without exceeding the maximum temperature versus local ambient temperature (TA) for natural convection through 3 m/s (600 ft./min.) for the best and worst orientation, respectively. Figures 24 and 26 show the maximum power that can be dissipated by the JAHW075F-S without exceeding the maximum temperature versus local ambient temperature (TA) for natural convection through 3 m/s (600 ft./min.) for best and worst orientation, respectively. 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 Figures 23 and 25 is shown in the following example. Example What is the minimum airflow necessary for a JAHW050F-S operating at VI = 75 V, an output current of 10 A, and a maximum ambient temperature of 55 C? THERMOCOUPLE IS ATTACHED TO THE TOP CENTER OF THE OPTOCOUPLER HERE Solution Given: VI = 75 V IO = 10 A TA = 55 C Determine PD (Use Figure 27.): 8-3021 (F) Figure 22. Temperature Measurement Location (Bottom View) PD = 6 W Determine airflow (v) (Use Figures 23 and 25.): v = nat. conv. (Best orientation) v = 0.5 m/s (100 ft./min.) (Worst orientation) 12 Tyco Electronics Corp. Data Sheet November 2000 JAHW050F-S and JAHW075F-S Power Modules; dc-dc Converters: 36 Vdc to 75 Vdc Input, 3.3 Vdc Output; 50 W to 75 W Thermal Considerations (continued) POWER DISSIPATION, PD (W) 7 Heat Transfer (continued) POWER DISSIPATION, PD (W) 7 6 5 4 3 6 5 4 3 2 1 3.0 m/s (600 ft./min) 2.0 m/s (400 ft./min) 1.0 m/s (200 ft./min) 0.1 m/s (20 ft./min) (NAT. CONV) 2 1 0 0 10 20 30 40 50 60 10 20 30 40 50 60 70 90 100 80 LOCAL AMBIENT TEMPERATURE, TA (C) 8-3023 (F) 0 0 3.0 m/s (600 ft./min) 2.0 m/s (400 ft./min) 1.0 m/s (200 ft./min) 0.1 m/s (20 ft./min) (NAT. CONV) 70 90 100 80 Figure 25. JAHW050F-S Forced Convection Power Derating; Worst Orientation LOCAL AMBIENT TEMPERATURE, TA (C) 8-3022 (F) POWER DISSIPATION, PD (W) 9 8 7 6 5 3.0 m/s (600 ft./min.) 4 10 20 30 40 5 3.0 m/s (600 ft./min.) 4 2.0 m/s (400 ft./min.) 3 1.0 m/s (200 ft./min.) 2 0.1 m/s (20 ft./min.) (NAT. CONV) 1 10 20 30 40 50 60 70 80 90 100 1-0013 0 0 6 LOCAL AMBIENT TEMPERATURE, TA (C) 0.1 m/s (20 ft./min.) (NAT. CONV) 1 7 0 1.0 m/s (200 ft./min.) 2 8 0 2.0 m/s (400 ft./min.) 3 9 POWER DISSIPATION, PD (W) Figure 23. JAHW050F-S Forced Convection Power Derating; Best Orientation 50 60 70 80 90 100 Figure 26. JAHW075F-S Forced Convection Power Derating; Worst Orientation LOCAL AMBIENT TEMPERATURE, TA (C) 1-0012 Figure 24. JAHW075F-S Forced Convection Power Derating; Best Orientation Tyco Electronics Corp. 13 JAHW050F-S and JAHW075F-S Power Modules; dc-dc Converters: 36 Vdc to 75 Vdc Input, 3.3 Vdc Output; 50 W to 75 W Thermal Considerations (continued) Data Sheet November 2000 Surface-Mount Power Module Solder Reflow Recommendation Heat Transfer (continued) The JAHW-Series surface-mount power modules are constructed with SMT (surface-mount technology) components and assembly guidelines. Such large mass/low thermal resistance devices heat up slower than typical SMT components. It is recommended that the customer review data sheets in order to customize the solder reflow profile for application board assembly. POWER DISSIPATION, PD (W) 6 5 4 3 2 VI = 75 V VI = 48 V VI = 36 V 1 0 0 1 2 3 4 5 6 7 8 OUTPUT CURRENT, IO (A) 9 10 8-3274 (F) Figure 27. JAHW050F-S Power Dissipation vs. Output Current at 25 C There are several types of SMT reflow technologies currently used in the industry. These surface-mount power modules can be adequately soldered using natural convection, IR (radiant infrared), convection/IR, or forced convection technologies. The surface-mount power module solder reflow profile is established by accurately measuring the module balls temperature. POWER DISSIPATION, PD (W) 8 7 6 5 4 3 VI = 75 V VI = 48 V VI = 36 V 2 1 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 OUTPUT CURRENT, IO (A) 8-3275 (F) Figure 28. JAHW075F-S Power Dissipation vs. Output Current at 25 C 14 It is recommended that a reflow profile be characterized for the module on the application board assembly. The solder paste type, component, and board thermal sensitivity must be considered in order to form the desired fused solder fillet. The power module balls are plated with tin/lead (Sn/Pb) solder to prevent corrosion and ensure good solderability. Typically, the eutectic solder melts at 183 C, wets the land, and subsequently wicks the device connection. Sufficient time must be allocated to fuse the plating on the connection and ensure a reliable solder joint. The maximum oven temperature and conveyor speed