Data Sheet May 1998 JC050F, JC075F, JC100F Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 3.3 Vdc Output; 33 W to 66 W Features Small size: 61.0 mm x 57.9 mm x 12.7 mm (2.40 in. x 2.28 in. x 0.50 in.) High power density High efficiency: 80% typical Low output noise Constant frequency Industry-standard pinout Metal baseplate 2:1 input voltage range The JC050F, JC075F, JC100F Power Modules use advanced, surface-mount technology and deliver high-quality, efficient, and compact dc-dc conversion. Overtemperature protection (66 W only) Remote sense Applications Remote on/off Adjustable output voltage Case ground pin UL* Recognized, CSA Certified, VDE Licensed Distributed power architectures Workstations EDP equipment Telecommunications Options Choice of remote on/off logic configuration Heat sink available for extended operation * UL is a registered trademark of Underwriters Laboratories, Inc. CSA is a registered trademark of Canadian Standards Assn. Description The JC050F, JC075F, JC100F Power Modules are dc-dc converters that operate over an input voltage range of 18 Vdc to 36 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 33 W to 66 W at a typical full-load efficiency of 80%. 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. JC050F, JC075F, JC100F Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 3.3 Vdc Output; 33 W to 66 W Data Sheet May 1998 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. Symbol Min Max Unit Input Voltage Continuous Parameter VI -- 50 Vdc I/O Isolation Voltage -- -- 1500 Vdc Operating Case Temperature (See Thermal Considerations section.) TC -40 100 C Storage Temperature Tstg -55 125 C Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Table 1. Input Specifications Parameter Operating Input Voltage Maximum Input Current (VI = 0 V to 36 V; IO = IO, max): JC050F (See Figure 1) JC075F JC100F (See Figure 2.) Inrush Transient 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 Min 18 Typ 28 Max 36 Unit Vdc II, max II, max II, max i2t -- -- -- -- -- -- -- -- -- -- 5 2.4 3.7 4.9 1.0 -- A A A A2s mAp-p -- -- 60 -- dB Fusing Considerations CAUTION: This power module is not internally fused. An input line fuse must always be used. This encapsulated power module can be used in a wide variety of applications, ranging from simple stand-alone operation to an integrated part of a sophisticated power architecture. To preserve maximum flexibility, internal fusing is not included; however, to achieve maximum safety and system protection, always use an input line fuse. The safety agencies require a normal-blow, 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 Tyco Electronics Corp. JC050F, JC075F, JC100F Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 3.3 Vdc Output; 33 W to 66 W Data Sheet May 1998 Electrical Specifications (continued) Table 2. Output Specifications Parameter Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life. See Figure 15) Output Voltage Set Point (VI = 28 V; IO = IO, max; TC = 25 C) Output Regulation: Line (VI = 18 V to 36 V) Load (IO = IO, min to IO, max) Temperature (TC = -40 C to +100 C) Output Ripple and Noise Voltage (See Figure 14.): RMS Peak-to-peak (5 Hz to 20 MHz) External Load Capacitance (electrolytic) Output Current (At IO < IO, min, the modules may exceed output ripple specifications.) Output Current-limit Inception (VO = 90% of VO, nom) Output Short-circuit Current (VO = 250 mV) Efficiency (VI = 28 V; IO = IO, max; TC = 70 C) Dynamic Response (IO/t = 1 A/10 s, VI = 28 V, TC = 25 C): 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) Device All Symbol VO Min 3.20 Typ -- Max 3.40 Unit Vdc All VO, set 3.25 3.3 3.35 Vdc All All All -- -- -- -- -- -- 0.01 0.05 15 0.1 0.2 50 % % mV All All All JC050F JC075F JC100F JC050F JC075F JC100F All JC050F JC075F JC100F -- -- -- IO IO IO IO, cli IO, cli IO, cli -- -- -- 0 0.5 0.5 0.5 -- -- -- -- 78 78 78 -- -- -- -- -- -- 12.0 18.0 23.0 170 81 81 80 40 150 10,000 10 15 20 -- -- -- -- -- -- -- mVrms mVp-p F A A A A A A %IO, max % % % All All -- -- -- -- 3.8 300 -- -- %VO, set s All All -- -- -- -- 3.8 300 -- -- %VO, set s Table 3. Isolation Specifications Parameter Isolation Capacitance Isolation Resistance Tyco Electronics Corp. Min -- 10 Typ 2500 -- Max -- -- Unit pF M 3 JC050F, JC075F, JC100F Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 3.3 Vdc Output; 33 W to 66 W Data Sheet May 1998 General Specifications Parameter Calculated MTBF (IO = 80% of IO, max; TC = 40 C) Weight Min -- Typ 2,600,000 -- Max 100 (3.5) Unit hr. g (oz.) Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See Feature Descriptions for additional information. Parameter Remote On/Off Signal Interface (VI = 0 V to 36 V; open collector or equivalent compatible; signal referenced to VI(-) terminal; see Figure 15 and Feature Descriptions.): JCxxxF1 Preferred Logic: Logic Low--Module On Logic High--Module Off JCxxxF 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 12) (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 Clamp Overtemperature Shutdown (66 W only; see Feature Descriptions.) 4 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 4.0 -- -- -- -- 105 0.5 110 5.0 -- V %VO, nom V C VO, clamp Tc Tyco Electronics Corp. Data Sheet May 1998 JC050F, JC075F, JC100F Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 3.3 Vdc Output; 33 W to 66 W Characteristic Curves The following figures provide typical characteristics for the JC050F, JC075F, JC100F power modules. The figures are identical for both on/off configurations. 3.5 IO = 10.0 A IO = 5.0 A IO = 0.5 A INPUT CURRENT, II (A) 2.5 2.0 1.5 1.0 0.5 OUTPUT VOLTAGE, VO (V) 3.0 3.0 VI = 36 V VI = 24 V VI = 18 V 2.5 2.0 1.5 1.0 0.5 0.0 0.0 0 4 8 12 16 20 24 28 32 36 0 1 2 3 INPUT VOLTAGE, V O (V) 4 5 6 7 8 9 10 11 12 13 14 15 OUTPUT CURRENT, IO (A) 8-1585 (C) Figure 1. Typical JC050F Input Characteristics at Room Temperature 8-1587 (C) Figure 3. Typical JC050F Output Characteristics at Room Temperature 6 3.5 IO = 20.0 A IO = 10.0 A IO = 1.0 A 3.0 OUTPUT VOLTAGE, VO (V) INPUT CURRENT, II(A) 5 4 3 2 2.5 VI = 36 V VI = 28 V VI = 18 V 2.0 1.5 1.0 0.5 1 0.0 0 0 4 8 12 16 20 24 28 32 36 2 4 6 8 10 12 14 16 18 20 OUTPUT CURRENT, IO (A) INPUT VOLTAGE, V O (V) 8-1586 (C) Figure 2. Typical JC100F Input Characteristics at Room Temperature Tyco Electronics Corp. 0 8-1588 (C) Figure 4. Typical JC075F Output Characteristics at Room Temperature 5 JC050F, JC075F, JC100F Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 3.3 Vdc Output; 33 W to 66 W Data Sheet May 1998 Characteristic Curves (continued) 80 79 3.5 78 EFFICIENCY, (%) OUTPUT VOLTAGE, VO (V) 3.0 2.5 VI = 18 V VI = 28 V VI = 36 V 2.0 1.5 77 76 VI = 18 V VI = 28 V VI = 36 V 75 74 73 72 1.0 71 0.5 70 4 2 0.0 0 2 4 6 8 10 12 14 16 18 20 6 22 24 8 10 12 OUTPUT CURRENT, IO (A) 8-1591 (C) OUTPUT CURRENT, IO (A) 8-1589 (C) Figure 5. Typical JC100F Output Characteristics at Room Temperature. Figure 7. Typical JC075F Converter Efficiency vs. Output Current at Room Temperature 80 79 79 77 77 EFFICIENCY, (%) EFFICIENCY, (%) 78 VI = 18 V VI = 24 V VI = 36 V 78 76 75 74 73 76 74 73 72 71 71 2 3 4 5 6 7 8 9 10 OUTPUT CURRENT, IO (A) VI = 18 V VI = 27 V VI = 36 V 75 72 70 70 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 OUTPUT CURRENT, IO (A) 8-1592 (C) 8-1590 (C) Figure 6. Typical JC050F Converter Efficiency vs. Output Current at Room Temperature. 6 14 Figure 8. Typical JC100F Converter Efficiency vs. Output Current at Room Temperature Tyco Electronics Corp. Data Sheet May 1998 JC050F, JC075F, JC100F Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 3.3 Vdc Output; 33 W to 66 W OUTPUT VOLTAGE, VO (V) (100 mV/div) Characteristic Curves (continued) OUTPUT CURRENT, IO (A) (1 A/div) OUTPUT VOLTAGE, VO (V) (20 mV/div) 18 V 28 V 36 V TIME, t (50 s/div) 8-1905 (C) TIME, t (1 s/div) 8-1903 (C) REMOTE ON/OFF VOLTAGE, VON/OFF (V) OUTPUT CURRENT, IO (A) (1 A/div) OUTPUT VOLTAGE, VO (V) (1 V/div) OUTPUT VOLTAGE, VO (V) (100 mV/div) Figure 9. Typical JC100F Output Ripple Voltage at Room Temperature, and 20 A Output TIME, t (2 ms/div) TIME, t (50 s/div) 8-1904 (C) Figure 10.Typical JC100F Transient Response to Step Decrease in Load from 50% to 25% of Full Load at Room Temperature and 28 V Input (Waveform Averaged to Eliminate Ripple Component.) Tyco Electronics Corp. Figure 11.Typical JC100F Transient Response to Step Increase in Load from 50% to 75% of Full Load at Room Temperature and 28 V Input (Waveform Averaged to Eliminate Ripple Component.) 