Data Sheet July 1998 FC250A1 Power Module: dc-dc Converter; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W Features The FC250A1 Power Modules use advanced, surface-mount technology and deliver high-quality, compact dc-dc conversion at an economical price. Applications Redundant and distributed power architectures Options Heat sinks available for extended operation Small size: 61.0 mm x 116.8 mm x 13.5 mm (2.40 in. x 4.60 in. x 0.53 in.) Wide input voltage range High efficiency: 81% typical Parallel operation with load sharing Adjustable output voltage Thermal protection Synchronization Power good signal Current monitor Output overvoltage and overcurrent protection Constant frequency Case ground pin Input-to-output isolation Remote Sense Remote on/off Short-Circuit protection Output overvoltage clamp UL* Recognized, CSA Certified, VDE Licensed * UL is a registered trademark of Underwriters Laboratories, Inc. CSA is a registered trademark of Canadian Standards Association. Description The FC250A1 Power Module is a 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 of 100 W at a typical full-load efficiency of 85%. 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. FC250A1 Power Module: dc-dc Converter; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W Data Sheet July 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. 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 (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 -- -- -- -- 3.8 3.3 A A Inrush Transient i2t -- -- 1 A2s Input Reflected-ripple Current, Peak-to-peak (5 Hz to 20 MHz, 12 H source impedance; see Figure 7.) 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 Figure 1.) VI = 36 V to 75 V; IO = IO, max 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 15 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. FC250A1 Power Module: dc-dc Converter; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W Data Sheet July 1998 Electrical Specifications (continued) Table 2. Output Specifications Parameter Symbol Min Typ Max Unit VO, set 2.46 2.5 2.54 Vdc VO 2.425 -- 2.575 Vdc Output Regulation: Line (VI = 36 V to 75 V) Load (IO = IO, min to IO, max) Temperature (TC = -40 C to +100 C) -- -- -- -- -- -- 0.01 0.05 15 0.1 0.2 50 %VO %VO mV Output Ripple and Noise Voltage (See Figure 8.): RMS Peak-to-peak (5 Hz to 20 MHz) -- -- -- -- -- -- 40 150 mVrms mVp-p External Load Capacitance -- 0 -- * F Output Current IO 2 -- 40 A -- 52 A Output Voltage Set Point (VI = 48 V; IO = IO, max; TC = 25 C) Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life. See Figure 9.) Output Overcurrent Protection IO 42 Output Short-circuit Current (VO = 250 mV) -- 0 -- 70 A Efficiency (VI = 48 V; IO = IO, max; TC = 25 C; see Figure 2 and Figure 9.) -- 85 -- % Switching Frequency -- -- 330 -- kHz -- -- -- -- 8 0.2 -- -- %VO, set ms -- -- -- -- 9 0.2 -- -- %VO, set ms Dynamic Response (IO/t = 1 A/10 s, VI = 48 V, TC = 25 C; tested with a 10 F tantalum and a 1 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) * 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 -- 2800 -- pF Isolation Resistance 10 -- -- M Tyco Electronics Corp. 3 FC250A1 Power Module: dc-dc Converter; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W Data Sheet July 1998 General Specifications Parameter Min Calculated MTBF (IO = 80% of IO, max; TC = 40 C) Weight Typ Max Unit 2,500,000 -- -- hours 130 (4.6) 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): JWxxxG1 Preferred Logic: Logic Low--Module On Logic High--Module Off JWxxxG 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 6.) (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 -- -- -- -- -- -- 50 15 50 85 V A ms -- -- -- 60 -- -- 0.5 110 V %VO, nom VO, sd 3.0* -- 3.8* 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 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). 4 Tyco Electronics Corp. FC250A1 Power Module: dc-dc Converter; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W Data Sheet July 1998 Characteristic Curves The following figures provide typical characteristics for the power modules. The figures are identical for both on/off configurations. 