Advance Data Sheet May 1999 JAW050A and JAW075A Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W Features The JAW Series Power Modules use surface-mount technology and deliver efficient and compact dc-dc conversion. Applications Distributed power architectures Options Heat sinks available for extended operation Choice of remote on/off logic configuration Small size: 61.0 mm x 57.9 mm x 12.7 mm (2.40 in. x 2.28 in. x 0.50 in.) High power density High efficiency: 84% typical Low output noise Constant frequency Industry-standard pinout Metal case 2:1 input voltage range Overtemperature protection Remote sense Remote on/off Adjustable output voltage Overvoltage and overcurrent protection Case ground pin ISO9001 and ISO14001 Certified manufacturing facilities UL* 1950 Recognized, CSA C22.2 No. 950-95 Certified, VDE 0805 (EN60950, IEC950) Licensed CE mark meets 73/23/EEC and 93/68/EEC directives Description The JAW050A and JAW075A Power Modules are dc-dc converters that operate over an input voltage range of 36 Vdc to 75 Vdc and provide a regulated dc output. The outputs are fully isolated from the inputs, allowing versatile polarity configurations and grounding connections. The modules have maximum power ratings from 50 W to 75 W at a typical full-load efficiency of 84%. The sealed modules offer a metal baseplate for improved 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. * 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.) JAW050A and JAW075A Power Modules: Advance Data Sheet dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W May 1999 Absolute Maximum Ratings Stresses in excess of the absolute maximum ratings can cause permanent damage to the device. These are absolute stress ratings only. Functional operation of the device is not implied at these or any other conditions in excess of those given in the operations sections of the data sheet. Exposure to absolute maximum ratings for extended periods can adversely affect device reliability. Parameter Symbol Min Max Unit VI VI, trans -- -- 80 100 Vdc V Operating Case Temperature (See Thermal Considerations section.) TC -40 100 C Storage Temperature Tstg -55 125 C I/O Isolation Voltage -- -- 1500 Vdc Input Voltage: Continuous Transient (100 ms) Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Table 1. Input Specifications Parameter Symbol Min Typ Max Unit VI 36 48 75 Vdc II, max II, max -- -- -- -- 3.0 3.5 A A Inrush Transient i2t -- -- 1.0 A2s Input Reflected-ripple Current, Peak-to-peak (5 Hz to 20 MHz, 12 H source impedance; see Figure 9.) -- -- 5 -- mAp-p Input Ripple Rejection (120 Hz) -- -- 60 -- dB Operating Input Voltage Maximum Input Current (VI = 0 V to 75 V; IO = IO, max): JAW050A1 (See Figure 1.) JAW075A1 (See Figure 2.) Fusing Considerations CAUTION: This power module is not internally fused. An input line fuse must always be used. This encapsulated power module can be used in a wide variety of applications, ranging from simple stand-alone operation to an integrated part of a sophisticated power architecture. To preserve maximum flexibility, internal fusing is not included; however, to achieve maximum safety and system protection, always use an input line fuse. The safety agencies require a normal-blow fuse with a maximum rating of 6 A (see Safety Considerations section). Based on the information provided in this data sheet on inrush energy and maximum dc input current, the same type of fuse with a lower rating can be used. Refer to the fuse manufacturer's data for further information. 