TECHNICAL DATASHEET Rev. B JF48S3.3-3500 36-75VDC Wide Input Voltage Range 3.3VDC Output at 3.5A DIP and SMT Type Packages 11.55W Open Frame DC/DC Power Converter FEATURES 11.55 Watts Maximum Output Power 3.3VDC Single Output Cost Efficient Open Frame Design Small Size and Low Profile: 1.10” x 0.94” x 0.34” 85% High Efficiency 36-75VDC Input Voltage Range Fixed Switching Frequency Input to Output Isolation: 2250VDC APPLICATIONS Wireless Networks Telecom / Datacom Industry Control Systems Measurement Equipment Semiconductor Equipment Distributed Power Architectures OPTIONS SMT Type Without Trim Pin Without ON/OFF Pin Negative Logic Remote ON/OFF No Minimum Load Requirement Output Voltage Adjustability Industry Standard Pin-out Negative or Positive Remote ON/OFF Control Short Circuit, Over Current, Over Voltage, and Input Under Voltage Protection Surface Mount and Through Hole Types Available SMT Package Qualified for Lead-free Reflow Solder Process According to IPC J-STD-020D Compliant to RoHS EU Directive 2002/95/EC CE Mark Meets 2006/95/EC, 93/68/EEC, and 2004/108/EC UL60950-1, EN60950-1, and IEC60950-1 Licensed DESCRIPTION The JF48S3.3-3500 DC/DC power converter provides 11.55 Watts of output power in a low profile industry standard package and footprint. This converter has a 3.3VDC single output and operate over a 2:1 input voltage range of 36-75VDC. The JF48S3.3-3500 is also protected against short circuit, over current, over voltage, and input under voltage conditions. Some features include 85% high efficiency, adjustable output voltage, and positive or negative remote ON/OFF control. This converter is RoHS compliant and has UL60950-1, EN60950-1, and IEC60950-1 safety approvals. Both surface mount (“S” suffix) and DIP (standard) packages are available. (888) 597-WALL www.wallindustries.com 1 of 18 Rev B TECHNICAL SPECIFICATIONS TECHNICAL DATASHEET JF48S3.3-3500 Model No. JF48S3.3-3500 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 INPUT SPECIFICATIONS Input Voltage Range 36 48 75 VDC Input Current Nominal input and full load 297 mA Input Standby Current Nominal input and no load 15 mA Input Surge Voltage (100ms) 100 VDC UVLO Turn-On Threshold 36 VDC UVLO Turn-Off Threshold 30.5 VDC Power Up 12 30 Start-Up Time Nominal input and constant resistive load ms Remote ON/OFF 12 30 Input Reflected Ripple Current (See Page 10) 30 mAp-p OUTPUT SPECIFICATIONS Output Voltage Nominal input, full load, and 25°C 3.267 3.3 3.333 VDC Line Regulation Low line to high line at full load -0.2 +0.2 % Load Regulation No load to full load -0.2 +0.2 % Voltage Adjustability (See Page 7) -10 +10 % Output Power 11.55 W Output Current 3.5 A Output Capacitor Load 10000 µF Ripple & Noise (See Page 10) Measured with a 1µF M/C and a 10µF T/C at 20MHz BW 75 100 mVp-p Output Voltage Overshoot Low line to high line at full load and 25°C 3 %Vout Minimum Load 0 % Transient Response Recovery Time 50% to 75% to 50% load change, ΔIo/Δt=0.1A/µs 300 µs Temperature Coefficient -0.02 +0.02 %/°C REMOTE ON/OFF (See Page 5) DC/DC ON (Open) 3 15 Positive Logic (standard) The ON/OFF pin is referenced to -Input VDC DC/DC OFF (Short) 0 1.2 DC/DC ON (Short) 0 1.2 Negative Logic (optional) The ON/OFF pin is referenced to -Input VDC DC/DC OFF (Open) 3 15 Input Current of Remote Control Pin Nominal Input -0.5 1 mA Remote Off State Input Current Nominal Input 20 mA PROTECTION Over Voltage Protection Voltage clamped 3.7 5.4 VDC Over Current