Data Sheet April 2008 FW300A1-A Power Module; dc-dc Converter: 36 Vdc to 75 Vdc Input, 5 Vdc Output; 300 W Features n n The FW300A1-A Power Module uses advanced, surface-mount technology and delivers high-quality, compact, dc-dc conversion at an economical price. Applications n Redundant and distributed power architectures n Computer equipment n Communications equipment n Size: 61.0 mm x 116.8 mm x 13.5 mm (2.40 in. x 4.60 in. x 0.53 in.) n Wide input voltage range n High efficiency: 84% typical n Constant frequency n Case ground pin n Input-to-output isolation n Parallel operation with load sharing n Output voltage set-point adjustment (trim) n Synchronization n Enhanced power good signal n Output current monitor n n n Options Enhanced version of FW300 family n Heat sinks available for extended operation n Output overvoltage, overtemperature, and overcurrent protection Remote sense and remote on/off Manufacturing facilities registered against the ISO* 9000 series standards 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 FW300A1-A Power Module is a dc-dc converter that operates over an input voltage range of 36 Vdc to 75 Vdc and provides a precisely regulated dc output. The output is fully isolated from the input, allowing versatile polarity configurations and grounding connections. The module has a maximum power rating of 300 W at a typical full-load efficiency of 84%. These modules are an enhanced version of the FW300 family of power modules. Two or more modules may be paralleled with forced load sharing for redundant or enhanced power applications. The package, which mounts on a printed-circuit board, accommodates a heat sink for high-temperature applications. * 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.) FW300A1-A Power Module; dc-dc Converter: 36 Vdc to 75 Vdc Input, 5 Vdc Output; 300 W Data Sheet April 2008 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 and Figure 16.) 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 -- -- -- -- 14.5 13.2 A A Inrush Transient i2 t -- -- 2.0 A2s Input Reflected-ripple Current, Peak-to-peak (5 Hz to 20 MHz, 12 H source impedance; see Figure 8.) II -- 10 -- mAp-p Input Ripple Rejection (120 Hz) -- -- 60 -- dB Operating Input Voltage Maximum Input Current: VI = 0 V to 75 V; see Figure 1. VI = 36 V to 75 V 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 Lineage Power Data Sheet April 2008 FW300A1-A Power Module; dc-dc Converter: 36 Vdc to 75 Vdc Input, 5 Vdc Output; 300 W Electrical Specifications (continued) Table 2. Output Specifications Parameter Symbol Min Typ Max Unit VO, set 4.92 5.0 5.08 Vdc 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) -- -- -- -- -- -- 0.01 0.05 15 0.1 0.2 50 %VO %VO mV Output Ripple and Noise Voltage (See Figures 4 and 9.): RMS Peak-to-peak (5 Hz to 20 MHz) -- -- -- -- -- -- 40 150 mVrms mVp-p External Load Capacitance -- 0 -- * F Output Current (At IO < IO, min, the modules may exceed output ripple specifications.): IO 0.5 -- 60 A Output Current-limit Inception (VO = 90% of VO, set; see Feature Descriptions.) IO, cli -- -- 130 %IO, max Output Short-circuit Current (VO = 1.0 V; indefinite duration, no hiccup mode; see Figure 2.) -- -- 170 -- %IO, max Efficiency (VI = 48 V; IO = IO, max; TC = 70 C; see Figures 3 and 10.): -- 84 -- % Switching Frequency All -- 500 -- KHz -- -- -- -- 200 300 -- -- mV s -- -- -- -- 200 300 -- -- mV s Min Typ Max Unit Isolation Capacitance -- 1700 -- pF Isolation Resistance 10 -- -- M3/4 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 10 and Feature Descriptions.) Dynamic Response (yIO/yt = 1 A/10 s, VI = 48 V, TC = 25 C; tested with a 10 F aluminum and a 1.0 F ceramic capacitor across the load; see Figures 5 and 6.): 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 Lineage Power 3 FW300A1-A Power Module; dc-dc Converter: 36 Vdc to 75 Vdc Input, 5 Vdc Output; 300 W Data Sheet April 2008 General Specifications Parameter Min Typ Calculated MTBF (IO = 80% of IO, max; TC = 40 C) Max