Data Sheet August 2006 QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Features n n High power density n Extra high efficiency: 87.5% typical n Low output noise n Constant frequency n Metal baseplate n 2:1 input voltage range n The QHW Series Power Modules use advanced, surfacemount technology and deliver high-quality, efficient, and compact dc-dc conversion. Applications n Distributed power architectures n Communications equipment n Computer equipment Options n n Heat sinks available for extended operation Auto-restart after overtemperature, overvoltage, or overcurrent shutdown n Case ground pin n Short pins Small size: 36.8 mm x 57.9 mm x 12.7 mm (1.45 in. x 2.28 in. x 0.50 in.) Overvoltage and overcurrent, overtemperature protection n Negative remote on/off n Remote sense n Adjustable output voltage n n n ISO* 9001 and ISO 14001 Certified manufacturing facilities UL60950 Recognized, CSA C22.2 No. 60950-00 Certified, and VDE 0805 (EN60950) Licensed CE mark meets 73/23/EEC and 93/68/EEC directives** * ISO is a registered trademark of the International Organization for Standardization. UL is a registered trademark of Underwriters Laboratories, Inc. CSA is a registered trademark of Canadian Standards Association. VDE is a trademark of Verband Deutscher Elektrotechniker e.V. ** This product is intended for integration into end-use equipment. All the required procedures for CE marking of end-use equipment should be followed. (The CE mark is placed on selected products.) Description The QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules are dc-dc converters that operate over an input voltage range of 36 Vdc to 75 Vdc and provide a precisely regulated dc output. The outputs are fully isolated from the inputs, allowing versatile polarity configurations and grounding connections. The modules have maximum power ratings from 50 W to 100 W at a typical full-load efficiency of 87.5%. 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. QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 2006 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 -- -- 75 100 Vdc V Operating Case Temperature (See Thermal Considerations section.) TC -40 100 C Storage Temperature Tstg -55 125 C I/O Isolation Voltage (for 1 minute) -- -- 1500 Vdc Input Voltage: Continuous Transient (100 ms) Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Table 1. Input Specifications Parameter Symbol Min Typ Max Unit VI 36 48 75 Vdc II, max II, max II, max -- -- -- -- -- -- 2.5 3.5 4.5 A A A II, max II, max II, max -- -- -- -- -- -- 1.9 2.7 3.5 A A A Inrush Transient i 2t -- -- 1.0 A2s Input Reflected-ripple Current, Peak-to-peak (5 Hz to 20 MHz, 12 H source impedance; see Figure 17.) II -- 10 -- mAp-p Input Ripple Rejection (120 Hz) -- -- 60 -- dB Operating Input Voltage Maximum Input Current: VI = 0 V to 75 V; IO = IO, max; see Figures 1--3: QHW050A1-Q QHW075A1-Q QHW100A1-Q VI = 36 V to 75 V; IO = IO, max: QHW050A1-Q QHW075A1-Q QHW100A1-Q 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 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. QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 2006 Electrical Specifications (continued) Table 2. Output Specifications Parameter Device Symbol All All CO CO 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 19.) 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 18.): RMS Peak-to-peak (5 Hz to 20 MHz) All All -- -- -- -- -- -- 40 150 mVrms mVp-p External Load Capacitance All -- 0 -- * F Output Current (At IO < IO, min, the modules may exceed output ripple specifications.) QHW050A1-Q QHW075A1-Q QHW100A1-Q IO IO IO 0.5 0.5 0.5 -- -- -- 10 15 20 A A A Output Current-limit Inception (VO = 90% of VO, nom) QHW050A1-Q QHW075A1-Q QHW100A1-Q IO, cli IO, cli IO, cli -- -- -- 15 20 25 20 26 32 A A A Efficiency (VI = 48 V; IO = IO, max; TC = 70 C; see Figure 19.) QHW050A1-Q QHW075A1-Q QHW100A1-Q -- -- -- 87.5 88.5 87.5 -- -- -- % % % All -- -- 400 -- kHz All All -- -- -- -- 5 700 -- -- %VO, Output Capacitance Standard Version -T version Switching Frequency Dynamic Response (IO/t = 1 A/10 s, VI = 48 V, TC = 25 C; tested with a 1000 F aluminum and a 1.0 F ceramic capacitor across the load.): Load Change from IO = 50% to 75% of IO, max: Peak Deviation Settling Time (VO < 10% of