4 IO = 40 A IO = 22 A IO = 4 A 3 75 V OUTPUT VOLTAGE, VO (V) (20 mV/div) INPUT CURRENT, II (A) 3.5 2.5 2 1.5 1 0.5 0 0 48 V 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 INPUT VOLTAGE, VI (V) 36 V 8-3358 (F) Figure 1. Typical FC250A1 Input Characteristics at 25 C TIME, t (2 s/div) 8-3360 (F) Note: See Figure 8 for test conditions. Figure 3. Typical FC250A1 Output Ripple Voltage at Room Temperature, IO = IO, max 89 88 OUTPUT VOLTAGE, VO (V) (100 mV/div) 86 85 84 83 VI = 36 V VI = 54 V VI = 75 V 82 81 80 79 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 OUTPUT CURRENT, IO (A) 8-3359 (F) Figure 2. Typical FC250A1 Efficiency vs. Output Current at 25 C OUTPUT CURRENT, IO (A) (2 A/div) EFFICIENCY, (%) 87 TIME, t (200 s/div) 8-3361 (F) Note: Tested with a 10 F tantalum and a 1 F ceramic capacitor across the load. Figure 4. Typical FC250A1 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.) Tyco Electronics Corp. 5 FC250A1 Power Module: dc-dc Converter; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W Characteristic Curves (continued) Data Sheet July 1998 Test Configurations OUTPUT VOLTAGE, VO (V) (100 mV/div) TO OSCILLOSCOPE CURRENT PROBE LTEST VI(+) 12 H CS 220 F ESR < 0.1 @ 20 C, 100 kHz BATTERY 100 F ESR < 0.7 @ 100 kHz OUTPUT CURRENT, IO (A) (2 A/div) VI(-) 1-0096(F) 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 7. Input Reflected-Ripple Test Setup TIME, t (50 s/div) COPPER STRIP 8-3362 (F) Note: Tested with a 10 F tantalum and a 1 F ceramic capacitor across the load. Figure 5. Typical FC250A1 Transient Response to Step Decrease in Load from 50% to 25% of IO, max at Room Temperature and 75 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) VO(+) 1.0 F 10 F SCOPE VO(-) 8-513 (F).d REMOTE ON/OFF, VON/OFF (V) 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. Figure 8. Peak-to-Peak Output Noise Measurement Test Setup OUTPUT VOLTAGE, VO (V) (1 V/div) SENSE(+) VI(+) CONTACT AND DISTRIBUTION LOSSES VO(+) II IO LOAD SUPPLY VI(-) VO(-) CONTACT RESISTANCE SENSE(-) 8-749 (F) TIME, t (20 ms/div) 8-3363 (F) Note: Tested with a 10 F tantalum and a 1 F ceramic capacitor across the load. Figure 6. Typical Start-Up from Remote On/Off; IO = IO, max 6 RESISTIVE LOAD 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 ---------------------------------------------- [ V I (+) - V I (-) ]I I x 100 % Figure 9. Output Voltage and Efficiency Measurement Test Setup Tyco Electronics Corp. Data Sheet July 1998 FC250A1 Power Module: dc-dc Converter; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W Design Considerations Feature Descriptions Input Source Impedance Overcurrent Protection 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 7, a 100 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. To provide protection in a fault (output overload) condition, the unit is equipped with internal current-limiting circuitry and delayed overcurrent shutdown. 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). If the overcurrent persists for more than 50 ms, the unit will latch off. 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. 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. 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 10). A logic low is Von/off = 0 V to 1.2 V. The maximum Ion/off during a logic low is 1 mA. The switch should maintain a logic-low voltage while sinking 1 mA. During a logic high, the maximum Von/off generated by the power module is 15 V. The maximum allowable leakage 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 to turn the unit on: For negative logic, short the ON/OFF pin to VI(-). For positive logic, leave the ON/OFF pin open. 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 15 A normal-blow fuse in the ungrounded lead. Tyco Electronics Corp. 7 FC250A1 Power Module: dc-dc Converter; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W Feature Descriptions (continued) Data Sheet July 1998 The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. Remote On/Off (continued) V O ( 100 + % ) R adj-up = -------------------------------- 1.225% + 2% ----------------------------- k - 100 % Ion/off + ON/OFF V on/off - SENSE(+) VO(+) LOAD VI(+) VI(-) VO(-) SENSE(-) 8-720 (F).c Figure 10. Remote On/Off Implementation 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(s) open. With an external resistor between the TRIM and SENSE(-) pins (Radj-down), the output voltage set point (VO, adj) decreases (see Figure 11). The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. 