Power Mate Technology Data Sheet August 2002 FEC 40 series of Power Modules: Dc/Dc Converter 18to 75 Vdc Input, 3.3 to 15Vdc Single Output, 40W Features ■ Low profile: 2 x 2.0 x 0.4 inches (50.8 × 50.8 × 10.2 mm) ■ Wide input voltage range: 18 to 36Vdc, 36 to 75 Vdc ■ Input to output isolation: 1600Vdc, min ■ Operating case temperature range: 100℃ max ■ Over-current protection, auto-recovery ■ Output over voltage protection ■ Under Voltage shoutdown ■ Remote on/off control The FEC40-S Series Power Modules use Advanced and deliver high ■ Adjustable output voltage ■ ISO 9001 certified manufacturing facilities quality, compact, dc/dc converter at an economical prices. ■ UL 1950 Recognized E193009 ■ TUV EN60950 R 50009835 ■ CB JPTUV-003843 Applications: ■ CE mark (Certificate No.: C211708) ■ Distributed power architectures ■ Within FCC class A radiated limits ■ Communications equipment Options: ■ Computer equipment ■ W series ■ Test equipment ■ Negative remote on/off General Description The FEC40 offer 40 Watts of output power from a 2 x 2 x 0.4 inch package without de-rating to 55ºC. The FEC40-S series with 2:1 wide input voltage of 18-36VDC and 36-75VDC and features 1600VDC of isolation, short-circuit and over-voltage protection, as well as six sided shielding. The safety designed meet to EN60950 and UL1950. All models are particularly suited to telecommunications, industrial, mobile telecom and test equipment applications. Table of contents EMC Consideration Absolute Maximum Rating Mechanical Data Electrical Specification Safety and Installation Instruction Feature Description MTBF and Reliability Thermal consideration Solder, Clearing, and Drying Considerations Characteristic Curve Test Configurations 1/19 Power Mate Technology Data Sheet August 2001 Absolute Maximum Ratings Stress in excess of the absolute maximum ratings can cause permanent damage to the device. …. Parameter Device Input Voltage continuous FEC40-24Sxx Transient(100ms) FEC40-48Sxx Symbol Min Vin 0 Max 50 Unit Vdc 100 Operating temperature range All Ta -40 85NOTE ℃ Operating Case Temperature All Tc — 100 ℃ Storage Temperature All Tstg -55 105 ℃ I /O Isolation Voltage All — 1600 — Vdc Isolation capacitance All 1000 pF Note: Operating temperature will be depended on Derating cure. Electrical Specification Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Table 1: Input Specifications Parameter Device Symbol FEC40-24Sxx Vin Operating input range FEC40-48Sxx Maximum Input current See Note1 Iin, max Input reflected-ripple current (Nominal Vin and full load, All Iin Raise time (Start up time) Nominal Vin and full load (constant resistor load) All typ Input voltage variation All dv/dt Min Typ Max 18 24 36 36 48 75 — — — 40 Unit Vdc A mAp-p 300kHz, TA=25℃)Note 2 Input Filter 25mS 5v/ms max (Complies with ETS300 132 part 4.4) L-C Type An external filter capacitor is required for normal operation. The capacitor should be capable of handling 1A ripple current for 48V/24V models. Power Mate suggests: Nippon Chemi-con KMF series,220uF/100V, ESR 90mΩ. Note1: Maximum Input Current Iin = (Vo * Io)/(η*Vin, min) xx input voltage range xxS3P3 xxS05 xxS12 xxS15 Unit 24 18~36 1.685 2.50 2.525 2.50 A 48 36~75 0.833 1.23 1.25 1.25 Note 2: Simulated source impendence of 12uH. 12uH inductor in series with +Vin. 2/19 Power Mate Technology Data Sheet December 2001 Table 2: Output Specifications Parameter Output Volt range Device Symbol FEC40-xxS3P3 FEC40-xxS05 FEC40-xxS12 FEC40-xxS15 Vout Min Typ Max 3.267 4.95 11.88 14.85 3.3 5 12 15 3.333 5.05 12.12 15.15 Unit Vdc Output Regulation Line, HH-LL(at Full Load) Load, FL- 1/10 FL All — -0.5% -0.5% — 0.5% 0.5%Vout 0.5% 0.5%Vout Temp. (Tc =-40~100℃) Output Ripple & Noise Volt FEC40-xxS3P3 Peak-to-peak FEC40-xxS05 20MHz BW FEC40-xxS12 50 mVp-p 75 mVp-p FEC40-xxS15 Output Current FEC40-xxS3P3 FEC40-xxS05 FEC40-xxS12 FEC40-xxS15 Voltage Adjustability FEC40-xxSxx Io 0 — — — — 8000 8000 3333 2666 MA ± 10% of Vout Maximum output deviation is 10% inclusive of remote sense and trim. If remote sense is not being used, the +Vsense should be connected to its corresponding +OUTPUT and likewise the sense should be connected its corresponding –OUTPUT. 