QW075A1 - Tyco Electronics - Product.Network

Data Sheet

May 2000

QW050A1 and QW075A1 Power Modul es:

dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W and 75 W

Applications

■Distr i buted power architecture s

■Workstations

■Computer equ ipm ent

■Communications equipment

Options

■Heat sinks available for ex tended operation

■Auto-restart after overcurrent shutdown

Features

■Small size: 36.8 mm x 57.9 mm x 12.7 mm

(1.45 in. x 2.28 in. x 0.50 in.)

■High power density

■High efficiency: 84% typical

■Low output n oise

■Constant frequency

■Industry-standard pinout

■Metal basepl ate

■2:1 input voltage range

■Overvoltage and overcurrent protection

■Remote on/off

■Remote sense

■Adjustable output voltage

■Ov ertemperat ure pro tection

■

ISO

* 9001 Certified manufacturing facilities

■

†1950

Recognized,

CSA

‡ C22.2 No. 950-95

Certified, and

VDE

§ 0805 (EN60950, IEC950)

Licensed

■CE mark meets 73/23/EEC and 93/68/EEC direc-

tives**

ISO

is a registered trademark of the International Organization

for Standardization.

†

is a registered trademark of Underwriters Laboratories, Inc.

‡

CSA

is a registered trademark of Canadian Standards Associa-

tion.

VDE

is a trademark of Verband Deutscher Elektrotechniker e.V.

** This product is intended f or integration into end-use equipment.

All the required procedures for CE marking of end-use equip-

ment should be followed. (The CE mark is placed on selected

products.)

The QW Series Power Modules use advanced, surface-mount

tech nology and deliver high-quality, efficient, and compac t

dc-dc conver sion.

Description

The QW050A1 and QW075A1 P o w er 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 rat-

ings from 50 W to 75 W at a typical full-load efficiency of 84%.

The sealed modules off er a metal baseplate for e xcellent thermal perf ormance. Threaded-through holes are pro-

vided to allow easy mounting or addition of a heat sink f or high-temperature applications. The standard f eature set

includes remote sensing, output trim, and remote on/off for conv enient flexibility in distributed power applications.

2Tyco Electronics Corp.

Data Sheet

May 2000dc-dc Con verters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W and 75 W

QW050A1 and QW075A1 Power Modules:

Absolute Maximum Ratings

Stresses in excess of the absolute maximum ratings can cause permanent damage to the device. These are abso-

lute 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.

Electrical Specifications

Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature

conditions.

Table 1. Input Specifications

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 fus-

ing is not included; however, to achieve maximum saf ety and system protection, always use an input line fuse. The

safety agencies require a normal-blow fuse with a maximum rating of 3 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.

Parameter Symbol Min Max Unit

Input Voltage:

Continuous

Transient (100 ms) VI

VI, trans —

—75

100 Vdc

Operating Case Temperature

(See Thermal Considerations section; see

Figure 22.)

TC–40 100 °C

Storage Temperature Tstg –55 125 °C

I/O Isolation Voltage (for 1 minute) ——1500 Vdc

Parameter Symbol Min Typ Max Unit

Operating Input Voltage VI36 48 75 Vdc

Maximum Input Current

(VI = 0 V to 75 V; IO = IO, max; see Figures 1 and

2):

QW050A1

QW075A1 II, max

II, max —

——

—2.5

3.5 A

Inru sh Transient i2t——1.3 A2s

Input Reflected-ripple Current, Peak -to-peak

(5 Hz to 20 MHz, 12 µH source impedance;

see Figure 13.)

II —10 —mAp-p

Input Ripple Rejection (120 Hz) ——60 —dB

Tyco Electronics Corp. 3

Data Sheet

May 2000 dc-dc Con verters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W and 75 W

QW050A1 and QW075A1 Power Modules:

Electrical Specifications (continued)

Table 2. Output Specifications

* Consult your sales representative or the fa ctory.

† These are manufac turi ng test limits. In some situations, results may differ.

Table 3. Isolation Specifications

Parameter Device Symbol Min Typ Max Unit

Output Voltage Set Point

(VI = 48 V; IO = IO, max; TC = 25 °C) All VO, set 4.92 5.0 5.08 Vdc

Output Voltage

(Over all operating input voltage, resistive load,

and temperature conditions until end of lif e. See

Figure 15.)

All VO4.85 —5.15 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

—

0.01

0.05

0.1

0.2

%VO

Output Ripp le and Noise Voltage

(See Figure 14.):

RMS

Peak-to-peak (5 Hz to 20 MHz) All

All —

——

—40

150 mVrms

mVp-p

External Load Capacitance All —0—*µF

Output Current

(At IO < IO, m in, the modules may exceed output

ripple specifications.)

