Data Sheet September 1998 JW060 Triple-Output-Series Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 and 12 Vdc, or 5 and 15 Vdc Outputs; 60 W Features The JW060 Triple-Output-Series Power Modules use advanced, surface-mount technology and deliver high-quality, efficient, and compact dc-dc conversion. Applications Distributed power architectures Telecommunications Options Choice of remote on/off logic configuration Heat sink available for extended operation Small size: 61.0 mm x 57.9 mm x 13.3 mm (2.40 in. x 2.28 in. x 0.52 in.) High power density High efficiency: 86% typical Low output noise Constant frequency Wide operating temperature range Metal baseplate 2:1 input voltage range Overvoltage and overcurrent protection Overtemperature protection Remote on/off Adjustable output voltage UL* Recognized, CSA Certified, VDE 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 JW060 Triple-Output-Series Power Modules are dc-dc converters that operate over an input voltage range of 36 Vdc to 75 Vdc and provide three dc outputs. The outputs are fully isolated from the inputs, allowing versatile grounding connections. Built-in shielding provides improved EMI performance. The modules have a maximum power rating of 60 W at a typical full-load efficiency of 86%. The total output power of the JW060 Triple-Output-Series Power Modules is limited to 60 W. The main output (VO1) is tightly regulated and designed to deliver up to 45 W. The auxiliary outputs (VO2 and VO3) are cross-regulated and can provide a total of 58 W with the main output loaded at its minimum of 2 W. The modules have a metal baseplate for excellent thermal performance in a small package. Threaded-through holes are provided to allow easy mounting or addition of a heat sink for high-temperature applications. The standard feature set includes output trim and remote on/off for convenient flexibility in distributed power applications. Data Sheet September 1998 JW060 Triple-Output Series Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 and 12 Vdc, or 5 and 15 Vdc Outputs; 60 W 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 Transient (100 ms) I/O Isolation Voltage Operating Baseplate Temperature Storage Temperature Symbol Min Max Unit VI VI, trans -- TC Tstg -- -- -- -40 -55 80 100 1500 100 125 V Vdc Vdc C C Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Table 1. Input Specifications Parameter Operating Input Voltage Maximum Input Current (VI = 0 V to 75 V) Inrush Transient Energy (i2t = Wfuse/Rfuse; J/ = A2s) Input Reflected-ripple Current, Peak-to-peak (5 Hz to 20 MHz, 12 H source impedance; see Figure 13.) Input Ripple Rejection (120 Hz) Symbol VI II, max Wfuse Min 36 -- -- Typ 48 -- -- Max 75 3.0 4.0 Unit Vdc A mJ -- -- 50 -- mAp-p -- -- 57 -- dB Fusing Considerations CAUTION: This power module is not internally fused. An input line fuse must always be used. This 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, dc 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 Lucent Technologies Inc. Data Sheet September 1998 JW060 Triple-Output Series Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 and 12 Vdc, or 5 and 15 Vdc Outputs; 60 W Electrical Specifications (continued) Table 2. Output Specifications Parameter Output Voltage Set Point (VI = 48 V; TC = 25 C, IO1 = 5.00 A; for JW060ABK, IO2 = IO3 = 1.45 A; for JW060ACL, IO2 = IO3 = 1.12 A) Device JW060ABK Output Voltage with Typical Loads (Over all operating input voltage and temperature conditions until end of life with resistive loads greater than the following minimums: IO1 > 2.0 A; IO2 & IO3 > 1.0 A) JW060ABK Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life; see Figures 2--5 and Figures 9--12.) JW060ABK Output Regulation: Line (VI = 36 V to 75 V) Load (IO1 = 1.67 A to 5.00 A; for JW060ABK, IO2 = IO3 = 0.48 A to 1.45 A; for JW060ACL, IO2 = IO3 = 0.37 A to 1.12 A) Temperature (TC = -40 C to +100 C) Output Ripple and Noise Voltage (5 Hz to 20 MHz; see Figure 14.): RMS VO1 VO2 VO3 VO1 VO2 VO3 Min 4.90 11.70 -11.70 4.90 15.30 -15.25 4.83 11.25 -11.25 4.83 14.60 -14.60 VO1 VO2 VO3 VO1 VO2 VO3 4.83 10.55 -10.45 4.83 14.00 -13.90 Typ 5.00 12.05 -12.05 5.00 15.60 -15.60 -- -- -- -- -- -- -- -- -- -- -- -- All JW060ABK JW060ACL VO1 VO2, VO3 VO2, VO3 -0.1 -0.5 -0.35 0.01 0.05 -0.03 0.1 0.6 0.3 % % % All JW060ABK JW060ACL VO1 VO2, VO3 VO2, VO3 -0.2 -2.0 0.4 0.0 0.2 1.4 0.1 2.0 2.5 % % % All JW060ABK JW060ACL VO1 VO2, VO3 VO2, VO3 -- -- -- 15 -220 -230 -- -- -- mV mV mV JW060ABK VO1 VO2 VO3 VO1 VO2 VO3 VO1 VO2 VO3 VO1 VO2 VO3 -- -- -- -- -- -- -- -- -- -- -- -- -- 0 -- -- -- -- -- -- -- -- -- -- -- -- -- 25 35 30 30 50 40 80 120 90 100 160 120 18,000 mVrms mVrms mVrms mVrms mVrms mVrms mVp-p mVp-p mVp-p mVp-p mVp-p mVp-p F JW060ACL JW060ACL JW060ACL JW060ACL Peak-to-peak JW060ABK JW060ACL Total External Load Capacitance Referred to Output 1 (electrolytic; multiply output 2 & 3 load capacitances by 5.44 for JW060ABK or 9 for JW060ACL) Lucent Technologies Inc. All Symbol VO1, set VO2, set VO3, set VO1, set VO2, set VO3, set Max 5.10 12.35 -12.35 5.10 15.90 -15.90 Unit Vdc Vdc Vdc Vdc Vdc Vdc 5.17 12.85 -12.85 5.17 16.60 -16.60 5.17 13.65 -13.65 5.17 17.25 -17.25 Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc Vdc 3 Data Sheet September 1998 JW060 Triple-Output Series Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 and 12 Vdc, or 5 and 15 Vdc Outputs; 60 W Electrical Specifications (continued) Table 2. Output Specifications (continued) Parameter Output Currents (At IO < IO, min, the modules may exceed output ripple and output 2 and 3 voltage specifications. Operation is not recommended at IO1 < 200 mA or IO2 < 100 mA due to possible control malfunction. No load is necessary on output 3, but at no load, its voltage may rise to the Output Overvoltage Clamp specified on page 7.) Output Current-limit Inception: Typical (VI = 48 V, TC = 40 C): For JW060ABK: IO1 = 3.33 A, IO2 = IO3 = 0.97 A For JW060ACL: IO1 = 3.33 A, IO2 = IO3 = 0.75 A Worst Case (minimum loads on other outputs) Device JW060ABK JW060ACL JW060ABK JW060ACL JW060ABK JW060ACL Output Short-circuit Current (foldback current limit; output voltage = 0.5 V) JW060ABK JW060ACL Symbol IO1 IO2, IO3 IO1 IO2, IO3 Min 0.5 0.3 0.5 0.2 Typ -- -- -- -- Max 9.0 3.0 9.0 2.2 Unit A A A A IO1 IO2, IO3 IO1 IO2, IO3 IO1 IO2, IO3 IO1 IO2, IO3 IO1 IO2, IO3 IO1 IO2, IO3 -- -- -- -- 14.0* 4.0* 14.0* 3.0* -- -- -- -- 12.5 5.0 12.5 3.9 -- -- -- -- 5.5 4.5 6.0 3.0 -- -- -- -- 18.0* 8.5* 18.0* 7.0* 7.5 6.5 7.5 4.5 A A A A A A A A Adc Adc Adc Adc * These are manufacturing test limits. In some situations, results may differ. 4 Lucent Technologies Inc. Data Sheet September 1998 JW060 Triple-Output Series Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 and 12 Vdc, or 5 and 15 Vdc Outputs; 60 W Electrical Specifications (continued) Table 2. Output Specifications (continued) Parameter Device Symbol Min Typ Max Unit Efficiency (VI = 48 V; TC = 25 C, IO1 = 5.0 A, IO2 = IO3 = 1.45 A for JW060ABK, 1.12 A for JW060ACL) Switching Frequency Dynamic Response (IO/t = 1 A/s, VI = 48 V, TC = 25 C, load capacitance per Figure 14): VO1 for a Step Load Change: IO1 Step from 3.0 A to 6.0 A for JW060ABK, IO2 = IO3 = 0.62 A; for JW060ACL, IO2 = IO3 = 0.48 A: Peak Deviation JW060ABK JW060ACL -- -- 86 87 -- -- % % All -- -- 320 -- kHz JW060ABK JW060ACL -- -- -- -- 4.0 4.4 -- -- %VO, set %VO, set Settling Time (VO < 10% of peak deviation) IO1 Step from 0.5 A to 9.0 A, Other Loads at Their Minimum: Peak Deviation JW060ABK JW060ACL -- -- -- -- 680 850 -- -- s s JW060ABK JW060ACL -- -- -- -- 11.6 13.0 -- -- %VO, set %VO, set Settling Time (VO < 10% of peak deviation) VO2 for a Step Load Change: for JW060ABK, IO2 Step from 0.62 A to 1.87 A, IO1 = 3.0 A, IO3 = 0.62 A; for JW060ACL, IO2 Step