3/19 Power Mate Technology Data Sheet December 2001 Table 3: General Specification Parameter Min Typ Max Efficiency See Table Frequency 300 kHz 1600 I/O Isolation In to case Unit Vdc 1000 or Out to case Weight 60g (2.11 oz) Humidity 10%~95% RH Non-condensing Vibration 10~55Hz, 2G, 3minitues period, 30minitues along X,Y and Z Parameter Efficiency ( nominal input voltage and full load) Device typical FEC40-24S3P3 FEC40-24S05 FEC40-24S12 FEC40-24S15 87 89 88 89 Device FEC40-48S3P3 FEC40-48S05 FEC40-48S12 FEC40-48S15 typical 88 90 89 89 Feature Description Output Over voltage protection Over voltage clamps with Zener diode. 3.3 Vout 5 Vout 12 Vout 15 Vout with Zener diode with Zener diode with Zener diode with Zener diode 3.9 6.2 15 18 V V V V Output over current protection When excessive output currents occur in the system, circuit protection is required on all power supplies. Normally, overload current is maintained at approximately 118~142 percent of rated current for FEC40-S-singel. Hiccup-mode is a method of operation in a power supply whose purpose is to protect the power supply from being damaged during an over-current fault condition. It also enables the power supply to restart when the fault is removed. There are other ways of protecting the power supply when it is over-loaded, such as the maximum current limiting or current foldback methods. One of the problems resulting from over current is that excessive heat may be generated in power devices, especially MOSFET and Schottky diodes and the temperature of those devices may exceed their specified limits. A protection mechanism has to be used to prevent those power devices from being damaged. The operation of hiccup is as follows. When the current sense circuit sees an over-current event, the controller shuts off the power supply for a given time and then tries 4/19 Power Mate Technology Data Sheet December 2001 to start up the power supply again. If the over-load condition has been removed, the power supply will start up and operate normally; otherwise, the controller will see another over-current event and shut off the power supply again, repeating the previous cycle. Hiccup operation has none of the drawbacks of the other two protection methods, although its circuit is more complicated because it requires a timing circuit. The excess heat due to overload lasts for only a short duration in the hiccup cycle, hence the junction temperature of the power devices is much lower. The hiccup operation can be done in various ways. For example, one can start hiccup operation any time an over-current event is detected; or prohibit hiccup during a designated start-up is usually larger than during normal operation and it is easier for an over-current event is detected; or prohibit hiccup during a designated start-up interval(usually a few milliseconds). The reason for the latter operation is that during start-up, the power supply needs to provide extra current to charge up the output capacitor. Thus the current demand during start-up is usually larger than during normal operation and it is easier for an over-current event to occur. If the power supply starts to hiccup once there is an over-current, it might never start up successfully. Hiccup mode protection will give the best protection for a power supply against over current situations, since it will limit the average current to the load at a low level, so reducing power dissipation and case temperature in the power devices. 