JAHW075A1

Data Sheet June 2001 JAHW050A and JAHW075A Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W Features ■ The JAHW Series Power Modules use advanced, surfacemount technology and deliver high-quality, efficient, and compact dc-dc conversion. Applications ■ Distributed power architectures ■ Workstations ■ Computer equipment ■ Communications equipment ■ High power density ■ Very high efficiency: 90% typical ■ Low output noise ■ Constant frequency ■ Industry-standard pinout ■ Metal baseplate ■ 2:1 input voltage range ■ Overcurrent protection (hiccup mode) ■ Remote on/off ■ Adjustable output voltage ■ Remote sense ■ Output overvoltage protection (hiccup mode) ■ Overtemperature protection (hiccup mode) ■ Case ground pin ■ ISO* 9001 Certified manufacturing facilities ■ Options ■ Heat sinks available for extended operation ■ Choice of remote on/off logic configuration ■ Latching protection features ■ ■ Description Small size: 61.0 mm x 57.9 mm x 12.7 mm (2.40 in. x 2.28 in. x 0.50 in.) Meets the voltage and current requirements for ETSI 300-132-2 and complies with and is Licensed for Basic Insulation rating per EN60950 (-B version only) UL† 60950 Recognized, CSA‡ 22.2 No. 60950-00 Certified, and VDE § 0805 (IEC60950, IEC950) Licensed CE mark meets 73/23/EEC and 93/68/EEC directives** The JAHW050A and JAHW075A 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 75 W at a typical full-load efficiency of 90%. 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. * 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.) JAHW050A and JAHW075A Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W Data Sheet June 2001 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 — — — — 1.7 2.6 A A Inrush Transient i2t — — 1.0 A2s Input Reflected-ripple Current, Peak-to-peak (5 Hz to 20 MHz, 12 µH source impedance; see Figure 12.) II — 5 — mAp-p Input Ripple Rejection (120 Hz) — — 60 — dB Operating Input Voltage Maximum Input Current (VI = 0 V to 75 V; IO = IO, max): JAHW050A (See Figure 1.) JAHW075A (See Figure 2.) Fusing Considerations CAUTION: This power module is not internally fused. An input line fuse must always be used. This encapsulated power module can be used in a wide variety of applications, ranging from simple stand-alone operation to an integrated part of a sophisticated power architecture. To preserve maximum flexibility, internal fusing is not included; however, to achieve maximum safety and system protection, always use an input line fuse. The safety agencies require a normal-blow fuse with a maximum rating of 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. JAHW050A and JAHW075A Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W Data Sheet June 2001 Electrical Specifications (continued) Table 2. Output Specifications Device Symbol Min Typ Max Unit Output Voltage Set Point (VI = 48 V; IO = IO, max; TC = 25 °C) Parameter 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 14.) 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 13.): RMS Peak-to-peak (5 Hz to 20 MHz) All All — — — — — — 50 100 mVrms mVp-p External Load Capacitance (electrolytic) All — 0‡ — * µF Output Current (At IO < IO, min, the modules may exceed output ripple specifications.) JAHW050A JAHW075A IO IO 0.5 0.5 — — 10 15 A A Output Current-limit Inception (VO = 90% of VO, nom) JAHW050A JAHW075A IO, cli IO, cli — — 12 18 — — A A Output Short-circuit Current (VO = 250 mV) Efficiency (VI = 48 V; IO = IO, max; TC = 70 °C) Switching Frequency Dynamic Response (∆IO/∆t = 1 A/10 µs, VI = 48 V, TC = 25 °C; tested with a 10 µF tantalum and a 1.0 µF 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) All — 0 — 22 A JAHW050A JAHW075A η η — — 89.5 90.4 — — % % All — — 340 — kHz All All — — — — 5 200 — — %VO, set µs All All — — — — 5 200 — — %VO, set µs * Stability consideration, (See Design Considerations, Output Capacitance Section) † These are manufacturing test limits. In some situations, results may differ. ‡ Some characteristic are specified with 10 µF aluminum and 1 µF ceramic. Table 3. Isolation Specifications Parameter Min Typ Max Unit Isolation Capacitance — 2500 — pF Isolation Resistance 10 — — MΩ Tyco Electronics Corp. 3 JAHW050A and JAHW075A Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W Data Sheet June 2001 General Specifications Parameter Min Calculated MTBF (IO = 80% of IO, max; TC = 40 °C) Weight Typ Max 2,000,000 — — Unit hours 100 (3.5) g (oz.) Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See Feature Descriptions for additional information. Parameter Remote On/Off Signal Interface (VI = 0 V to 75 V; open collector or equivalent compatible; signal referenced to VI(–) terminal; see Figure 15 and Feature Descriptions.): JAHWxxxA1 Preferred Logic: Logic Low—Module On Logic High—Module Off JAHWxxxA 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 µA Leakage Current Turn-on Time (See Figure 11.) (IO = 80% of IO, max; VO within ±1% of steady state) Output Voltage Adjustment (See Feature Descriptions.): Output Voltage Remote-sense Range Output Voltage Set-point Adjustment Range (trim) Output Overvoltage Protection Overtemperature Protection (See Feature Descriptions.) 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 µA ms — — — 60 — — 0.5 110 V %VO, nom VO, sd 5.9* — 7.0* V TC — 110 — °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 the Board-Mounted Power Modules Soldering and Cleaning Application Note (AP97-021EPS). 4 Tyco Electronics Corp. JAHW050A and JAHW075A Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W Data Sheet June 2001 Characteristic Curves 1.8 91 1.6 90 IO = 10 A IO = 5 A IO = 0.5 A 1.4 1.2 1.0 0.8 0.6 89 EFFICIENCY, η (%) INPUT CURRENT, II (A) The following figures provide typical characteristics for the power modules. The figures are identical for both on/off configurations. 0.4 88 87 86 85 84 VI = 36 V VI = 48 V VI = 75 V 83 0.2 82 0.0 81 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 4 3 5 INPUT VOLTAGE, VI (V) 6 7 8 8-2241 (F) Figure 1. Typical JAHW050A Input Characteristics at Room Temperature 10 8-2242 (F) Figure 3. Typical JAHW050A Converter Efficiency vs. Output Current at Room Temperature 3 91 IO = 15 A IO = 7.5 A IO = 0.75 A 2 1.5 1 0.5 90 89 EFFICIENCY, η (%) 2.5 INPUT CURRENT, II (A) 9 OUTPUT CURRENT, IO (A) 88 87 86 VI = 36 V VI = 48 V VI = 75 V 85 84 83 82 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 INPUT VOLTAGE, VI (V) 8-2075 (F) 81 3 4 5 6 7 8 9 10 11 12 13 14 15 OUTPUT CURRENT, IO (A) 8-2076 (F) Figure 2. Typical JAHW075A Input Characteristics at Room Temperature Tyco Electronics Corp. Figure 4. Typical JAHW075A Converter Efficiency vs. Output Current at Room Temperature 5 JAHW050A and JAHW075A Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W Data Sheet June 2001 OUTPUT CURRENT, IO (A) OUTPUT VOLTAGE, VO (V) (5 A/div) (100 mV/div) Characteristic Curves (continued) OUTPUT VOLTAGE, VO (V) (50 mV/div) VI = 36 V VI = 48 V 7.5 A 5.0 A TIME, t (50 µs/div) 8-3203 (F) VI = 75 V Note: Tested with a 10 µF tantalum and a 1.0 µF ceramic capacitor across the load. TIME, t (2 µs/div) 8-3201 (F) Note: See Figure 13 for test conditions. OUTPUT CURRENT, IO (A) OUTPUT VOLTAGE, VO (V) (5 A/div) (100 mV/div) Figure 5. Typical JAHW050A Output Ripple Voltage at Room Temperature, IO = IO, max VI = 36 V OUTPUT VOLTAGE, VO (V) (50 mV/div) Figure 7. Typical JAHW050A 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.) VI = 48 V VI = 75 V TIME, t (100 µs/div) TIME, t (2 µs/div) 8-1886 (F) 8-1884 (F) Note: See Figure 13 for test conditions. Figure 6. Typical JAHW075A Output Ripple Voltage at Room Temperature, IO = IO, max 6 Note: Tested with a 10 µF tantalum and a 1.0 µF ceramic capacitor across the load. Figure 8. Typical JAHW075A 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. Data Sheet June 2001 JAHW050A and JAHW075A Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W