from 0.48 A to 1.44 A, IO1 = 3.0 A, IO3 = 0.48 A: Peak Deviation JW060ABK JW060ACL -- -- -- -- 700 800 -- -- s s JW060ABK JW060ACL -- -- -- -- 4.5 4.5 -- -- %VO, set %VO, set Settling Time (VO < 10% of peak deviation) JW060ABK JW060ACL -- -- -- -- 580 780 -- -- s s Lucent Technologies Inc. 5 JW060 Triple-Output Series Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 and 12 Vdc, or 5 and 15 Vdc Outputs; 60 W Data Sheet September 1998 Electrical Specifications (continued) Table 3. Isolation Specifications Parameter Isolation Capacitance: Baseplate to I/O Pins Input to Output Pins Isolation Resistance: Baseplate to I/O Pins Input to Output Pins Min Typ Max Unit -- -- 1100 300 -- -- pF pF 10 10 -- -- -- -- M M Min Typ Max Unit -- 15 -- 5,500,000 -- -- 51 (1.8) 500 -- 55 (2) hr. ppm years g (oz.) General Specifications Parameter Calculated MTBF (IO = 80% of IO, max; TC = 40 C) Failure Rate in the First 2 Years of Operation* Useful Life at 55 C Ambient, 80% Full Load* Weight * Based on other similar products. Cleanliness Requirements The open frame (no case or potting) power module will meet requirements per J-STD-001B. These requirements state that solder balls must be attached and their size should not compromise minimum electrical spacing of the power module. The cleanliness designator of the open frame power module is C00 (per J specification). 6 Lucent Technologies Inc. Data Sheet September 1998 JW060 Triple-Output Series Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 and 12 Vdc, or 5 and 15 Vdc Outputs; 60 W Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See Feature Descriptions for further 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 16 and Feature Descriptions.): JW060xxx Preferred Logic: Logic Low--Module Off Logic High--Module On JW060xxx1 Optional Logic: Logic Low--Module On Logic High--Module Off Logic Low (ON/OFF pin tied to VI (-)): At Von/off = 0.0 V Logic High (ON/OFF pin open): At Ion/off = 0.0 A Leakage Current Turn-on Time (See Figure 8.) (IO = 80% of IO, max; VO within 1% of steady state) Output Voltage Overshoot Output Voltage Adjustment (See Feature Descriptions.): Output Voltage Set-point Adjustment Range (trim) Set-point Accuracy with Trim Output Overvoltage Shutdown for VO1 Output Overvoltage Clamp for VO2 and VO3 Overtemperature Threshold Device Symbol Min Typ Max Unit -- -- Von/off Ion/off 0 -- -- -- -- -- V mA -- -- -- Von/off Ion/off -- -- -- 20 -- -- -- -- -- 60* V A ms All -- -- 0 5 % -- -- 70 -- 110 %VO, nom % V V V C All -- -2.5 -- 3.0 All JW060ABK JW060ACL All VO1 VO2, VO3 VO2, VO3 TC 5.55* -- -- 100 6.00 -- -- 105 6.15* 17.0* 20.0* -- * These are manufacturing test limits. In some situations, results may differ. Lucent Technologies Inc. 7 JW060 Triple-Output Series Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 and 12 Vdc, or 5 and 15 Vdc Outputs; 60 W Data Sheet September 1998 Characteristic Curves The following figures provide typical characteristics for the JW060ABK and JW060ACL power modules. The figures are identical for both on/off configurations. 12 11 OUTPUT VOLTAGE, VO2 (V) 2.5 FULL LOAD MID LOAD LIGHT LOAD 2.0 LIN (A) 1.5 1.0 0.5 10 9 8 7 6 36 VIN 48 VIN 75 VIN 5 4 3 2 1 0 0 0 10 20 30 40 50 60 70 0 80 1 2 3 4 5 6 7 8 OUTPUT CURRENT, IO2 (A) INPUT VOLTAGE (V) 8-1530 (C) 8-1512 (C) Figure 1. Typical JW060xxx Input Characteristics at Room Temperature, IO = Full Load Figure 3. Typical JW060ABK VO2 Characteristics at Room Temperature, VIN = 48 V, IO1 = 0.5 A, IO3 = 0.3 A 5.0 6 OUTPUT VOLTAGE, VO1 (V) OUTPUT VOLTAGE, VO1 (V) 4.5 4.0 3.5 3.0 2.5 36 VIN 48 VIN 75 VIN 2.0 1.5 1.0 0.5 5 4 3 36 VIN 48 VIN 75 VIN 2 1 0.0 2 4 6 8 10 12 14 16 18 8-1529 (C) Figure 2. Typical JW060ABK VO1 Characteristics at Room Temperature, VIN = 48 V, IO2 = IO3 = 0.3 A 8 0 0 OUTPUT CURRENT, IO1 (A) 2 4 6 8 10 12 14 16 18 OUTPUT CURRENT, IO1 (A) 8-1531 (C) Figure 4. Typical JW060ACL