5/19 Power Mate Technology Data Sheet December 2001 Under voltage shoutdown Input Power status Voltage 24 V DC/DC ON 17.8VDC DC/DC OFF 16VDC DC/DC ON 36VDC DC/DC OFF 34VDC 48V Remote On/Off Control Two remote on/off control are available. Positive logic remote on/off turns the module on during a logic-high voltage on the remote on/off pin, and off during a logic low. Negative logic remote on/off turns the module of during a logic high and on during a logic low or when the remote on/off pin is shorted to the Vi(-) pin. The FEC40-S series used a positive logic 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(Von/off)and the Vi(-). The switch may be an open collector or equivalent. A logic low is Von/off = 0V to 1.2V. The maximum Ion/off during a logic low is 100uA. The switch should maintain a logic-low voltage while sinking 100uA. During a logic high, the maximum Von/off generated by the power module is 12V. The maximum allowable leakage current of the switch at Von/off = 12V is 200uA. The module has internal capacitance to reduce noise at the on/off pin. Additional capacitance is not generally needed and may degrade the start-up characteristics of the module. Figure A details five possible circuits for driving the ON/OFF Pin. On/Off Control On/Off Control On/Off Control Vin (-) Positive Logic (Permanently Enabled) Vin (-) Negative Logic (Permanently Enabled) Vin (-) Remote Enable Circuit 5V On/Off Control TTL/ CMOS Vin (-) On/Off Control Vin (-) Negative Logic (Permanently Enabled) Open Collector Enable Circuit 6/19 Power Mate Technology Data Sheet December 2001 Short Circuitry Protection Continuous, hiccup and auto-recovery mode. During short circuit, converter still shut down. The average current during this condition will be very low and the device can be safety in this condition. External trim adjustment Output voltage set point adjustment 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 Vo(+) or Vo(-) pins. With an external resistor between the TRIM and Vo(+) pin, the output voltage set point decreases. With an external resistor between the TRIM and Vo(-) pin, the output voltage set point increases. ●Ctrl Tri m● －Vo ● Trim down +Vo ● + Sense● ●－Vi ●+Vi - Sense ● ●Ctrl Tri m● －Vo ● +Vo ● ●－Vi + Sense● - Sense ● ●+Vi EXTERNAL OUTPUT TRIMMING 7/19 Trim up Power Mate Technology Data Sheet December 2001 TRIM TABLE FEC40-XXS3P3 Trim up 1 2 3 4 Vout= 3.333 3.366 3.399 3.432 Ru= 5 7 8 9 10 % 3.465 3.498 3.531 3.564 3.597 3.63 Volts 57.9599 26.1726 15.5801 10.2844 7.1073 4.9892 3.4764 2.3418 1.4593 0.7533 KOhms Trim down 1 2 3 4 Vout= 3.267 3.234 3.201 3.168 Rd= 6 5 6 7 8 9 10 % 3.135 3.102 3.069 3.036 3.003 2.97 Volts 69.4348 31.2263 18.4861 12.1153 8.2926 5.7441 3.9236 2.5582 1.4963 0.6467 KOhms FEC40-XXS05 Trim up 1 2 3 4 5 6 7 8 9 Vout= 5.05 5.1 5.15 5.2 5.25 5.3 5.35 5.4 5.45 Ru= 10 5.5 Volts 43.2232 18.1319 10.5959 6.9661 4.8305 3.4240 2.4276 1.6848 1.1097 0.6512 KOhms Trim down 1 2 3 4 5 6 7 8 9 Vout= 4.95 4.9 4.85 4.8 4.75 4.7 4.65 4.6 4.55 Rd= % 10 % 4.5 Volts 39.4177 18.9991 11.5799 7.7436 5.3996 3.8189 2.6809 1.8225 1.1519 0.6135 KOhms FEC40-XXS12 Trim up 1 2 3 4 5 6 7 8 9 Vout= 12.12 12.24 12.36 12.48 12.6 12.72 12.84 12.96 13.08 Ru= 13.2 Volts 1019.4475 257.4148 134.3919 84.0552 56.6768 39.4668 27.6475 19.0290 12.4663 7.3021 KOhms Trim down 1 2 3 4 5 6 7 8 9 Vout= 11.88 11.76 11.64 11.52 11.4 11.28 11.16 11.04 10.92 Rd= 10 10 % 10.8 Volts 270.2050 149.6275 95.7604 65.2378 45.5871 31.8777 21.7690 14.0070 7.8596 2.8704 KOhms FEC40-XXS15 Trim up 1 2 3 4 5 6 7 8 9 Vout= 15.15 15.3 15.45 15.6 15.75 15.9 16.05 16.2 16.35 Ru= % 16.5 Volts 455.6690 192.8897 111.4831 71.8484 48.3988 32.9014 21.8975 13.6802 7.3099 2.2269 KΩ Trim down 1 2 3 4 5 6 7 8 9 Vout= 14.85 14.7 14.55 14.4 14.25 14.1 13.95 13.8 13.65 Rd= 10 10 % 13.5 Volts 449.0121 210.2234 125.3763 81.8946 55.4567 37.6837 24.9156 15.2991 7.7956 1.7777 KΩ 8/19 Power Mate Technology Data Sheet December 2001 Thermal Consideration The power module operates in a variety of thermal environments; POWER MATE however, sufficient cooling should be provided to help ensure TECHNOLOGY CO., reliable operation of the unit. Heat is removed by