QW050A1

QW075A1 IO

IO0.5

0.5 —

—10

15 A

Output Current-limit Inception

(VO = 90% of VO, nom)QW050A1

QW075A1 IO, cli

IO , cli —

—15

20 20†

26†A

Efficiency (VI = 48 V; IO = IO, max; TC = 70 °C) QW050A1

QW075A1 η

η—

—84

84 —

—%

Switching Frequency All ——380 —kHz

Dynamic Response

(ýIO/ýt = 1 A/10 µs, VI = 48 V, TC = 25 °C; tested

with a 1000 µF aluminum and a 1.0 µF ceramic

capaci tor acr os s the load.) :

Load Change from IO = 50% to 75% of IO, max:

Peak Deviation

Settling Time (VO < 10% of peak deviation)

Load Change from IO = 50% to 25% of IO, max:

Peak Deviation

Settling Time (VO < 10% of peak deviation)

All

—

700

—

%VO, set

µs

%VO, set

µs

Parameter Min Typ Max Unit

Isolation Capacitance —2500 —pF

Isolation Resistance 10 ——M¾

4Tyco Electronics Corp.

Data Sheet

May 2000dc-dc Con verters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W and 75 W

QW050A1 and QW075A1 Power Modules:

General Specifications

Feature Specifications

Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature

conditions. See Feature Descriptions for additional information.

* These are manufacturing test limits. In some situations, results 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 inad-

equate 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).

Parameter Min Typ Max Unit

Calculated MTBF (IO = 80% of IO, max ; TC = 40 °C):

QW050A1

QW075A1 4,000,000

3,500,000 hours

hours

Weight ——75 (2.7) g (oz.)

Parameter Symbol Min Typ Max Unit

Remote On/Off Signal Interface

(VI = 0 V to 75 V; open collector or equivalent compatible;

signal referenced to VI(–) ter mi nal; see Figu re 16 and

Feature Descriptions.):

Logic Low—Module On

Logic High—Module Off

Logic Low:

At Ion/off = 1.0 mA

At Von/off = 0.0 V

Logic High:

At Ion/off = 0.0 µA

Leakage Current

Turn-on Time (See Figures 11 and 12.)

(IO = 80% of IO, max; VO within ±1% of steady state)

Von/off

Ion/off

Von/off

Ion/off

—

1.2

1.0

µA

Output Voltage Adjustment (See Feature Descriptions.):

Output Voltage Remote-sense Range

Output Voltage Set-point Adjustment Range (trim) —

——

60 —

—0.5

110 V

%VO, nom

Output Overvoltage Protection VO, sd 5.7* —6.8* V

Overtemperature Protection TC—105 —°C

dc-dc Con verters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W and 75 W

QW050A1 and QW075A1 Power Modules:Data Sheet

May 2000

Tyco Electronics Corp. 5

Characteristic Curves

The following figures provide typical characteristics for the power modules. The figures are identical for both on/off

configurations.

8-2949 (F)

Figure 1. T ypical QW050A1 Input Characteristics at

Room Temperature

8-2327 (C)

Figure 2. T ypical QW075A1 Input Characteristics at

Room Temperature

8-2950 (F)

Note: Pending improvement will add 1% to the above curv es.

Figure 3. Typical QW050A1 Converter Efficiency

vs. Output Current at Room Temperature

8-2951 (F)

Note: Pending improvement will add 1% to the above curv es.

Figure 4. Typical QW075A1 Converter Efficiency

vs. Output Current at Room Temperature

2.5

2.0

1.5

0.5

0.020 30 40 45 50 55 60 65 70

INPU T VOLTAGE, VI (V)

INPUT CURRENT, II (A)

1.0

IO = 10 A

IO = 6 A

IO = 1 A

30 35 40 45 75

0.0

INPUT V OLTA GE, VI (V)

INPUT CURRENT, II (A)

3.5

20 50 55 60 65 70

0.5

2.5

3.0

1.0

1.5

2.0

IO = 15 A

IO = 7.5 A

IO = 1.5 A

75 2345678910

OUTPUT CURRENT, IO (A)

EFFICIENCY, η (%)

VI = 36 V

VI = 48 V

VI = 75 V

75 3 4 7 101112131415

OUTPUT CURRENT, IO (A)

EFFICIENCY, η (%)

5 6 8 9

VI = 36 V

VI = 54 V

VI = 75 V

6Tyco Electronics Corp.