VO1 Characteristics at Room Temperature, VIN = 48 V, IO2 = IO3 = 0.2 A Lucent Technologies Inc. Data Sheet September 1998 JW060 Triple-Output Series Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 and 12 Vdc, or 5 and 15 Vdc Outputs; 60 W Characteristic Curves (continued) 16 88 12 87 EFFICIENCY, (%) OUTPUT VOLTAGE, VO2 (V) 89 14 10 8 36 VIN 48 VIN 75 VIN 6 4 86 85 84 LOW LINE 36 V NOM LINE 54 V HIGH LINE 75 V 83 82 81 2 80 0 0 1 2 3 4 5 79 15 6 OUTPUT CURRENT, IO2 (A) 25 35 45 55 65 75 85 95 PERCENT OF FULL LOAD 8-1532 (C) Figure 5. Typical JW060ACL VO2 Characteristics at Room Temperature, VIN = 48 V, IO1 = 0.5 A, IO3 = 0.2 A 88 EFFICIENCY, (%) 87 86 85 84 LOW LINE 36 V NOM LINE 54 V HIGH LINE 75 V 83 82 81 80 79 15 25 35 45 55 65 75 85 95 PERCENT OF FULL LOAD 8-1513 (C) Figure 6. Typical JW060ABK Converter Efficiency vs. Output Current at Room Temperature OUTPUT VOLTAGE, VO1 (V) (1 V/div) REMOTE ON/OFF VOLTAGE, VON/OFF (V) (2 V/div) 89 8-1514 (C) Figure 7. Typical JW060ACL Converter Efficiency vs. Output Current at Room Temperature TIME, t (10 ms/div) 8-1515 (C) Figure 8. Typical Start-Up from Remote On/Off JW060xxx; Full Load Lucent Technologies Inc. 9 JW060 Triple-Output Series Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 and 12 Vdc, or 5 and 15 Vdc Outputs; 60 W Data Sheet September 1998 Characteristic Curves (continued) 13.0 16.4 IO2 = 1.0 A 12.6 IO2 = 0.2 A 16.2 12.4 16.0 12.2 15.8 12.0 IO2 = 2.0 A 11.8 VO2 (V) VO2 (V) 16.6 IO2 = 0.3 A 12.8 IO2 = 3.0 A 11.6 IO2 = 2.0 A 15.4 15.2 IO2 = 4.0 A 11.4 IO2 = 1.0 A 15.6 IO2 = 3.0 A 15.0 11.2 14.8 11.0 0 1 2 3 4 5 6 7 8 9 14.6 10 0 1 2 3 4 IO1 (A) 5 6 7 8 Figure 9. Typical JW060ABK VO2 Load Regulation for IO3, min IO3 IO3, max 8-1533 (C) Figure 11. Typical JW060ACL VO2 Load Regulation for IO3, min IO3 IO3, max 13.0 16.6 IO3 = 0.3 A 16.4 12.6 16.0 12.2 12.0 IO3 = 2.0 A 11.8 IO3 = 3.0 A 11.6 -VO3 (V) -VO3 (V) IO3 = 0.2 A 16.2 IO3 = 1.0 A 12.4 15.8 IO3 = 1.0 A 15.6 15.4 IO3 = 2.0 A 15.2 11.4 11.2 IO3 = 3.0 A 15.0 IO3 = 4.0 A 14.8 11.0 0 1 2 3 4 5 6 7 8 9 10 IO1 (A) 14.6 0 1 2 3 4 5 6 7 8 9 10 IO1 (A) 8-1517 (C) Figure 10. Typical JW060ABK VO3 Load Regulation for IO2, min IO2 IO2, max 10 10 IO1 (A) 8-1516 (C) 12.8 9 8-1534 (C) Figure 12. Typical JW060ACL VO3 Load Regulation for IO2, min IO2 IO2, max Lucent Technologies Inc. Data Sheet September 1998 JW060 Triple-Output Series Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 and 12 Vdc, or 5 and 15 Vdc Outputs; 60 W Test Configurations CONTACT AND DISTRIBUTION LOSSES VO2(+) TO OSCILLOSCOPE VI(+) CURRENT PROBE LTEST II V I (+) COM IO2 VO3(-) IO3 LOAD2 LOAD3 SUPPLY 12 H BATTERY VI(-) CS 220 F ESR < 0.1 33 F @ 20 C, 100 kHz ESR < 0.7 @ 100 kHz CONTACT RESISTANCE VO1(+) V I (-) 8-203 (C).l Note: Input reflected-ripple current is measured with a simulated source inductance (LTEST) of 12 H. Capacitor CS offsets possible battery impedance. Current is measured at the input of the module. Figure 13. Input Reflected-Ripple Test Setup LOAD1 IO1 8-749 (C).e 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 1 (+) - V CO M ] I O 1 + [ V O 2 (+) - V CO M ] I O 2 - [ V O 3 (-) - V C OM ] I O3 = -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- x 100 [ V I (+) - V I (-) ] I I Figure 15. Triple-Output-Voltage and Efficiency Measurement Test Setup Design Considerations COPPER STRIP Input Source Impedance VO1(+) 47 F 2 F SCOPE R LOAD1 COM SCOPE 20 F 1 F SCOPE R LOAD2 R LOAD3 VO2(+) 20 F 1 F 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 13, 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. VO3(-) 8-811.b (C) Note: Use the specified tantalum (larger value) and ceramic capacitors across each output. Scope measurement should be made by using a BNC socket. Position the load between 51 mm and 76 mm (2 in. and 3 in.) from the module. Figure 14. Output Noise Measurement Test Setup Lucent Technologies Inc. 11 JW060 Triple-Output Series Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 and 12 Vdc, or 5 and 15 Vdc Outputs; 60 W Data Sheet September 1998 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., UL-1950, CSA 22.2-950, and EN60950. 