Unit 200 (7) g (oz.) 1,700,000 Weight -- -- hours Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See the Feature Descriptions section for further information. Parameter Symbol Min Typ Max Unit Von/off Ion/off 0 -- -- -- 1.2 1.0 V mA Von/off Ion/off -- -- -- -- -- -- 30 15 50 50 V A ms -- -- 0 5 %VO, set Output Voltage Adjustment: Output Voltage Remote-sense Range Output Voltage Set-point Adjustment Range (trim) -- -- -- 60 -- -- 0.7 114 V %VO, nom Output Overvoltage Protection -- 6.0* -- 7.0* V 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 (IO = 80% of IO, max; VO within 1% of steady state) Output Voltage Overshoot Output Current Monitor (IO = IO, max, TC = 70 C) IO, mon -- 0.065 -- V/A Synchronization: Clock Amplitude Clock Pulse Width Fan-out Capture Frequency Range -- -- -- -- 4.00 0.4 -- 425 -- -- -- -- 5.00 -- 1 575 V s -- kHz Overtemperature Protection (See Figure 16.) TC -- 105 -- C Forced Load Share Accuracy -- -- 10 -- %IO, rated Rpwr/good Ipwr/good Rpwr/good Vpwr/good -- -- 1 -- -- -- -- -- 100 1 -- 40 3/4 mA M3/4 V Power Good Signal Interface: Low Impedance--Module Operating High Impedance--Module Off * 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 the Board-Mounted Power Modules Soldering and Cleaning Application Note (AP97-021EPS). 4 Lineage Power Data Sheet April 2008 FW300A1-A Power Module; dc-dc Converter: 36 Vdc to 75 Vdc Input, 5 Vdc Output; 300 W Characteristic Curves 90 12 IO = 60 A IO = 30 A IO = 6 A INPUT CURRENT, II (A) 10 85 EFFICIENCY, (%) The following figures provide typical characteristics for the power module. VI = 36 V VI = 54 V VI = 75 V 80 75 70 8 65 6 60 6 16 4 26 36 46 56 66 OUTPUT CURRENT, IO (A) 8-2971 (F) 2 Figure 3. Typical FW300A1-A Efficiency vs. Output Current at 25 C 0 0 10 20 30 40 50 60 70 80 INPUT VOLTAGE, VI (V) 8-2969 (F) Figure 1. Typical FW300A1-A Input Characteristics at 25 C OUTPUT VOLTAGE, VO (V) (50 mV/div) OUTPUT VOLTAGE, VO (V) 6 5 VI = 75 V VI = 54 V VI = 36 V 4 VI = 36 V 3 VI = 54 V VI = 75 V 2 1 0 TIME, t (500 ns/div) 0 10 20 30 40 50 60 70 80 OUTPUT CURRENT, IO (A) 8-2972 (F) Note: See Figure 9 for test conditions. 8-2970 (F) Figure 2. Typical FW300A1-A Output Characteristics at 25 C Lineage Power Figure 4. Typical FW300A1-A Output Ripple Voltage at Room Temperature and 60 A Output 5 FW300A1-A Power Module; dc-dc Converter: 36 Vdc to 75 Vdc Input, 5 Vdc Output; 300 W Data Sheet April 2008 OUTPUT CURRENT, IO (A) (10 A/div) OUTPUT VOLTAGE, VO (V) (2 V/div) OUTPUT VOLTAGE, VO (V) (100 mV/div) REMOTE ON/OFF VOLTAGE, VON/OFF (V) Characteristic Curves (continued) NO CAP TIME, t (5 ms/div) TIME, t (200 s/div) 8-2262 (C).a 8-2973 (F) Note: Tested with a 10 F aluminum and a 1.0 F ceramic capacitor across the load. Figure 7. Typical FW300A1-A Start-Up from Remote On/Off; IO = IO, max OUTPUT CURRENT, IO (A) (10 A/div) OUTPUT VOLTAGE, VO (V) (100 mV/div) Figure 5. Typical FW300A1-A Transient Response to Step Decrease in Load from 50% to 25% of Full Load at Room Temperature and 54 V Input (Waveform Averaged to Eliminate Ripple Component.) TIME, t (200 s/div) 8-2974 (F) Note: Tested with a 10 F aluminum and a 1.0 F ceramic capacitor across the load. Figure 6. Typical FW300A1-A Transient Response to Step Increase in Load from 50% to 75% of Full Load at Room Temperature and 54 V Input (Waveform Averaged to Eliminate Ripple Component.) 6 Lineage Power Data Sheet April 2008 FW300A1-A Power Module; dc-dc Converter: 36 Vdc to 75 Vdc Input, 5 Vdc Output; 300 W Test Configurations Design Considerations Input Source Impedance TO OSCILLOSCOPE LTEST VI(+) 12 H Cs 220 F ESR < 0.1 @ 20 C, 100 kHz BATTERY 100 F ESR < 0.3 @ 100 kHz VI(-) 8-203 (C).o 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 8. Input Reflected-Ripple Test Setup COPPER STRIP V O (+) 1.0 F 10.0 F SCOPE RESISTIVE LOAD V O (-) 8-513 (C).m Note: Use a 0.1 F ceramic capacitor and a 10 F aluminum or tantalum capacitor. Scope measurement should be made using a BNC socket. Position the load between 50 mm and 76 mm (2 in. and 3 in.) from the module. Figure 9. Peak-to-Peak Output Noise Measurement Test Setup SENSE(+) SENSE(-) VI(+) SUPPLY VO(+) IO II VI(-) CONTACT RESISTANCE LOAD VO(-) CONTACT AND DISTRIBUTION LOSSES 8-683 (C).