100 R adj-down = ---------- - 2 k % With an external resistor connected between the TRIM and SENSE(+) pins (R adj-up), the output voltage set point (VO, adj) increases (see Figure 12). 8 The voltage between the VO(+) and VO(-) terminals must not exceed the minimum output overvoltage shutdown value indicated 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 13). 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. VI(+) ON/OFF CASE VO(+) SENSE(+) TRIM RLOAD Radj-down VI(-) SENSE(-) VO(-) 8-748 (F).b Figure 11. Circuit Configuration to Decrease Output Voltage Tyco Electronics Corp. Data Sheet July 1998 FC250A1 Power Module: dc-dc Converter; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W Feature Descriptions (continued) 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. Output Voltage Set-Point Adjustment (Trim) (continued) VI(+) ON/OFF VO(+) SENSE(+) Radj-up TRIM CASE RLOAD SENSE(+) VI(-) SENSE(-) SENSE(-) VO(-) SUPPLY 8-715 (F).b Figure 12. Circuit Configuration to Increase Output Voltage 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 shutdown voltage as indicated 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 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. 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. Tyco Electronics Corp. VI(+) VO(+) VI(-) VO(-) IO II CONTACT RESISTANCE LOAD CONTACT AND DISTRIBUTION LOSSES 8-651 (F).m Figure 13. Effective Circuit Configuration for Single-Module Remote-Sense Operation 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 attempt to restart. Overtemperature Protection To provide protection in a fault condition, the unit is equipped with an overtemperature protection circuit. This circuit will not engage unless the case temperature exceeds the maximum limit. When activated, the overtemperature protection circuit temporarily shuts down the unit. Recovery from the overtemperature protection is automatic after the unit cools below the overtemperature protection threshold. 9 FC250A1 Power Module: dc-dc Converter; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W 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 14. Data Sheet July 1998 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 15 is shown in the following example. Example What is the minimum airflow necessary for a FC250A1 operating at VI = 54 V, an output current of 26 A, and a maximum ambient temperature of 60 C? Solution 15.0 (0.6) MEASURE CASE TEMPERATURE HERE 15.0 (0.6) Given: VI = 54 V IO = 26 A TA = 60 C Determine PD (Use Figure 16.): VI(+) PD = 10 W VO(+) ON/OFF + SEN Determine airflow (v) (Use Figure 15.): TRIM v = 1 m/s (200 ft./min.) CASE - SEN 30 VO (-) 8-716 (F).k Note: Top view, pin locations are for reference only. Measurements shown in millimeters and (inches). Figure 14. 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. POWER DISSIPATION, PD (W) VI(-) 3.0 m/s (600 ft./min.) 2.0 m/s (400 ft./min.) 1.0 m/s (200 ft./min.) NATURAL CONVECTION 20 10 0 0 10 20 30 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (C) 8-3364 (F) Figure 15. FC250A1 Forced Convection Power Derating with No Heat Sink; Either Orientation Heat Transfer Without Heat Sinks Increasing airflow over the module enhances the heat transfer via convection. Figure 15 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.). 10 Tyco Electronics Corp. FC250A1 Power Module: dc-dc Converter; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W Data Sheet July 1998 Thermal Considerations (continued) Heat Transfer Without Heat Sinks (continued) POWER DISSIPATION, PD (W) 20 18 16 14 VI = 75 V VI = 54 V VI = 36 V 12 10 CASE-TO-AMBIENT THERMAL RESISTANCE, CA (C/W) 8 7 1 1/2 IN. HEAT SINK 1 IN. HEAT SINK 1/2 IN. HEAT SINK 1/4. HEAT SINK NO HEAT SINK 6 5 4 3 2 1 0 0 8 6 0.5 (100) 1.0 (200) 1.5 (300) 2.0 (400) 2.5 (500) 3.0 (600) AIR VELOCITY MEASURED IN m/s (ft./min.) 8-3365.a 4 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 OUTPUT CURRENT, IO (A) Figure 17. FC250A1 Case-to-Ambient Thermal Resistance Curves; Either Orientation 8-3400 (F) Figure 16. FC250A1 Power Dissipation vs. Output Current at 25 C 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): (TC - TA ) C, max --------------------- = ----------------------- ca = T PD PD The location to measure case temperature (TC) is shown in Figure 14. Case-to-ambient thermal resistance vs. airflow is shown, for various heat sink configurations and heights, in Figure 17. These curves were obtained by experimental testing of heat sinks, which are offered in the product catalog. 