peak deviation) Load Change from IO = 50% to 25% of IO, max: Peak Deviation Settling Time (VO < 10% of peak deviation) Min Typ Max -- -- Unit f f set s -- -- All All -- -- -- -- 5 700 %VO, set s * Consult your sales representative or the factory. These are manufacturing test limits. In some situations, results may differ. Table 3. Isolation Specifications Min Typ Max Unit Isolation Capacitance Parameter -- 2500 -- pF Isolation Resistance 10 -- -- M3/4 Tyco Electronics Corp. 3 QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 2006 General Specifications Parameter Min Calculated MTBF (IO = 80% of IO, max; TC = 40 C) Weight Typ Max 2,231,000 -- Unit hours -- 75 (2.7) g (oz.) Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See the Feature Descriptions section 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): 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 A Leakage Current Turn-on Time (See Figure 16.) (IO = 80% of IO, max; VO within 1% of steady state) Output Voltage Adjustment: Output Voltage Remote-sense Range Output Voltage Set-point Adjustment Range (trim) Output Overvoltage Protection Overtemperature Protection 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 -- -- -- 65 -- -- 0.5 110 V %VO, nom VO, sd 5.7* -- 6.8* V TC -- 105 -- C * 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 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 Tyco Electronics Board-Mounted Power Modules Soldering and Cleaning Application Note (AP97-021EPS). In addition follow below listed guidelines. Cleaning & Application Warning: If this module is processed through de-ionized cleaning process, we recommend that end user exercise listed precautions. n n 4 Application Assembly Cooling requirement after Solder Process: Power modules and their associated application PWB assemblies should not be wash-cleaned after soldering until the power modules have had an opportunity to cool to within 10 xC of the cleaning solution temperature. This will prevent vacuum absorption of the cleaning liquid into the module between the pins and the potting during cooling. Washing Nozzle pressure: Modules should be carefully washed with nozzle pressures less the 50 PSI. Tyco Electronics Corp. QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 2006 Cleaning & Application Precautions (continued) n n n Drying: It is recommended that after washing these modules be dried at 100 xC for a minimum of 10 min and possibly more depending on use (see below). Power Module PEM Stud use: 1) For module applications using the PEMs in any way, the drying time at 100 xC should be increased to 30 minutes since liquid is more prone to enter any stress fractures induced between the PEMs and the potting compound during fastener insertion and tightening. 2) The PEMs are specifically intended to enable mounting heat sinks onto the top surface of the module with fasteners inserted through the heat sink. 3) It is recommended that threaded objects or other components not be inserted into the threaded PEMs from the under-surface side of these modules. Objects inserted at the underside can lead to cleaning solution entrapment in the fastener hole area and subsequent ingestion of the liquid into the module and failure. If such objects or attachments are used, then the drying method of 100 xC for longer than 30 minutes may be required for adequate liquid purging. PEM torque: Maximum fastener/ PEM stud torque when attaching items from the heat sink mounting surface is 5.0 in lbs.; Maximum fastener/ PEM stud torque when attaching items from the potting surface is 2.5 in lbs. Characteristic Curves The following figures provide typical characteristics for the power modules. 