conduction, convention, and radiation to the surrounding environment. Proper cooling can be verified by measuring the case temperature. The case temperature (Tc) should be measured at the position indicated ●Ctrl OUT: xxVDC ●－Vi ●+Vi Tri m● －Vo ● mA +Vo ● + Sense● - Sense ● FEC40-xxSxx in right figure. The temperature at this location should not exceed 100℃. When operating the power module, adequate cooling must be provided to maintain the power module case temperature at or below 100℃. Although the maximum case temperature of the power modules is 100℃, you can limit this temperature to a lower value for extremely high reliability. Optimum cooling is obtained with forced convention. Some typical thermal resistance numbers are tabulated below: Thermal resistance vs. air flow chart Typical θca Air flow rate Natural Convention 9.2℃/W 200LFM 6.50℃/W 300LFM 5.30℃/W 400LFM 4.0℃/W 500LFM 3.5℃/W These numbers are typical only. The natural convention data was recorded with the case of the unit mounted on a vertical plane. The forced convention data was recorded with the air flow parallel to the top of the case. Note: Heat sink is optional and P/N: 7G-0026A Soldering, Clearing and Drying Considerations soldering Flow soldering : 260±10℃ less than 15 seconds Soldering iron : 370±10℃ less than 5 seconds Note: The pin of this module is coated with Tin. To assure the solder-ability, modules should be kept in their original shipping containers to provide adequate protection. Also, the storage environment shall be well controlled to protect the oxidation. 9/19 Power Mate Technology Data Sheet December 2001 Characteristic Curve Efficiency a. Efficiency with load change under different line condition at room temperature FEC40-48S05 100.00% 90.00% Eff.(%) 80.00% 70.00% 60.00% 36Vin 48Vin 50.00% 75Vin 40.00% 800 1600 2400 3200 4000 4800 5600 6400 7200 8000 Load(mA) b. Efficiency with line change under different load condition at room temperature FEC40-48S05 94.00% 92.00% 4000mA 6000mA 8000mA Eff.(%) 90.00% 88.00% 86.00% 84.00% 82.00% 80.00% 36 40 44 48 52 10/19 56 60 64 68 72 Vin Power Mate Technology Data Sheet December 2001 Power Dissipation Curve Power Loss Vs Output Current for 5V FEC40-48S05 6.00 5.00 Pd(W) 4.00 3.00 36Vin 2.00 48Vin 1.00 75Vin 800 1600 2400 3200 4000 4800 5600 6400 7200 8000 Iout(mA) 11/19 Power Mate Technology Data Sheet December 2001 Output ripple & noise FEC40-48S05 Low Line, Full Load Output Ripple & Noise = 36.8mV Normal Line, Full Load Output Ripple & Noise = 47.6mV High Line, Full Load Output Ripple & Noise = 48.8mV Note: The standard of measurement is measured with a 0.1uF/50V MLCC on the output side (see Testing Configurations). Tthe results shown above is measured without capacitor. Transient Peak FEC40-48S05 Low Line, Full Load Transient Peak = 87.0mV Normal Line, Full Load Transient Peak =93.0mV High Line, Full Load Transient Peak =104mV Transient Response FEC40-48S05 Low Line, Full Load Normal Line, Full Load High Line, Full Load 12/19 Transient Response = Transient Response = 152uS Transient Response = 152uS Power Mate Technology Data Sheet December 2001 Inrush current FEC40-48S05 I Low Line, Full Load Inrush current = (18.4/10)* 1A = 1.84A Low Line, Full Load Duration:616uS Normal Line, Full Load Inrush current = (33/10)* 1A =3.3A Normal Line, Full Load Duration: 616uS 13/19 Normal Line, Full Load Inrush current = (10.2/10)* 1A = 1.02A High Line, Full Load Duration: 608 uS Power Mate Technology Data Sheet December 2001 Raise time and Delay time FEC40-48S05 Normal Line, Full Load Raise time = 112 uS Normal Line, Full Load Delay time = 332uS 14/19 Power Mate Technology Data Sheet December 2001 Testing Configurations Input reflected-ripple current Measurement Test up To Oscilloscope ● Current Probe ● ● ● 12uH 220uF 100V ESR 90mΩ Battery Vi(+) DC/DC Converter ● ● Vi(-) . Peak-to-peak output ripple & noise Measurement Test up 0.1uF Multilayer capacitor Resistive Load Output