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. [VO(+) - VO(-)]IO = -------------------------------------------------- x 100 [VI(+) - VI(-)]II % 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 8, a 100 F electrolytic capacitor (ESR < 0.3 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., UL1950, 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 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 allow 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. Figure 10. Output Voltage and Efficiency Measurement Test Setup Lineage Power 7 Data Sheet April 2008 FW300A1-A Power Module; dc-dc Converter: 36 Vdc to 75 Vdc Input, 5 Vdc Output; 300 W Feature Descriptions 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 an unlimited duration. At the point of current-limit inception, the unit shifts from voltage control to current control. If the output voltage is pulled very low during a severe fault, the current-limit circuit can exhibit either foldback or tailout characteristics (output-current decrease or increase). The unit operates normally once the output current is brought back into its specified range. Remote On/Off 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 11). A logic low is Von/off = 0 V to 1.2 V, during which the module is on. 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. The voltage between the VO(+) and VO(-) terminals must not exceed the minimum value indicated in the output overvoltage shutdown section of 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 12. If not using the remote-sense feature to regulate the output at the point of load, 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. SENSE(+) If not using the remote on/off feature, short the ON/OFF pin to VI(-). SENSE(-) SUPPLY SENSE(+) CASE SENSE(-) Ion/off ON/OFF + Von/off - VI(+) VO(+) VI(-) VO(-) IO II CONTACT RESISTANCE LOAD CONTACT AND DISTRIBUTION LOSSES 8-651 (C).e VO(+) Figure 12. Effective Circuit Configuration for Single-Module Remote-Sense Operation VI(+) VO(-) VI(-) 8-580 (C).d Figure 11. 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.: 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. [VO(+) - VO(-)] - [SENSE(+) - SENSE(-)] 0.7 V 8 Lineage Power Data Sheet April 2008 FW300A1-A Power Module; dc-dc Converter: 36 Vdc to 75 Vdc Input, 5 Vdc Output; 300 W Feature Descriptions (continued) VI(+) VO(+) Output Voltage Set-Point Adjustment (Trim) ON/OFF (continued) With an external resistor between the TRIM and SENSE(-) pins (Radj-down), the output voltage set point (VO, adj) decreases (see Figure 13). The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. R adj-down = 205 - 2.255 -------- %- k CASE SENSE(+) RLOAD TRIM Radj-down VI(-) SENSE(-) VO(-) 8-748 (C).b Figure 13. Circuit Configuration to Decrease Output Voltage With an external resistor connected between the TRIM and SENSE(+) pins (Radj-up), the output voltage set point (VO, adj) increases (see Figure 14). The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. R adj-up % --------- - 1.225 V O, nom 1 + 100 = ----------------------------------------------------------------- 205 - 2.255 k ( 1.225% ) The voltage between the VO(+) and VO(-) terminals must not exceed the minimum value of the output overvoltage protection 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 12. 