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. For the converter output to be considered meeting the requirements of safety extra-low voltage (SELV), one of the following must be true: All inputs are SELV and floating, with the output also floating. All inputs are SELV and grounded, with the output also grounded. Any non-SELV input must be provided with reinforced insulation from any other hazardous voltages, including the ac mains, and must have a SELV reliability test performed on it in combination with the converters. Inputs must meet SELV requirements. If the input meets extra-low voltage (ELV) requirements, then the converter's output is considered ELV. 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 16). 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. The input to these units is to be provided with a maximum 20 A normal-blow fuse in the ungrounded lead. During a logic high, the maximum Von/off generated by the power module is 15 V. The maximum allowable leakage current of the switch is 50 A. It is not recommended to drive the ON/OFF pin with an external source; however, if one is used, current into the pin must not exceed 1 mA. 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. Assembly Considerations Ion/off The power module is not encapsulated. It is designed to be mounted to the printed-wiring board (PWB) after the assembly cleaning process. + ON/OFF Von/off - VO1(+) Feature Descriptions Overcurrent Protection To provide protection in a fault (output overload) condition, the unit is equipped with internal current-limiting circuitry and can endure current limiting for an unlimited duration. At the point of current-limit inception, the unit shifts from voltage control to current control. If the output voltage is pulled very low during a severe fault, the current-limit circuit exhibits foldback characteristics (output current decrease). The unit operates normally once the overload condition is removed. 12 LOAD VI(+) COM VI(-) 8-720 (C).g Figure 16. Remote On/Off Implementation Lucent Technologies Inc. Data Sheet September 1998 JW060 Triple-Output Series Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 and 12 Vdc, or 5 and 15 Vdc Outputs; 60 W Output Voltage Set-Point Adjustment (Trim) Output voltage trim allows the user to increase or decrease the output voltage set points of all outputs simultaneously. This is accomplished by connecting an external resistor between the TRIM pin and either the VO1(+) or COM pins. With an external resistor between the TRIM and COM pins (Radj-down), the output voltage set points decrease (see Figure 17). The following equation, plotted in Figure 18, gives the required external-resistor value to lower the output voltages by a percentage (%). RESISTANCE BETWEEN TRIM AND COM PINS () Feature Descriptions (continued) 1M 100k 10k 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 PERCENT DECREASE FROM NOMINAL VOUT (%) R adj-down 100 = 10,000 ---------- - 2 % 8-1536 (C) With an external resistor connected between the TRIM and VO1(+) pins (Radj-up), the output voltage set points increase (see Figure 19). The following equation, plotted in Figure 20, gives the required external-resistor value to raise the output voltages by a percentage (%). 