8-1906 (C) Figure 12.Typical Start-Up from Remote On/Off JC100F1; lO = Full Load 7 JC050F, JC075F, JC100F Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 3.3 Vdc Output; 33 W to 66 W Test Configurations Data Sheet May 1998 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(-) 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. 8-203 (C).l Note:Measure input reflected-ripple current with a simulated source inductance (LTEST) of 12 H. Capacitor CS offsets possible battery impedance. Measure current as shown above. Safety Considerations COPPER STRIP 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. 1.0 F For the converter output to be considered meeting the requirements of safety extra-low voltage (SELV), the input must meet SELV requirements. Figure 13.Input Reflected-Ripple Test Setup V O (+) 10 F SCOPE RESISTIVE LOAD If the input meets extra-low voltage (ELV) requirements, then the converter's output is considered ELV. V O (-) 8-513 (C).d Note: Use a 1.0 F ceramic capacitor and a 10 F aluminum or tantalum capacitor. Scope measurement should be made using a BNC socket. Position the load between 51 mm and 76 mm (2 in. and 3 in.) from the module. VI(+) CONTACT AND DISTRIBUTION LOSSES VO(+) IO II LOAD SUPPLY VI(-) CONTACT RESISTANCE Electrical Descriptions Current Limit Figure 14.Peak-to-Peak Output Noise Measurement Test Setup SENSE(+) The input to these units is to be provided with a maximum 20 A normal-blow fuse in the ungrounded lead. VO(-) SENSE(-) To provide protection in a fault (output overload) condition, the unit is equipped with internal current-limiting circuitry and can endure current limiting for an unlimited duration. At the point of current-limit inception, the unit shifts from voltage control to current control. If the output voltage is pulled very low during a severe fault, the current-limit circuit can exhibit either foldback or tailout characteristics (output current decrease or increase). The unit operates normally once the output current is brought back into its specified range. 8-749(C) Note:All measurements are taken at the module terminals. When socketing, place Kelvin connections at module terminals to avoid measurement errors due to socket contract resistance. [ V O ( + ) - ( V O ( - ) ) ]I O = ------------------------------------------------------- x 100 [ V I ( + ) - ( V I ( - ) ) ]I I Figure 15. Output Voltage and Efficiency Measurement Test Setup 8 Tyco Electronics Corp. Data Sheet May 1998 JC050F, JC075F, JC100F Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 3.3 Vdc Output; 33 W to 66 W Feature Descriptions Remote Sense Remote On/Off 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.: Two remote on/off options are available. Positive logic remote on/off turns the module on during a logic-high voltage on the ON/OFF pin, and off during a logic low. Negative logic remote on/off turns the module off during a logic high and on during a logic low. Negative logic (code suffix "1") is the factory-preferred configuration. 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. [VO(+) - VO(-)] - [SENSE(+) - SENSE(-)] 0.5 V The voltage between the VO(+) and VO(-) terminals must not exceed 3.8 V. 