Data Sheet March 2005 JAHW050Y, JAHW075Y, and JAHW100Y Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Features The JAHW Series Power Modules use advanced, surfacemount technology and deliver high-quality, efficient, and compact dc-dc conversion. Applications Distributed power architectures Communications equipment Computer equipment Options Heat sinks available for extended operation Choice of remote on/off logic configuration 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 Very high efficiency: 88% typical Low output noise Constant frequency Industry-standard pinout Metal baseplate 2:1 input voltage range Overtemperature protection Overcurrent protection Output overvoltage protection Remote sense Remote on/off Adjustable output voltage Case ground pin Auto-restart after overcurrent shutdown ISO* 9001 Certified manufacturing facilities UL60950 Recognized, CSA C22.2 No. 60950-00 Certified, and VDE 0805 (IEC60950) Licensed CE mark meets 73/23/EEC and 93/68/EEC directives** Description The JAHW050Y, JAHW075Y, and JAHW100Y 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 18 W to 36 W at a typical full-load efficiency of 88%. 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. * 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 Aisne. 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.) JAHW050Y, JAHW075Y, and JAHW100Y Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet March 2005 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 Case Temperature (See Thermal Considerations section.) TC -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 II, max -- -- -- -- -- -- 0.9 1.3 1.7 A A A Inrush Transient i2 t -- -- 1.0 A2s Input Reflected-ripple Current, Peak-to-peak (5 Hz to 20 MHz, 12 H source impedance; see Figure 17.) 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): JAHW050Y (See Figure 1.) JAHW075Y (See Figure 2.) JAHW100Y (See Figure 3.) 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 6 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. JAHW050Y, JAHW075Y, and JAHW100Y Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet March 2005 Electrical Specifications (continued) Table 2. Output Specifications Parameter Device Symbol Min Typ Max Unit Output Voltage Set Point (VI = 48 V; IO = IO, max; TC = 25 C) All VO, set 1.76 1.8 1.84 Vdc Output Voltage (Over all operating input voltage, static resistive load, and temperature conditions until end of life. See Figure 19.) All VO 1.7 -- 1.9 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 15 0.1 0.2 50 %VO %VO mV Output Ripple and Noise Voltage (See Figure 18.): 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.) JAHW050Y JAHW075Y JAHW100Y IO IO IO 0.5 0.5 0.5 -- -- -- 10 15 20 A A A Output Current-limit Inception (VO = 90% of VO, nom) JAHW050Y JAHW075Y JAHW100Y IO, cli IO, cli IO, cli -- -- -- 15 20 26 -- -- -- A A A All -- -- 120 -- %IO, max JAHW050Y JAHW075Y JAHW100Y -- -- -- 86 88 88.4 -- -- -- % % % All -- -- 230 -- kHz All All -- -- -- -- 200 200 -- -- mV s All All -- -- -- -- 200 200 -- -- mV s 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 tantalum 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 typical test results. In some situations, actual numbers may differ. Table 3. Isolation Specifications Parameter Min Typ Max Unit Isolation Capacitance -- 2500 -- pF Isolation Resistance 10 -- -- M Tyco Electronics Corp. 3 JAHW050Y, JAHW075Y, and JAHW100Y Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet March 2005 General Specifications Parameter Min Calculated MTBF (IO = 80% of IO, max; TC = 40 C) Weight Typ Max 3,000,000 -- -- Unit hours 100 (3.5) 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. Table 4. Feature Specifications 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.): JAHWxxxY1 Preferred Logic: Logic Low--Module On Logic High--Module Off JAHWxxxY 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 (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 2.1 2.4* 4.0 V TC -- 110 -- C * These are typical test results. In some situations, actual numbers may differ. 