3 IO = 10 A IO = 5.5 A IO = 1 A 1.6 1.4 INPUT CURRENT, II (A) INPUT CURRENT, II (A) 2 1.8 1.2 1 0.8 0.6 0.4 0.2 0 2.5 IO = 15 A IO = 8.25 A IO = 1.5 A 2 1.5 1 0.5 0 20 25 30 35 40 45 50 55 60 65 70 75 80 30 35 40 45 50 55 60 65 70 75 INPUT VOLTAGE, VI (V) INPUT VOLTAGE, VI (V) 8-3250 (F) Figure 1. Typical QHW050A1-Q Input Characteristics at Room Temperature Tyco Electronics Corp. 20 25 8-3449 (F) Figure 2. Typical QHW075A1-Q Input Characteristics at Room Temperature 5 QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 2006 Characteristic Curves (continued) 89 88 EFFICIENCY, (%) INPUT CURRENT, II (A) 3.5 3.0 2.5 IO = 20 A 2.0 IO = 11 A 1.5 87 86 85 84 83 82 VI = 36 V VI = 48 V VI = 75 V 81 1.0 80 79 IO = 2 A 0.5 3 0.0 20 25 30 35 40 45 50 60 55 65 5 6 7 8 9 10 11 12 13 14 15 OUTPUT CURRENT, IO (A) 75 70 4 INPUT VOLTAGE, VI (V) 8-3450 (F) 1-0120 Figure 3. Typical QHW100A1-Q Input Characteristics at Room Temperature Figure 5. Typical QHW075A1-Q Converter Efficiency vs. Output Current at Room Temperature 90 89 90 88 EFFICIENCY, (%) EFFICIENCY, (%) 85 80 75 VI = 36 V VI = 48 V VI = 75 V 70 86 85 84 83 VI = 36 V VI = 48 V VI = 75 V 82 65 81 80 60 1 2 3 4 5 6 7 8 9 10 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 OUTPUT CURRENT IO (A) OUTPUT CURRENT IO (A) 8-3252 (F) Figure 4. Typical QHW050A1-Q Converter Efficiency vs. Output Current at Room Temperature 6 87 8-3253 (F) Figure 6. Typical QHW100A1-Q Converter Efficiency vs. Output Current at Room Temperature Tyco Electronics Corp. QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 2006 Characteristic Curves (continued) OUTPUT VOLTAGE, VO (V) (50 mV/div) VI = 75 V OUTPUT VOLTAGE, VO (V) (50 mV/div) VI = 36 V VI = 48 V VI = 48 V VI = 36 V VI = 75 V TIME, t (1 s/div) 8-3255 (F) Note: See Figure 18 for test conditions. 8-3254 (F) Note: See Figure 18 for test conditions. Figure 7. Typical QHW050A1-Q Output Ripple Voltage at Room Temperature and IO = IO, max OUTPUT VOLTAGE, VO (V) (50 mV/div) VI = 36 V VI = 48 V VI = 75 V Figure 9. Typical QHW100A1-Q Output Ripple Voltage at Room Temperature and IO = IO, max OUTPUT CURRENT, IO (A) OUTPUT VOLTAGE, VO (V) (2 A/div) (100 mV/div) TIME, t (1 s/div) TIME, t (100 s/div) 8-3256 (F) Note: Tested with a 1000 F aluminum and a 1.0 F ceramic capacitor across the load. TIME, t (1 s/div) 8-3451 (F) Note: See Figure 18 for test conditions. Figure 8. Typical QHW075A1-Q Output Ripple Voltage at Room Temperature and IO = IO, max Tyco Electronics Corp. Figure 10. Typical QHW050A1-Q Transient Response to Step Increase in Load from 50% to 75% of IO, max at Room Temperature and 48 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) 7 QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 2006 OUTPUT CURRENT, IO (A) (5 A/div) OUTPUT CURRENT, IO (A) (1 A/div) OUTPUT VOLTAGE, VO (V) (100 mV/div) OUTPUT VOLTAGE, VO (V) (100 mV/div) Characteristic Curves (continued) TIME, t (100 s/div) TIME, t (200 s/div) 8-3452 (F) 1-0090 Note: Tested with a 1000 F aluminum and a 1.0 F ceramic capacitor across the load. Figure 11. Typical QHW075A1-Q 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.) Figure 13. Typical QHW050A1-Q Transient Response to Step Decrease in Load from 50% to 25% of IO, max at Room Temperature and 48 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) OUTPUT CURRENT, IO (A) (2 A/div) OUTPUT CURRENT, IO (A) OUTPUT VOLTAGE, VO (V) (5 A/div) (200 mV/div) OUTPUT VOLTAGE, VO (V) (100 mV/div) Note: Tested with a 1000 F aluminum and a 1.0 F ceramic capacitor across the load. TIME, t (100 s/div) 8-3453 (F) TIME, t (100 s/div) 8-3257 (F) Note: Tested with a 1000 F aluminum and a 1.0 F ceramic capacitor across the load. Figure 12. Typical QHW100A1-Q 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 Note: Tested with a 1000 F aluminum and a 1.0 F ceramic capacitor across the load. Figure 14. Typical QHW075A1-Q Transient Response to Step Decrease in Load from 50% to 25% of IO, max at Room Temperature and 54 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) Tyco Electronics Corp. Data Sheet August 2006 QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Characteristic Curves (continued) Test Configurations OUTPUT VOLTAGE, VO (V) (200 mV/div) 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 OUTPUT CURRENT, IO (A) (5 A/div) VI(-) 8-203 (F).l Note: Measure input reflected-ripple current with a simulated source inductance (LTEST) of 12 H. Capacitor CS offsets possible battery impedance. Measure current as shown above. Figure 17. Output Reflected-Ripple Test Setup TIME, t (100 s/div) COPPER STRIP 1-0091 Note: Tested with a 1000 F aluminum and a 1.0 F ceramic capacitor across the load. Figure 15. Typical QHW100A1-Q Transient Response to Step Decrease in Load from 50% to 25% of IO, max at Room Temperature and 54 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) VO(+) 1.0 