Data Sheet

May 2000dc-dc Con verters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W and 75 W

QW050A1 and QW075A1 Power Modules:

Characteristic Curves (continued )

8-2062 (C)

Figure 5. Typical QW050A1 Output Ripple Voltage

at Room Temperature and IO = IO, max

8-2298 (C)

Note: See Figure 14 for test conditions.

Figure 6. Typical QW075A1 Output Ripple Voltage

at Room Temperature and IO = IO, max

8-2952 (F)

Note: Tested with a 1000 µF aluminum and a 1.0 µF ceramic capaci-

tor across the load.

Figure 7. Typical QW050A1 Transient Response to

Step Decrease in Load from 50% to 25%

of IO, max at Room Temperature and

54 Vdc Input (Waveform Av erag ed to

Eliminate Ripple Component.)

8-2953 (F)

Note: Tested with a 1000 µF aluminum and a 1.0 µF ceramic capaci-

tor across the load.

Figure 8. Typical QW075A1 Transient Response to

Step Decrease in Load from 50% to 25%

of IO, max at Room Temperature and

54 Vdc Input (Waveform Av erag ed to

Eliminate Ripple Component.)

TIME, t (1 µs/div)

OUTPUT VOLTAGE, VO (V)

(50 mV/div)

VI = 75 V

VI = 54 V

VI = 36 V

TIME, t (1 µs/div)

OUTPUT VOLTAGE, VO (V)

(50 mV/div)

VI = 36 V

VI = 54 V

VI = 75 V

TIME, t (500 µs/div)

OUTPUT VOLTAGE, VO (V)

(100 mV/div)

OUTPUT CURRENT, IO (A)

(1 A/div)

5 A

2.5 A

TIME, t (200 ns/div)

OUTPUT VOLTAGE, VO (V)

(100 mV/div)

OUTPUT CURRENT, IO (A)

(1 A/div)

7.5 A

3.75 A

Tyco Electronics Corp. 7

Data Sheet

May 2000 dc-dc Con verters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W and 75 W

QW050A1 and QW075A1 Power Modules:

Characteristic Curves (continued )

8-2954 (F)

Note: Tested with a 1000 µF aluminum and a 1.0 µF ceramic capaci-

tor across the load.

Figure 9. Typical QW050A1 Transient Response to

Step Increase in Load from 50% to 75% of

IO, max at Room Temperature and 54 Vdc

Input (Waveform Averaged to Eliminate

Ripple Component.)

8-2 955 ( F)

Note: Tested with a 220 µF aluminum and a 1.0 µF ceramic capacitor

across the load.

Figure 10. Typical QW075A1 Transient Response

to Step Increase in Load from 50% to

75% of IO, max at Room Temperature and

54 Vdc Input (Waveform Averaged to

Eliminate Ripple Component.)

8-3027 (F)

Note: Tested with a 1000 µF aluminum and a 1.0 µF ceramic capaci-

tor across the load.

Figure 11. QW050A1 T ypical Start-Up from Remote

On/Off; IO = IO, max

8-2956 (F)

Note: Tested with a 1000 µF aluminum and a 1.0 µF ceramic capaci-

tor across the load.

Figure 12. QW075A1 T ypical Start-Up from Remote

On/Off; IO = IO, max

TIME, t (500 µs/div)

OUTPUT VOLTAGE, VO (V)

(100 mV/div)

OUTPUT CURRENT, IO (A)

(1 A/div)

7.5 A

5.0 A

TIME, t (200 µs/div)

OUTPUT VOLTAGE, VO (V)

(100 mV/div)

OUTPUT CURRENT, IO (A)

(1 A/div)

11.25 A

7.5 A

TIME, t (5 ms/div)

OUTPUT VOLTAGE, VO (V)

(2 V/div) REM O TE, ON/OFF

VON/OFF (V)

TIME, t (2 ms/div)

REMOTE ON/OFF,

VON/OFF (V)

OUTPUT VOLTAGE, VO (V)

(1 V/div)

QW050A1 and QW075A1 Power Modules:

88 Tyco Electronics Corp.

Data Sheet

May 2000dc-dc Con verters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W and 75 W

Test Configurations

8-203 (C).l

Note: Measure input reflected-ripple current with a simulated source

inductance (LTEST) of 12 µH. Capacitor CS offsets possible bat-

tery impedance. Measure current as shown above.

Figure 13. Input Reflected-Ripple Test Setup

8-513 (C).d

Note: Use a 1.0 µF ceramic capacitor and a 10 µF aluminum or tan-

talum 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 14. Peak-to-Peak Output Noise

Measurement Test Setup

8-749 (C)

Note: All measurements are taken at the module terminals. When

socket ing, place Kelvin connections at module terminals to

av oid measurement errors due to socket contact resistance.