OUTPUT VOLTAGE, VO (V) (1 V/div) OUTPUT CURRENT, IO (A) OUTPUT VOLTAGE, VO (V) (5 A/div) (100 mV/div) REMOTE ON/OFF PIN, VON/OFF (V) Characteristic Curves (continued) 5.0 A 2.5 A 0 0 TIME, t (2 µs/div) TIME, t (50 µs/div) 8-1143 (F).a 8-3205 (F) Note: Tested with a 10 µF tantalum and a 1.0 µF ceramic capacitor across the load. Figure 11. Typical Start-Up from Remote On/Off; IO = IO, max OUTPUT CURRENT, IO (A) OUTPUT VOLTAGE, VO (V) (5 A/div) (100 mV/div) Figure 9. Typical JAHW050A 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.) Note: Tested with a 10 µF tantalum and a 1.0 µF ceramic capacitor across the load. TIME, t (50 µs/div) 8-1885 (F) Note: Tested with a 10 µF tantalum and a 1.0 µF ceramic capacitor across the load. Figure 10. Typical JAHW075A 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.) Tyco Electronics Corp. 7 JAHW050A and JAHW075A Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W Test Configurations Design Considerations Input Source Impedance TO OSCILLOSCOPE CURRENT PROBE LTEST VI(+) 12 µH CS 220 µF ESR < 0.1 Ω @ 20 °C, 100 kHz BATTERY Data Sheet June 2001 33 µF ESR < 0.7 Ω @ 100 kHz VI(–) The power module should be connected to a low ac-impedance input source. Highly inductive source impedances can affect the stability of the power module. For the test configuration in Figure 12, a 33 µF electrolytic capacitor (ESR < 0.7 Ω at 100 kHz) mounted close to the power module helps ensure stability of the unit. For other highly inductive source impedances, consult the factory for further application guidelines. 8-203 (F).l Note: Measure input reflected-ripple current with a simulated source inductance (LTEST) of 12 µH. Capacitor CS offsets possible battery impedance. Measure current as shown above. Figure 12. Input Reflected-Ripple Test Setup COPPER STRIP VO(+) 1.0 µF 10 µF RESISTIVE LOAD SCOPE 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. VO(–) 8-513 (F).d Note: Use a 1.0 µF ceramic capacitor and a 10 µF 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 13. Peak-to-Peak Output Noise Measurement Test Setup SENSE(+) VI(+) CONTACT AND DISTRIBUTION LOSSES VO(+) II IO LOAD SUPPLY VI(–) Output capacitance and load impedance interact with the power module’s output voltage regulation control system and may produce and ‘unstable’ output condition for the required values of capacitance and E.S.R.. Minimum and maximum values of output capacitance and of the capacitor’s associated E.S.R. may be dictated, depending on the modules control system. 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. 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 η =  ------------------------------------------------ x 100  [ V I (+) – V I (–) ]I I  1. 2. 3. 4. Access the web at power.tycoelectronics.com/power Under Products, click on the DC-DC link Under Design Tools, click on Application Tools Download Various design tools will be found, including tools for determining stability of power module systems§. §Not available for all codes, Where not available, use minimum values in table above % Figure 14. Output Voltage and Efficiency Measurement Test Setup 8 Tyco Electronics Corp. Data Sheet June 2001 JAHW050A and JAHW075A Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W Safety Considerations Feature Descriptions 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 (IEC60950, IEC950). Overcurrent Protection 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 15 A normal-blow fuse in the ungrounded lead. To provide protection in an output overload condition, the unit is provided with internal shut down and autorestart mechanism. At the instance of current-limit inception, the module enters a "hiccup" mode of operation whereby it shuts down and automatically attempts to restart. As long as the fault persists, the module remains in this mode. The protection mechanism is such that the unit can continue in this condition for a sufficient interval of time until the fault is cleared. A latch-off option is also available 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 15). 