F SCOPE RESISTIVE LOAD VO(-) 8-513 (F).d Note: Use a 1.0 F ceramic capacitor and a 10 F aluminum or tantalum capacitor. Scope measurement should be made using a BNC socket. Position the load between 51 mm and 76 mm (2 in. and 3 in.) from the module. REMOTE ON/OFF VON/OFF (V) Figure 18. Peak-to-Peak Output Noise Measurement Test Setup SENSE(+) VI(+) OUTPUT VOLTAGE, VO (V) (1 V/div) CONTACT AND DISTRIBUTION LOSSES VO(+) II IO LOAD SUPPLY VI(-) NO CAP NO LOAD 800 F 3300 F 9400 F TIME, t (5 ms/div) 8-3258 (F) Figure 16. QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Typical Start-Up from Remote On/Off; IO = IO, max Tyco Electronics Corp. 10 F VO(-) CONTACT RESISTANCE SENSE(-) 8-749 (F) Note: All measurements are taken at the module terminals. When socketing, place Kelvin connections at module terminals to avoid measurement errors due to socket contact resistance. [ V O (+) - V O (-) ]I O = ------------------------------------------------ x 100 [ V I (+) - V I (-) ]I I % Figure 19. Output Voltage and Efficiency Measurement Test Setup 9 QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Design Considerations 5. The Excel download file will allow calculation of phase and gain margin for specific values of load, including output capacitance, associated E.S.R., and interconnect impedance. Be sure the Analysis tool-pak add-in is enabled in Excel. Tutorials on acceptable gain and phase margin are also available using the appropriate links. Input Source Impedance The power module should be connected to a low ac-impedance input source. Highly inductive source impedances can affect the stability of the power module. For the test configuration in Figure 17, a 33 F electrolytic capacitor (ESR < 0.7 at 100 kHz) mounted close to the power module helps ensure stability of the unit. For other highly inductive source impedances, consult the factory for further application guidelines. Output Capacitance High output current transient rate of change (high di/dt) loads may require high values of output capacitance to supply the instantaneous energy requirement to the load. To minimize the output voltage transient drop during this transient, low E.S.R. (equivalent series resistance) capacitors may be required, since a high E.S.R. will produce a correspondingly higher voltage drop during the current transient. Output capacitance and load impedance interact with the power module's output voltage regulation control system and may produce an 'unstable' output condition for the required values of capacitance and E.S.R. may be dictated, depending on the modules control system. Variations to a module's control system to accommodate larger values of capacitance are referred to by a '-T' suffix to the model number. There may be several different '-T' variations for a specific basic module. The process of determining the acceptable values of capacitance and E.S.R. is complex and is load-dependant. Tyco provides Web-based tools to assist the power module end-user in appraising and adjusting the effect of various load conditions and output capacitances on specific power modules for various load conditions. 1. Access the web at power.tycoelectronics.com/ power 2. Under Products, click on the DC-DC link Data Sheet August 2006 Safety Considerations For safety-agency approval of the system in which the power module is used, the power module must be installed in compliance with the spacing and separation requirements of the end-use safety agency standard, i.e., UL60950, CSA C22.2 No. 60950-00, and VDE 0805 (EN60950). 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: n n n n The input source is to be provided with reinforced insulation from any hazardous voltages, including the ac mains. One VI pin and one VO pin are to be grounded, or both the input and output pins are to be kept floating. The input pins of the module are not operator accessible. Another SELV reliability test is conducted on the whole system, as required by the safety agencies, on the combination of supply source and the subject module to verify that under a single fault, hazardous voltages do not appear at the module's output. Note: Do not ground either of the input pins of the module without grounding one of the output pins. This may allows a non-SELV voltage to appear between the output pin and ground. The power module has extra-low voltage (ELV) outputs when all inputs are ELV. The input to these units is to be provided with a maximum 20 A normal-blow fuse in the ungrounded lead. 3. Under Design Tools, click on Stability Assessment 4. Various design tools will be found under the appropriate code. Each of these tools has certain benefits to aid in the application of the power module to capacitive loads. 