100 O1 , nom R adj-up = 10,000 V - 1 ---------- + 1 - 1 -------------------- % 1.225 Figure 18. Resistor Selection for Decreased Output Voltage VI(+) VO1(+) ON/OFF Radj-up TRIM RLOAD VI(-) The voltage between the VO1(+) and COM terminals must not exceed the minimum output overvoltage shutdown voltage as indicated in the Feature Specifications table. If not using the trim feature, leave the TRIM pin open. VI(+) COM 8-715 (C).f Figure 19. Circuit Configuration to Increase Output Voltage VO1(+) ON/OFF TRIM RLOAD Radj-down VI(-) COM 8-748 (C).d Figure 17. Circuit Configuration to Decrease Output Voltage Lucent Technologies Inc. 13 JW060 Triple-Output Series Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 and 12 Vdc, or 5 and 15 Vdc Outputs; 60 W Data Sheet September 1998 Thermal Considerations Output Voltage Set-Point Adjustment (Trim) (continued) Introduction RESISTANCE BETWEEN TRIM AND VO1 PINS () Feature Descriptions (continued) 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 metal baseplate. Heat is removed by conduction, convection, and radiation to the surrounding environment. Proper cooling can be verified by measuring the metal baseplate temperature. Peak temperature (TC) occurs at the position indicated in Figure 21. 10M 1M 28.9 (1.14) MEASURE BASEPLATE TEMPERATURE HERE 100k 0 1 2 3 4 5 6 7 8 9 10 30.5 (1.20) VI(+) Vo2(+) TRIM Figure 20. Resistor Selection for Increased Output Voltage VI(-) Vo1(+) Output Overvoltage Protection ON/OFF COM Vo3(-) PERCENT INCREASE FROM NOMINAL VOUT (%) 8-1535 (C) The output overvoltage clamp consists of circuitry that monitors the voltage on the output terminals. If the voltage on the output terminals exceeds the overvoltage protection threshold, then the module will shut down and attempt to restart periodically. 8-716 (C).g Note: Top view, pin locations are for reference. Measurements shown in millimeters and (inches). Figure 21. Case Temperature Measurement Location Overtemperature Protection To provide protection in a fault condition, the unit is equipped with a temperature limiting circuit. This circuit will not engage unless the unit is operated above the absolute maximum temperature limit. When active, the overtemperature circuit lowers all output voltages sufficiently to prevent exceeding the overtemperature threshold. Recovery from the temperature limit is automatic after the unit cools below the overtemperature threshold. 14 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. Thermal performance of the module varies with the direction of airflow, assumed to be parallel to one edge of the baseplate. The best orientation has air entering the side with input pins, and the second best orientation has air entering the side closest to the ON/OFF and VO3(-) pins. Lucent Technologies Inc. JW060 Triple-Output Series Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 and 12 Vdc, or 5 and 15 Vdc Outputs; 60 W Introduction (continued) Total power dissipation for the modules at 48 V input is given by Figure 24 and Figure 25. Power dissipation at 36 V input is approximately 0.3 W higher than shown for 48 V input, and power dissipation at 75 V input is approximately 0.6 W higher than shown for 48 V input. Heat Transfer Without Heat Sinks Increasing airflow over the module enhances the heat transfer via convection. Figure 22 shows the maximum power that can be dissipated by the module without exceeding the maximum base plate temperature versus local ambient temperature (TA), for natural convection through 4 m/s (800 ft./min.) in transverse (better) orientation, where the air flows parallel to the shorter side. 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 22 and Figure 23 is shown in the following example. Example What is the minimum airflow necessary for a JW060ABK operating at nominal line, an output current of 9 A on 5 V, 1.25 A on +12 V, and 0 A on -12 V, and a maximum ambient temperature of 50 C? Solution Given: VI = 54 V IO1 @5 V = 9 A IO2 @ +12 V = 1.25 A IO3 @ -12 V = 0 A TA = 50 C Determine PD (Use Figure 24.): Determine airflow 1 (v) (Use Figure 22.): v = 0.75 m/s (150 ft./min.) Determine airflow 2 (v) (Use Figure 23.): v = 0.9 m/s (180 ft./min.) 16.0 POWER DISSIPATION, PD (W) Thermal Considerations (continued) 14.0 12.0 10.0 8.0 800 ft./min. 700 