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. JAHW050Y, JAHW075Y, and JAHW100Y Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet March 2005 Characteristic Curves The following figures provide typical characteristics for the power modules. The figures are identical for both on/off configurations. 1.6 0.7 IO = 10 A IO = 5 A IO = 0 A 0.6 0.5 0.4 0.3 0.2 INPUT CURRENT, II (A) INPUT CURRENT, II (A) 0.8 0.1 1.4 IO = 20 A IO = 10 A IO = 0 A 1.2 1 0.8 0.6 0.4 0.2 0 0 0 10 20 30 40 50 60 70 0 80 10 20 INPUT VOLTAGE, VI (V) 30 40 50 60 70 8-3236 (F) Figure 1. Typical JAHW050Y Input Characteristics at Room Temperature 8-3238 (F) Figure 3. Typical JAHW100Y Input Characteristics at Room Temperature 1.2 90 1 IO = 15 A IO = 7.5 A IO = 0 A 0.8 0.6 0.4 0.2 85 EFFICIENCY, (%) INPUT CURRENT, II (A) 80 INPUT VOLTAGE, VI (V) 80 75 VI = 36 V VI = 48 V VI = 75 V 70 65 0 0 10 20 30 40 50 60 70 80 0 1 2 3 4 5 6 7 8 9 10 OUTPUT CURRENT, IO (A) INPUT VOLTAGE, VI (V) 8-3237 (F) Figure 2. Typical JAHW075Y Input Characteristics at Room Temperature Tyco Electronics Corp. 60 8-3239 (F) Figure 4. Typical JAHW050Y Converter Efficiency vs. Output Current at Room Temperature 5 JAHW050Y, JAHW075Y, and JAHW100Y Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet March 2005 Characteristic Curves (continued) OUTPUT VOLTAGE, VO (V) (10 mV/div) VI = 36 V 90 EFFICIENCY, (%) 85 80 75 VI = 36 V VI = 48 V VI = 75 V 70 65 VI = 48 V VI = 75 V 60 0 2 4 6 8 10 12 14 TIME, t (2 s/div) 16 8-3242 (F) OUTPUT CURRENT, IO (A) Note: See Figure 18 for test conditions. 8-3240 (F) Figure 5. Typical JAHW075Y Converter Efficiency vs. Output Current at Room Temperature Figure 7. Typical JAHW050Y Output Ripple Voltage at Room Temperature and IO = IO, max VI = 36 V 90 OUTPUT VOLTAGE, VO (V) (10 mV/div) EFFICIENCY, (%) 85 80 75 VI = 36 V VI = 48 V VI = 75 V 70 65 VI = 48 V 60 0 2 4 6 8 10 12 14 16 18 20 VI = 75 V OUTPUT CURRENT, IO (A) 8-3241 (F) Figure 6. Typical JAHW100Y Converter Efficiency vs. Output Current at Room Temperature TIME, t (2 s/div) 8-3243 (F) Note: See Figure 18 for test conditions. Figure 8. Typical JAHW075Y Output Ripple Voltage at Room Temperature and IO = IO, max 6 Tyco Electronics Corp. JAHW050Y, JAHW075Y, and JAHW100Y Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet March 2005 OUTPUT CURRENT, IO (A) OUTPUT VOLTAGE, VO (V) (7.5 A/div) (100 mV/div) Characteristic Curves (continued) OUTPUT VOLTAGE, VO (V) (10 mV/div) VI = 36 V VI = 48 V VI = 75 V TIME, t (100 s/div) TIME, t (2 s/div) 8-3174 (F) 8-3244 (F) Note: See Figure 18 for test conditions. OUTPUT VOLTAGE, VO (V) (100 mV/div) Figure 11. Typical JAHW075Y Transient Response to Step Decrease in Load from 50% to 25% of Full Load at Room Temperature and 48 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) TIME, t (100 s/div) 8-3173 (F) Note: Tested with a 10 F aluminum and a 1.0 F tantalum capacitor across the load. Figure 10. Typical JAHW050Y Transient Response to Step Decrease in Load from 50% to 25% of Full Load at Room Temperature and 48 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) Tyco Electronics Corp. OUTPUT CURRENT, IO (A) (5 A/div) OUTPUT CURRENT, IO (A) (5 A/div) OUTPUT VOLTAGE, VO (V) (100 mV/div) Figure 9. Typical JAHW100Y Output Ripple Voltage at Room Temperature and IO = IO, max Note: Tested with a 10 F aluminum and a 1.0 F tantalum capacitor across the load. TIME, t (100 s/div) 8-3175 (F) Note: Tested with a 10 F aluminum and a 1.0 F tantalum capacitor across the load. Figure 12. Typical JAHW100Y Transient Response to Step Decrease in Load from 50% to 25% of Full Load at Room Temperature and 48 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) 7 JAHW050Y, JAHW075Y, and JAHW100Y Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W OUTPUT CURRENT, IO (A) (5 A/div) OUTPUT CURRENT, IO (A) (5 A/div) OUTPUT VOLTAGE, VO (V) (100 mV/div) OUTPUT VOLTAGE, VO (V) (100 mV/div) VO (V) Characteristic Curves (continued) Data Sheet March 2005 TIME, t (100 s/div) 8-3178 (F) Note: Tested with a 10 F aluminum and a 1.0 F tantalum capacitor across the load. TIME, t (100 s/div) 8-3176 (F) Note: Tested with a 10 F aluminum and a 1.0 F tantalum capacitor across the load. REMOTE ON/OFF, VON/OFF (V) OUTPUT VOLTAGE, VO (V) (1 mV/div) OUTPUT CURRENT, IO (A) (11.25 A/div) OUTPUT