10 Tyco Electronics Corp. Data Sheet August 2006 QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Feature Descriptions Ion/off Overcurrent Protection To provide protection in a fault (output overload) condition, the unit is equipped with internal current-limiting circuitry and can endure current limiting for up to one second. If overcurrent 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 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 module is available in two overcurrent configurations. 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 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 Negative logic remote on/off turns the module off during 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(-) terminal (Von/off). The switch can be an open collector or equivalent (see Figure 20). A logic low is Von/off = 0 V to 1.2 V. The maximum Ion/off during a logic low is 1 mA. The switch should maintain a logiclow voltage while sinking 1 mA. During a logic high, the maximum Von/off generated by the power module is 15 V. The maximum allowable leakage current of the switch at Von/off = 15 V is 50 A. If not using the remote on/off feature, short the ON/OFF pin to VI(-). + ON/OFF Von/off - SENSE(+) VO(+) LOAD VI(+) VI(-) VO(-) SENSE(-) 8-720 (F).c Figure 20. 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 value shown in the Feature Specifications table. This limit includes any increase in voltage due to remote-sense compensation and output voltage setpoint adjustment (trim). See Figure 21. If not using the remote-sense feature to regulate the output at the point of load, then connect SENSE(+) to VO(+) and SENSE(-) to VO(-) at the module. Although the output voltage can be increased by both the remote sense and by the trim, the maximum increase for the output voltage is not the sum of both. The maximum increase is the larger of either the remote sense or the trim. Consult the factory if you need to increase the output voltage more than the above limitation. The amount of power delivered by the module is defined as the voltage at the output terminals multiplied by the output current. When using remote sense and trim, the output voltage of the module can be increased, which at the same output current would increase the power output of the module. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power. Tyco Electronics Corp. 11 QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Feature Descriptions (continued) Although the output voltage can be increased by both the remote sense and by the trim, the maximum increase for the output voltage is not the sum of both. The maximum increase is the larger of either the remote sense or the trim. Consult the factory if you need to increase the output voltage more than the above limitation. Remote Sense (continued) SENSE(+) SENSE(-) VI(+) SUPPLY VO(+) IO II VI(-) LOAD VO(-) CONTACT RESISTANCE CONTACT AND DISTRIBUTION LOSSES 8-651 (F).m Figure 21. Effective Circuit Configuration for Single-Module Remote-Sense Operation The amount of power delivered by the module is defined as the voltage at the output terminals multiplied by the output current. When using remote sense and trim, the output voltage of the module can be increased, which at the same output current would increase the power output of the module. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power. VI(+) 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 22). The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. 510 R adj-down = ---------- - 10.2 k % With an external resistor connected between the TRIM and SENSE(+) pins (Radj-up), the output voltage set point (VO, adj) increases (see Figure 23). The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. 