Wall JFW48S5-3000 Dc/dc converter Datasheet

TECHNICAL DATASHEET
JFW48S5-3000
DC/DC Converter
18-75 VDC Input
5 VDC Output at 3A
Features:
UL
TUV
CB
CE MARK
(Pending)
Applications:
•
15 Watts Output Power
•
4:1 Ultra Wide Input Voltage of 9-36 and 18-75VDC
•
Industry Standard Pin-Out
•
High Efficiency Up to 87%
•
Low Profile: 1.10 x 0.94 x 0.335 inches
•
Fixed Switching Frequency
•
RoHS Directive Compliant
•
No Minimum Load
•
Distributed Power Architectures
•
Input to Output Isolation: 2250VDC, min
•
Communication Equipment
•
Input Under-Voltage Protection
•
Computer Equipment
•
Output Over-Voltage Protection
•
Test Equipment
•
Over-Current Protection, Auto-Recovery
•
Output Short Circuit Protection
•
Remote ON/OFF Control
•
Adjustable Output Voltage
•
Surface Mount or Through Hole
•
Cost Efficient Open Frame Design
Options:
•
Positive Remote ON/OFF
•
On/Off Control Function
•
Trim Function
•
Surface Mount
Description:
JFW Series single output DC/DC converters provide up to 15 watts of output power in an industry standard
package and footprint. These units are specifically designed to meet the power needs of low profile. All models
feature with 4:1 ultra wide input voltage of 9-36VDC and 18-75VDC, comprehensively protected against overcurrent, over-voltage and input under-voltage protection conditions, and trimmable output voltage.
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TECHNICAL DATASHEET
JFW48S5-3000
Technical Specifications
Model No. JFW48S5-3000
All specifications are based on 25 oC, Nominal Input Voltage and Maximum Output Current unless otherwise noted.
We reserve the right to change specifications based on technological advances.
SPECIFICATION
Related condition
Min
Nom
Max
Unit
Switching Frequency
Test at nominal Vin and full load
350
kHz
INPUT (Vin)
Operating Voltage Range
18
48
75
Vdc
Input Voltage (Continuous)
75
Vdc
Input Voltage (Transient 100ms)
100
Vdc
UVLO Turn-on Threshold
18
Vdc
UVLO Turn-off Threshold
16
Vdc
Input Standby Current
Nominal Vin and No Load
40
mA
Input Voltage Variation
Complies with EST300 132 part 4.4
5
V/ms
Input Current
Nominal Vin and Full Load
377
mA
5 to 20MHz, 12µH source impedance
Reflected Ripple Current
30
mApk-pk
(See the Test Setup section - pg 9)
Remote Off Input Current
2.5
mA
Input Current of Remote Control Pin
-0.5
1.0
mA
Test at nominal Vin and full load
87
%
EFFICIENCY
(See the Test Setup section – pg 9)
OUTPUT (Vo)
4.95
5.05
Operating Output Range
Nominal Vin and Full Load
5
Vdc
-1%
+1%
4.5
5.5
Voltage Adjustment
See the External Trim Adjustment section (pg 6)
5
Vdc
-10%
+10%
Load Regulation
0% to 100% Full Load
-0.2
+0.2
%
Line Regulation
LL to HL at Full Load
-0.2
+0.2
%
1uF Ceramic & 10uF Tantalum at 20MHz bandwidth
Output Ripple & Noise
100
mVpk-pk
(See the Test Setup section - pg 9)
Output Current
0
3.0
A
Output Voltage Overshoot
LL to HL at Full Load
3
% Vout
Over Voltage Protection
Voltage clamped
5.6
7.0
Vdc
Over Current Protection
150
% FL
Short Circuit Protection
Hiccup, automatic recovery
Test at nominal Vin
DYNAMIC LOAD RESPONSE
Peak Deviation
Load step change from 75 to 100% or 100 to 75 % of FL
300
mV
Setting Time (Vout < 10% peak deviation)
250
µs
The ON/OFF pin voltage is referenced to -Vin
REMOTE ON/OFF
(See the Remote ON/OFF Control section - pg 5)
Negative Logic DC-DC ON (Short)
0
1.2
Vdc
DC-DC OFF (Open)
3
12
Vdc
Positive Logic DC-DC ON (Open)
3
12
Vdc
DC-DC OFF (Short)
0
1.2
Vdc
Test at nominal Vin and constant resistive load
START UP TIME