Figure 15. Output Voltage and Efficiency

Measurement Test Setup

Design Considerations

Input Source Im pedance

The power module should be connected to a low

ac-impedance input source. Highly inductive source

impedances can affect the stability of the power mod-

ule. For the test configuration in Figure 13, a 33 µF

electrolytic capacitor (ESR < 0. 7 ¾ at 100 kHz)

mounted close to the power module helps ensure sta-

bility 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

requir eme nts of the end-u se sa fety agency stan dard,

i.e.,

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 reinf orced

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 acces-

sible.

■Another SELV reliability test is conducted on the

whole system, as required b y 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 e x tra-low voltage (ELV) outputs

when all inputs are ELV.

The input to these units is to be provided with a maxi-

mum 3 A normal-blo w fuse in the ungrounded lead.

TO OSCILLOSCOPE

12 µH

220 µF

ESR < 0.1 Ω

@ 20 ˚C, 100 kHz

(+)

(-)

BATTERY 33 µF

CURRENT

PROBE

TEST

ESR < 0.7 Ω

@ 100 kHz

VO(+)

VO(–)

1.0 µF RESISTIVE

LOAD

SCOPE

COPPER STRIP

10 µF

(+)

SUPPLY

CONTACT

RESISTANCE

CONTACT AND

DISTRIBUTION LOSSES

LOAD

SENSE(+)

(–)

(+)

(–)

SENSE(–)

ηVO(+) –VO(–)

[]

VI(+) –VI(–)

[]

------------------------------------------------





x100=%

Tyco Electronics Corp. 9

Data Sheet

May 2000 dc-dc Con verters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W and 75 W

QW050A1 and QW075A1 Power Modules:

Feature Descriptions

Overcurrent Protection

To provide protection in a fault (output overload) condi-

tion, the unit is equipped with internal current-limiting

circuitry and can endure current limiting for up to one

second. If ov ercurrent exists for more than one second,

the unit will shut down.

At the point of current-limit inception, the unit shifts

from voltage control to current control. If the output volt-

age is pulled very low during a sev ere fault, the current-

limit circuit can exhibit either foldback or tailout charac-

teris tics (output current decr ease or increase).

The module is available in two overcurrent configura-

tions. In one configuration, when the unit shuts down it

will latch off. The overcurrent latch is reset by either

cycling the input power or by toggling the ON/OFF pin

for one second. In the other configuration, the unit will

try to restart after shutdown. If the output overload con-

dition still exists when the unit restarts, it will shut down

again. This operation will continue indefinitely until the

overcurrent condition is corrected.

Remote On/Off

Negative logic remote on/off turns the module off dur-

ing a logic high and on during a logic low. 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(–) termina l (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.

During a logic high, the maximum Von/off generated by

the power module is 15 V. The maximum allowable

leakage cu rren t of the switch at Von/off = 15 V is 50 µA.

If not using the remote on/off feature, short the ON/OFF

pin to VI(–).

8-720 (C).c

Figure 16. Remote On/Off Implementation

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 out-

put voltage sense range giv en in the Feature Specifica-

tions table, i.e.:

[VO(+) – VO(–)] – [SENSE(+) – SENSE( –)] ð 0.5 V

The voltage between the VO( +) and VO(–) terminal s

must not exceed the minimum output overvoltage pro-

tection v alue shown in the F eature Specifications table .

This limit includes any increase in voltage due to

remote-sense compensation and output voltage set-

point adjustment (trim). See Figure 17.

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 limitati on.

The amount of power delivered by the module is

defined as the v oltage at the output terminals multiplied

by the output current. When using remote sense and

trim, the output voltage of the module can be

increased, which at the same output current would

increase the power output of the module. Care should

be taken to ensure that the maximum output power of

the module remains at or below the maximum rated

power.

SENSE(+)

VO(+)

SENSE(–)

VO(–)

VI(-)

–

Ion/off ON/OFF

VI(+)

LOAD

Von/off

QW050A1 and QW075A1 Power Modules:

1010 Tyco Electronics Corp.

Data Sheet

May 2000dc-dc Con verters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W and 75 W

Feature Descriptions (continued)

Remote Sense (continued)

8-651 (C).m

Figure 17. Effective Circuit Configuration for

Single-Module Remote-Se nse 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.

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 18). The following equa-

ti on determines the requir ed external-resistor value to

obtain a percentage output voltage change of ý%.

The test results for this configuration are displayed in

Figure 19. 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 20).