VOLTAGE, VO (V) (100 mV/div) Figure 13. Typical JAHW050Y Transient Response to Step Increase in Load from 50% to 75% of Full Load at Room Temperature and 48 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) Figure 15. Typical JAHW100Y Transient Response to Step Increase in Load from 50% to 75% of Full Load at Room Temperature and 48 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) TIME, t (100 s/div) TIME, t (2 ms/div) 8-3177 (F) Note: Tested with a 10 F aluminum and a 1.0 F tantalum capacitor across the load. Figure 14. Typical JAHW075Y Transient Response to Step Increase in Load from 50% to 75% of Full Load at Room Temperature and 48 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) 8 8-3245 (F) Note: Tested with a 10 F aluminum and a 1.0 F tantalum capacitor across the load. Figure 16. JAHW075Y Typical Start-Up from Remote On/Off; IO = IO, max Tyco Electronics Corp. JAHW050Y, JAHW075Y, and JAHW100Y Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet March 2005 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 17. 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 18. Peak-to-Peak Output Noise Measurement Test Setup SENSE(+) VI(+) CONTACT AND DISTRIBUTION LOSSES VO(+) II IO LOAD SUPPLY VI(-) 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 % Figure 19. Output Voltage and Efficiency Measurement Test Setup Tyco Electronics Corp. 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. 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., UL60950, CSA C22.2 No. 60950-00, and VDE 0805 (IEC60950). 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 6 A normal-blow fuse in the ungrounded lead. 9 JAHW050Y, JAHW075Y, and JAHW100Y Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet March 2005 Feature Descriptions Overcurrent Protection To provide protection in an output overload condition, the unit is provided with internal shutdown and autorestart 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 for a sufficient interval of time until the fault is cleared. Ion/off + ON/OFF Von/off - SENSE(+) VO(+) LOAD VI(+) VI(-) VO(-) SENSE(-) 8-720 (F).c Figure 20. Remote On/Off Implementation Remote Sense 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 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 to turn the unit on: For negative logic, short ON/OFF pin to VI(-). For positive logic, leave ON/OFF 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.: [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 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. 10 Tyco Electronics Corp. JAHW050Y, JAHW075Y, and JAHW100Y Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet March 2005 Feature Descriptions (continued) The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. Remote Sense (continued) SENSE(+) SENSE(-) SUPPLY VI(+) VO(+) VI(-) VO(-) IO II CONTACT RESISTANCE LOAD CONTACT AND DISTRIBUTION LOSSES 8-651 (F).m Figure 21. Effective Circuit Configuration for Single-Module Remote-Sense Operation 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. % ( V O, nom ) ( 1 + ------ - ) - 1.225 100 R adj-up = -------------------------------------------------------------------------- 1000 - 11 k 1.225% 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 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. 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 %. 1000 R adj-down = ------------- - 11 k % VI(+) ON/OFF CASE VO(+) SENSE(+) TRIM RLOAD Radj-down VI(-) SENSE(-) VO(-) 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). Tyco Electronics Corp. 8-748 (F).b Figure 22. Circuit Configuration to Decrease Output Voltage 11 JAHW050Y, JAHW075Y, and JAHW100Y Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet March 2005 Output Overvoltage Protection Output Voltage Set-Point Adjustment (Trim) (continued) The output overvoltage protection consists of circuitry that monitors the voltage on the output terminals. If the voltage on the output terminals exceeds the overvoltage protection threshold, the module will shut down and restart automatically. ADJUSTMENT RESISTOR VALUE () Feature Descriptions (continued) 1M Overtemperature Protection To provide protection in a fault condition, the unit is equipped with an overtemperature circuit. In the event of such a fault, the module enters into an auto-restart "hiccup" mode with low output voltage until the fault is removed. Recovery from the overtemperature protection is automatic after the unit cools below the overtemperature protection threshold. 