5.1V O ( 100 + % ) 510 R adj-up = ---------------------------------------------- - ---------- - 10.2 k % 1.225% The voltage between the VO(+) and VO(-) terminals must not exceed the minimum output overvoltage protection value shown in the Feature Specifications table. This limit includes any increase in voltage due to remote-sense compensation and output voltage setpoint adjustment (trim). See Figure 21. 12 Data Sheet August 2006 ON/OFF CASE VO(+) SENSE(+) TRIM RLOAD Radj-down VI(-) SENSE(-) VO(-) 8-748 (F).b Figure 22. Circuit Configuration to Decrease Output Voltage VI(+) ON/OFF VO(+) SENSE(+) Radj-up CASE VI(-) TRIM RLOAD SENSE(-) VO(-) 8-715 (F).b Figure 23. Circuit Configuration to Increase Output Voltage Note: The output voltage of this module may be increased by a maximum of 0.5 V. The 0.5 V is the combination of both the remote-sense and the output voltage set-point adjustment (trim). Do not exceed 5.5 V between the VO(+) and VO(-) terminals. Tyco Electronics Corp. QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 2006 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 latch off. The overvoltage latch is reset by either cycling the input power for one second or by toggling the on/off signal for one second. If the auto-restart option is chosen, the unit will "hiccup" until the temperature is within specification. Overtemperature Protection These modules feature an overtemperature protection circuit to safeguard against thermal damage. The circuit 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 one second or by toggling the remote on/off signal for at least one second. If the auto-restart option is chosen, the unit will "hiccup" until the temperature is within specification. 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 25 and 26 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 3 m/s (600 ft./min.). 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 25 is shown in the following example. Example What is the minimum airflow necessary for a QHW075A1-Q operating at VI = 48 V, an output current of 15 A, transverse orientation, and a maximum ambient temperature of 40 C? 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 24. VI(+) ON/OFF VI(-) Given: VI = 48 V IO = 15 A TA = 40 C Determine PD (Use Figure 28.): PD = 10.25 W Determine airflow (v) (Use Figure 25.): v = 1.0 m/s (200 ft./min.) 33 (1.30) 14 (0.55) Solution VO(+) (+)SENSE TRIM (-)SENSE VO(-) 8-2104 (F) Note: Top view, pin locations are for reference only. Measurements shown in millimeters and (inches). Figure 24. Case Temperature Measurement Location Tyco Electronics Corp. 13 QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 2006 Thermal Considerations (continued) POWER DISSIPATION, PD (W) 20 15 3.0 m/s (600 ft./min.) 2.0 m/s (400 ft./min.) 1.0 m/s (200 ft./min.) 0.1 m/s (20 ft./min.) NATURAL CONVECTION 10 POWER DISSIPATION, PD (W) 9 Heat Transfer Without Heat Sinks (continued) 8 7 6 5 4 3 VI = 75 V VI = 48 V VI = 36 V 2 1 0 1 2 3 4 5 6 7 8 9 10 OUTPUT CURRENT, IO (A) 5 8-3259 (F) 0 0 10 20 30 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (C) Figure 27. QHW050A1-Q Power Dissipation vs. Output Current at 25 C 8-2321 (F).a Figure 25. Forced Convection Power Derating with No Heat Sink; Transverse Orientation 15 3.0 m/s (600 ft./min.) 2.0 m/s (400 ft./min.) 1.0 m/s (200 ft./min.) 0.1 m/s (20 ft./min.) NATURAL CONVECTION 10 POWER DISSIPATION, PD (W) POWER DISSIPATION, PD (W) 20 14 12 10 8 6 4 VI = 75 V VI = 48 V VI = 36 V 2 0 1 2 5 0 0 3 4 5 6 7 8 9 10 11 12 13 14 15 OUTPUT CURRENT, IO (A) 8-3454 (F) 10 20 30 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (C) Figure 28. QHW075A1-Q Power Dissipation vs. Output Current at 25 C 8-2318 (F).c Figure 26. Forced Convection Power Derating with No Heat Sink; Longitudinal Orientation 14 Tyco Electronics Corp. QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 2006 Heat Transfer Without Heat Sinks (continued) POWER DISSIPATION, PD (W) 16 14 12 10 VI = 75 V VI = 48 V VI = 36 V CASE-TO-AMBIENT THERMAL RESISTANCE, CA (C/W) Thermal Considerations (continued) 8 10 9 NO HEAT SINK 1/4 IN. HEAT SINK 1/2 IN. HEAT SINK 1 IN. HEAT SINK 8 7 6 5 4 3 2 1 0 0 0.5 (100) 1.0 (200) 1.5 (300) 2.0 (400) 2.5 (500) 3.0 (600) VELOCITY, m/s (ft./min.) 6 8-2323 (F).a 4 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 OUTPUT CURRENT, IO (A) Figure 30. Case-to-Ambient Thermal Resistance Curves; Transverse Orientation 8-3260 (F) 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.