The following equation determines the required exter-

nal-resistor v alue to obtain a percentage output v oltage

change of ý%.

The test results for this configuration are displayed in

Figure 21.

The voltage between the VO(+) and VO(–) terminals

must not exceed the minimum output overvoltage pro-

tection v alue shown in the Feature Specifications table.

This limit includes any increase in voltage due to

remote-sense compensation and output voltage set-

point adjustment (trim). See Figure 17.

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 limitati on.

The amount of power delivered by the module is

defined as the v oltage 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.

8-748 (C).b

Figure 18. Circuit Configuration to Decrease

Output Voltage

8-2577 (C)

Figure 19. Resistor Selection for Decreased

Output Voltage

VO(+)

SENSE(+)

SENSE(–)

VO(–)

VI(+)

VI(-)

IOLOAD

CONTACT AND

DISTRIBUTION LOSSES

SUPPLY II

CONTACT

RESISTANCE

Radj-down 510

∆%

---------- 10.2–





kΩ

Radj-up 5.1VO100 ∆%+

()

1.225∆%

-----------------------------------------------510

∆%

----------

–10.2

–





kΩ

VI(+)

VI(–)

ON/OFF

CASE

VO(+)

VO(–)

SENSE(+)

TRIM

SENSE(–)Radj-down

RLOAD

10 20 30 40

10k

100k

ADJUSTMENT RESIST OR VALUE ( Ω)

% CHANGE IN OUTPUT VOLTAGE (∆%)

Tyco Electronics Corp. 11

Data Sheet

May 2000 dc-dc Con verters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W and 75 W

QW050A1 and QW075A1 Power Modules:

Feature Descriptions (continued)

Output Voltage Set-Point Adjustment

(Trim) (continued)

8-715 (C).b

Figure 20. Circuit Configuration to Increase

Output Voltage

8-2855 (F)

Figure 21. Resistor Selection for Increased Output

Voltage

Output Overvoltage Protection

The output overvoltage protection consists of circuitry

that monitors the voltage on the output terminals. If the

voltage on the output terminals exceeds the overvolt-

age protection threshold, then the module will shut

down and latch off. The overv oltage latch is reset by

either cycling the input power for 1.0 second or by tog-

gling the on/off signal for 1.0 second.

Overtemperature Protection

These modules feature an overtemperature protection

circuit to safeguard against thermal damage. The cir-

cuit shuts down and latches off the module when the

maximum case temperature is exceeded. The module

can be restarted by cycling the dc input power for at

least 1.0 second or by toggling the remote on/off signal

for at least 1.0 second.

Thermal Considerations

Introduction

The power modules operate in a variety of thermal

environments; however, sufficient cooling should be

provided to help ensure reliable operation of the unit.

Heat-dissipating components inside the unit are ther-

mally coupled to the case. Heat is removed by conduc-

tion, convection, and radiation to the surrounding

environment. Proper cooling can be verified by mea-

suring the case temperature. Peak temperature (TC)

occurs at the position indicated in Figure 22.

8-2104 (C)

Note: Top view, pin locations are for reference only.

Measurements shown in millimeters and (inches).

Figure 22. Case Temperature Measurement

Location

The temperature at this location should not exceed

100 °C. The output power of the module should not

exceed the rated power for the module as listed in the

Ordering Information table.

Although the maximum case temperature of the power

modules is 100 °C, you can limit this temperature to a

lower value for extremely high reliability.

VI(+)

VI(–)

ON/OFF

CASE

VO(+)

VO(-)

SENSE(+)

TRIM

SENSE(–)

Radj-up RLOAD

10M

100k 0246810

% CHANGE IN OUTPUT VOLTAGE ( ∆%)

ADJUSTMENT RESISTOR VALUE (Ω)

(0.55)

VI(-)

ON/OFF

VI(+)

VO(–)

TRIM

VO(+)

(+)SENSE

(-)SENSE

33 (1.30)

QW050A1 and QW075A1 Power Modules:

1212 Tyco Electronics Corp.

Data Sheet

May 2000dc-dc Con verters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W and 75 W

Thermal Considerations (continued)

Heat Transfer Without Heat Sinks

Increasing airflow over the module enhances the heat

transfer via convection. Figure 25 shows the maximum

power that can be dissipated by the module without

ex ceeding the maximum case temperature versus local

ambient temperature (TA) for natural convection

through 4 m/s (800 ft./min.).

Note that the natural convection condition was mea-

sured 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 typic all y gen erate natural co nvection airflow

rates of 0.3 m/s (60 ft./min.) due to other heat dissipat-

ing components in the system. The use of Figure 25 is

shown in the following example.