2 Tyco Electronics Corp. Advance Data Sheet JAW050A and JAW075A Power Modules: May 1999 dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W Electrical Specifications (continued) Table 2. Output Specifications Parameter Device Symbol Min Typ Max Unit Output Voltage Set Point (VI = 48 V; IO = IO, max; 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 life. See Figure 11.) All VO 4.85 -- 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 All All -- -- -- -- -- -- 0.01 0.05 15 0.1 0.2 50 %VO %VO mV Output Ripple and Noise Voltage (See Figure 10.): RMS Peak-to-peak (5 Hz to 20 MHz) All All -- -- -- -- -- -- 40 150 mVrms mVp-p All -- 0 -- --* F Output Current (At IO < IO, min, the modules may exceed output ripple specifications.) External Load Capacitance JAW050A1 JAW075A1 IO IO 0.5 0.5 -- -- 10 15 A A Output Current-limit Inception (VO = 90% of VO, nom) JAW050A1 JAW075A1 IO, cli IO, cli -- -- 12.0 18.0 14 21 A A All -- -- 170 -- %IO, max JAW050A1 JAW075A1 -- -- 84 84 -- -- % % All -- -- 320 -- kHz All All -- -- -- -- 5 300 -- -- %VO, set s All All -- -- -- -- 5 300 -- -- %VO, set s Output Short-circuit Current (VO = 250 mV) Efficiency (VI = 48 V; IO = IO, max; TC = 70 C) Switching Frequency Dynamic Response (yIO/yt = 1 A/10 s, VI = 48 V, TC = 25 C; tested without any load capacitance.): 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) * Please consult your sales representative or the factory. These are manufacturing test limits. In some situations, results may differ. Table 3. Isolation Specifications Parameter Min Typ Max Unit Isolation Capacitance -- 2500 -- pF Isolation Resistance 10 -- -- M3/4 Tyco Electronics Corp. 3 JAW050A and JAW075A Power Modules: Advance Data Sheet dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W May 1999 General Specifications Parameter Min Calculated MTBF (IO = 80% of IO, max; TC = 40 C) Weight Typ Max 3,000,000 -- Unit hours -- 100 (3.5) g (oz.) Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See Feature Descriptions for additional information. Parameter Remote On/Off Signal Interface (VI = 0 V to 75 V; open collector or equivalent compatible; signal referenced to VI(-) terminal; see Figure 12 and Feature Descriptions.): JAWxxxA1 Preferred Logic: Logic Low--Module On Logic High--Module Off JAWxxxA 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 8.) (IO = 80% of IO, max; VO within 1% of steady state) Output Voltage Adjustment (See Feature Descriptions.): Output Voltage Remote-sense Range Output Voltage Set-point Adjustment Range (trim) Output Overvoltage Protection (shutdown) Overtemperature Protection (shutdown) Symbol Min Typ Max Unit Von/off Ion/off 0 -- -- -- 1.2 1.0 V mA Von/off Ion/off -- -- -- -- -- -- 40 15 50 80 V A ms -- -- -- 60 -- -- 0.5 110 V %VO, nom VO, sd 5.9* 6.0 7.0* V TC -- 105 -- C * These are manufacturing test limits. In some situations, results may differ. 4 Tyco Electronics Corp. Advance Data Sheet JAW050A and JAW075A Power Modules: May 1999 dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W Characteristic Curves The following figures provide typical characteristics for the power modules. The figures are identical for both on/off configurations. 84 1.8 83 IO = 10A 1.4 1.2 1.0 IO = 5A 0.8 82 EFFICIENCY, (%) INPUT CURRENT, II (A) 1.6 0.6 0.4 81 80 79 VI = 36 V VI = 55 V VI = 75 V 78 77 76 IO = 0.5A 0.2 75 0.0 0 5 74 10 15 20 25 30 35 40 45 45 55 60 65 70 75 3 4 5 6 7 8 9 INPUT VOLTAGE, V I (V) 8-2110(C) 8-2113(C) Figure 3. Typical JAW050A1 Converter Efficiency vs. Output Current at Room Temperature 3.0 85 84 2.5 83 EFFICIENCY, (%) INPUT CURRENT, I I (A) Figure 1. Typical JAW050A1 Input Characteristics at Room Temperature IO = 15 A 2.0 10 OUTPUT CURRENT, I O (A) 1.5 IO = 7.5 A 1.0 82 VI = 36 V VI = 55 V VI = 75 V 81 80 79 78 77 0.5 IO = 1.5 A 76 75 0.0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 4 5 6 7 8 9 10 11 12 13 14 15 OUTPUT CURRENT, IO (A) INPUT VOLTAGE, V I (V) 8-1896(C) Figure 2. Typical JAW075A1 Input Characteristics at Room Temperature Tyco Electronics Corp. 