ft./min. 6.0 600 ft./min. 500 ft./min. 400 ft./min. 4.0 300 ft./min. 200 ft./min. 2.0 100 ft./min. 20 ft./min. (nat. conv.) 0.0 0 10 20 30 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (C) 8-1509 (C) Figure 22. Forced Convection Power Derating with No Heat Sink; Transverse Orientation 16.0 POWER DISSIPATION, PD (W) Data Sheet September 1998 14.0 12.0 10.0 8.0 800 ft./min. 700 ft./min. 600 ft./min. 500 ft./min. 400 ft./min. 4.0 300 ft./min. 200 ft./min. 2.0 100 ft./min. 20 ft./min. (nat. conv.) 6.0 0.0 0 10 20 30 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (C) 8-1510 (C) Figure 23. Forced Convection Power Derating with No Heat Sink; Longitudinal Orientation PD = 11.5 W Lucent Technologies Inc. 15 JW060 Triple-Output Series Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 and 12 Vdc, or 5 and 15 Vdc Outputs; 60 W Thermal Considerations (continued) Heat Transfer Without Heat Sinks (continued) customer's PWB around the mounting holes is 0.130 0.005 inches. If a larger hole is used, the mounting torque from the pin side must not exceed 0.25 N-m (2.2 in.-lb.). Thermal derating with heat sinks is expressed by using the overall thermal resistance of the module. Total module thermal resistance (ca) is defined as the maximum case temperature rise (TC, max) divided by the module power dissipation (PD): IO2 + IO3 = 6.0 A IO2 + IO3 = 5.0 A IO2 + IO3 = 4.0 A 14 13 POWER DISSIPATION, PD (W) Data Sheet September 1998 12 11 (TC - TA) T C, max = ----------------------- ca = --------------------PD PD 10 9 8 IO2 + IO3 = 3.0 A 7 IO2 + IO3 = 2.0 A 6 IO2 + IO3 = 1.3 A 5 4 IO2 + IO3 = 0.6 A 3 2 0 1 2 3 4 5 6 7 8 9 10 The location to measure case temperature (TC) is shown in Figure 21. Case-to-ambient thermal resistance vs. airflow is shown, for various heat sink configurations and heights, in Figure 26. These curves were obtained by experimental testing of heat sinks, which are offered in the product catalog. IO1 (A) 8-1537 (C) 8.0 Figure 24. JW060ABK Power Dissipation vs. Output Current for VI = 48 V 7.0 1 1/2 IN. HEAT SINK 1 IN. HEAT SINK 1/2 IN. HEAT SINK 1/4 IN. HEAT SINK NO HEAT SINK RCA (C/W) 6.0 IO2 + IO3 = 5.0 A IO2 + IO3 = 4.0 A POWER DISSIPATION, PD (W) IO2 + IO3 = 3.0 A 5.0 4.0 3.0 14 13 2.0 12 1.0 11 0.0 10 0 100 200 300 400 500 600 9 VELOCITY (ft./min.) 8 7 IO2 + IO3 = 2.0 A 6 5 IO2 + IO3 = 1.2 A 4 8-1511 (C) Figure 26. Case-to-Ambient Thermal Resistance Curves; Either Orientation IO2 + IO3 = 0.4 A 3 2 0 1 2 3 4 5 6 7 8 9 10 IO1 (A) 8-1538 (C) Figure 25. JW060ACL Power Dissipation vs. Output Current for VI = 48 V Heat Transfer with Heat Sinks 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 26 had a thermal-conductive dry pad between the case and the heat sink to minimize contact resistance. The use of Figure 26 is shown in the following example. 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 16 Lucent Technologies Inc. Data Sheet September 1998 JW060 Triple-Output Series Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 and 12 Vdc, or 5 and 15 Vdc Outputs; 60 W Thermal Considerations (continued) Custom Heat Sinks Heat Transfer with Heat Sinks (continued) 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 27). Example If an 85 C case temperature is desired, what is the minimum airflow necessary? Assume the JW060ABK module is operating at nominal line and an output current of 9 A on 5 V, 1.25 A on +12 V, and 0 A on -12 V, maximum ambient air temperature of 40 C, and a heat sink that is 0.25 inches. PD TC TS cs TA sa Solution 8-1304 (C) Given: VI = 54 V IO1 @ 5 V = 9 A IO2 @ +12 V = 1.25 A IO3 @ -12 V = 0 A TA = 40 C TC = 85 C Heat sink = 0.25 in. Determine PD by using Figure 24: Figure 27. 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 PD = 11.5 W Then solve the following equation: (TC - TA) ca = ----------------------PD 85 - 40 ) ca = (----------------------11.5 - ca = 3.9 C/W Use Figure 26 to determine air velocity for the 0.25 inch heat sink. The minimum airflow necessary for the JW060ABK module is 0.6 m/s (110 ft./min.). 