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. Lineage Power VI(+) ON/OFF VO(+) SENSE(+) Radj-up CASE VI(-) TRIM RLOAD SENSE(-) VO(-) 8-715 (C).b Figure 14. Circuit Configuration to Increase Output Voltage Output Overvoltage Protection The output voltage is monitored at the VO(+) and VO(-) pins of the module. If the voltage at these pins exceeds the value indicated in the Feature Specifications table, the module will shut down and latch off. Recovery from latched shutdown is accomplished by cycling the dc input power off for at least 1.0 second or toggling the primary referenced on/off signal for at least 1.0 second. Overtemperature Protection To provide protection in a fault condition, the unit is equipped with an overtemperature shutdown circuit. The shutdown circuit will not engage unless the unit is operated above the maximum case temperature. Recovery from overtemperature shutdown is accomplished by cycling the dc input power off for at least 1.0 second or toggling the primary referenced on/off signal for at least 1.0 second. 9 Data Sheet April 2008 FW300A1-A Power Module; dc-dc Converter: 36 Vdc to 75 Vdc Input, 5 Vdc Output; 300 W Feature Descriptions (continued) SYNC OUT Pin Output Current Monitor This pin contains a clock signal referenced to the VI(-) pin. The frequency of this signal will equal either the module's internal clock frequency or the frequency established by an external clock applied to the SYNC IN pin. The CURRENT MON pin provides a dc voltage proportional to the dc output current of the module given in the Feature Specifications table. For example, on the FW300A1-A, the V/A ratio is set at 65 mV/A 10% @ 70 C case. At a full load current of 50 A, the voltage on the CURRENT MON pin is 3.25 V. The current monitor signal is referenced to the SENSE(-) pin on the secondary and is supplied from a source impedance of approximately 2 k. It is recommended that the CURRENT MON pin be left open when not in use, although no damage will result if the CURRENT MON pin is shorted to secondary ground. Directly driving the CURRENT MON pin with an external source will detrimentally affect operation of the module and should be avoided. Synchronization Any module can be synchronized to any other module or to an external clock using the SYNC IN or SYNC OUT pins. The modules are not designed to operate in a master/slave configuration; that is, if one module fails, the other modules will continue to operate. SYNC IN Pin This pin can be connected either to an external clock or directly to the SYNC OUT pin of another FW300x module. If an external clock signal is applied to the SYNC IN pin, the signal must be a 500 kHz (50 kHz) square wave with a 4 Vp-p amplitude. Operation outside this frequency band will detrimentally affect the performance of the module and must be avoided. If the SYNC IN pin is connected to the SYNC OUT pin of another module, the connection should be as direct as possible, and the VI(-) pins of the modules must be shorted together. Unused SYNC IN pins should be tied to VI(-). If the SYNC IN pin is unused, the module will operate from its own internal clock. 10 When synchronizing several modules together, the modules can be connected in a daisy-chain fashion where the SYNC OUT pin of one module is connected to the SYNC IN pin of another module. Each module in the chain will synchronize to the frequency of the first module in the chain. To avoid loading effects, ensure that the SYNC OUT pin of any one module is connected to the SYNC IN pin of only one module. Any number of modules can be synchronized in this daisy-chain fashion. Forced Load Sharing (Parallel Operation) For either redundant operation or additional power requirements, the power modules can be configured for parallel operation with forced load sharing (see Figure 15). For a typical redundant configuration, Schottky diodes or an equivalent should be used to protect against short-circuit conditions. Because of the remote sense, the forward-voltage drops across the Schottky diodes do not affect the set point of the voltage applied to the load. For additional power requirements, where multiple units are used to develop combined power in excess of the rated maximum, the Schottky diodes are not needed. Good layout techniques should be observed for noise immunity. To implement forced load sharing, the following connections must be made: The parallel pins of all units must be connected