3 8-1925(C) Figure 4. Typical JAW075A1 Converter Efficiency vs. Output Current at Room Temperature 5 JAW050A and JAW075A Power Modules: Advance Data Sheet dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W May 1999 OUTPUT VOLTAGE, VO (V) (100 mV/div) Characteristic Curves (continued) OUTPUT CURRENT, IO (A) (1 A/div) OUTPUT VOLTAGE, V O (V) (50 mV/div) IO = 1.0 A IO = 7.5 A 3.7 TIME, t (200 ms/div) IO = 15 A 8-1928(C) Note: Tested without any load capacitance. TIME, t (5 s/div) 8-1968(C) REMOTE ON/OFF, VON/OFF (V) OUTPUT VOLTAGE, VO (V) (1 V/div) OUTPUT CURRENT, IO (A) (1 A/div) OUTPUT VOLTAGE, VO (V) (100 mV/div) Figure 5. Typical JAW075A1 Output Ripple Voltage at Room Temperature and 48 Vdc Input Figure 7. Typical JAW075A1 Transient Response to Step Decrease in Load from 50% to 25% of Full Load at Room Temperature and 48 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) 7.5 TIME, t (200 s/div) 0 0 8-1890(C) Note: Tested without any load capacitance. TIME, t (5 ms/div) 8-1892(C) Figure 6. Typical JAW075A1 Transient Response to Step Increase in Load from 50% to 75% of Full Load at Room Temperature and 48 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) 6 Note: Tested without any load capacitance. Figure 8. JAW075A1 Typical Start-Up from Remote On/Off; IO = IO, max Tyco Electronics Corp. Advance Data Sheet JAW050A and JAW075A Power Modules: May 1999 dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W Test Configurations Design Considerations Input Source Impedance TO OSCILLOSCOPE CURRENT PROBE LTEST VI(+) 12 H CS 220 F ESR < 0.1 @ 20 C, 100 kHz BATTERY 33 F ESR < 0.7 @ 100 kHz VI(-) 8-203(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. Figure 9. Input Reflected-Ripple Test Setup COPPER STRIP V O (+) 1.0 F 10 F RESISTIVE LOAD SCOPE 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. 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 9, a 33 F electrolytic capacitor (ESR < 0.7 3/4 at 100 kHz) mounted close to the power module helps ensure stability of the unit. For other highly inductive source impedances, consult the factory for further application guidelines. Safety Considerations For safety-agency approval of the system in which the power module is used, the power module must be installed in compliance with the spacing and separation requirements of the end-use safety agency standard, i.e., UL 1950, CSA C22.2 No. 950-95, and VDE 0805 (EN60950, IEC950). If the input source is non-SELV (ELV or a hazardous voltage greater than 60 Vdc and less than or equal to 75 Vdc), for the module's output to be considered meeting the requirements of safety extra-low voltage (SELV), all of the following must be true: The input source is to be provided with reinforced insulation from any other hazardous voltages, including the ac mains; and One VI pin and one VO pin are to be grounded or both the input and output pins are to be kept floating; and The input pins of the module are not operator accessible; and Another SELV reliability test is conducted on the whole system, as required by the safety agencies, on the combination of supply source and the subject module to verify that under a single fault, hazardous voltages do not appear at the module's output. Figure 10. Peak-to-Peak Output Noise Measurement Test Setup SENSE(+) VI (+) CONTACT AND DISTRIBUTION LOSSES VO(+) IO II LOAD SUPPLY VI (- ) CONTACT RESISTANCE VO(- ) SENSE(- ) 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 contact resistance. [ V O (+) - V O (-) ]I O = ------------------------------------------------ x 100 [ V I (+) - V I (-) ]I I % Note: Do not ground either of the input pins of the module without grounding one of the output pins. This may allow a non-SELV voltage to appear between the output pins and ground. The power module