Example

What is the minimum airflow necessary for a QW050A1

operating at VI = 54 V, an output current of 10 A, and a

maximum ambient temperature of 40 °C?

Solution

Given: VI = 54 V

IO = 10 A

TA = 40 °C

Determine PD (Use Figure 23.):

PD = 10 W

Determine airflow (v) (Use Figure 25.):

v = 1.25 m/s (250 ft./min .)

Note: Pending improvement will lower the power dissi-

pation and reduce the airflow needed.

8-2957 (F)

Note: Pending improvement will lower the power dissipation.

Figure 23. QW050A1 Power Dissipation vs.

Output Current at 25 °C

8-2958 (F)

Note: Pending improvement will lower the power dissipation.

Figure 24. QW075A1 Power Dissipation vs.

Output Current at 25 °C

312345678910

POWER D I SSI PA T IO N, PD (W)

OUTPUT CURRENT, IO (A)

VI = 75 V

VI = 48 V

VI = 36 V

SEE NOTE

4123456789

10 11 12 13 14 15

OUTPUT CURRENT, IO (A)

POWER DISSIPATION, PD (W)

VI = 75 V

VI = 54 V

VI = 36 VSEE NOTE

Tyco Electronics Corp. 13

Data Sheet

May 2000 dc-dc Con verters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W and 75 W

QW050A1 and QW075A1 Power Modules:

Thermal Considerations (continued)

Heat Transfer Without Heat Sinks (continued)

8-2306 (C).a

Figure 25. Forc ed Con vection P o wer Derating with

No Heat Sink; Either Orientation

Heat Transfer with Heat Sinks

The power modules have through-threaded, M3 x 0.5

mounting holes, which enab le heat sinks or cold plates

to attach to the module. The mounting torque must not

exceed 0.56 N-m (5 in.-lb.). For a screw attachment

from the pin side, the recommended hole size on the

customer’s PWB around the mounting holes is 0.130

± 0.005 inches. If a larger hole is used, the mounting

torque from the pin side must not exceed 0.25 N-m

(2.2 in.-lbs.).

Thermal derating with heat sinks is e xpressed by using

the overall thermal resistance of the module. Total

module thermal resistance (θca) is defined as the max-

imum case temperature rise (∆TC, max) divided by the

module power dissipation (PD):

The location to measure case temperature (TC) is

shown in Figure 22. Case-to-ambient thermal resis-

tance vs. airflow is shown, for various heat sink config-

urations, heights, and orientations, as shown in

Figures 26 and 27. Longitudinal orientation is defined

as the long axis of the module that is parallel to the air-

flow direction, whereas in the transverse orientation,

the long axis is perpendicular to the airflow. These

curves were obtained by experimental testing of heat

sinks, which are offered in the product catalog.

8-2107 (C)

Figure 26. Case-to-Ambient Thermal Resistance

Curves; Transverse Orientation

8-2108 (C)

Figure 27. Case-to-Ambient Thermal Resistance

Curves; Longitudinal Orientation

10 20 30 40 50 60

LOCAL AMBIENT TEMPERATURE, T

(˚C)

1000

4.0 m/s (800 ft./min.)

3.5 m/s (700 ft./min.)

3.0 m/s (600 ft./min.)

2.5 m/s (500 ft./min.)

2.0 m/s (400 ft./min.)

1.5 m/s (300 ft./min.)

1.0 m/s (200 ft./min.)

0.5 m/s (100 ft./min.)

0.1 m/s (20 ft./min.)

NATURAL CONVECTION

POWER DISSIPATION, P

(W)

70 80 90

θca ∆TCmax,

--------------------- TCTA

–

()

------------------------

0.5

(100) 1.5

(300) 2.0

(400) 2.5

(500) 3.0

(600)

NAT

CONV 1.0

(200)

RESISTANCE, θCA (˚C/W)

CASE-TO-AMBIENT THERMAL

1 IN. HEAT SINK

1/2 IN. HEAT SINK

NO HEAT SINK

1/4 IN. HEAT SINK

AIR VELOCITY, m/s (ft./min.)

0.5

(100) 1.0

(200) 1.5

(300) 2.0

(400) 2.5

(500)

AIR VELOCITY, m/s (ft./min.)