together. The paths of these connections should be as direct as possible. All remote-sense pins should be connected to the power bus at the same point, i.e., connect all SENSE(+) pins to the (+) side of the power bus at the same point and all SENSE(-) pins to the (-) side of the power bus at the same point. Close proximity and directness are necessary for good noise immunity. When not using the parallel feature, leave the PARALLEL pin open. Lineage Power Data Sheet April 2008 FW300A1-A Power Module; dc-dc Converter: 36 Vdc to 75 Vdc Input, 5 Vdc Output; 300 W Feature Descriptions (continued) Forced Load Sharing (Parallel Operation) (continued) For redundant applications, the ORing diodes would keep the other module voltages from being applied to the failed module output and the power good signal would indicate a failure. Thermal Considerations PARALLEL SENSE(+) Introduction SENSE(-) CASE 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 occurs at the position indicated in Figure 16. VO(+) ON/OFF VI(+) VO(-) VI(-) PARALLEL SENSE(+) SENSE(-) CASE VO(+) ON/OFF VI(+) VO(-) VI(-) AIRFLOW (LONGITUDINAL) VI(+) 8-581 (C) MEASURE CASE TEMPERATURE HERE VO(+) VI(-) ON/OFF Figure 15. Wiring Configuration for Redundant Parallel Operation SYNC IN 30.5 (1.20) VO(-) SYNC OUT CASE AIRFLOW (TRANSVERSE) Power Good Signal The power good signal (PWRGOOD pin) is an opencollector, secondary-referenced pin that is pulled low when all five of the following conditions are met: 1. The sensed output voltage is greater than half the rated nominal output voltage. 2. The overvoltage shutdown latch is not set. 3. The thermal shutdown latch is not set. 4. The unit is not in current limit. 5. Secondary internal bias is present. There is one situation where the power good signal can be low even though the module has failed. This can occur when the module is paralleled with other modules for additional output power (i.e., the output ORing diodes would not be used). If one module power train stops delivering power (fails), the other paralleled module(s) would provide a voltage at the output pin of the failed module. The failed module would then not detect that its output power is not being delivered. However, in this situation, the current monitor pins of the paralleled modules would indicate that current is not being delivered from one module and that module had failed. Lineage Power 82.6 (3.25) 8-1303 (F).e Note: Top view, measurements shown in millimeters and (inches). Pin locations are for reference only. Figure 16. Case Temperature Measurement Location The temperature at this location should not exceed 100 C. The maximum case temperature can be limited to a lower value for extremely high reliability. The output power of the module should not exceed the rated power for the module as listed in the Ordering Information table. For additional information about these modules, refer to the Thermal Management for FC- and FW-Series 250 W--300 W Board-Mounted Power Modules Technical Note (TN96-009EPS). 11 Data Sheet April 2008 FW300A1-A Power Module; dc-dc Converter: 36 Vdc to 75 Vdc Input, 5 Vdc Output; 300 W Thermal Considerations (continued) Derating curves for forced-air cooling without a heat sink are shown in Figures 18 and 19. These curves can be used to determine the appropriate airflow for a given set of operating conditions. For example, if a unit with a longitudinal direction airflow dissipates 20 W of heat, the correct airflow in a 40 C environment is 1.0 m/s (200 ft./min.). POWER DISSIPATION, P D (W) 70 POWER DISSIPATION, PD (W) 70 Heat Transfer Without Heat Sinks 4.0 m/s (800 ft./min.) 3.5 m/s (700 ft./min.) 3.0 m/s (600 ft./min.) 2.5 m/s (500 ft./min.) 2.0 m/s (400 ft./min.) 1.5 m/s (300 ft./min.) 1.0 m/s (200 ft./min.) 0.5 m/s (100 ft./min.) 60 50 40 30 20 10 0.1 m/s (20 ft./min.) NAT. CONV. 0 0 10 20 30 40 50 60 70 80 90 100 60 LOCAL AMBIENT TEMPERATURE, TA (C) 50 8-1314 (C) Figure 19. Convection Power Derating with No Heat Sink; Airflow