Protection % of FL at nominal input 3.85 4.375 5.25 A Short Circuit Protection Hiccup, automatic recovery GENERAL SPECIFICATIONS Efficiency Nominal input and full load 85 % Switching Frequency Nominal input and full load 243 270 297 KHz Isolation Voltage (Input to Output) For 1 minute 2250 VDC Isolation Resistance 10 MΩ Isolation Capacitance 1000 pF ENVIRONMENTAL SPECIFICATIONS Operating Ambient Temperature (See Note 1) With derating -40 +85 °C Storage Temperature -55 +125 °C Relative Humidity 5 95 % RH Thermal Shock MIL-STD-810F Vibration MIL-STD-810F Lead-Free Reflow Solder Process IPC J-STD-020D Moisture Sensitivity Level (MSL) IPC J-STD-033B Level 2a BELLCORE TR-NWT-000332, Tc=40°C 2,200,000 hours MTBF (See Page 17) MIL-HDBK-217F 1,314,000 hours PHYSICAL SPECIFICATIONS Weight 0.36oz (10.5g) Dimensions (L x W x H) 1.10 x 0.94 x 0.34 inches (27.9 x 23.9 x 8.5 mm) SAFETY & EMI CHARACTERISTICS Safety Approvals IEC60950-1, UL60950-1, EN60950-1 EMI (See Page 11) EN55022 Class A Radiated Immunity EN61000-4-3 10 V/m Perf. Criteria A Fast Transient (See Note 2) EN61000-4-4 ±2KV Perf. Criteria B Surge (See Note 2) EN61000-4-5 ±1KV Perf. Criteria A Conducted Immunity EN61000-4-6 10 Vrms Perf. Criteria A Notes 1. The power module can operate in a variety of thermal environments; however, sufficient cooling should be provided to help ensure reliable operation. 2. An external input filter capacitor is required if the module has to meet EN61000-4-4 and EN61000-4-5. The filter capacitor suggested is Nippon Chemi-con KY series 220µF/100V, ESR 48mΩ. (888) 597-WALL www.wallindustries.com Page 2 of 18 Rev B TECHNICAL DATASHEET JF48S3.3-3500 MECHANICAL DRAWING DIP TYPE (Standard) SMT TYPE (Suffix “S”) 1. Unit: inches (mm) 2. Tolerance: X.XX±0.02 (X.X±0.5) X.XXX±0.01 (X.XX±0.25) 3. Pin pitch tolerance: ±0.01 (±0.25) 4. Pin dimension tolerance: ±0.004 (±0.1) PIN CONNECTIONS ETERNAL OUTPUT TRIMMING Output can be externally trimmed by using the method shown below. TRIM UP TRIM DOWN 5 6 RU 5 (888) 597-WALL RD 4 PIN JF SERIES 1 +INPUT 2 -INPUT 3 CTRL 4 +OUTPUT 5 TRIM 6 -OUTPUT PRODUCT OPTIONS Option Positive Remote ON/OFF with DIP (standard) Positive remote ON/OFF with SMT Negative Remote ON/OFF with DIP Negative Remote ON/OFF with SMT DIP type without ON/OFF pin SMT type without ON/OFF pin DIP type without ON/OFF & TRIM pin SMT type without ON/OFF & TRIM pin DIP type, negative remote ON/OFF, without TRIM pin SMT type, negative remote ON/OFF, without TRIM pin DIP type, positive remote ON/OFF, without TRIM pin SMT type, positive remote ON/OFF, without TRIM pin www.wallindustries.com Suffix No Suffix S R SR D SD G SG F SF J SJ Page 3 of 18 Rev B TECHNICAL DATASHEET JF48S3.3-3500 DESIGN CONSIDERATIONS Output Over Current Protection When excessive output currents occur in the system, circuit protection is required on all power supplies. Normally, over load current is maintained at approximately 110~140% of rated current for the JF 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 maximum current limiting and current foldback 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. Hiccup operates in the following way. 