3.0

(600)

NAT

CONV

1 IN. HEAT SINK

1/2 IN. HEAT SINK

NO HEAT SINK

1/4 IN. HEAT SINK

RESISTANCE, θCA

(˚C/W)

CASE-T O-AMBIENT THERMAL

QW050A1 and QW075A1 Power Modules:

1414 Tyco Electronics Corp.

Data Sheet

May 2000dc-dc Con verters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W and 75 W

Thermal Considerations (continued)

Heat Transfer with Heat Sinks (continued)

8-2380 (C)

Figure 28. Heat Sink Power Derating Curves;

Natural Convection; Transverse

Orientation

8-2381 (C)

Figure 29. Heat Sink Power Derating Curves;

Natural Convection; Longitudinal

Orientation

8-2382 (C)

Figure 30. Heat Sink Power Derating Curves;

1.0 m/s (200 lfm); Transverse

Orientation

8-2383 (C)

Figure 31. Heat Sink Power Derating Curves;

1.0 m/s (200 lfm); Longitudinal

Orientation

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 gener-

ally lower than the resistance of the heat sink by itself.

The module used to collect the data in Figures 26 and

27 had a thermal-conductive dry pad between the case

and the heat sink to minimize contact resistance. The

use of Figures 26 and 27 are shown in the following

example.

10 20 30 40 50 60

LOCAL AMBIENT TEMPERATURE, TA (˚C)

1000

POWER DISSIPATION, PD (W)

70 80 90

1 IN. HEAT SINK

1/2 IN. HEAT SINK

1/4 IN. HEAT SINK

NO HEAT SINK

10 20 30 40 50 60

LOCAL AMBIENT TEMPERATURE, T

(˚C)

1000

POWER DISSIPATION, P

(W)

70 80 90

1 IN. HEAT SINK

1/2 IN. HEAT SINK

1/4 IN. HEAT SINK

NO HEAT SINK

10 20 30 40 50 60

LOCAL AMBIENT TEMPERATURE, T

A (˚C)

1000

POWER DISSIPATION, PD (W)

70 80 90

1 IN. HEAT SINK

1/2 IN. HEAT SINK

1/4 IN. HEAT SINK

NO HEAT SINK

10 20 30 40 50 60

LOCAL AMBIENT TEMPERATURE, T

(˚C)

1000

POWER DISSIPATION, P

(W)

70 80 90

1 IN. HEAT SINK

1/2 IN. HEAT SINK

1/4 IN. HEAT SINK

NO HEAT SINK

Tyco Electronics Corp. 15

Data Sheet

May 2000 dc-dc Con verters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W and 75 W

QW050A1 and QW075A1 Power Modules:

Thermal Considerations (continued)

Heat Transfer with Heat Sinks (continued)

Example

If an 85 °C case temperature is desired, what is the

minimum airflow necessary? Assume the QW075A1

module is operating at VI = 54 V and an output current

of 15 A, maximum ambient air temperature of 40 °C,

and the heat sink is 1/2 inch. The module is oriented in

the transverse direction.

Solution

Given: VI = 54 V

IO = 15 A

TA = 40 °C

TC = 85 °C

Heat sink = 1/2 inch

Determine PD by using Figure 24:

PD = 16 W

Then solve the following equation:

Use Figure 26 to determine air velocity for the 1/2 inch

heat sink.

The minimum airflow necessary for the QW075A1

module is 1.2 m/s (240 ft./min.).

Note: Pending improv ement will lower the power dissi-

pation and reduce the airflow needed.

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 (θcs) and

sink-to-ambient (θsa) as shown in Figure 32.

8-1304 (C)

Figure 32. Resistance from Case-to-Sink and

Sink-to-Ambient

For a managed interface using thermal grease or foils,

a value of θcs = 0.1 °C/W to 0.3 °C/W is typical. The

solution for heat sink resistance is:

This equation assumes that all dissipated power must

be shed by the heat sink. Depending on the user-

defined application environment, a more accurate

model, including heat transfer from the sides and bot-

tom of the module, can be used. This equation pro-

vides a conservative estimate for such instances.

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 guide-

lines, refer to the FLTR100V10 data sheet

(DS99-294EPS).

θca TCTA

–

()

------------------------

θca 85 40–

()

------------------------

θca 2.8 °C/W=

θcs θsa

→

θsa TCTA

–

()

------------------------ θcs–=

16 Tyco Electronics Corp.

Data Sheet

May 2000dc-dc Con verters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W and 75 W

QW050A1 and QW075A1 Power Modules:

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

Side View

Bottom View

8-1769 (F).b

* Side label includes Tyco name, product designation, safety agency markings, input/output voltage and current ratings, and bar code.