has extra-low voltage (ELV) outputs when all inputs are ELV. The input to these units is to be provided with a maximum 6 A normal-blow fuse in the ungrounded lead. Figure 11. Output Voltage and Efficiency Measurement Test Setup Tyco Electronics Corp. 7 JAW050A and JAW075A Power Modules: Advance Data Sheet dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W May 1999 Feature Descriptions Ion/off + Overcurrent Protection Von/off - To provide protection in a fault (output overload) condition, the unit is equipped with internal current-limiting circuitry and can endure an overcurrent condition indefinitely. 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 currentlimit circuit can exhibit either foldback or tailout characteristics (output current decrease or increase). The unit will try to restart after an overcurrent shut down. If the output overload condition 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 Two remote on/off options are available. Positive logic remote on/off turns the module on during a logic-high voltage on the ON/OFF pin, and off during a logic low. Negative logic remote on/off turns the module off during a logic high and on during a logic low. Negative logic, device code suffix "1," is the factory-preferred configuration. To turn the power module on and off, the user must supply a switch to control the voltage between the on/off terminal and the VI(-) terminal (Von/off). The switch can be an open collector or equivalent (see Figure 12). 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. ON/OFF SENSE(+) VO(+) LOAD VI(-) For negative logic, short ON/OFF pin to VI(-). For positive logic, leave ON/OFF pin open. SENSE(-) 8-720(C).c Figure 12. 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 output voltage sense range given in the Feature Specifications table, i.e.: [VO(+) - VO(-)] - [SENSE(+) - SENSE(-)] 0.5 V The voltage between the VO(+) and VO(-) terminals must not exceed the minimum output overvoltage protection voltage as indicated 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 13. 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: VO(-) VI(+) SENSE(+) SENSE(-) SUPPLY VI(+) VO(+) VI(-) VO(-) II CONTACT RESISTANCE IO LOAD CONTACT AND DISTRIBUTION LOSSES 8-651(C).m Figure 13. Effective Circuit Configuration for Single-Module Remote-Sense Operation 8 Tyco Electronics Corp. Advance Data Sheet JAW050A and JAW075A Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W May 1999 Feature Descriptions (continued) 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 14). The following equation determines the required external-resistor value to obtain a percentage output voltage change of y%. 1000 R adj-down = ------------- - 11 k % ADJUSTMENT RESISTOR VALUE () 10 M 1M 100 k 10 k 0 10 20 30 40 PERCENT CHANGE IN OUTPUT VOLTAGE (%) 8-1783(C) Figure 15. Resistor Selection for Decreased Output Voltage The test results for this configuration are displayed in Figure 15. This figure applies to all output voltages. VO(+) VI(+) With an external resistor connected between the TRIM and SENSE(+) pins (Radj-up), the output voltage set point (VO, adj) increases (see Figure 16). ON/OFF SENSE(+) Radj-up CASE The following equation determines the required external-resistor value to obtain a percentage output voltage change of y%. R adj-up % ( V O, nom ) ( 1 + ------ - ) - 1.225 100 = -------------------------------------------------------------------------- 1000 - 11 k 1.225% RLOAD TRIM VI(-) SENSE(-) VO(-) 8-715(C).b Figure 16. Circuit Configuration to Increase Output Voltage The voltage between the VO(+) and VO(-) terminals must not exceed the minimum output overvoltage protection voltage as indicated 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 13. VI (+) ON/OFF CASE VO (+) SENSE(+) RLOAD TRIM Radj-down VI (-) ADJUSTMENT RESISTOR VALUE () The test results for this configuration are displayed in Figure 17. 