Along Length; Longitudinal Orientation 40 30 VI = 72 V 20 Heat Transfer with Heat Sinks VI = 36 V 10 VI = 54 V 0 0 10 20 30 40 50 60 OUTPUT CURRENT, IO (A) 8-1759 (C) Figure 17. FW300A1-A Power Dissipation vs. Output Current at 25 C POWER DISSIPATION, PD (W) 70 4.0 m/s (800 ft./min.) 3.5 m/s (700 ft./min.) 3.0 m/s (600 ft./min.) 2.5 m/s (500 ft./min.) 2.0 m/s (400 ft./min.) 1.5 m/s (300 ft./min.) 1.0 m/s (200 ft./min.) 0.5 m/s (100 ft./min.) 60 50 40 30 20 10 0.1 m/s (20 ft./min.) NAT. CONV. 0 0 10 20 30 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (C) The power modules have through-threaded, M3 x 0.5 mounting holes, which enable heat sinks or cold plates to be attached to the module. The mounting torque must not exceed 0.56 N-m (5 in.-lb.). For the screw attachment from the pin side, the recommended hole size on the customer's PWB around the mounting holes is 0.130 0.005 inches. If a larger hole is used, the mounting torque from the pin side must not exceed 0.25 N-m (2.2 in.-lb.). 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 16. Case-to-ambient thermal resistance vs. airflow for various heat sink configurations is shown in Figures 20 and 21. These curves were obtained by experimental testing of heat sinks, which are offered in the product catalog. 8-1315 (C) Figure 18. Convection Power Derating with No Heat Sink; Airflow Along Width; Transverse Orientation 12 Lineage Power Data Sheet April 2008 FW300A1-A Power Module; dc-dc Converter: 36 Vdc to 75 Vdc Input, 5 Vdc Output; 300 W Thermal Considerations (continued) To choose a heat sink, determine the power dissipated as heat by the unit for the particular application. Figure 17 shows typical heat dissipation for a range of output currents and three voltages for the FW300A1-A. Heat Transfer with Heat Sinks (continued) Example CASE-TO-AMBIENT THERMAL RESISTANCE, CA (C/W) 4.5 1 1/2 IN. HEAT SINK 1 IN. HEAT SINK 1/2 IN. HEAT SINK 1/4 IN. HEAT SINK NO HEAT SINK 4.0 3.5 3.0 If an 85 C case temperature is desired, what is the minimum airflow necessary? Assume the FW300A1-A module is operating at VI = 54 V and an output current of 50 A, maximum ambient air temperature of 40 C, and the heat sink is 1 inch. 2.5 2.0 Solution 1.5 1.0 0.5 0.0 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.) Given: VI = 54 V IO = 50 A TA = 40 C TC = 85 C Heat sink = 1 inch Determine PD by using Figure 17: 8-1321 (C) Figure 20. Case-to-Ambient Thermal Resistance Curves; Transverse Orientation PD = 48 W Then solve the following equation: TC - TA) ca = (----------------------PD CASE-TO-AMBIENT THERMAL RESISTANCE, CA (C/W) 4.5 85 - 40 ) ca = (---------------------48 1 1/2 IN. HEAT SINK 1 IN. HEAT SINK 1/2 IN. HEAT SINK 1/4 IN. HEAT SINK NO HEAT SINK 4.0 3.5 3.0 2.5 ca = 0.94 C/W 1.0 Use Figures 20 and 21 to determine air velocity for the 1 inch heat sink. The minimum airflow necessary for this module depends on heat sink fin orientation and is shown below: 0.5 1.5 m/s (300 ft./min.) (transverse airflow) 1.75 m/s (350 ft./min.) (longitudinal airflow) 2.0 1.5 0.0 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.) 8-1320 (C) Figure 21. Case-to-Ambient Thermal Resistance Curves; Longitudinal Orientation These measured resistances are from heat transfer from the sides and bottom of the module as well as the top side with the attached heat sink; therefore, the case-to-ambient thermal resistances shown are generally lower than the resistance of the heat sink by itself. The module used to collect the data in Figures 20 and 21 had a thermal-conductive dry pad between the case and the heat sink to minimize contact resistance. Lineage Power 13 FW300A1-A Power Module; dc-dc Converter: 36 Vdc to 75 Vdc Input, 5 Vdc Output; 300 W Thermal Considerations (continued) 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 22. PD TC TS cs Data Sheet April 2008 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. EMC Considerations For assistance with designing for EMC compliance, please refer to the