Power Mate Technology Data Sheet August 2001 FDC 10 Series of Power Modules: Dc/Dc Converter 9 to 75 Vdc Input, 3.3 to 15Vdc Single Output, 10W Features ■ Low profile: 2.0 × 1.0 × 0.4 inches (50.8 × 25.4 × 10.2 inches) ■ Wide input voltage range: 9 to 18Vdc, 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 UL UL1950 E193009 TUV EN60950 R2054609 CB JPTUV-001422 CE CE MARK ■ ISO 9001 certified manufacturing facilities ■ UL 1950 Recognized E193009 The FDC10 Series Power Modules ■ TUV EN60950 R2054609 use Advanced and deliver high quality, compact, dc/dc converter at an economical prices. ■ CB JPTUV-001422 ■ CE mark ■ Within FCC class A radiated limits Applications: ■ Distributed power architectures Options: ■ Communications equipment ■ W series ■ Computer equipment ■ M1, M2 series ■ Choice of Remote on/off logic configuration General Description The FDC10 Power Modules provide 10 watts of isolated, regulated output power, in a standard TWO BY ONE MODULE SIZE, from wide input voltages of either 12, 24 or 48 Voltages DC. It is available with output voltages set from 3.3 Voltage DC to 15 Voltage DC. The physical design of the unit employs a full five sides metallic case for heat dissipation, and encloses the circuitry in a six-sided shield. Table of contents Characteristic Curve Absolute Maximum Rating Test Configurations Electrical Specification EMC Consideration Feature Description Mechanical Data Thermal consideration Safety and Installation Instruction Solder, Clearing, and Drying Considerations MTBF and Reliability 1/26 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 FDC10-12Sxx Transient(100ms) FDC10-24Sxx Symbol Min Max Unit 36 Vin 0 50 Vdc 100 FDC10-48Sxx Operating temperature range All Ta -25 85Note ℃ Operating Case Temperature All Tc — 100 ℃ Storage Temperature All Tstg -55 105 ℃ I/O Isolation Voltage All — 1600 — Vdc Isolation capacitance All 300 pF Note: Operating temperature will be depended on De-rating cure. Electrical Specification Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Table 1: Input Specifications The Input filter of FDC10-S is established with Pi filter internally. Parameter Device Symbol FDC10-12Sxx Operating input range Vin FDC10-24Sxx FDC10-48Sxx Maximum Input current (See Note 1) Iin, max All Iin Input reflected-ripple current Min Typ Max 9 12 18 18 24 36 36 48 75 — — 30 Unit Vdc mAp-p (300kHz, TA=25℃) Note 2 Note: 1. Maximum Input Current Iin = (Vo * Io)/(η*Vin, min) xx input voltage range xxS33 xxS05 xxS12 xxS15 12 9~18 0.96 1.41 1.35 1.36 24 18~36 0.47 0.69 0.66 0.66 48 36~75 0.23 0.32 0.32 0.32 2. Simulated source impendence of 12uH. 12uH inductor in series with +Vin. 2/26 unit A Power Mate Technology Data Sheet August 2001 Table 2: Output Specifications Parameter Device Symbol Min Typ Max 3.234 3.3 3.366 4.9 5 5.1 FDC10-xxS12 11.76 12 12.24 FDC10-xxS15 14.7 15 15.3 FDC10-xxS33 Output Volt range FDC10-xxS05 Vout Unit Vdc Output Regulation Line, HH-LL Load, FL- 1/10 FL 1% 1%Vout 1% 1%Vout — 50 mVp-p 200 — 2000 200 — 2000 83 — 830 67 — 670 All — — — All — — Temp. (Tc =-40~100℃) Output Ripple & Noise Volt Peak-to-peak 20MHz BW Output Current FDC10-xxS33 ( At Io < Io, min, the FDC10-xxS05 modules may exceed output ripple specification ) FDC10-xxS12 Io FDC10-xxS15 Io,min = 1/10 * Full Load 3/26 mA Power Mate Technology Data Sheet August 2001 Table 3: General Specification Parameter Min Typ Efficiency See Table Frequency 300 Isolation Max Unit kHz 1600 Vdc Weight 27g (0.95oz) Humidity 10%~95% RH Non-condensing Vibration 10~55Hz, 2G, 3minitues period, 30minitues along X,Y and Z Table Efficiency Parameter Efficiency ( nominal input voltage and full load) Device Typical(%) 80 81 82 81 80 82 FEC10-12S33 FEC10-12S05 FEC10-12S12 FEC10-12S15 FEC10-24S33 FEC10-24S05 Device Typical(%) FEC10-24S12 FEC10-24S15 FEC10-48S33 FEC10-48S05 FEC10-48S12 FEC10-48S15 84 84 79 84 86 85 Feature Description Over voltage protection Over voltage clamps with Zener diode. 3.3 Vout with Zener diode 3.9 V 5 Vout with Zener diode 6.2 V 12 Vout with Zener diode 15 V 15 Vout with Zener diode 18 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 120~140 percent of rated current (normal Vi) for FDC10-S. 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 4/26 Power Mate Technology Data Sheet August 2001 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 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. 