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 µA. If not using the remote on/off feature, do one of the following to turn the unit on: Tyco Electronics Corp. ■ For negative logic, short ON/OFF pin to VI(–). ■ For positive logic, leave ON/OFF pin open. 9 JAHW050A and JAHW075A Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W Data Sheet June 2001 Feature Descriptions (continued) Remote On/Off (continued) SENSE(+) SENSE(–) Ion/off + VI(+) ON/OFF SUPPLY IO II VI(–) Von/off – VO(+) CONTACT RESISTANCE SENSE(+) LOAD VO(–) CONTACT AND DISTRIBUTION LOSSES VO(+) 8-651 (F).m LOAD VI(+) VI(–) Figure 16. Effective Circuit Configuration for Single-Module Remote-Sense Operation VO(–) SENSE(–) 8-720(F).c Output Voltage Set-Point Adjustment (Trim) Figure 15. 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 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). 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. 10 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 17). The following equation determines the required external-resistor value to obtain a percentage output voltage change of ∆%. 1000 R adj-down =  ------------- – 11 kΩ  ∆%  The test results for this configuration are displayed in Figure 18. This figure applies to all output voltages. With an external resistor connected between the TRIM and SENSE(+) pins (Radj-up), the output voltage set point (VO, adj) increases (see Figure 19). The following equation determines the required external-resistor value to obtain a percentage output voltage change of ∆%. R adj-up ∆%  ( V O, nom ) ( 1 + ------ - ) – 1.225 100  = -------------------------------------------------------------------------- 1000 – 11 kΩ   1.225∆%   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). Tyco Electronics Corp. JAHW050A and JAHW075A Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W Data Sheet June 2001 Feature Descriptions (continued) VI(+) Output Voltage Set-Point Adjustment (continued) ON/OFF SENSE(+) Radj-up CASE 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 VI(–) TRIM RLOAD SENSE(–) VO(–) 8-715 (F).b Figure 19. Circuit Configuration to Increase Output Voltage 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. A latch-ff option is also available.* VO(+) Overtemperature Protection SENSE(+) TRIM RLOAD Radj-down VI(–) SENSE(–) VO(–) 8-748 (F).b Figure 17. Circuit Configuration to Decrease Output Voltage ADJUSTMENT RESISTOR VALUE (Ω) VO(+) To provide protection in a fault condition, the unit is equipped with an overtemperature circuit. In a event of such a fault, the module enters into an auto-restart “hiccup” mode with low output voltage until the fault is removed. Recovery from the overtemperature protection is automatic after the unit cools below the overtemperature protection threshold. A latch-ff option is also available.* * Protection latch-off causes the ouput to be disabled until input power is recyeled or until the remote on-off is recycled off-on. 1M Thermal Considerations Introduction 100k 10k 0 10 20 30 40 % CHANGE IN OUTPUT VOLTAGE (∆%) 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 20. 8-3207 (F) Figure 18. Resistor Selection for Decreased Output Voltage Tyco Electronics Corp. 11 JAHW050A and JAHW075A Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W Data Sheet June 2001 Thermal Considerations (continued) Example Introduction (continued) What is the minimum airflow necessary for a JAHW075A operating at VI = 55 V, an output current of 15 A, and a maximum ambient temperature of 55 °C? MEASURE CASE TEMPERATURE HERE VI(+) ON/OFF Solution Given: VI = 55 V IO = 15 A TA = 55 °C VO(+) + SEN Determine PD (Use Figure 23.): TRIM 30.5 (1.20) CASE PD = 8 W – SEN Determine airflow (v) (Use Figure 21.): VI(–) VO(–) v = 0.5 m/s (100 ft./min.) 29.0 (1.14) 12 Note: Top view, pin locations are for reference only. Measurements shown in millimeters and (inches). Figure 20. 