TECHNICAL DATASHEET JF48S15-1000 DC/DC Converter 36-75 VDC Input 15 VDC Output at 1.0A Features: UL TUV CB CE Mark Applications: • RoHS Directive Compatible • Low Profile: 1.10 x 0.94 x 0.335 inches • Industry Standard Pin-Out • 2:1 Wide Input Voltage of 18-36, 36-75VDC • 15 Watts Output Power • