JFCW48D24-30 30 Watt DC/DC Power Converter Rev A Wall Industries, Inc. FEATURES • High Efficiency up to 92% • 4:1 Wide Input Voltage Range: 18-75 VDC • ±24VDC Dual Output • 1600VDC I/O Isolation • Remote ON/OFF Control • Short Circuit, Over Voltage, Over Current, & Over Temp. Protection • Six-Sided Continuous Shielding • Wide Operating Temperature Range: -40°C to +100°C • Ultra Low Quiescent Current • Compliant to RoHS EU Directive 2011/65/EU • No Minimum Load Requirements • UL60950-1, EN60950-1, & IEC60950-1 Safety Approvals • 30 Watts Maximum Output Power • Optional Heatsink Available (Suffix “HC”) DESCRIPTION Size: 1.00 x 1.00 x 0.39 inches 25.4 x 25.4 x 9.9 mm Weight: 0.58oz (16.5g) Options: • Negative Logic Remote ON/OFF • Without CTRL Pin • Heatsink The JFCW48D24-30 is a DC/DC power converter that provides 30 Watts of output power in an industry standard 1.00” x 1.00” x 0.39” package and footprint. This model has a ±24VDC dual output and a 4:1 wide input voltage ranges of 18-75VDC. Some features include high efficiency up to 92%, 1600VDC I/O isolation, sixsided shielding, and remote ON/OFF control. This converter is also protected against short circuit, over load, over voltage, and over temperature conditions. The JFCW48D24-30 is RoHS compliant and has UL60950-1, EN60950-1, and IEC60950-1 safety approvals. This converter is best suited for use in wireless networks, industry control systems, telecom/datacom, and semiconductor equipment. TECHNICAL SPECIFICATIONS MODEL NO.: JFCW48D24-30 All specifications are based on 25°C, Nominal Input Voltage, and Maximum Output Current unless otherwise noted. We reserve the right to change specifications based on technological advances. SPECIFICATION TEST CONDITIONS Min Typ Max Unit 18 48 75 100 VDC INPUT SPECIFICATIONS Continuous 1 sec max. Transient Input Standby Current Nominal Vin and no load Turn-on Threshold Under Voltage Lockout Turn-off threshold Input Reflected Ripple Current (see page 9) 5 to 20MHz, 12µH source impedance Input Current No Load Input Filter OUTPUT SPECIFICATIONS Output Voltage Nominal Vin, full load, Ta=25°C Line Regulation Low line to high line at full load No load to full load Load Regulation 10% load to 90% load Cross Regulation Asymmetrical load 25% / 100% FL Output Voltage Overshoot Minimum Vin to maximum Vin, full load, Ta=25°C Output Power Output Current Minimum Load Maximum Capacitive Load Minimum input and constant resistive load Ripple & Noise (see page 9) 20MHz BW; with 4.7µF/50V X7R 1812 MLCC for each output Power Up Start-Up Time Nominal Vin and constant resistive load Remote ON/OFF Temperature Coefficient REMOTE ON/OFF (See page 8) DC/DC ON Positive Logic (standard) The Ctrl pin voltage is referenced to –Input pin DC/DC OFF DC/DC ON Negative Logic (optional) The Ctrl pin voltage is referenced to –Input pin DC/DC OFF Input Current of Remote Control Pin Nominal Vin Remote OFF State Input Current Nominal Vin DYNAMIC RESPONSE Peak Deviation Nominal Vin, Ta=25°C, Load Step change from 75% to 100% or 100% to 75% Setting Time (Vout < 10% peak deviation) Nominal Vin, Ta=25°C, Load Step change from 75% to 100% or 100% to 75% Input Voltage Range 05/20/2014 10 mA 18 VDC 16 30 10 mAp-p mA Pi type ±23.76 -0.5 -1.0 -0.8 -5.0 ±24 ±24.24 +0.5 +1.0 +0.8 +5.0 5 30 ±625 0 75 -0.02 -0.5 ±180 100 30 30 +0.02 Open or 3V ~ 15 VDC Short or 0 ~ 1.2 VDC Short or 0 ~ 1.2 VDC Open or 3V ~ 15 VDC 1.0 2.0 3 250 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] VDC % % % % %Vout W mA % µF mVp-p ms %/°C mA mA % of Vo µs Page 1 of 13 JFCW48D24-30 30 Watt DC/DC Power Converter Rev A Wall Industries, Inc. TECHNICAL SPECIFICATIONS MODEL NO.: JFCW48D24-30 All specifications are based on 25°C, Nominal Input Voltage, and Maximum Output Current unless otherwise noted. We reserve the right to change specifications based on technological advances. SPECIFICATION TEST CONDITIONS PROTECTION Short Circuit Protection (see page 7) Over Current Protection (see page 7) Over Voltage Protection (See page 7) Over Temperature Protection GENERAL SPECIFICATIONS Efficiency Switching Frequency Min Typ Max continuous, automatic recovery 170 % of FL 58.5 64.5 VDC +115 °C Zener diode clamp Nominal Vin, full load, Ta=25°C Input to Output Input to Case Output to Case Isolation Voltage 1 minute Isolation Resistance Isolation Capacitance ENVIRONMENTAL SPECIFICATIONS 500VDC Operating Ambient Temperature Vertical direction by natural convection (20LFM) 92 330 297 1600 1000 1000 1 VDC Without derating With derating -40 +50 GΩ pF +50 +100 +105 +125 -55 Without Heatsink With Heatsink Natural Convection (20LFM) Relative Humidity Thermal Shock Vibration MTBF PHYSICAL SPECIFICATIONS Weight Dimensions (L x W x H) Case Material Base Material Potting Material Shielding SAFETY & EMC CHARACTERISTICS Safety Approvals EMI (See page 11) % kHz 363 1500 Maximum Case Temperature Storage Temperature Thermal Impedance Unit °C °C °C 15.0 13.8 5 MIL-HDBK-217F, Tc=70°C, full load °C/W 95 MIL-STD-810F MIL-STD-810F 1,259,000 hours % RH 0.58oz (16.5g) 1.00x1.00x0.39 inch (25.4x25.4x9.9 mm) Copper FR4 PCB Silicon (UL94-V0) Six-sided IEC60950-1, UL60950-1, EN60950-1 Class A, Class B EN55022 ESD EN61000-4-2 Radiated Immunity Fast Transient (See page 12) Surge (See page 12) Conducted Immunity EN61000-4-3 EN61000-4-4 EN61000-4-5 EN61000-4-6 Air ±8kV Contact ±6kV 10 V/m ±2kV ±2kV 10 Vrms Perf. Criteria A Perf. Criteria A Perf. Criteria A Perf. Criteria A Perf. Criteria A CONDUCTED EMISSIONS Conducted Emissions of EN55022 Class A 100 Conducted Emissions of EN55022 Class B Level (dbuv) 100 90 90 80 cispr class-a cispr class-b 80 70 70 -13dB 60 50 40 40 30 30 20 20 10 10 0.15 0.2 0.5 1 2 Frequency (MHz) 5 Nominal Vin and full load 05/20/2014 10 20 30 -10dB 60 50 0 Level (dbuv) 0 0.15 0.2 0.5 1 2 Frequency (MHz) 5 10 20 30 Nominal Vin and full load Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 2 of 13 JFCW48D24-30 30 Watt DC/DC Power Converter Rev A Wall Industries, Inc. DERATING CURVES Derating Curve with Heatsink 120 120 100 100 Output Power (%) Output Power (%) Derating Curve 80 60 40 Natural Convection 100LFM 200LFM 300LFM 400LFM 500LFM 20 0 -40 80 60 40 Natural Convection 100LFM 200LFM 300LFM 400LFM 500LFM 20 0 -20 0 20 40 60 80 100 -40 120 -20 0 20 40 60 80 100 120 Ambient Temperature (°C) Ambient Temperature (°C) CHARACTERISTIC CURVES Efficiency vs Input Voltage 96 96 89 89 Efficiency (%) Efficiency (%) Efficiency vs Output Current 82 75 68 Vin=18V Vin=24V Vin=48V Vin=75V 61 82 75 68 61 54 54 10 20 30 40 50 60 70 80 90 100 18 24 30 36 42 48 54 60 66 72 75 Input Voltage (VDC) % of Full Load Power Dissipation vs Output Current Power Dissipation (W) 6 5 4 3 2 Vin=18V Vin=24V Vin=48V Vin=75V 1 0 10 20 30 40 50 60 70 80 90 100 % of Full Load 05/20/2014 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 3 of 13 Wall Industries, Inc. Rev A JFCW48D24-30 30 Watt DC/DC Power Converter CHARACTERISTIC CURVES Typical Output Ripple & Noise Transient Response to Dynamic Load Change from 100% to 75% to 100% of Full load nominal Vin and full load nominal Vin and full load Typical Input Start-up and Output Rise Characteristics Using ON/OFF Voltage Start-up and Output Rise Characteristics nominal Vin and full load nominal Vin and full load 05/20/2014 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 4 of 13 Rev A Wall Industries, Inc. JFCW48D24-30 30 Watt DC/DC Power Converter MECHANICAL DRAWING HEATSINK OPTIONS Heatsink + Clamp (Suffix “HC”) Unit: inches (mm) 05/20/2014 Heatsink (Suffix “H”) Unit: inches (mm) Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 5 of 13 Rev A Wall Industries, Inc. JFCW48D24-30 30 Watt DC/DC Power Converter RECOMMENDED PAD LAYOUT SOLDERING & REFLOW CONSIDERATIONS Lead-free wave solder profile for JFCW30 seies DIP type. T1 + T2 260°C MAX Temperature (°C) 300 First Wave 250 Second Wave Hand Welding: Soldering Iron: Power 150W Welding Time: 2~4 sec Temp.: 380~400°C 200 Preheat Zone 150 Reference Solder: Sn-Ag-Cu, Sn-Cu 100 50 0 0 100 200 Time (sec) Zone Preheat Zone Actual Heating 05/20/2014 Reference Parameter Rise Temp. speed: 3°C / sec max. Preheat Temp: 100~130°C Rise Temp.: 250~260°C Preheat Temp (T1+T2 time): 4~6 sec Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 6 of 13 JFCW48D24-30 30 Watt DC/DC Power Converter Rev A Wall Industries, Inc. DESIGN CONSIDERATIONS Output Over Current Protection When excessive output current occurs in the system, circuit protection is required on all power supplies. Normally, over load current is maintained at approximately 170% of rated current for the JFCW30 series. 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 condition is removed. There are other ways of protecting the power supply when it is over-loaded, such as the maximum current limiting or current fold-back methods. One of the problems resulting from over current is that excessive heat may be generated in the 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 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. (1) One can start hiccup operation at any time an over-current event is detected, (2) or prohibit hiccup during a designated start-up which is usually larger than during normal operation and it is easier for an over-current event to be detected, (3) or prohibit hiccup during a designated start-up interval (usually a few milliseconds). The reason for the (3) 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. Output Over Voltage Protection The output over voltage protection consists of a Zener diode that monitors the output voltage on the feedback loop. If the voltage on the output terminals exceeds the over voltage protection threshold, then the Zener diode will send a current signal to the control IC to limit the output voltage. Input Source Impedance The power module should be connected to a low impedance input source. Highly inductive source impedance can affect the stability of the power module. Input external Pi filter is recommended to minimize input reflected ripple current. The inductor is simulated source impedance of 12μH and capacitor is Nippon chemi-con KZE series 10μF/100V and 10μF/100V. The capacitor must be placed as close as possible to the input terminals of the power module for lower impedance. Short Circuit Protection Continuous, auto-recovery mode. During a short circuit the converter will shut down. The average current during this condition will be very low and the device can be handled safely in this condition. Thermal Considerations 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 point shown in the figure below. The temperature at this location should not exceed 105°C. When operating, adequate cooling must be provided to maintain the test point temperature at or below 105°C. Although the maximum point temperature of the power modules is 105°C, you can limit this temperature to a lower value for extremely high reliability. 0.50 [12.7] Unit: inches [mm] 0.50 [12.7] 05/20/2014 Temp. Test Point Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 7 of 13 Rev A Wall Industries, Inc. JFCW48D24-30 30 Watt DC/DC Power Converter REMOTE ON/OFF CONTROL The CTRL pin allows the user to turn the DC/DC power module on and off from a remote switch device. The ON/OFF input can be switched by a number of switching devices. Figure 2 gives several examples of acceptable configurations. The remote ON/OFF switch is activated by the voltage difference between the ON/OFF pin and the –Vin pin (with –Vin as the reference voltage). The user-supplied switch must be capable of sinking up to 1mA of current at low-level logic voltage. The leakage current of the user-supplied switch must be 50µA or less at 15Vdc. There are two remote control options available: Positive Logic and Negative Logic a. The positive logic structure turns the converter ON when the CTRL pin is at high-level logic and turns the converter OFF when the CTRL pin is at low-level logic. Converter Turned ON at High-Level Logic Converter Turned OFF at Low-Level logic b. The negative logic structure turns the converter ON when the CTRL pin is at low-level logic and turns the converter OFF when the CTRL pin is at high-level logic. Converter Turned ON at Low-Level Logic Converter Turned OFF at High-Level logic Remote ON/OFF Implementation Isolated Closure Remote ON/OFF 05/20/2014 Level Control Using TTL Output Level Control Using Line Voltage Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 8 of 13 JFCW48D24-30 30 Watt DC/DC Power Converter Rev A Wall Industries, Inc. TEST SETUP Input Reflected-Ripple Current Measurement Test Setup Component Value Voltage L1 12µH - - 100V Aluminum Electrolytic Capacitor C1, C2 10µF Reference Peak-to-Peak Output Ripple & Noise Measurement Test Setup 05/20/2014 Correct Method Incorrect Method Probe contacts to the pins directly Ground ring is connected to the pin by a wire that induces noise Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 9 of 13 Rev A Wall Industries, Inc. JFCW48D24-30 30 Watt DC/DC Power Converter TEST SETUP Output Voltage and Efficiency Measurement Setup Voltage meters should be connected to the input or output terminals directly; otherwise, voltage drop of contact and distribution losses can cause the measurements to be incorrect. Output Voltage Accuracy = Line Regulation = Max. Load Regulation = Cross Regulation = Efficiency = 05/20/2014 Vout – Vout,typ. x 100% Vout,typ. Vout(Low-Line) – Vout(Nom.-Line) Vout(High-Line) – Vout(Nom.-Line) x 100%, x 100% Vout(Nom.-Line) Vout(Nom.-Line) Vout(Min. Load) – Vout(Full Load) x 100% Vout(Full load) Vout1(25% of Full Load) – Vout1(Full Load) x 100%; Vout2(25% of Full Load) Vout1(Full load) Max.1 Vout1(25% of Full Load) – Vout1(Full Load) x 100%; Vout2(Full Load) Vout1(Full load) Vout2(25% of Full Load) – Vout2(Full Load) x 100%; Vout1(25% of Full Load) Vout2(Full load) Max.2 Vout2(25% of Full Load) – Vout2(Full Load) x 100%; Vout1(Full Load) Vout2(Full load) Vout x Iout x 100% Vin x Iin Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 10 of 13 JFCW48D24-30 30 