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. Layout Considerations Copper paths must not be routed beneath the power module mounting inserts, which are conductive and connected together electrically. Furthermore, it is not recommended that any copper paths be routed underneath or near the power module because they are likely to pick up noise from the module. For improved EMI performance, follow the layout guidelines given in data sheet DS97-053EPS for the FLTR100V10 filter module, or data sheet DS96-215EPS for the FLTR100V20 filter module. For best EMI performance, use either of these filter modules at the input of one or more power modules. Lucent Technologies Inc. 17 JW060 Triple-Output Series Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 and 12 Vdc, or 5 and 15 Vdc Outputs; 60 W Data Sheet September 1998 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 13.33 (0.525) MAX 5.1 (0.20) MIN 1.02 (0.040) DIA SOLDER-PLATED BRASS 8 PLCS Bottom View MOUNTING INSERTS M3 x 0.5 THROUGH, 4 PLCS ON/OFF VO3(-) COM 17.78 (0.700) 50.8 (2.00) 5.08 (0.200) 12.70 (0.500) VI(-) VO1(+) 48.26 (1.900) 17.78 (0.700) 12.70 (0.500) TRIM VO2(+) VI(+) 5.08 (0.200) 12.7 (0.50) 5.1 (0.20) 12.7 (0.50) 48.3 (1.90) 4.8 (0.19) 8-1190 (C).d 18 Lucent Technologies Inc. Data Sheet September 1998 JW060 Triple-Output Series Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 and 12 Vdc, or 5 and 15 Vdc Outputs; 60 W Recommended Hole Pattern Component-side footprint. Dimensions are in millimeters and (inches). 5.1 (0.20) 57.9 (2.28) MAX 4.8 (0.19) 48.3 (1.90) 12.7 (0.50) VO2(+) VI(+) 50.8 (2.00) 61.0 (2.40) MAX TRIM 17.78 (0.700) 48.26 (1.900) 5.08 (0.200) 12.70 (0.500) VO1(+) VI(-) 12.70 (0.500) 17.78 (0.700) COM ON/OFF 5.08 (0.200) VO3(-) MODULE OUTLINE 8-1190 (C).d Ordering Information Input Voltage 36 V--75 V 36 V--75 V 36 V--75 V Output Voltage +5 V, 12 V +5 V, 15 V +5 V, 12 V Output Power 60 W 60 W 60 W Remote On/Off Logic positive positive negative Device Code JW060ABK JW060ACL JW060ABK1 107880296 107880312 108237124 36 V--75 V +5 V, 15 V 60 W negative JW060ACL1 108237108 Lucent Technologies Inc. Comcode 19 JW060 Triple-Output Series Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 and 12 Vdc, or 5 and 15 Vdc Outputs; 60 W Data Sheet September 1, 1998 For additional information, contact your Lucent Technologies Account Manager or the following: POWER SYSTEMS UNIT: Network Products Group, Lucent Technologies Inc., 3000 Skyline Drive, Mesquite, TX 75149, USA +1-800-526-7819 (Outside U.S.A.: +1-972-284-2626, FAX +1-972-284-2900) (product-related questions or technical assistance) INTERNET: http://www.lucent.com/networks/power E-MAIL: techsupport@lucent.com ASIA PACIFIC: Lucent Technologies Singapore Pte. Ltd., 750A Chai Chee Road #05-01, Chai Chee Industrial Park, Singapore 469001 Tel. (65) 240 8041, FAX (65) 240 8053 JAPAN: Lucent Technologies Japan Ltd., 7-18, Higashi-Gotanda 2-chome, Shinagawa-ku, Tokyo 141-0022, Japan Tel. (81) 3 5421 1600, FAX (81) 3 5421 1700 LATIN AMERICA: Lucent Technologies Inc., Room 9N128, One Alhambra Plaza, Coral Gables, FL 33134, USA Tel. +1-305-569-4722, FAX +1-305-569-3820 EUROPE: Data Requests: DATALINE: Tel. (44) 1189 324 299, FAX (44) 1189 328 148 Technical Inquiries:GERMANY: (49) 89 95086 0 (Munich), UNITED KINGDOM: (44) 1344 865 900 (Bracknell), FRANCE: (33) 1 40 83 68 00 (Paris), SWEDEN: (46) 8 594 607 00 (Stockholm), FINLAND: (358) 9 4354 2800 (Helsinki), ITALY: (39) 02 6608131 (Milan), SPAIN: (34) 91 807 1441 (Madrid) Lucent Technologies Inc. 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. Copyright (c) 1998 Lucent Technologies Inc. All Rights Reserved Printed in U.S.A. September 1998 DS98-384EPS (Replaces DS97-127EPS) Printed On Recycled Paper