FLTR100V20 Filter Module Data Sheet (DS99-295EPS). TA sa 8-1304(C) Figure 22. Resistance from Case-to-Sink and Sinkto-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: Layout Considerations Copper paths must not be routed beneath the power module mounting inserts. For additional layout guidelines, refer to the FLTR100V20 Filter Module Data Sheet (DS99-295EPS). T C - T A ) - cs sa = (----------------------PD 14 Lineage Power Data Sheet April 2008 FW300A1-A Power Module; dc-dc Converter: 36 Vdc to 75 Vdc Input, 5 Vdc Output; 300 W 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 116.8 (4.60) 61.0 (2.40) Side View SIDE LABEL* 13.5 (0.53) 1.57 (0.062) DIA SOLDER-PLATED, 11 PLACES (VO-, VO+, VI-, VI+, CASE) 5.1 (0.20) MIN 1.02 (0.040) DIA SOLDER-PLATED, 9 PLACES Bottom View 106.7 (4.20) 5.1 (0.20) 50.8 (2.00) 30.48 (1.200) VI+ VO+ 35.56 (1.400) 20.32 5.08 (0.800) (0.200) 15.24 25.40 (0.600) 10.16 (1.000) (0.400) VO- SENSE- SENSE+ TRIM PARALLEL CURRENT MON PWR GOOD VI- 30.48 (1.200) ON/OFF SYNC IN SYNC OUT 2.54 (0.100) TYP 22.86 (0.900) 12.70 17.78 (0.500)(0.700) CASE 7.62 (0.300) 5.1 (0.20) 12.7 (0.50) 2.54 (0.100) TYP MOUNTING INSERTS M3 x 0.5 THROUGH, 4 PLACES 66.04 (2.600) 8-1650 (C).c * Side label includes Lineage name, product designation, safety agency markings, input/output voltage and current ratings, and bar code. Lineage Power 15 FW300A1-A Power Module; dc-dc Converter: 36 Vdc to 75 Vdc Input, 5 Vdc Output; 300 W Data Sheet April 2008 Recommended Hole Pattern Component-side footprint. Dimensions are in millimeters and (inches). MOUNTING INSERTS 66.04 (2.600) 2.54 (0.100) TYP 7.62 (0.300) 5.1 (0.20) 7.62 12.7 (0.300) (0.50) 30.48 (1.200) 35.56 (1.400) 20.32 (0.800) 10.16 (0.400) 5.08 (0.200) VO- 25.40 (1.000) PWR GOOD CURRENT MON PARALLEL TRIM SENSE+ SENSE- 15.24 (0.600) 2.54 (0.100) TYP 7.62 (0.300) CASE SYNC OUT SYNC IN ON/OFF VI- VO+ VI+ 12.70 (0.500) 17.78 (0.700) 22.86 (0.900) 30.48 (1.200) 50.8 (2.00) 5.1 (0.20) 106.68 (4.200) 8-1650 (C).c Ordering Information Please contact your Lineage Power Account Manager or Field Application Engineer for pricing and availability. Input Voltage 48 V 16 Output Voltage 5V Output Power 300 W Output Current 60 A Device Code FW300A1-A Comcode 108507799 Lineage Power Data Sheet April 2008 FW300A1-A Power Module; dc-dc Converter: 36 Vdc to 75 Vdc Input, 5 Vdc Output; 300 W Ordering Information (continued) Table 4. 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) 847308335 847308327 847308350 847308343 847308376 847308368 847308392 847308384 Dimension are in millimeters and (inches). 1/4 IN. 1/4 IN. 1/2 IN. 59.94 1/2 IN. (2.36) 115.82 (4.56) 1 IN. 1 IN. 115.82 (4.56) 1 1/2 IN. 1 1/2 IN. 8-2831 (F) 60.45 (2.38) Figure 24. Transverse Heat Sink 8-2830 (F) Figure 23. Longitudinal Heat Sink Lineage Power 17 FW300A1-A Power Module; dc-dc Converter: 36 Vdc to 75 Vdc Input, 5 Vdc Output; 300 W Data Sheet April 2008 Notes 18 Lineage Power Data Sheet April 2008 FW300A1-A Power Module; dc-dc Converter: 36 Vdc to 75 Vdc Input, 5 Vdc Output; 300 W Notes Lineage Power 19 FW300A1-A Power Module; dc-dc Converter: 36 Vdc to 75 Vdc Input, 5 Vdc Output; 300 W Data Sheet April 2008 A sia-Pacific Head qu art ers T el: +65 6 41 6 4283 World W ide Headq u arters Lin eag e Po wer Co rp oratio n 30 00 Sk yline D riv e, Mes quite, T X 75149, U SA +1-800-526-7819 (Outs id e U .S.A .: +1- 97 2-2 84 -2626) www.line ag ep ower.co m e-m ail: tech sup port1@ lin ea gep ower.co m Eu ro pe, M id dle-East an d Afric a He ad qu arters T el: +49 8 9 6089 286 Ind ia Head qu arters T el: +91 8 0 28411633 Lineage Power reserves the right to make changes to the produc t(s) or information contained herein without notice. No liability is ass umed as a res ult of their use or applic ation. No rights under any patent acc ompany the sale of any s uc h pr oduct(s ) or information. (c) 2008 Lineage Power Corpor ation, (Mesquite, Texas ) All International Rights Res er ved. April 2008 DS99-299EPS (Replaces DS99-298EPS)