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. During a logic high, the maximum Von/off generated by the power module is 15 V. The maximum allowable leakage current of the switch at Von/off = 15 V is 50 A. If not using the remote on/off feature, do one of the following: For negative logic, short ON/OFF pin to VI(-). For positive logic, leave ON/OFF pin open. VI(+) VO(+) VI(-) VO(-) II IO LOAD CONTACT AND DISTRIBUTION LOSSES 8-651 m Output Voltage Set-Point Adjustment (Trim) SENSE(+) VO(+) LOAD VO(-) VI(+) VI(-) SUPPLY Figure 17. Effective Circuit Configuration for Single-Module Remote-Sense Operation ON/OFF Von/off - SENSE(-) CONTACT RESISTANCE Ion/off + SENSE(+) SENSE(-) 8-720 c Figure 16.Remote On/Off Implementation 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. 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 equation determines the required external-resistor value to obtain a percentage output voltage change of %. 100 R adj-down = ---------- - 2 k % 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). Tyco Electronics Corp. 9 JC050F, JC075F, JC100F Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 3.3 Vdc Output; 33 W to 66 W Data Sheet May 1998 Feature Descriptions (continued) VI(+) Output Voltage Set-Point Adjustment (Trim) (continued) VO(+) ON/OFF SENSE(+) Radj-up The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. CASE VI(-) SENSE(-) VO(-) V O ( 100 + % ) ( 100 + 2% ) R adj-up = ------------------------------------- - k 1.225% - --------------------------------% 8-715 b If not using the trim feature, leave the TRIM pin open. ON/OFF CASE VO (+) SENSE(+) RLOAD TRIM Radj-down VI (-) SENSE(-) Figure 20. Circuit Configuration to Increase Output Voltage 10M ADJUSTMENT RESISTOR VALUE () The test results for this configuration are displayed in Figure 21. The voltage between the VO(+) and VO(-) terminals must not exceed 3.8 V. This limit includes any increase in voltage due to remote-sense compensation and output voltage set-point adjustment (trim). See Figure 17. VI (+) RLOAD TRIM 1M 100k 10k 0 VO(-) 2 4 6 8 10 % CHANGE IN OUTPUT VOLTAGE (%) 8-880 a 8-748 b Figure 21. Resistor Selection for Increased Output Voltage Figure 18. Circuit Configuration to Decrease Output Voltage Output Overvoltage Clamp ADJUSTMENT RESISTOR VALUE () 1M The output overvoltage clamp consists of control circuitry, independent of the primary regulation loop, that monitors the voltage on the output terminals. The control loop of the clamp has a higher voltage set point than the primary loop (see Feature Specifications table). This provides a redundant voltage control that reduces the risk of output overvoltage. 100k 10k Overtemperature Protection (Shutdown) 1k 100 0 10 20 30 40 % CHANGE IN OUTPUT VOLTAGE (%) The 66 W module features an overtemperature protection circuit to safeguard against thermal damage. The circuit shuts down the module when the maximum case temperature is exceeded. The module restarts automatically after cooling. 8-879 Figure 19. Resistor Selection for Decreased Output Voltage 10 Tyco Electronics Corp. Data Sheet May 1998 JC050F, JC075F, JC100F Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 3.3 Vdc Output; 33 W to 66 W Thermal Considerations Heat Transfer Without Heat Sinks Introduction Increasing airflow over the module enhances the heat transfer via convection. Figure 23 shows the maximum power that can be dissipated by the module without exceeding the maximum case temperature versus local ambient temperature (TA) for natural convection through 4 m/s (800 ft./min.). The power modules operate in a variety of thermal environments; however, sufficient cooling should be provided to help ensure reliable operation of the unit. Heat-dissipating components inside the unit are thermally coupled to the case. Heat is removed by conduction, convection, and radiation to the surrounding environment. Proper cooling can be verified by measuring the case temperature. Peak temperature (Tc) occurs at the position indicated in Figure 22. 