100k 10k 0 10 20 30 40 Thermal Considerations % CHANGE IN OUTPUT VOLTAGE (%) 8-2470 (F) Introduction Figure 23. Resistor Selection for Decreased Output Voltage VI(+) ON/OFF VO(+) SENSE(+) Radj-up CASE VI(-) TRIM RLOAD 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 25. SENSE(-) MEASURE CASE TEMPERATURE HERE VO(-) 8-715 (F).b Figure 24. Circuit Configuration to Increase Output Voltage VI(+) VO(+) ON/OFF +SEN CASE -SEN VI(-) VO(-) TRIM 30.5 (1.20) 29.0 (1.14) 8-716 (F).h Note: Top view, pin locations are for reference only. Measurements shown in millimeters and (inches). Figure 25. Case Temperature Measurement Location 12 Tyco Electronics Corp. Data Sheet March 2005 JAHW050Y, JAHW075Y, and JAHW100Y Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Thermal Considerations (continued) Introduction (continued) 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. POWER DISSIPATION, PD (W) 7 6 5 4 3.0 m/s (600 ft./min.) 2.0 m/s (400 ft./min.) 3 1.0 m/s (200 ft./min.) 2 0.1 m/s (20 ft./min.) 1 (NATURAL CONVECTION) 0 0 10 20 30 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (C) Heat Transfer Without Heat Sinks 8-3246 (F) 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 26 is shown in the following example. Example What is the minimum airflow necessary for a JAHW100Y operating at VI = 48 V, an output current of 20 A, and a maximum ambient temperature of 65 C? Figure 26. Forced Convection Power Derating with No Heat Sink; Either Orientation 4.5 POWER DISSIPATION, PD (W) Increasing airflow over the module enhances the heat transfer via convection. Figure 26 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 3 m/s (600 ft./min.). 4 3.5 3 2.5 2 1.5 VI = 75 V VI = 48 V VI = 36 V 1 0.5 0 0 1 2 3 4 5 6 7 8 9 10 LOCAL AMBIENT TEMPERATURE, TA (C) 8-3247 (F) Solution Given: VI = 48 V IO = 20 A TA = 65 C Figure 27. JAHW050Y Power Dissipation vs. Output Current at 25 C Determine PD (Use Figure 29.): PD = 5.2 W Determine airflow (v) (Use Figure 26.): v = 0.46 m/s (90 ft./min.) Tyco Electronics Corp. 13 JAHW050Y, JAHW075Y, and JAHW100Y Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Thermal Considerations (continued) 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 5 4.5 PD PD 4 3.5 3 2.5 2 VI = 75 V VI = 48 V VI = 36 V 1.5 The location to measure case temperature (TC) is shown in Figure 25. Case-to-ambient thermal resistance vs. airflow is shown, for various heat sink configurations and heights, in Figure 30. These curves were obtained by experimental testing of heat sinks, which are offered in the product catalog. 1 9 0.5 0 0 2 4 6 8 10 12 14 16 OUTPUT CURRENT, IO (A) 8-3248 (F) Figure 28. JAHW075Y Power Dissipation vs. Output Current at 25 C CASE-TO-AMVIENT THERMAL RESISTANCE, ca (C/W) POWER DISSIPATION, PD (W) Heat Transfer Without Heat Sinks (continued) Data Sheet March 2005 8 7 6 NO HEAT SINK 1/4 IN. HEAT SINK 1/2 IN. HEAT SINK 1 IN. HEAT SINK 5 4 3 2 1 0 0 POWER DISSIPATION, PD (W) 7 6 0.5 (100) 1.0 (200) 1.5 (300) 2.0 (400) 2.5 (500) 3.0 (600) AIR VELOCITY, m/s (ft./min.) 8-3184 (F) 5 Figure 30. Case-to-Ambient Thermal Resistance Curves; Either Orientation 4 3 VI = 75 V VI = 48 V VI = 36 V 2 1 0 0 2 4 6 8 10 12 14 16 18 20 OUTPUT CURRENT, IO (A) 8- 3249 (C) Figure 29. JAHW100Y Power Dissipation vs. Output Current at 25 C 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 30 had a thermal-conductive dry pad between the case and the heat sink to minimize contact resistance. The use of Figure 30 is shown in the following example. Example 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.). 