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. 5/26 Power Mate Technology Data Sheet August 2001 Thermal Consideration The power module operates in a variety of thermal environments; however, sufficient cooling should be provided to help ensure 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 1.00(25.4) position indicated 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 0.50(12.7) 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. Soldering, Clearing and Drying Considerations soldering Flow (wave) soldering : 250±10℃ less than 10 seconds (See below) 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. ---- Wave Soldering Wave soldering is the most popular mass soldering method for the solder attachment of through-hole component leads. Power modules are designed to be compatible with single-wave or dual-wave soldering machines. The suggested soldering process will keep the power module’s internal temperature below the critical continuous temperature of 183℃. 6/26 Data Sheet Power Mate Technology August 2001 The typical recommended preheat temperature range is 90℃ to 105℃ on the top side (component side) of the circuit board. The circuit-board bottom-side preheat temperature is typically recommended to be less than 120℃, and preferable within 100℃ of the solder-wave temperature, A maximum preheat rate of 3℃/s is suggested. The maximum recommended solder pot temperature is 250 ℃ R e c o m m e n d e d W a v e S o ld e rin g P ro file 300 3~6 S 240 230~260℃ S e c o nd 200 F o r c e d c o o lin g 150 100 50 W a ve F ir s t W a v e 95~105℃ P re -H e a t 0 50 90 100 150 200 2 5T I M E ( S e c o n d ) ℃, with the solder-wave dwell time of 3 seconds typical and 6 seconds maximum. 7/26 Power Mate Technology Data Sheet August 2001 Cleaning process In aqueous cleaning, it is preferred to have an in-line cleaner system consisting of several cleaning stages (pre-wash , wash, rinse, final rinse, and drying). Deionized(DI) water is recommended for aqueous cleaning; the minimum resistivity level is 1MΩ-cm. Tap-water quality varies per region in terms of hardness, chloride, and solid contents; therefore, the use of tap water is not recommended for aqueous cleaning. --- Cooling Prior to Cleaning Power modules and their associated application PCB assemblies should not be wash-cleaned after soldering until the power modules have had an opportunity to cool to within 10℃ of the cleaning solution temperature. This will prevent vacuum absorption of the cleaning liquid into the module between the pins and the potting during cooling. Drying The drying section of the cleaner system should be equipped with blowers capable of generating 1000 cfm-1500 cfm of air so that the amount of rinse water left to be dried off with heat is minimal. Handheld air guns are not recommended due to the variability and consistency of the operation. Note: After post-wash, the marking (date code) of converter may fall off. This only impacts the appearance and does not affect the operation of the module. 8/26 Power Mate Technology Data Sheet August 2001 Characteristic Curve Efficiency a. Efficiency with load change under different line condition at room temperature EFF.(%) 200 400 600 800 1000 1200 1400 1600 1800 2000 36Vin 60.54% 73.04% 78.11% 80.49% 81.85% 82.75% 83.08% 83.21% 83.23% 82.94% 48Vin 58.06% 71.13% 76.72% 79.40% 80.90% 82.25% 82.64% 83.10% 83.25% 82.94% 72Vin 53.33% 65.92% 72.71% 76.15% 78.53% 80.02% 80.93% 81.61% 81.94% 82.11% 67 134 201 268 335 402 469 536 603 36Vin 62.28% 78.16% 81.30% 83.86% 85.49% 86.47% 86.91% 87.14% 87.26% 87.24% 48Vin 60.30% 75.30% 78.81% 81.64% 83.69% 85.06% 85.81% 86.22% 86.49% 86.24% 72Vin 44.82% 69.44% 75.87% 77.27% 80.86% 81.97% 83.20% 83.98% 84.64% 85.53% 9/26 670 Power Mate Technology Data Sheet August 2001 b. Efficiency with line change under different load condition at room temperature 36 40 44 48 52 56 60 64 68 72 1000mA 81.66% 82.12% 81.57% 81.37% 81.00% 80.70% 80.17% 79.50% 79.05% 78.72% 1500mA 83.08% 83.43% 83.09% 83.04% 82.84% 82.71% 82.39% 81.95% 81.70% 81.45% 2000mA 82.96% 83.20% 83.08% 83.04% 83.04% 83.05% 82.83% 82.78% 82.40% 82.19% 36 40 44 48 52 56 60 64 68 72 168mA 79.34% 78.72% 78.30% 78.00% 77.68% 76.86% 76.14% 75.13% 74.39% 73.46% 335mA 85.39% 84.77% 84.36% 83.70% 83.09% 82.51% 81.82% 81.31% 80.78% 80.16% 670mA 