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. One can start hiccup operation any time an over current event is detected, 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, or one can 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; therefore, 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 C-L-C 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 220μF/100V and 33μF/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, hiccup and 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. (888) 597-WALL www.wallindustries.com Page 4 of 18 Rev B TECHNICAL DATASHEET JF48S3.3-3500 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 point shown in the figure below. The temperature at this location should not exceed 120°C. When operating, adequate cooling must be provided to maintain the test point temperature at or below 120°C. Although the maximum point temperature of the power modules is 120°C, you can limit this temperature to a lower value for extremely high reliability. TOP VIEW Figure 1 Temperature Measurement Point Remote ON/OFF Control The remote ON/OFF 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 0.5mA or less at 15Vdc. (888) 597-WALL www.wallindustries.com Page 5 of 18 Rev B TECHNICAL DATASHEET JF48S3.3-3500 Remote ON/OFF Implementation Circuits Figure 2 Isolated-Closure Remote ON/OFF Level Control Using TTL Output Level Control Using Line Voltage There are two remote control options available: Positive logic and Negative logic a. The positive logic structure turned the DC/DC module ON when the ON/OFF pin is at high-level logic and turned the DC/DC module OFF when the ON/OFF pin is at low-level logic. Figure 3 When JF module is turned OFF at Low-level logic When JF module is turned ON at High-level logic b. The negative logic structure turned the DC/DC module ON when the ON/OFF pin is at low-level logic and turned the DC/DC module OFF when the ON/OFF pin is at high-level logic. Figure 4 When JF module is turned ON at Low-level logic (888) 597-WALL When JF module is turned OFF at High-level logic www.wallindustries.com Page 6 of 18 TECHNICAL DATASHEET Rev B JF48S3.3-3500 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 +Vout or -Vout pins. With an external resistor between the TRIM and +Vout pin, the output voltage set point decreases. With an external resistor between the TRIM and -Vout pin, the output voltage set point increases. The external TRIM resistor needs to be at least 1/16W. 5110 2.5 2050 Rup (Vout , up 2.5 0.8) (Vout , down 2.5) 5110 2050 Rdown (Vout Vout , down) Vout,up is the desired up output voltage Vout,down is the desired down output voltage Trim Resistor Values Figure 5 -OUTPUT Rup -INPUT TRIM +INPUT Rdown +OUTPUT (888) 597-WALL Trim Vout,up Rup Vout,down Rdown 1% 2% 3% 4% 5% 6% 7% 8% 9% 10% 3.333V 3.366V 3.399V 3.432V 3.465V 3.498V 3.531V 3.564V 3.597V 3.630V 385.071 kΩ 191.511 kΩ 126.99 kΩ 94.73 kΩ 75.374 kΩ 62.47 kΩ 53.253 kΩ 46.34 kΩ 40.963 kΩ 36.662 kΩ 3.267V 3.234V 3.201V 3.168V 3.135V 3.102V 3.069V 3.036V 3.003V 2.97V 116.719 kΩ 54.779 kΩ 34.133 kΩ 23.810 kΩ 17.616 kΩ 13.486 kΩ 10.537 kΩ 8.325 kΩ 6.604 kΩ 5.228 kΩ www.wallindustries.com Page 7 of 18 TECHNICAL DATASHEET Rev B Graph 1: Efficiency vs. Output Current JF48S3.3-3500 Graph 2: Efficiency vs. Input Voltage (Full Load) 86 85.5 85 84.5 84 83.5 83 82.5 82 36 40 44 48 52 56 60 64 68 75 Graph 3: Output Current vs. Ambient Temperature & Airflow (Nominal Vin) Graph 4: Typical Output Ripple and Noise (Nominal Vin and Full Load) Graph 5: Typical Input Start-Up and Output Rise Characteristic (Nominal Vin and Full Load) Graph 6: Using ON/OFF Voltage Start-Up and Output Rise Characteristic (Nominal Vin and Full Load) (888) 597-WALL www.wallindustries.com Page 8 of 18 TECHNICAL DATASHEET Rev B Graph 7: Transient Response to Dynamic Load Change from 75% to 50% to 75% of Full Load (888) 597-WALL JF48S3.3-3500 Graph 8: Conducted Emission of EN55022 Class B (Nominal Vin and Full Load) www.wallindustries.com Page 9 of 18 TECHNICAL DATASHEET Rev B JF48S3.3-3500 TEST SETUP: The JF48S3.3-3500 specifications are tested with the following configurations: Input Reflected-Ripple Current Measurement Test Setup Figure 6 Component L C C Value 12μH 220μF 33μF Voltage ---100V 100V Reference ---Aluminum Electrolytic Capacitor Aluminum Electrolytic Capacitor Peak-to-Peak Output Ripple & Noise Measurement Setup Figure 7 Figure 8 Output Voltage and Efficiency Measurement Setup Figure 9 Vout Iout Efficiency 100% Vin Iin NOTE: All measurements are taken at the module terminals (888) 597-WALL www.wallindustries.com Page 10 of 18 TECHNICAL DATASHEET Rev B JF48S3.3-3500 EMI Considerations: Suggested Schematic for EN55022 Conducted Emission Class A Limits C3 L1 +INPUT +Vin +Vout Figure 10 C1 DC/DC CONVERTER -Vin -INPUT Load -Vout C2 To meet conducted emissions EN55022 CLASS A the following components are needed: JF48S3.3-3500 Component Value Voltage L1 18µH ---- C1 C2, C3 2.2µF 470pF 100V 3KV Reference 1.2A 0.15Ω 0504 SMD Inductor P/N: PMT-046 1812 MLCC 1808 MLCC Recommended Layout with Input Filter Figure 11 (888) 597-WALL www.wallindustries.com Page 11 of 18 TECHNICAL DATASHEET Rev B JF48S3.3-3500 EMI Considerations (Continued): Suggested Schematic for EN55022 Conducted Emission Class B Limits C5 L1 L2 +Vin +INPUT C1 Figure 12 C2 C3 +Vout DC/DC CONVERTER -Vin -INPUT LOAD -Vout C4 To meet conducted emissions EN55022 CLASS B the following components are needed: JF48S3.3-3500 Component L1 Value 145µF Voltage ---- L2 18µF ---- C1, C2 C3 C4, C5 2.2µF 2.2µF 470pF 100V 100V 3KV Reference Common Choke, P/N: PMT-051 1.2A 0.15Ω 0504 SMD Inductor P/N: PMT-046 1812 MLCC 1812 MLCC 1808 MLCC Recommended Layout with Input Filter Figure 13 (888) 597-WALL www.wallindustries.com Page 12 of 18 Rev B TECHNICAL DATASHEET JF48S3.3-3500 Recommended Pad Layout for DIP Type Figure 14 Recommended Pad Layout for SMT Type Figure 15 (888) 597-WALL www.wallindustries.com Page 13 of 18 TECHNICAL DATASHEET Rev B JF48S3.3-3500 Soldering and Reflow Considerations: Lead Free Wave Solder Profile for DIP Type Figure 16 Zone Preheat Zone Actual Heating Reference Parameter Rise temp. speed: 3°C/sec max. Preheat temp: 100~130°C Peak temp: 250~260°C Peak time (T1+T2 time): 4~6 sec Lead free reflow profile for SMT type Figure 17 Zone Preheat Zone Actual Heating Cooling Reference Parameter Rise temp. speed: 1~3°C/sec Preheat time: 60~120sec Preheat temp.155~185°C Rise temp. speed: 1~3°C/sec Melting time: 30~60 sec Melting temp: 217°C Peak temp: 240~245°C Peak time: 10 sec max Rise temp. speed: -1~ -5°C/sec NOTES: 1. Reference Solder: Sn-Ag-Cu 2. The curves define the maximum peak reflow temperature permissable to be measured on pin 1 or Vin pin of the DC/DC converter (888) 597-WALL www.wallindustries.com Page 14 of 18 Rev B TECHNICAL DATASHEET JF48S3.3-3500 Cleaning & Drying Considerations: Cleaning a. PWB Cooling Prior to Cleaning: Power modules and their associated application PWB assemblies should not be wash-cleaned after soldering until the power modules have had an opportunity to cool to within the cleaning solution temperature. This will prevent vacuum absorption of the cleaning liquid into the module between the pins and the potting during cooling. b. Cleaning Process In aqueous cleaning, it is preferred to have an in-line cleaner system consisting of several cleaning stages (prewash, wash, rinse, final rinse, and drying). Deion-ized (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. The total time of ultrasonic wave shall be less than 3 minutes. Drying After cleaning, dry converters at 100°C, more than 10 minutes to assure that the moisture and other potential foreign contaminants are driven out. For open power module constructions with magnetic structures (transformers and inductors) that have unspotted windings, a baking process of 100°C for 30 min. is recommended for the assembly to ensure that the moisture and other potential foreign contaminants are driven out from the open windings. The drying section of the cleaner system should be equipped with blowers capable of generating 1000CFM1500CFM 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. Product Post-Wash External Appearance The marking or date-code may fade or disappear after cleaning. This is not a problem on the converter’s characteristics. (888) 597-WALL www.wallindustries.com Page 15 of 18 Rev B TECHNICAL DATASHEET JF48S3.3-3500 Packaging Information: DIP Type Figure 18 SMT Type Figure 19 (888) 597-WALL www.wallindustries.com Page 16 of 18 TECHNICAL DATASHEET Rev B JF48S3.3-3500 Safety and Installation Instructions: Isolation Consideration The JF series features 2250VDC isolation from input to output. The input to output resistance is greater than 10MΩ. If the system using the power module needs to receive safety agency approvals certain rules must be followed in the design of the system using this model. In particular, all of the creepage and clearance requirements of the end-use safety requirements must be observed. These documents include UL60950-1, EN60950-1, 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 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 2A for JF24Sxx-xxxx modules and 1A for JF48Sxxxxxx 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. MTBF and Reliability The MTBF of the JF Series of DC/DC converters has been calculated using Bellcore TR-NWT-000332 Case I: 50% stress, Operating Temperature at 40°C (Ground fixed and controlled environment). The resulting figure for MTBF is 2.2 × 106 hours. MIL-HDBK 217F NOTICE2 FULL LOAD, Operating Temperature at 25°C. The resulting figure for MTBF is 1.3 × 106 hours. Ordering Information Part Number Example: JF 48 S 3.3 – 3500 S Series Designation Maximum Output Current (mA) Nominal Input Voltage Single Output Nominal Output Voltage (888) 597-WALL www.wallindustries.com PRODUCT OPTIONS Option Positive Remote ON/OFF with DIP (standard) Positive remote ON/OFF with SMT Negative Remote ON/OFF with DIP Negative Remote ON/OFF with SMT DIP type without ON/OFF pin SMT type without ON/OFF pin DIP type without ON/OFF & TRIM pin SMT type without ON/OFF & TRIM pin DIP type, negative remote ON/OFF, without TRIM pin SMT type, negative remote ON/OFF, without TRIM pin DIP type, positive remote ON/OFF, without TRIM pin SMT type, positive remote ON/OFF, without TRIM pin Suffix No Suffix S R SR D SD G SG F SF J SJ Page 17 of 18 Rev B TECHNICAL DATASHEET JF48S3.3-3500 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: (888) 597-WALL (603)778-2300 (888)587-9255 (603)778-9797 [email protected] www.wallindustries.com 5 Watson Brook Rd. Exeter, NH 03833 www.wallindustries.com Page 18 of 18