-lbs.). 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 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) Figure 29. QHW100A1-Q Power Dissipation vs. Output Current at 25 C 11 10 NO HEAT SINK 1/4 IN. HEAT SINK 1/2 IN. HEAT SINK 1 IN. HEAT SINK 9 8 7 6 5 4 3 2 1 0 0 0.5 (100) 1.0 (200) 1.5 (300) 2.0 (400) 2.5 (500) 3.0 (600) VELOCITY, m/s (ft./min.) 8-2324 (F).a Figure 31. Case-to-Ambient Thermal Resistance Curves; Longitudinal Orientation ( TC - TA) C, max ca = T --------------------- = -----------------------PD PD The location to measure case temperature (TC) is shown in Figure 24. Case-to-ambient thermal resistance vs. airflow is shown, for various heat sink configurations, heights, and orientations, as shown in Figures 30 and 31. Longitudinal orientation is defined as when the long axis of the module is parallel to the airflow 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. Tyco Electronics Corp. 15 QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 2006 Thermal Considerations (continued) POWER DISSIPATION, PD (W) 20 1 IN. HEAT SINK 1/2 IN. HEAT SINK 1/4 IN. HEAT SINK NO HEAT SINK 15 POWER DISSIPATION, PD (W) 20 Heat Transfer with Heat Sinks (continued) 10 15 10 5 0 0 1 IN. HEAT SINK 1/2 IN. HEAT SINK 1/4 IN. HEAT SINK NO HEAT SINK 10 20 30 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (C) 5 8-2315 (F) 0 0 10 20 30 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (C) Figure 34. Heat Sink Power Derating Curves; 1.0 m/s (200 lfm); Transverse Orientation 8-2317 (F).a POWER DISSIPATION, PD (W) 20 1 IN. HEAT SINK 1/2 IN. HEAT SINK 1/4 IN. HEAT SINK NO HEAT SINK 15 10 20 POWER DISSIPATION, PD (W) Figure 32. Heat Sink Power Derating Curves; Natural Convection; Transverse Orientation 15 10 5 0 0 1 IN. HEAT SINK 1/2 IN. HEAT SINK 1/4 IN. HEAT SINK NO HEAT SINK 10 20 30 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (C) 5 8-2314 (F) 0 0 10 20 30 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (C) Figure 35. Heat Sink Power Derating Curves; 1.0 m/s (200 lfm); Longitudinal Orientation 8-2316 (F).a Figure 33. Heat Sink Power Derating Curves; Natural Convection; Longitudinal Orientation 16 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 30 and 31 had a thermal-conductive dry pad between the case and the heat sink to minimize contact resistance. The use of Figure 30 is shown in the following example. Tyco Electronics Corp. QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 2006 Thermal Considerations (continued) Custom Heat Sinks Heat Transfer with Heat Sinks (continued) A more detailed model can be used to determine the required thermal resistance of a heat sink to provide necessary cooling. The total module resistance can be separated into a resistance from case-to-sink (cs) and sink-to-ambient (sa) as shown in Figure 36. Example If an 85 C case temperature is desired, what is the minimum airflow necessary? Assume the QHW075A1-Q module is operating at VI = 48 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. PD TC TS cs TA sa 8-1304 (F).e Solution Given: VI = 48 V IO = 15 A TA = 40 C TC = 85 C Heat sink = 1/2 inch Determine PD by using Figure 28: PD = 10.25 W Then solve the following equation: (TC - TA) ca = ----------------------PD 85 - 40 ) ca = (----------------------10.25 ca = 4.39 C/W Figure 36. Resistance from Case-to-Sink and Sink-to-Ambient For a managed interface using thermal grease or foils, a value of cs = 0.1 C/W to 0.3 C/W is typical. The solution for heat sink resistance is: ( TC - TA) PD sa = ------------------------- - cs 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. Use Figure 30 to determine air velocity for the 1/2 inch heat sink. EMC Considerations The minimum airflow necessary for this module is 0.6 m/s (120 ft./min.). For assistance with designing for EMC compliance, please refer to the FLTR100V10 Filter Module Data Sheet (DS99-294EPS). Layout Considerations Copper paths must not be routed beneath the power module mounting inserts. For additional layout guidelines, refer to the FLTR100V10 Filter Module Data Sheet (DS99-294EPS). Tyco Electronics Corp. 17 QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 2006 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 36.8 (1.45) 57.9 (2.28) Side View 12.7 (0.50) 0.51 (0.020) 4.1 (0.16) MIN, 2 PLACES 4.1 (0.16) MIN, 6 PLACES 3.5 (0.14) MIN 1.57 (0.062) DIA SOLDER-PLATED BRASS, 2 PLACES 1.02 (0.040) DIA SOLDER-PLATED BRASS, 6 PLACES Bottom View RIVETED CASE PIN (OPTIONAL) 1.09 x 0.76 (0.043 x 0.030) 50.80 (2.000) 3.6 (0.14) 5.3 (0.21) 10.9 (0.43) 11.2 (0.44) VO(-) VI(-) 15.24 (0.600) 26.16 (1.030) - SENSE TRIM ON/OFF MOUNTING INSERTS M3 x 0.5 THROUGH, 4 PLACES 3.81 11.43 (0.150) (0.450) 12.7 (0.50) 7.62 (0.300) 15.24 (0.600) + SENSE VO(+) VI(+) 7.62 (0.300) 5.3 (0.21) 47.2 (1.86) SIDE LABEL* 8-1769 (F).b * Side label includes Tyco name, product designation, safety agency markings, input/output voltage and current ratings, and bar code. 18 Tyco Electronics Corp. QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 2006 Recommended Hole Pattern Component-side footprint. Dimensions are in millimeters and (inches). 5.3 (0.21) 7.62 (0.300) 26.16 (1.030) 15.24 (0.600) 47.2 (1.86) VI(+) VO(+) + SENSE TRIM ON/OFF 7.62 (0.300) - SENSE VI(-) 15.24 (0.600) VO(-) 3.81 (0.150) 10.9 (0.43) 5.3 3.6 (0.21) (0.14) 11.2 (0.44) 50.80 (2.000) 12.7 (0.50) 11.43 (0.450) MOUNTING INSERTS M3 x 0.5 THROUGH, 4 PLACES CASE PIN (OPTIONAL) 8-1769 (F).b Tyco Electronics Corp. 19 QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 2006 Post Solder Cleaning and Drying Consideratrions Post solder cleaning is usually the final circuit-board assembly process prior to electrical board testing.The result of inadequate 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 Tyco Electonics Board Mounted Power Modules:Soldering and Cleaning Application Note. Through-Hole Lead Free Soldering Information The RoHS-compliant through-Hole products use the SAC(Sn/Ag/Cu) Pb-free solder and RoHS- compliant components.They are designed to be processed through single or dual wave soldering machines.The pins have an RoHS-compliant finish that is compatible with both Pb and Pb-free wave soldering processes.A Maximum preheat rate 30C/s is suggested.The wave preheat process should be such that the temperature of the power module board is kept below 2100C.For Pb solder,the recommended pot temperature is 2600C,while the Pb-free solder pot is 2700C max.Not all RoHS-compliant through-hole products can be processed with paste-through-hole Pb or Pb-free reflow process.If additional information is needed,please consult with your Tyco Electronics Power System representative for more details. 20 Tyco Electronics Corp. QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 2006 Ordering Information Please contact your Tyco Electronics Account Manager or Field Application Engineer for pricing and availability. Table 4. Device Codes Input Voltage Output Voltage Output Power Output Current Remote On/Off Logic Device Code Comcode 48 Vdc 5 Vdc 50 W 10 A Negative QHW050A1-Q 108741588 48 Vdc 5 Vdc 75 W 15 A Negative QHW075A1-Q 108741604 48 Vdc 5 Vdc 100 W 20 A Negative QHW100A1-Q 108741562 Optional features can be ordered using the suffixes shown in Table 5. To order more than one option, list device codes suffixes in numerically descending order. For example, the device code for a QHW075A1-Q module with the following option is shown below: Auto-restart after overtemperature, overvoltage, or overcurrent shutdown QHW075A41-Q Table 5. Device Options Option Case ground pin Short pins: 3.68 mm 0.25 mm (0.145 in. 0.010 in.) Auto-restart after overtemperature, overvoltage, or overcurrent shutdown Tyco Electronics Corp. Device Code Suffix 7 6 4 21 QHW050A1-Q, QHW075A1-Q, and QHW100A1-Q Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 2006 Ordering Information (continued) Table 6. 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) 848060992 848061008 848061016 848061024 848061032 848061040 Dimensions are in millimeters and (inches). 1/4 IN. 57.91 0.38 (2.280 0.015) 1/4 IN. 36.83 0.38 (1.450 0.015) 1/2 IN. 1/2 IN. 1 IN. 1 IN. 47.24 0.13 (1.850 0.005) 26.16 0.13 (1.030 0.005) 8-2472 (F) 8-2473 (F) Figure 37. Longitudinal Heat Sink Figure 38. Transverse Heat Sink 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. August 2006 FDS01-053EPS (Replaces DS00-183EPS) Printed on Recycled Paper