100 M 10 M 1M 100 k 0 1 2 3 4 5 6 7 8 9 10 SENSE(-) PERCENT CHANGE IN OUTPUT VOLTAGE (%) VO(-) 8-1784(C) 8-748(C).b Figure 14. Circuit Configuration to Decrease Output Voltage Tyco Electronics Corp. Figure 17. Resistor Selection for Increased Output Voltage 9 JAW050A and JAW075A Power Modules: Advance Data Sheet dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W May 1999 Feature Descriptions (continued) The temperature at this location should not exceed 100 C. The output power of the module should not exceed the rated power for the module as listed in the Ordering Information table. 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 overvoltage protection threshold, then the module will shut down and try to restart. The unit will continue in this condition until the cause of the overvoltage condition is removed. Overtemperature Protection These modules feature an overtemperature protection circuit to safeguard against thermal damage. The circuit shuts down when the maximum case temperature is exceeded. The module will automatically restart when the case temperature cools sufficiently. 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 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 18. MEASURE CASE TEMPERATURE HERE VI(+) ON/OFF 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. Heat Transfer Without Heat Sinks Increasing airflow over the module enhances the heat transfer via convection. Figures 21 and 22 show 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.). Note that the thermal performance is orientation dependent. Longitudinal orientation occurs when the long direction of the module is parallel to the airflow, whereas transverse orientation occurs when the short direction of the module is parallel to the airflow. 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 21 is shown in the following example. Example What is the minimum airflow necessary for a JAW075A1 operating at VI = 55 V, an output current of 15 A, longitudinal orientation, and a maximum ambient temperature of 55 C? Solution Given: VI = 55 V IO = 15 A TA = 55 C VO(+) + SEN Determine PD (Use Figure 20.): TRIM 30.5 (1.20) CASE - SEN VI(-) VO(-) PD = 14 W Determine airflow (v) (Use Figure 21.): v = 2.3 m/s (460 ft./min.) 29.0 (1.14) 8-716(C).h Note: Top view, pin locations are for reference only. Measurements shown in millimeters and (inches). Figure 18. Case Temperature Measurement Location 10 Tyco Electronics Corp. Advance Data Sheet JAW050A and JAW075A Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W May 1999 Thermal Considerations (continued) Heat Transfer Without Heat Sinks (continued) 12 POWER DISSIPATION, PD (W) 11 VI = 75V VI = 55V VI = 36V 10 9 8 POWER DISSIPATION, PD (W) 20 7 18 3.0 m/s (600 ft./min.) 4.0 m/s (800 ft./min.) 16 14 12 10 0.1 m/s 8 (20 ft./min.) 1.0 m/s 6 (200 ft./min.) 4 2.0 m/s (400 ft./min.) 2 0 0 6 5 10 20 30 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (C) 8-2465(C) 4 3 0 1 2 3 4 6 5 7 8 9 10 Figure 21. Forced Convection Power Derating with No Heat Sink; Longitudinal Orientation OUTPUT CURRENT, I O (A) 8-2112(C).a 20 POWER DISSIPATION, PD (W) Figure 19. JAW050A1 Power Dissipation vs. Output Current POWER DISSIPATION, PD (W) 16 15 14 13 12 11 10 VI = 75 V VI = 55 V VI = 36 V 9 8 7 18 3.0 m/s (600 ft./min.) 4.0 m/s (800 ft./min.) 16 14 12 10 8 0.1 m/s (20 ft.min.) 6 1.0 m/s (200 ft./min.) 4 2.0 m/s 2 (400 ft./min.) 0 0 10 20 30 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (C) 8-2466(C) 6 5 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Figure 22. Forced Convection Power Derating with No Heat Sink; Transverse Orientation OUTPUT CURRENT, IO (A) 8-1897(C) Figure 20. JAW075A1 Power Dissipation vs. Output Current Tyco Electronics Corp. 11 JAW050A and JAW075A Power Modules: Advance Data Sheet dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W May 1999 Thermal Considerations (continued) 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.). 