Power Up
30
ms
Remote ON/OFF
30
ms
ISOLATION
Isolation Voltage (Input-Output)
2250
Vdc
Isolation Resistance
10
GΩ
Isolation Capacitance
1000 pF
ENVIRONMENTAL
o
Operating Ambient Temperature (w/ derating)
-40
+85
C
Storage Temperature
-55
+125 oC
Temperature Coefficient
-0.02
+0.02 % / oC
See the MTBF and Reliability section (pg 15)
MTBF
Bellcore TR-NWT-000332, TC=40°C
1,322,000
hours
MIL-STD-217F
514,700
hours
MECHANICAL
See Figure 1
Weight
10.5
grams
Dimensions
1.10 x 0.94 x 0.335
inches
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TECHNICAL DATASHEET
JFW48S5-3000
Figure 1: Mechanical Dimensions
max
m ax
(0.6)
m in stand-off
height
0.09(2.3)
SMT
SM D TYPE
TYPE
0.03
(0.75)
DIP TYPE
DIP
TYPE
SECTIO N A-A
A
0.02(0.5) max
A
0.02(0.5)
B-B
0.05(1.3)typ
com pliance
m ax
0.30(7.62)
0.94(23.88)
0.4(10.16)
0.80(20.32)
0.50(12.7)
0.07(1.78)
0.94(23.88)
0.4(10.16)
0.80(20.32)
0.50(12.7)
0.30(7.62)
0.07(1.78)
SECTIO N B-B
Table 1
PIN CONNECTION
PIN
JFW48S5-3000
1
+ INPUT
2
- INPUT
3
ON/OFF
4
+VOUT
5
TRIM
6
-VOUT
Figure 2
Table 2
EXTERNAL OUTPUT TRIMMING
PRODUCT STANDARD TABLE
Output can be externally trimmed by using
the method shown below.
6
TRIM
UP
RT1
or
5
TRIM
DOWN
RT2
4
NOTES:
Option
Negative Remote ON/OFF with DIP
Negative Remote ON/OFF with SMT
Positive Remote ON/OFF with DIP
Positive 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 without TRIM pin
SMT type without TRIM pin
Suffix
R
SR
Blank
S
D
SD
G
SG
F
SF
1. All dimensions in inches (mm)
2. Tolerance: x.xx±0.02 (x.x±0.5)
x.xxx±0.010 (x.xx±0.25)
3. Pin pitch tolerance: ±0.014 (0.35)
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TECHNICAL DATASHEET
JFW48S5-3000
DESIGN CONSIDERATIONS:
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 150% of rated current for the JFW 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
is removed.
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.
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 limiting 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&33µF/100V. The capacitor must 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 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.
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 as 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.
Figure 3
TOP VIEW
Temperature Measure Point
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TECHNICAL DATASHEET
JFW48S5-3000
Remote ON/OFF Control
The Remote ON/OFF Pin is controlled DC/DC power module to turn on and off; the user must use a switch to
control the logic voltage high or low level of the pin referenced to Vi (-). The switch can be open collector
transistor, FET and Photo-Couple. The switch must be capable of sinking up to 1mA at low-level logic Voltage.
High-level logic of the ON/OFF signal maximum voltage is allowable leakage current of the switch at 15V is
50uA.
Figure 4
Remote ON/OFF Implementation Circuits
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 on the DC/DC module when the ON/OFF pin is at high-level logic
and low-level logic is turned off it.
Figure 5
When JFW module is turned off at Low-level logic
When JFW module is turned on at High-level logic
b. The Negative logic structure turned on the DC/DC module when the ON/OFF pin is at low-level logic
and turned off when at high-level logic.
Figure 6
When JFW module is turned on at Low-level logic
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TECHNICAL DATASHEET
JFW48S5-3000
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.