38.0 (1.50) MEASURE CASE TEMPERATURE HERE Note that the natural convection condition was measured at 0.05 m/s to 0.1 m/s (10 ft./min. to 20 ft./min.); however, systems in which these power modules may be used typically generate natural convection airflow rates of 0.3 m/s (60 ft./min.) due to other heat dissipating components in the system. The use of Figure 23 is shown in the following example. Example 7.6 (0.3) VI(+) ON/OFF What is the minimum airflow necessary for a JC100F operating at nominal line, an output current of 20 A, and a maximum ambient temperature of 40 C? VO(+) + SEN Solution TRIM CASE VI(-) Given: VI = 28 V IO = 20 A TA = 40 C - SEN VO(-) Determine PD (Use Figure 26.): 8-716 f 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. For additional information on these modules, refer to the Thermal Management JC-, JFC-, JW-, and JFW-Series 50 W to 150 W Board-Mounted Power Modules Technical Note (TN97-008EPS). PD = 18.2 W Determine airflow (v) (Use Figure 23.): v = 2.3 m/s (450 ft./min.) 35 POWER DISSIPATION, PD (W) Note: Top view, pin locations are for reference. Measurements shown in millimeters and (inches). 4.0 m/s (800 ft./min.) 3.5 m/s (700 ft./min.) 3.0 m/s (600 ft./min.) 2.5 m/s(500 ft./min.) 2.0 m/s(400 ft./min.) 1.5 m/s (300 ft./min.) 1.0 m/s (200 ft./min.) 0.5 m/s (100 ft./min.) 30 25 20 15 10 5 0.1 m/s (NAT. CONV.) (20 ft./min.) 0 0 10 20 30 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (C) 8-1150 a Figure 23. Forced Convection Power Derating with No Heat Sink; Either Orientation Tyco Electronics Corp. 11 JC050F, JC075F, JC100F Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 3.3 Vdc Output; 33 W to 66 W Data Sheet May 1998 Thermal Considerations (continued) POWER DISSIPATION, PD (W) 12 11 10 9 VI = 36 V VI = 27 V VI = 18 V 8 POWER DISSIPATION, PD (W) Heat transfer Without Heat Sinks (continued) 24 22 20 VI = 36 V VI = 28 V VI = 18 V 18 16 14 12 10 8 6 4 2 0 7 6 0 5 2 4 6 8 10 12 14 16 18 20 OUTPUT CURRENT, IO (A) 8-1596 4 1 2 3 4 5 6 7 8 9 10 OUTPUT CURRENT, IO (A) Figure 26. JC100F Power Dissipation vs. Output Current 8-1594 Figure 24. JC050F Power Dissipation vs. Output Current Heat Transfer with Heat Sinks The power modules have through-threaded, M3 x 0.5 mounting holes, which enable heat sinks or cold plates to attach to the module. The mounting torque must not exceed 0.56 N-m (5 in.-lb.). For a screw attachment from the pin side, the recommended hole size on the customer's PWB around the mounting holes is 0.130 0.005 inches. If a larger hole is used, the mounting torque from the pin side must not exceed 0.25 N-m (2.2 in.-lb.). POWER DISSIPATION, PD (W) 20 18 16 VI = 18 V VI = 28 V VI = 36 V 14 12 10 8 6 4 2 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 OUTPUT CURRENT, IO (A) 8-1595 Figure 25. JC075F Power Dissipation vs. Output Current 12 Thermal derating with heat sinks is expressed by using the overall thermal resistance of the module. Total module thermal resistance (ca) is defined as the maximum case temperature rise (TC, max) divided by the module power dissipation (PD): (TC - TA) C, max ca = T -------------------- = -----------------------PD PD The location to measure case temperature (TC) is shown in Figure 22. Case-to-ambient thermal resistance vs. airflow is shown, for various heat sink configurations and heights, in Figure 27. These curves were obtained by experimental testing of heat sinks, which are offered in the product catalog. Tyco Electronics Corp. Data Sheet May 1998 JC050F, JC075F, JC100F Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 3.3 Vdc Output; 33 W to 66 W Thermal Considerations (continued) Example If an 85 C case temperature is desired, what is the minimum airflow necessary? Assume the JC100A module is operating at nominal line and an output current of 20 A, maximum ambient air temperature of 40 C, and the heat sink is 0.5 in. Heat transfer with Heat Sinks (continued) CASE-TO-AMBIENT THERMAL RESISTANCE, RCA (C/W) 8 7 1 1/2 IN HEAT SINK 1 IN HEAT SINK 1/2 IN HEAT SINK 1/4 IN HEAT SINK NO HEAT SINK 6 5 Solution 2 Given: VI = 28 V IO = 20 A TA = 40 C TC = 85 C Heat sink = 0.5 in. 1 Determine PD by using Figure 26: 4 3 0 PD = 18.2 W 0 0.5 (100) 1.0 (200) 1.5 (300) 2.0 (400) 2.5 3.0 (500) (600) AIR VELOCITY MEASURED IN m/s (ft./min.) Then solve the following equation: (TC - TA ) ca = ----------------------PD 8-1153 Figure 