57.9

(2.28)

36.8

(1.45)

1.02 (0.040) DIA

SOLDER-PLATED

BRASS, 6 PLACES

1.57 (0.062) DIA

SOLDER-PLATED

BRASS, 2 PLACES

12.7

(0.50)

4.1 (0.16) MIN, 2 PLACES

0.51

(0.020)

4.1 (0.16) MIN,

6 PLACES

SIDE LABE L*

3.5 (0.14) MIN

3.6

(0.14)

10.9

(0.43)

5.3

(0.21)

26.16

(1.030)

15.24

(0.600)

5.3

(0.21)

MOUNTING INSERTS

M3 x 0.5 THROUGH,

4 PLACES

– SENSE

TRIM

+ SENSE

ON/OFF

3.81

(0.150)

7.62

(0.300)

11.43

(0.450)

15.24

(0.600)

50.80

(2.000)

7.62

(0.300) 47.2

(1.86)

VO(+)

VO(–)

VI(–)

VI(+)

11.2

(0.44) 12.7

(0.50)

RIVETED CASE PIN (OPTIONAL)

1.09 x 0.76 (0.043 x 0.030)

Tyco Electronics Corp. 17

Data Sheet

May 2000 dc-dc Con verters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W and 75 W

QW050A1 and QW075A1 Power Modules:

Recommended Hole Patter n

Component-side footprint.

Dimensions are in millimeters and (inches).

8-1769 (F). b

Ordering Information

Table 4. Device Codes

Optional f eatures can be ordered using the suffix es shown in Table 5. The suffixes f ollow the last letter of the device

code and are placed in descending order . F or e xample, the device codes f or a QW050A1 module with the follo wing

options are shown below:

Auto-restart after overcurrent shutdown QW050A41

Table 5. Device Options

Input

Voltage Output

Power Remote On/Off

Logic Device

Code Comcode

48 V 5 V 50 W Negative QW050A1 108153669

48 V 5 V 75 W Negative QW075A1 107967218

Option Suffix

Auto-restart after overcurrent shutdown 4

3.6

(0.14)

10.9

(0.43)

26.16

(1.030)15.24

(0.600)

7.62

(0.300)

5.3

(0.21)

MOUNTING INSERTS

M3 x 0.5 THROUGH,

4 PLACES

– SENSE

TRIM

+ SENSE

ON/OFF

5.3

(0.21)

47.2

(1.86)

15.24

(0.600)7.62

(0.300)

11.43

(0.450)

3.81

(0.150)

VO(+)

VO(–)

VI(–)

VI(+)

CAS E PIN (OPTIONAL )

11.2

(0.44) 12.7

(0.50)

50.80

(2.000)

QW050A1 and QW075A1 Power Modules:

1818 Tyco Electronics Corp.

Data Sheet

May 2000dc-dc Con verters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W and 75 W

Ordering Information (continued)

Table 6. Device Accessories

Dimensions are in millimeters and (inches).

8-2473 (F)

Figure 33. Longitudinal Heat Sink 8-2472 (F)

Figure 34. Tra nsverse Heat Sink

Accessory Comcode

1/4 in. transverse kit (heat sink, thermal pad, and screws) 848060992

1/4 in. longitudinal kit (heat sink, thermal pad, and screws) 848061008

1/2 in. transverse kit (heat sink, thermal pad, and screws) 848061016

1/2 in. longitudinal kit (heat sink, thermal pad, and screws) 848061024

1 in. transverse kit (heat sink, thermal pad, and screws) 848061032

1 in. longitudinal kit (heat sink, thermal pad, and screws) 848061040

1.030 ± 0.005

(26.16 ± 0.13)

2.280 ± 0.015

(57.91 ± 0.38)

1/4 IN.

1/2 IN.

1 IN.

1.450 ± 0.015

(36.83 ± 0.38)

1.850 ± 0.005

(47.24 ± 0.13)

1/4 IN.

1/2 IN.

1 IN.

Tyco Electronics Corp. 19

Data Sheet

May 2000 dc-dc Con verters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W and 75 W

QW050A1 and QW075A1 Power Modules:

Notes

Data Sheet

May 2000dc-dc Con verters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W and 75 W

QW050A1 and QW075A1 Power Modules:

Printed on

Recycled Paper

Tyco Ele ct r onics Power Systems, Inc.

3000 Skyline Drive, Mesquite, TX 75149, USA

+1-800-526-7819 FAX: + 1-888 - 315-51 82

(Outs ide U.S.A.: +1-972-284-2626, FAX: +1-972-284-2900)

http://power.tycoelectronics.com

Tyco Electronics Corporation reser ves 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 inform ation.

Printed in U.S.A.

May 2000

DS00-178EPS (Replaces DS99-029EP S)