should prevent the customer board and surface-mount module temperature from exceeding the maximum thermal profile limits as shown in Figure 30. The thermocouple should be attached to the smallest pad, not connected to a heavy path for current conduction. The customer board temperature during a typical reflow profile is shown in Figure 31. Failure to observe these maximum module temperatures and duration may result in permanent damage to the power module. The maximum temperature of the power module tantalum capacitors should not exceed 220 C. The minimum temperature of the power module balls should be 210 C. Tyco Electronics Corp. Data Sheet November 2000 JAHW050F-S and JAHW075F-S Power Modules; dc-dc Converters: 36 Vdc to 75 Vdc Input, 3.3 Vdc Output; 50 W to 75 W Surface-Mount Power Module Solder Reflow Recommendation (continued) Ball grid packaging provides robust surface-mount connections Good Solder Joints JAHW MODULE BALL GRID ARRAY TEST BOARD Robust Connections Figure 29. Cross Section of Solder Connection CUSTOMER BOARD TEMPERATURE (C) 230 C MAX 183 C 150 C 4 s--80 s 120 C 60 MINUTES MAX 4 C/s MAX TIME (s) 8-2275 (F).a Figure 30. Maximum Thermal Profile Limits Tyco Electronics Corp. 15 JAHW050F-S and JAHW075F-S Power Modules; dc-dc Converters: 36 Vdc to 75 Vdc Input, 3.3 Vdc Output; 50 W to 75 W Data Sheet November 2000 Surface-Mount Power Module Solder Reflow Recommendation (continued) CUSTOMER BOARD TEMPERATURE (C) 250 MELTING POINT (60/40 SOLDER) 200 150 100 50 2:30 5:00 TIME (MIN.) 7:30 10:00 8-2274 (F).b Figure 31. Typical Reflow Soldering Profile Placement Recommendation Use of vacuum-disk grippers is not recommended for placing the JAHW-S modules on application PCBs. Vacuumactivated mechanical grippers or, alternatively, hand placement is recommended. EMC Considerations For assistance with designing for EMC compliance, please refer to the FLTR100V10 data sheet (DS99-294EPS). Layout Considerations Copper paths must not be routed beneath the power module mounting inserts. For additional layout guidelines, refer to the FLTR100V10 data sheet (DS99-294EPS). 16 Tyco Electronics Corp. Data Sheet November 2000 JAHW050F-S and JAHW075F-S Power Modules; dc-dc Converters: 36 Vdc to 75 Vdc Input, 3.3 Vdc Output; 50 W to 75 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 54.36 (2.14) 57.4 (2.26) VI(+) 48.26 TYPICAL (1.900) ON/OFF 35.56 (1.400) VO(+) 35.56 (1.400) +SEN 25.40 (1.000) TRIM 25.40 (1.000) NC -SEN VI(-) VO(-) 10.16 (0.400) 17.78 10.16 (0.700) (0.400) MODULE OUTLINE 10.92 (0.43) 3.05 (0.120) 3.05 (0.120) Side View 10.16 (0.40) MAX Bottom View VI(-) NC 35.56 (1.400) 48.26 (1.900) 3.18 (0.125) TYPICAL DIA BALL CONNECTOR VO(-) 35.56 TYPICAL (1.400) -SEN 25.40 (1.000) TRIM 25.40 (1.000) 10.16 (0.400) ON/OFF VI(+) +SEN 17.78 10.16 (0.700) (0.400) VO(+) MODULE OUTLINE 8-3024 (F).c Tyco Electronics Corp. 17 JAHW050F-S and JAHW075F-S Power Modules; dc-dc Converters: 36 Vdc to 75 Vdc Input, 3.3 Vdc Output; 50 W to 75 W Data Sheet November 2000 Recommended Hole Pattern Component-side footprint. Dimensions are in millimeters and (inches). 2.54 DIA. PAD (0.100) 48.26 (1.900) VI(+) VO(+) ON/OFF 35.56 (1.400) 35.56 (1.400) +SEN 25.40 (1.000) TRIM 25.40 (1.000) 10.16 (0.400) NC -SEN VI(-) VO(-) 17.78 10.16 (0.700) (0.400) FOOTPRINT PERIPHERY 8-2989 (F) Ordering Information Please contact your Tyco Electronics' Account Manager or Field Application Engineer for pricing and availability. Table 4. Device Codes Input Voltage Output Voltage Output Power Output Current Remote On/Off Logic Device Code Comcode 48 Vdc 3.3 Vdc 33 W 10 A Negative JAHW050F1-S 108625344 48 Vdc 3.3 Vdc 49.5 W 15 A Negative JAHW075F1-S 108855735 48 Vdc 3.3 Vdc 33 W 10 A Positive JAHW050F-S TBD 48 Vdc 3.3 Vdc 49.5 W 15 A Positive JAHW075F-S TBD Optional features can be ordered using the device code suffixes shown below. Table 5. Device Options 18 Option Device Code Suffix Approved for Basic Insulation -SB Tyco Electronics Corp. Data Sheet November 2000 JAHW050F-S and JAHW075F-S Power Modules; dc-dc Converters: 36 Vdc to 75 Vdc Input, 3.3 Vdc Output; 50 W to 75 W Notes Tyco Electronics Corp. 19 JAHW050F-S and JAHW075F-S Power Modules; dc-dc Converters: 36 Vdc to 75 Vdc Input, 3.3 Vdc Output; 50 W to 75 W Data Sheet February 6, 2001 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.tycoelectronics.com Tyco Electronics Corporation 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. November 2000 DS00-244EPS (Replaces DS00-040EPS) Printed on Recycled Paper