Rup =
5110 ∗ 2.5
− 2050 (in Ω)
Vo + − 2.5 − 2.5
Rdown =
Vo+ is the desired up output voltage
(Vo − − 2.5) ∗ 5110
− 2050 (in Ω)
Vout − (Vo − )
Vo- is the desired down output voltage
Table 3 Trim Resistor Values
Figure 7
-Vout
-Vin
+Vin
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RT1
Trim
RT2
+Vout
–
Trim
Vo+
Rup
Vo
Rdown
1%
2%
3%
4%
5%
6%
7%
8%
9%
10%
5.05V
5.1V
5.15V
5.2V
5.25V
5.3V
5.35V
5.4V
5.45V
5.5V
253.45 kΩ
125.7 kΩ
83.117 kΩ
61.825 kΩ
49.05 kΩ
40.533 kΩ
34.450 kΩ
29.888 kΩ
26.339 kΩ
23.5 kΩ
4.95V
4.9V
4.85V
4.8V
4.75V
4.7V
4.65V
4.6V
4.55V
4.5V
248.34 kΩ
120.59 kΩ
78.007 kΩ
56.715 kΩ
43.94 kΩ
35.423 kΩ
29.34 kΩ
24.778 kΩ
21.229 kΩ
18.39 kΩ
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TECHNICAL DATASHEET
JFW48S5-3000
Graph 2: Efficiency vs. Input Voltage (Full Load)
Efficiency (%)
Efficiency (%)
Graph 1: Efficiency vs. Output Current
% Of Full Load
Input Voltage (V)
Graph 3: Output Power vs. Ambient Temperature & Airflow
(Nominal Vin)
Output Power (%)
Power Dissipation (W)
Graph 4: Power Dissipation Vs. Output Current
18V
48V
75V
Ambient Temperature, Ta (°C)
% Of Full Load
Graph 5: Conducted Emission of EN55022 Class A
(Nominal Vin and Full Load)
Graph 6: Conducted Emission of EN55022 Class B
(Nominal Vin and Full Load)
Frequency (MHz)
Frequency (MHz)
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TECHNICAL DATASHEET
JFW48S5-3000
Graph 8: Typical Output Ripple and Noise
(Nominal Vin and Full Load)
Output
Voltage
Input
Voltage
Output Voltage
Graph 7: Typical Input Start-Up and Output Rise Characteristic
(Nominal Vin and Full Load)
Graph 10: Transient Response to Dynamic Load Change from
100% to 75% to 100% of Full Load at Nominal Vin
Output
Voltage
ON/ OFF
Voltage
Graph 9: Using ON/OFF Voltage Start-Up and Vo Rise
Characteristic (Nominal Vin and Full Load)
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TECHNICAL DATASHEET
JFW48S5-3000
TEST SETUP:
The JFW48S5-3000 specifications are tested with the following configurations:
Input Reflected-Ripple Current Measurement Test Setup
Figure 8
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 9
Output Voltage and Efficiency Measurement Setup
Figure 10
 Vout × Iout 
Efficiency = 
 × 100%
 Vin × Iin 
NOTE: All measurements are taken at the module terminals
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TECHNICAL DATASHEET
JFW48S5-3000
EMC Considerations
Suggested schematic for EN55022 conducted emission Class A limits
Figure 11
Recommended Layout with Input Filter
Figure 12
To meet conducted emissions EN55022 CLASS A needed the following components:
JFW24Sxx-xxxx
Component
Value
Voltage
Reference
L1
2.2uH
----
2.3A 0.025Ω 0504 SMD Inductor
P/N: PMT-059
C1
2.2uF
50V
1812 MLCC
C2, C3
470pF
3KV
1808 MLCC
JFW48Sxx-xxxx
Component
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Value
Voltage
Reference
L1
10uH
----
C1
2.2uF
100V
1812 MLCC
C2, C3
470pF
3KV
1808 MLCC
1.4A 0.1Ω 0504 SMD Inductor
P/N: PMT-047
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TECHNICAL DATASHEET
JFW48S5-3000
EMC Considerations (Continued)
Suggested schematic for EN55022 conducted emission Class B limits
Figure 13
Recommended layout with input filter
Figure 14
To meet conducted emissions EN55022 CLASS B needed the following components:
JFW24Sxx-xxxx
Component
C2, C3
C4
C3, C4
L1
L2
Value
2.2µF
---1000pF
550µH
Voltage
50V
---2KV
----
2.2µH
----
Reference