87.27% 87.15% 87.03% 86.70% 86.41% 86.24% 86.06% 85.76% 85.52% 85.26% 10/26 Power Mate Technology Data Sheet August 2001 c. Efficiency with line change under different ambient temperature at full load FDC10-48S05 84.00% Low 82.00% Nomial 80.00% 78.00% High -25 25 71 Low 82.04% 82.94% 82.94% Nomial 81.97% 82.94% 83.23% High 80.61% 82.11% 82.32% Degree C FDC10-48S15 87.50% 87.00% 86.50% 86.00% 85.50% Low 85.00% Nomial 84.50% High 84.00% 83.50% 83.00% 82.50% -25 25 71 Low 87.17% 87.24% 86.35% Nomial 86.36% 86.84% 85.86% High 84.61% 85.53% 84.32% Degree C 11/26 Power Mate Technology Data Sheet August 2001 Power Dissipation curve FDC10-48S05 2.50 2.00 36Vin Pd(W) 1.50 48Vin 1.00 72Vin 0.50 - 200 400 600 800 1000 1200 1400 1600 1800 2000 Iout(mA) Pd(W) FDC10-48S15 1.80 1.60 1.40 1.20 1.00 0.80 0.60 0.40 0.20 - 36Vin 48Vin 72Vin 67 134 201 268 335 402 469 536 603 670 Iout(mA) FDC10-48S33 2.50 36Vin Pd(W) 2.00 1.50 48Vin 1.00 75Vin 0.50 - 200 400 600 800 1000 1200 1400 1600 1800 2000 Iout(mA) 12/26 Power Mate Technology Data Sheet August 2001 Output ripple & noise Test condition: Normal Input line and full load. FDC10-48S05 FDC10-48S15 FDC10-48S33 13/26 Power Mate Technology Data Sheet August 2001 14/26 Power Mate Technology Data Sheet August 2001 Transient response Test condition: Normal Input line and full load. FDC10-48S05 FDC10-48S15 FDC10-48S33 15/26 Power Mate Technology Data Sheet August 2001 Transient Peak Test condition: Normal Input line and full load. FDC10-48S05 FDC10-48S15 FDC10-48S33 16/26 Data Sheet August 2001 Inrush current Test condition: Normal Input line and full load. Power Mate Technology FDC10-48S05 0.1A/DIV Inrush Current: (31.8/10) * 0.1A = 318mA 17/26 Power Mate Technology Data Sheet August 2001 FDC10-48S15 0.1A/DIV Inrush Current: (33.8/10) * 0.1A = 338mA 18/26 Power Mate Technology Data Sheet August 2001 FDC10-48S33 0.1A/DIV Inrush Current: (25.8/10) * 0.1A = 258mA 19/26 Power Mate Technology Data Sheet August 2001 Input ripple current Test condition: Normal Input line and full load. FDC10-48S05 5mA/DIV Input Ripple Current : (22.6/10) *5 = 11.3mA FDC10-48S15 5mA/DIV Input Ripple Current : (46.8/10) *5 = 23.4mA FDC10-48S33 5mA/DIV Input Ripple Current : (30.6/10) *5 = 15.3mA 20/26 Data Sheet August 2001 Raise time (Start up time) Test condition: Normal Input line and full load. FDC10-48S05 320uS FDC10-48S15 980uS FDC10-48S33 240uS 21/26 Power Mate Technology Power Mate Technology Data Sheet August 2001 Testing Configurations Input reflected-ripple current Measurement Test up To Oscilloscope ● Current Probe ● ● 12uH Vi(+) DC/DC Converter Battery ● Vi(-) . Peak-to-peak output ripple & noise Measurement Test up O.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 22/26 Power Mate Technology Data Sheet August 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 Please contact with for more detailed information. 23/26 L—N 1kV 2 Power Mate Technology Data Sheet August 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. ＋ ○＋ ○ ○ ○－ －○ × 24/26 Power Mate Technology Data Sheet August 2001 Mechanical Data Dimensions are in millimeters and (inches) Tolerances: x.xx in. ± 0.02 in. (x.x mm ± 0.5mm) x.xxx in. ± 0.015 in. (x.xx mm ± 0.4mm) ** Pin Pitch tolerance ± 0.014(0.35) Top View DIA. 0.04(1.0) 0.40(10.2) 0.80(20.3) Side View 0.22(5.6) Bottom View 1.00(25.4) 0.50 (12.7) 0.40 (10.2) 0.40 4 5 0.80(20.3) 3 Bottom View 1 2 6 0.60(15.2) 2.00(50.8) PIN CONNECTION 0.10(2.5) 0.20(5.1) 25/26 PIN SINGLE OUTPUT 1 2 3 4 5 6 + INPUT - INPUT + OUTPUT NO PIN - OUTPUT CTRL (Option) Power Mate Technology Data Sheet August 2001 Safety and Installation Instruction Isolation consideration The FDC10 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 slow-blow fuse with maximum rating of 3A. 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 10% (of full load) minimum load required. The 10% minimum load requirement is in order to meet all performance specifications. The FDC10 Series does not properly maintain regulation and operate with no load condition. The output voltage drops off by about 10%. MTBF and Reliability The MTBF of FDC10-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 5.342 × 105 hours. 2. Bell-core TR-NWT-000332 Case I: 50% stress, Operating Temperature at 40 ℃ (Ground fixed and controlled environment) The resulting figure for MTBF is 1.976 × 106 hours. 26/26