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. POWER DISSIPATION, PD (W) 8-716 (F).h 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. 9 6 4.0 m/s (800 ft./min.) 3.0 m/s (600 ft./min.) 2.0 m/s (400 ft./min.) 3 1.0 m/s (200 ft./min.) 0.1 m/s (20 ft./min.) NATURAL CONVECTION 0 10 0 20 30 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (°C) 8-2236 (F) Increasing airflow over the module enhances the heat transfer via convection. Figure 21 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.). Note that the natural convection condition was measured at 0.05 m/s to 0.1 m/s (10 ft./min. to 20 ft./min.); however, systems in which these power modules may be used typically generate natural convection airflow rates of 0.3 m/s (60 ft./min.) due to other heat dissipating components in the system. The use of Figure 21 is shown in the following example. Figure 21. JAHW050A and JAHW075A Forced Convection Power Derating with No Heat Sink; Either Orientation 8 POWER DISSIPATION, PD (W) Heat Transfer Without Heat Sinks 7 6 5 VI = 75 V VI = 48 V VI = 36 V 4 3 0 1 2 3 4 5 6 7 8 9 10 OUTPUT CURRENT, IO (A) 8-2243 (F) Figure 22. JAHW050A Power Dissipation vs. Output Current at 25 °C 12 Tyco Electronics Corp. JAHW050A and JAHW075A Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W Data Sheet June 2001 Thermal Considerations (continued) Heat Transfer Without Heat Sinks (continued) POWER DISSIPATION, PD (W) 10 9 VI = 75 V VI = 48 V VI = 36 V 8 7 6 CASE-TO-AMBIENT THERMAL RESISTANCE, θca (°C/W) 8.00 7.00 1 1/2 IN. HEAT SINK 1 IN. HEAT SINK 1/2 IN. HEAT SINK 1/4 IN. HEAT SINK NO HEAT SINK 6.00 5.00 4.00 3.00 2.00 1.00 0.00 5 0 0.5 (100) 4 1.0 (200) 1.5 (300) 2.0 (400) 2.5 3.0 (500) (600) AIR VELOCITY, m/s (ft./min.) 3 0 1 2 3 4 5 6 7 8 OUTPUT CURRENT, IO (A) 8-2238 (F) Figure 23. JAHW075A 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 (θca) is defined as the maximum case temperature rise (∆TC, max) divided by the module power dissipation (PD): (TC – TA) C, max --------------------- = -----------------------θ ca = ∆T PD 8-2239 (F) 9 10 11 12 13 14 15 PD The location to measure case temperature (TC) is shown in Figure 20. Case-to-ambient thermal resistance vs. airflow is shown, for various heat sink configurations and heights, in Figure 24. These curves were obtained by experimental testing of heat sinks, which are offered in the product catalog. Figure 24. JAHW050A and JAHW075A Case-toAmbient Thermal Resistance Curves; Either Orientation These measured resistances are from heat transfer from the sides and bottom of the module as well as the top side with the attached heat sink; therefore, the case-to-ambient thermal resistances shown are generally lower than the resistance of the heat sink by itself. The module used to collect the data in Figure 24 had a thermal-conductive dry pad between the case and the heat sink to minimize contact resistance. The use of Figure 24 is shown in the following example. Example If an 85 °C case temperature is desired, what is the minimum airflow necessary? Assume the JAHW075A module is operating at VI = 55 V and an output current of 15 A, maximum ambient air temperature of 55 °C, and the heat sink is 1/2 inch. Solution Given: VI = 55 V IO = 15 A TA = 55 °C TC = 85 °C Heat sink = 1/2 inch Determine PD by using Figure 23: PD = 8 W Tyco Electronics Corp. 13 JAHW050A and JAHW075A Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W Thermal Considerations (continued) Heat Transfer with Heat Sinks (continued) Data Sheet June 2001 For a managed interface using thermal grease or foils, a value of θcs = 0.1 °C/W to 0.3 °C/W is typical. The solution for heat sink resistance is: (TC – TA) θ sa = ------------------------- – θ cs Then solve the following equation: PD (TC – TA ) θ ca = ----------------------- 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. PD 85 – 55 ) θ ca = (----------------------8 θ ca = 3.8 °C/W Use Figure 24 to determine air velocity for the 1/2 inch heat sink. The minimum airflow necessary for the JAHW075A module is 0.5 m/s (100 ft./min.). EMC Considerations For assistance with designing for EMC compliance, please refer to the FLTR100V10 data sheet (DS99-294EPS). 