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): CASE-TO-AMBIENT THERMAL RESISTANCE, CA (C/W) 8 7 NO HEAT SINK 1/4 IN. HEAT SINK 1/2 IN. HEAT SINK 1 IN. HEAT SINK 1 1/2 IN. HEAT SINK 6 5 4 3 2 1 0 0 T C, max (TC - TA) = ----------------------- ca = --------------------PD 1.0 (200) 1.5 (300) 2.0 (400) 2.5 (500) 3.0 (600) AIR VELOCITY, m/s (ft./min.) PD 8-2165(C).a The location to measure case temperature (TC) is shown in Figure 18. Case-to-ambient thermal resistance vs. airflow is shown, for various heat sink configurations and heights, in Figures 23 and 24. These curves were obtained by experimental testing of heat sinks, which are offered in the product catalog. Figure 24. Case-to-Ambient Thermal Resistance Curves; Transverse Orientation 5 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 Figures 23 and 24 had a thermal-conductive dry pad between the case and the heat sink to minimize contact resistance. The use of Figure 23 is shown in the following example. 4 Example 3 If an 82 C case temperature is desired, what is the minimum airflow necessary? Assume the JAW075A1 module is operating at VI = 55 V, an output current of 15 A, longitudinal orientation, maximum ambient air temperature of 40 C, and the heat sink is 1/4 inch. 9 CASE-TO-AMBIENT THERMAL RESISTANCE, CA (C/W) 0.5 (100) 8 NO HEAT SINK 1/4 IN. HEAT SINK 1/2 IN. HEAT SINK 1 IN. HEAT SINK 1 1/2 IN. HEAT SINK 7 6 2 1 0 0 0.5 (100) 1.0 (200) 1.5 (300) 2.0 (400) 2.5 (500) 3.0 (600) AIR VELOCITY, m/s (ft./min.) 8-2164(C).a Figure 23. Case-to-Ambient Thermal Resistance Curves; Longitudinal Orientation 12 Tyco Electronics Corp. Advance Data Sheet JAW050A and JAW075A Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W May 1999 Thermal Considerations (continued) Heat Transfer with Heat Sinks (continued) For a managed interface using thermal grease or foils, a value of cs = 0.1 C/W to 0.3 C/W is typical. The solution for heat sink resistance is: ( TC - TA) sa = ------------------------ - cs PD Solution Given: VI = 55 V IO = 15 A TA = 40 C TC = 82 C Heat sink = 1/4 in. This equation assumes that all dissipated power must be shed by the heat sink. Depending on the userdefined application environment, a more accurate model, including heat transfer from the sides and bottom of the module, can be used. This equation provides a conservative estimate for such instances. Determine PD by using Figure 20: PD = 14 W Solder, Cleaning, and Drying Considerations Then solve the following equation: (TC - TA ) ca = ----------------------PD 82 - 40 ) ca = (----------------------14 ca = 3.0 C/W Use Figure 23 to determine air velocity for the 1/4 inch heat sink. The minimum airflow necessary for this module is 1.1 m/s (220 ft./min.). Custom Heat Sinks A more detailed model can be used to determine the required thermal resistance of a heat sink to provide necessary cooling. The total module resistance can be separated into a resistance from case-to-sink (cs) and sink-to-ambient (sa) as shown in Figure 25. TC TS TA PD cs Post solder cleaning is usually the final circuit-board assembly process prior to electrical board testing. The result of inadequate circuit-board cleaning and drying can affect both the reliability of a power module and the testability of the finished circuit-board assembly. For guidance on appropriate soldering, cleaning, and drying procedures, refer to the Board-Mounted Power Modules: Soldering and Cleaning Application Note (AP97-021EPS). EMC Considerations