1812 MLCC
---1808 MLCC
Common Choke, P/N: PMT-058
2.3A 0.025Ω 0504 SMD Inductor
P/N: PMT-059
JFW48Sxx-xxxx
Component
C2, C3
C4
C3, C4
L1
L2
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Value
2.2µF
---1000pF
550µH
Voltage
100V
---2KV
----
10µH
----
Reference
1812 MLCC
---1808 MLCC
Common Choke, P/N: PMT-058
1.4A 0.1Ω 0504 SMD Inductor
P/N: PMT-047
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TECHNICAL DATASHEET
JFW48S5-3000
Recommended Pad Layout for DIP Type
Figure 15
Recommended Pad Layout for SMT Type
Figure 16
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TECHNICAL DATASHEET
JFW48S5-3000
Soldering and Reflow Considerations:
Lead Free Wave Solder Profile for DIP Type
Figure 17
Zone
Preheat
Zone
Actual
Heating
Reference Parameter
Rise temp. speed: 3℃/sec max.
Preheat temp: 100~130℃
Peak temp: 250~260℃
Peak time (T1+T2 time): 4~6 sec
Lead free reflow profile for SMT type
Figure 18
Zone
Preheat
Zone
Actual
Heating
Cooling
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Reference Parameter
Rise temp. speed: 1~3℃/sec
Preheat time: 60~90sec
Preheat temp.155~185℃
Rise temp. speed: 1~3℃/sec
Melting time: 20~40 sec
Melting temp:220℃
Peak temp: 230~240℃
Peak time: 10~20 sec
Rise temp. speed: -1~ -5℃/sec
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TECHNICAL DATASHEET
JFW48S5-3000
Packaging Information:
DIP Type
DIP Type
Figure 19
NOTES:
1. Material: PS (thick=1.2mm)
SMT Type
Figure 20
NOTES:
1. 10 sprocket hole pitch cumulative tolerance ±0.2
2. Camber not to exceed 1mm in 100mm.
3. Material: Black Advantek Polystyrene.
4. Ao and Bo measured on a plane 0.3mm above
the bottom of the pocket.
5. Ko measured from a plane on the inside bottom of
the pocket to the top surface of the carrier tape.
6. Pocket position relative to sprocket hole measured
as true position of pocket, not pocket hole.
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TECHNICAL DATASHEET
JFW48S5-3000
Safety and Installation Instruction:
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 3A for JFW24Sxx-xxxx modules and 1.5A for
JFW48Sxx-xxxx 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 JFW 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 1.322 × 106 hours.
MIL-HDBK 217F NOTICE2 FULL LOAD, operating Temperature at 25°C. The resulting figure for MTBF is
5.147 × 105 hours.
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TECHNICAL DATASHEET
JFW48S5-3000
Ordering Information:
Part Number Example:
JFW 48 S 5 – 3000 S
Series
Designation
Nominal Input
Voltage
Single Output
Nominal Output
Voltage
Option
R
SR
Blank
S
D
SD
F
SF
G
SG
Description
Negative Remote ON/OFF with DIP
Negative Remote ON/OFF with SMT
Positive Remote ON/OFF with DIP
Positive Remote ON/OFF with SMT
DIP Type without ON/OFF pin
SMT Type without ON/OFF pin
DIP Type without TRIM pin
SMT Type without TRIM pin
DIP Type without ON/OFF & TRIM pin
SMT Type without ON/OFF & TRIM pin
Maximum Output
Current (mA)
Company Information:
Wall Industries, Inc. has created custom and modified units for over 40 years. Our in-house research and
development engineers will provide a solution that exceeds your performance requirements on-time and on
budget. Our ISO9001-2000 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]
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5 Watson Brook Rd.
Exeter, NH 03833
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