Voltage and Efficiency Measurement Test up Note: All measurements are taken at the module terminals. Vo × Io,max η= × 100% Vi, nominal × Ii 15/19 Power Mate Technology Data Sheet December 2001 EMC Consideration Phenomenon Standard Coupling Value Mode applied Wave form Test Procedure Class Level Electrostatic discharge to case IEC/EN 61000-4-2 Electromagnetic IEC/EN 61000-4-3 antenna Electrical fast transient/ burst IEC/EN 61000-4-4 + i/ -i 2000Vp Bursts of 5/50 On power supply nS 5kHz rep. ---0.5/1.0kV on Rate I/O signal, data transients with and control line--15 ms burst ±0.25/0.5kV duration and 300 ms period 3 Surge IEC/EN 61000-4-5 + i/ -i 1000Vp 1.2/50uS 2 Conducted disturbances IEC/EN 61000-4-6 + i/ -i 3V/rms AM Modulated 0.15 to 80MHz 80% 1kHz field Air discharge ± 2 / ± 4/ ± 1/50nS 8 kV 3 V/m AM 80% 10 positive and 10 negative discharges 2 80~1000MHz 2 1KH 16/19 L—N 1kV 2 Power Mate Technology Data Sheet December 2001 Installation method The unit can be mounted in any direction. Position them with proper intervals to allow enough air ventilation. Ambient temperature around each power supply should not exceed the temperature range shown in de-rating curve. Avoid placing the DC input line pattern layout underneath the unit because it will increase the line conducted noise. Make sure to leave an ample distance between the line pattern layout and the unit. Also, Avoid placing the DC output line pattern layout underneath the unit because it may increase the output noise. Lay out the pattern away from the unit. ＋ ○＋ ○ ○ ○－ －○ × 17/19 Power Mate Technology Data Sheet December 2001 Mechanical Data Dimensions are in inches and (millimeters) Tolerances: x.x mm ± 0.5mm (x.xx in. ± 0.02 in.) x.xx mm ± 0.4mm (x.xxx in. ± 0.015 in.) Top View POWER MATE TECHNOLOGY CO., ●Ctrl Tri m● －Vo ● mA +Vo ● + Sense● - Sense ● OUT: xxVDC ●－Vi ●+Vi DIA. 0.04 (1.0) 0.40 (10.2) FEC40-xxSxx Side View 2.00 (50.8) 1.15 (29.2) 0.40 (10.2) 2.00 (50.8) 3 0.20 (5.1) 2 1 Bottom 9 8 0.22 (5.6) 1.80 (45.7) Bottom View 7 6 5 4 EXTERNAL TRIMMING 0.10 (2.5) 8 0.30 (7.6) 0.60 (15.2) 0.80 (20.3) 0.20 (5.1) TRIM UP 9 TRIM DOWN 7 0.50 (12.7) PIN CONNECTION PIN SINGLE DUAL TRIPLE 1 2 3 4 5 6 7 8 9 + INPUT - INPUT CTRL NC - SENSE (Note6) + SENSE (Note6) + OUTPUT - OUTPUT TRIM + INPUT - INPUT CTRL 3.3V 3.3V RTN NC NC 5V 5V RTN + INPUT - INPUT CTRL + AUX COMMON - AUX + OUTPUT - OUTPUT NC 18/19 Power Mate Technology Data Sheet December 2001 Safety and Installation Instruction Isolation consideration The FEC40 series features 1.6k Volt DC isolation from input to output, input to case, and output to case. The input to output resistance is greater than 109 megohms. Nevertheless, if the system using the power module needs to receive safety agency approval, certain rules must be followed in the design of the system using the model. In particular, all of the creepage and clearance requirements of the end-use safety requirement must be observed. These documents include UL-1950, EN60950 and CSA 22.2-960, although specific applications may have other or additional requirements. Fusing Consideration 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 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 maximum rating of 5 A. Based on the information provided in this data sheet on inrush energy and maximum dc input current, the same type of fuse with lower rating can be used. Refer to the fuse manufacturer’s data for further information. Minimum Load Requirement The FEC40-S Series does not need the minimum Load when application. MTBF and Reliability The MTBF of FEC40-S series of DC/DC converters has been calculated using 1. MIL-HDBK-217F under the following conditions: Nominal Input Voltage Io = Io, max Ta = 25℃ The resulting figure for MTBF is 2.924 × 105 hours. 2. Bellcore TR-NWT-000332 Case I: 50% stress, Operating Temperature at 40 ℃ (Ground fixed and controlled environment) The resulting figure for MTBF is 1.398× 106 hours. 19/19