Watt DC/DC Power Converter Rev A Wall Industries, Inc. EMI CONSIDERATIONS Recommended Filter for EN55022 Class A Compliance Recommended Filter for EN55022 Class B Compliance C5 L1 L1 +Vin +INPUT +Vout +Vin +INPUT +Vout LOAD C1 LOAD C1 DC/DC Com CONVERTER C2 C3 DC/DC Com CONVERTER LOAD -Vin -INPUT LOAD -Vout -Vin -INPUT -Vout C4 Model JFCW48D24-30 C1 L1 4.7µF/100V 1812 MLCC 10µH SMD Inductor PMT-070 Model JFCW48D24-30 Recommended EN55022 Class A Filter Circuit Layout C1, C2, C3 4.7µF/100V 1812 MLCC C4, C5 L1 2200pF/2kV 1206 MLCC 10µF SMD Inductor PMT-070 Recommended EN55022 Class B Filter Circuit Layout Common Mode Chokes PMT-070 7.0±0.3 Inductance: 10µH±20% PMT-097 Unit: mm Inductance: 2.2µH±20% Rated Current: 2.6A Rated Current: 11A 2.1 ref. 7.8±0.3 Impedance: 12mΩ 4.2 max. Impedance: 40mΩ Unit: mm 7.6 max. 6.5±0.3 2.5 1.6±0.3 1.2±0.3 3.00 2.00 3.00 5.0±0.5 PCB PATTERN 6.5±0.3 PCB PATTERN 3.00 8.5 7.50 05/20/2014 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 11 of 13 JFCW48D24-30 30 Watt DC/DC Power Converter Rev A Wall Industries, Inc. EMS CONSIDERATIONS The JFCW30 series can meet Fast Transient EN61000-4-4 and Surge EN61000-4-5 performance criteria A with external components connected to the input terminals of the module. Please see the schematic below. Surge Fast Transient Component Value Voltage Reference Component Value Voltage Reference C1 220µF 100V Nippon chemi-con KY series C1 220µF 100V Nippon chemi-con KY series PACKAGING INFORMATION Tube Tray & Box 05/20/2014 Model Type Packing Material Quantity Without Heatsink Tube 10 PCS / TUBE With Heatsink Tray 20 PCS / TRAY Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 12 of 13 JFCW48D24-30 30 Watt DC/DC Power Converter Rev A Wall Industries, Inc. SAFETY & INSTALLATION INSTRUCTIONS 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 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 3A for JFCW48D24-30 modules. 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. MODEL NUMBER SETUP JFCW 48 D 24 Series Name Input Voltage Output Quantity 24: 9-36 VDC D: Dual Output 48: 18-75 VDC - 30 R H Ouptut Voltage Output Power Remote ON/OFF, CTRL Pins Heatsink 12: ±12 VDC 30: 30 Watts None: Positive Logic 15: ±15 VDC R: Negative Logic 24: ±24 VDC D: Without CTRL Pin None: No Heatsink H: Heatsink HC: Heatsink + Clamp COMPANY INFORMATION Wall Industries, Inc. has created custom and modified units for over 50 years. Our in-house research and development engineers will provide a solution that exceeds your performance requirements on-time and on budget. Our ISO9001-2008 certification is just one example of our commitment to producing a high quality, well-documented product for our customers. Our past projects demonstrate our commitment to you, our customer. Wall Industries, Inc. has a reputation for working closely with its customers to ensure each solution meets or exceeds form, fit and function requirements. We will continue to provide ongoing support for your project above and beyond the design and production phases. Give us a call today to discuss your future projects. Contact Wall Industries for further information: Phone: Toll Free: Fax: E-mail: Web: Address: 05/20/2014 (603)778-2300 (888)597-9255 (603)778-9797 [email protected] www.wallindustries.com 37 Industrial Drive Exeter, NH 03833 Wall Industries, Inc. • 37 Industrial Drive, Exeter, NH 03833 • Tel: 603-778-2300 • Toll Free: 888-597-9255 • Fax 603-778-9797 website: www.wallindustries.com • e-mail: [email protected] Page 13 of 13