14 If an 85 C case temperature is desired, what is the minimum airflow necessary? Assume the JAHW100Y module is operating at VI = 48 V and an output current of 20 A, maximum ambient air temperature of 65 C, and the heat sink is 1/4 inch. Tyco Electronics Corp. JAHW050Y, JAHW075Y, and JAHW100Y Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet March 2005 Thermal Considerations (continued) Heat Transfer with Heat Sinks (continued) 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 Solution PD Given: VI = 48 V IO = 20 A TA = 65 C TC = 85 C Heat sink = 1/4 inch. 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. Determine PD by using Figure 29: PD = 5.2 W EMC Considerations Then solve the following equation: ( TC - TA ) ca = ----------------------- For assistance with designing for EMC compliance, please refer to the FLTR100V10 data sheet (DS99-294EPS). PD 85 - 65 ) ca = (----------------------5.2 Layout Considerations ca = 3.85 C/W Use Figure 30 to determine air velocity for the 1/4 inch heat sink. The minimum airflow necessary for the JAHW100Y module is 0.91 m/s (180 ft./min.). Copper paths must not be routed beneath the power module mounting inserts. For additional layout guidelines, refer to the FLTR100V10 data sheet (DS99-294EPS). 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) as shown in Figure 31. PD TC TS cs TA sa 8-1304 (F).e Figure 31. Resistance from Case-to-Sink and Sink-to-Ambient Tyco Electronics Corp. 15 JAHW050Y, JAHW075Y, and JAHW100Y Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet March 2005 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) 61.0 (2.40) Side View SIDE LABEL* 0.51 (0.020) 12.7 (0.50) 4.1 (0.16) 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) STANDOFF, 4 PLACES 7.1 (0.28) 5.1 (0.20) 7.1 (0.28) 10.16 (0.400) 50.8 (2.00) MOUNTING INSERTS M3 x 0.5 THROUGH, 4 PLACES 25.40 (1.000) VI(-) VO(-) CASE -SEN TRIM 35.56 (1.400) ON/OFF +SEN VI(+) VO(+) 10.16 (0.400) 17.78 (0.700) 25.40 (1.000) 35.56 (1.400) 48.26 (1.900) 4.7 (0.19) 48.3 (1.90) 8-716 (F).m * Side label includes Tyco name, product designation, safety agency markings, input/output voltage and current ratings, and bar code. The case pin is 5.4 (0.21). i.e., 1.3 (0.05) longer than the other pins. 16 Tyco Electronics Corp. JAHW050Y, JAHW075Y, and JAHW100Y Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet March 2005 Recommended Hole Pattern Component-side footprint. Dimensions are in millimeters and (inches). 57.9 (2.28) 4.7 (0.19) 48.3 (1.90) MOUNTING HOLES VI(+) 35.56 (1.400) 50.8 (2.00) 48.26 (1.900) TERMINALS 61.0 (2.40) VO(+) 35.56 (1.400) +SEN ON/OFF 25.40 (1.000) TRIM 25.40 (1.000) 10.16 (0.400) CASE -SEN VI(-) VO(-) 10.16 (0.400) 17.78 (0.700) 5.1 (0.20) 12.7 (0.50) MODULE OUTLINE 8-716 (F).m Ordering Information Table 5. Device Codes Input Voltage Output Voltage Output Power Remote On/Off Logic Device Code Comcode 48 V 1.8 V 18 W Negative JAHW050Y1 TBD 48 V 1.8 V 27 W Negative JAHW075Y1 TBD 48 V 1.8 V 36 W Negative JAHW100Y1 108593682 48 V 1.8 V 18 W Positive JAHW050Y TBD 48 V 1.8 V 27 W Positive JAHW075Y TBD 48 V 1.8 V 36 W Positive JAHW100Y TBD Optional features can be ordered using the suffixes shown in Table 6. The suffixes follow the last letter of the device code and are placed in descending order. For example, the device codes for a JAHW075Y module with the following options are shown below: Positive logic JAHW075Y Negative logic JAHW075Y1 Table 6. Device Options Option Suffix Negative remote on/off logic Positive remote on/off logic 1 -- Tyco Electronics Corp. 17 JAHW050Y, JAHW075Y, and JAHW100Y Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet March 2005 Ordering Information (continued) Table 7. 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) 407243989 407243997 407244706 407244714 407244722 407244730 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. 61 (2.4) 57.9 (2.28) 8-2832 (F) Figure 32. Longitudinal Heat Sink 18 8-2833 (F) Figure 33. Transverse Heat Sink Tyco Electronics Corp. Data Sheet March 2005 JAHW050Y, JAHW075Y, and JAHW100Y Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Notes Tyco Electronics Corp. 19 JAHW050Y, JAHW075Y, and JAHW100Y Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet March 2005 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 Power Systems, Inc., (Mesquite, Texas) All International Rights Reserved. Printed in U.S.A. March 2005 ADS01-046EPS (Replaces DS00-196EPS) Printed on Recycled Paper