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 (θcs) and sink-to-ambient (θsa) as shown in Figure 25. PD TC TS θcs Layout Considerations Copper paths must not be routed beneath the power module standoffs. For additional layout guidelines, refer to the FLTR100V10 data sheet (DS99-294EPS). TA θsa 8-1304 (F).e Figure 25. Resistance from Case-to-Sink and Sink-to-Ambient 14 Tyco Electronics Corp. Data Sheet June 2001 JAHW050A and JAHW075A Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 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 57.9 (2.28) 61.0 (2.40) Side View SIDE LABEL* 0.51 (0.020) 12.7 (0.50) 1.02 (0.040) DIA SOLDER-PLATED BRASS, 7 PLACES 4.1 (0.16) MIN† 2.06 (0.081) DIA SOLDER-PLATED BRASS, 2 PLACES (– OUTPUT AND + OUTPUT) Bottom View 12.7 (0.50) STANDOFF, 4 PLACES 7.1 (0.28) 5.1 (0.20) 7.1 (0.28) 10.16 (0.400) 50.8 (2.00) MOUNTING INSERTS M3 x 0.5 THROUGH, 4 PLACES 25.40 (1.000) 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) 4.7 (0.19) 48.3 (1.90) 8-716 (F).k * Side label includes Tyco name, product designation, safety agency markings, input/output voltage and current ratings, and bar code. † The case pin is 1.3 (0.05) longer than the other pins. Tyco Electronics Corp. 15 JAHW050A and JAHW075A Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W Data Sheet June 2001 Recommended Hole Pattern Component-side footprint. Dimensions are in millimeters and (inches). 57.9 (2.28) 4.7 (0.19) 48.3 (1.90) MOUNTING HOLES VI(+) 35.56 (1.400) 50.8 (2.00) 48.26 (1.900) TERMINALS 61.0 (2.40) VO(+) 35.56 (1.400) +SEN ON/OFF 25.40 (1.000) TRIM 25.40 (1.000) 10.16 (0.400) CASE –SEN VI(–) VO(–) 17.78 10.16 (0.700) (0.400) 5.1 (0.20) 12.7 (0.50) MODULE OUTLINE 8-716 (F).k Ordering Information Table 4. Device Codes Input Voltage Output Voltage Output Power Remote On/Off Logic Device Code Comcode 48 V 5V 50 W Negative JAHW050A1 108289430 48 V 5V 75 W Negative JAHW075A1 108219312 48 V 5V 50 W Positive JAHW050A TBD 48 V 5V 75 W Positive JAHW075A TBD Optional features can be ordered using the suffixes shown in Table 5. The suffixes follow the last letter of the device code and are placed in descending order. For example, the device codes for a JAHW075A module with the following options are shown below: Positive logic JAHW075A Negative logic JAHW075A1 Table 5. Device Options 16 Option Device Code Suffix Negative remote on/off logic Positive remote on/off logic Approved for Basic Insulation Latching Protection 1 — –B 5 Tyco Electronics Corp. JAHW050A and JAHW075A Power Modules: dc-dc Converters; 36 Vdc to 75 Vdc Input, 5 Vdc Output; 50 W to 75 W Data Sheet June 2001 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) 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. 61 (2.4) 57.9 (2.28) 1 1/2 IN. 1 1/2 IN. 61 (2.4) 57.9 (2.28) 8-2832 (F) Figure 26. Longitudinal Heat Sink 8-2833 (F) Figure 27. Transverse Heat Sink Tyco Electronics Power Systems, Inc. 3000 Skyline Drive, Mesquite, TX 75149, USA +1-800-526-7819 FAX: +1-888-315-5182 (Outside U.S.A.: +1-972-284-2626, FAX: +1-972-284-2900) http://power.tycoelectronics.com Tyco Electronics Corporation reserves the right to make changes to the product(s) or information contained herein without notice. No liability is assumed as a result of their use or application. No rights under any patent accompany the sale of any such product(s) or information. © 2001 Tyco Electronics Power Systems, Inc., (Mesquite, Texas) All International Rights Reserved. Printed in U.S.A. June 2001 FDS01-063EPS (Replaces DS00-232EPS & DS99-024EPS) Printed on Recycled Paper