27. Case-to-Ambient Thermal Resistance Curves; Either 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 generally lower than the resistance of the heat sink by itself. The module used to collect the data in Figure 27 had a thermal-conductive dry pad between the case and the heat sink to minimize contact resistance. The use of Figure 27 is shown in the following example Tyco Electronics Corp. ( 85 - 40 ) ca = ----------------------18.2 ca = 2.47 C/W Use Figure 27 to determine air velocity for the 0.5 inch heat sink. The minimum airflow necessary for the JC100F module is 1.5 m/s (300 ft./min.). 13 JC050F, JC075F, JC100F Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 3.3 Vdc Output; 33 W to 66 W Thermal Considerations (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: Custom Heat Sinks A more detailed model can be used to determine the required thermal resistance of a heat sink to provide necessary cooling. The total module resistance can be separated into a resistance from case-to-sink (cs) and sink-to-ambient (sa) shown below (Figure 28). PD TC TS cs TA TC - TA) sa = (------------------------ - cs PD This equation assumes that all dissipated power must be shed by the heat sink. Depending on the userdefined application environment, a more accurate model, including heat transfer from the sides and bottom of the module, can be used. This equation provides a conservative estimate for such instances. sa 8-1304 Figure 28. Resistance from Case-to-Sink and Sink-to-Ambient 14 Data Sheet May 1998 Layout Considerations Copper paths must not be routed beneath the power module mounting inserts. Tyco Electronics Corp. JC050F, JC075F, JC100F Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 3.3 Vdc Output; 33 W to 66 W Data Sheet May 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 SIDE LABEL* 12.70 0.5 (0.500 0.020) 5.1 (0.20) MIN 2.06 (0.081) DIA SOLDER-PLATED BRASS, 2 PLACES-(OUTPUT AND +OUTPUT) 1.02 (0.040) DIA SOLDER-PLATED BRASS, 7 PLCS Bottom View MOUNTING INSERTS M3 x 0.5 THROUGH, 4 PLACES 12.7 (0.50) 5.1 (0.20) VI (-) VO (-) CASE -SEN 10.16 (0.400) 50.8 (2.00) 25.40 (1.000) TRIM 35.56 (1.400) ON/OFF VI (+) 4.8 (0.19) +SEN 48.26 (1.900) 10.16 (0.400) 17.78 (0.700) 25.40 (1.000) 35.56 (1.400) VO (+) 48.3 (1.90) 8-1945 * Side labels include Tyco name, product designation, safety agency markings, input/output voltage and current ratings, and bar code. 15 Tyco Electronics Corp. JC050F, JC075F, JC100F Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 3.3 Vdc Output; 33 W to 66 W Data Sheet May 1998 Recommended Hole Pattern Component-side footprint. Dimensions are in millimeters and (inches). 57.9 (2.28) MAX 4.8 (0.19) 48.3 (1.90) VI (+) 35.56 (1.400) 50.8 (2.00) 48.26 (1.900) ON/OFF VO (+) 35.56 (1.400) +SEN 25.40 (1.000) TRIM 25.40 (1.000) CASE -SEN VI (-) VO (-) 10.16 (0.400) 17.78 10.16 (0.700) (0.400) 61.0 (2.40) MAX 5.1 (0.20) 12.7 (0.50) MODULE OUTLINE MOUNTING INSERTS 3.30 0.15 (0.130 0.005) 4 PLCS 8-1945 Ordering Information Input Voltage 28 V 28 V 28 V 28 V 28 V 28 V Output Voltage 3.3 V 3.3 V 3.3 V 3.3 V 3.3 V 3.3 V Output Power 33 W 49.5 W 66 W 33 W 49.5 W 66 W Remote On/ Off Logic negative negative negative positive positive positive Device Code JC050F1 JC075F1 JC100F1 JC050F JC075F JC100F Comcode 107314684 107573289 107314700 107309890 TBD 107309973 Europe, Middle-East and Africa Headquarters Tyco Electronics (UK) Ltd Tel: +44 (0) 1344 469 300, Fax: +44 (0) 1344 469 301 World Wide Headquarters 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) www.power.tycoelectronics.com e-mail: techsupport1@tycoelectronics.com Central America-Latin America Headquarters Tyco Electronics Power Systems Tel: +54 11 4316 2866, Fax: +54 11 4312 9508 Asia-Pacific Headquarters Tyco Electronics Singapore Pte Ltd Tel: +65 482 0311, Fax: 65 480 9299 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 Power Systems, Inc. (Mesquite, Texas) All International Rights Reserved. Printed in U.S.A. May 1998 DS97-549EPS Printed on Recycled Paper