For assistance with designing for EMC compliance, refer to the FLTR100V10 Filter Module Data Sheet (DS98-152EPS). Layout Considerations Copper paths must not be routed beneath the power module standoffs. For additional layout guidelines, refer to the FLTR100V10 Filter Module Data Sheet (DS98152EPS). sa 8-1304(C) Figure 25. Resistance from Case-to-Sink and Sink-to-Ambient Tyco Electronics Corp. 13 JAW050A and JAW075A Power Modules: Advance Data Sheet dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W May 1999 Outline Diagram Dimensions are in millimeters and (inches). Tolerances: x.x mm 0.5 mm (x.xx in. 0.02 in.) x.xx mm 0.25 mm (x.xxx in. 0.010 in.) Top View 57.9 (2.28) 61.0 (2.40) Side View SIDE LABEL* 0.51 (0.020) 12.7 (0.50) 1.02 (0.040) DIA SOLDER-PLATED BRASS, 7 PLACES 2.06 (0.081) DIA SOLDER-PLATED BRASS, 2 PLACES (- OUTPUT AND + OUTPUT) 4.1 (0.16) MIN Bottom View 12.7 (0.50) STANDOFF, 4 PLACES 7.1 (0.28) 5.1 (0.20) 7.1 (0.28) 10.16 (0.400) 50.8 (2.00) MOUNTING INSERTS M3 x 0.5 THROUGH, 4 PLACES 25.40 (1.000) 35.56 (1.400) 4.8 (0.19) VI(-) VO(-) CASE -SEN TRIM ON/OFF +SEN VI(+) VO(+) 48.26 (1.900) 10.16 (0.400) 17.78 (0.700) 25.40 (1.000) 35.56 (1.400) 48.3 (1.90) 8-716(C).i * Side label includesTyco name, product designation, safety agency markings, input/output voltage and current ratings, and bar code. 14 Tyco Electronics Corp. Advance Data Sheet JAW050A and JAW075A Power Modules: May 1999 dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W Recommended Hole Pattern Component-side footprint. Dimensions are in millimeters and (inches). 57.9 (2.28) 48.3 (1.90) 4.8 (0.19) VI (+) 35.56 (1.400) 50.8 (2.00) 48.26 (1.900) TERMINALS 61.0 (2.40) VO (+) 35.56 (1.400) +SEN ON/OFF 25.40 (1.000) TRIM 25.40 (1.000) 10.16 (0.400) CASE -SEN VI(-) VO(-) 17.78 10.16 (0.700) (0.400) 5.1 (0.20) 12.7 (0.50) MODULE OUTLINE 8-716(C).i Ordering Information Table 4. Device Codes Input Voltage Output Voltage Output Power Remote On/Off Logic Device Code Comcode 48 V 5.0 V 50 W Negative JAW050A1 108209974 48 V 5.0 V 75 W Negative JAW075A1 108064353 48 V 5.0 V 50 W Positive JAW050A TBD 48 V 5.0 V 75 W Positive JAW075A TBD Tyco Electronics Corp. 15 JAW050A and JAW075A Power Modules: Advance Data Sheet dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W May 1999 Ordering Information (continued) Table 5. Device Accessories Accessory Comcode 1/4 in. transverse kit (heat sink, thermal pad, and screws) 1/4 in. longitudinal kit (heat sink, thermal pad, and screws) 1/2 in. transverse kit (heat sink, thermal pad, and screws) 1/2 in. longitudinal kit (heat sink, thermal pad, and screws) 1 in. transverse kit (heat sink, thermal pad, and screws) 1 in. longitudinal kit (heat sink, thermal pad, and screws) 1 1/2 in. transverse kit (heat sink, thermal pad, and screws) 1 1/2 in. longitudinal kit (heat sink, thermal pad, and screws) 407243989 407243997 407244706 407244714 407244722 407244730 407244748 407244755 1/4 IN. 1/4 IN. 1/2 IN. 1/2 IN. 1 IN. 1 IN. 61 (2.4) 57.9 (2.28) 1 1/2 IN. 1 1/2 IN. 57.9 (2.28) 61 (2.4) D000-c.cvs Figure 26. Longitudinal Heat Sink D000-d.cvs Figure 27. Transverse Heat Sink Tyco Electronics Power Systems, Inc. 3000 Skyline Drive, Mesquite, TX 75149, USA +1-800-526-7819 FAX: +1-888-315-5182 (Outside U.S.A.: +1-972-284-2626, FAX: +1-972-284-2900) http://power.tycoelectronics.com Tyco Electronics Corporation reserves the right to make changes to the product(s) or information contained herein without notice. No liability is assumed as a result of their use or application. No rights under any patent accompany the sale of any such product(s) or information. (c) 2001 Tyco Electronics Corporation, Harrisburg, PA. All International Rights Reserved. Printed in U.S.A. May 1999 DS97-472EPS Printed on Recycled Paper