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 17 had a thermal-conductive dry pad between the case and the heat sink to minimize contact resistance. The use of Figure 17 is shown in the following example. Example If an 85 C case temperature is desired, what is the minimum airflow necessary? Assume the FC250A1 module is operating at VI = 54 V and an output current of 26 A, maximum ambient air temperature of 55 C, and the heat sink is 1/4 inch. Solution Given: VI = 54 V IO = 26 A TA = 55 C TC = 85 C Heat sink = 1/4 inch Determine PD by using Figure 16: PD = 10 W Tyco Electronics Corp. 11 FC250A1 Power Module: dc-dc Converter; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W Thermal Considerations (continued) Heat Transfer with Heat Sinks (continued) Data Sheet July 1998 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 Then solve the following equation: 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. TC - TA) ca = (----------------------PD 85 - 55 ) ca = (---------------------- 10 ca = 3 C/W Use Figure 17 to determine air velocity for the 1/4 inch heat sink. The minimum airflow necessary for the FC250A1 module is 1.5 m/s (300 ft./min.). EMC Considerations For assistance with designing for EMC compliance, refer to the FLTR100V10 Filter Module Data Sheet (DS99-294EPS). Custom Heat Sinks Layout Considerations 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 18. Copper paths must not be routed beneath the power module mounting inserts. This module is designed for solder interconnection between its terminal pins and the customer's board. For additional layout guidelines, refer to the FLTR100V10 Filter Module Data Sheet (DS99-294EPS). PD TC TS cs TA sa 8-1304 (F).e Figure 18. Resistance from Case-to-Sink and Sink-to-Ambient 12 Tyco Electronics Corp. FC250A1 Power Module: dc-dc Converter; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W Data Sheet July 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* 12.7 (0.50) 2.06 (0.081) DIA SOLDER-PLATED TERMINALS, 2 PLACES (-OUTPUT AND + OUTPUT) 4.6 (0.18) MIN 1.02 (0.040) DIA SOLDER-PLATED TERMINALS, 7 PLACES Bottom View MOUNTING INSERTS M3 x 0.5 THROUGH, 4 PLACES 12.7 (0.50) 5.1 (0.20) 10.16 (0.400) 50.8 (2.00) 25.40 (1.000) VI(-) VO(-) CASE -SEN TRIM 35.56 (1.400) ON/OFF +SEN VI(+) VO(+) 10.16 (0.400) 17.78 (0.700) 25.40 (1.000) 35.56 (1.400) 48.26 (1.900) TERMINALS 4.8 (0.19) 48.3 (1.90) MOUNTING INSERTS 8-1190 (F).j * Side label includes Tyco name, product designation, safety agency markings, input/output voltage and current ratings, and bar code. Tyco Electronics Corp. 13 FC250A1 Power Module: dc-dc Converter; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W Data Sheet July 1998 Recommended Hole Pattern Component-side footprint. Dimensions are in millimeters and (inches). 57.9 (2.28) 4.8 (0.19) 48.3 (1.90) MOUNTING INSERTS VI(+) 35.56 (1.400) 50.8 (2.00) 48.26 (1.900) TERMINALS ON/OFF 61.0 (2.40) VO(+) 35.56 (1.400) +SEN 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 8-1190 (F).j Ordering Information Please contact your Tyco Electronics' Account Manager or Field Application Engineer for pricing and availability. Table 4. Device Codes 14 Input Voltage Output Voltage Output Power Output Current Remote On/ Off Logic Device Code Comcode 48 Vdc 2.5 Vdc 100 W 40 A Negative FC250A11 108841099 48 Vdc 2.5 Vdc 100 W 40 A Positive FC250A1 TBD Tyco Electronics Corp. FC250A1 Power Module: dc-dc Converter; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W Data Sheet July 1998 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 Dimensions are in millimeters and (inches). 1/4 IN. 1/4 IN. 1/2 IN. 1/2 IN. 1 IN. 1 IN. 57.9 (2.28) 61 (2.4) 1 1/2 IN. 1 1/2 IN. 61 (2.4) 57.9 (2.28) 8-2833 (F) 8-2832 (F).a Figure 19. Longitudinal Heat Sink Tyco Electronics Corp. Figure 20. Transverse Heat Sink 15 FC250A1 Power Module: dc-dc Converter; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W Data Sheet July 1998 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. July 1998 DS97-541EPS Printed on Recycled Paper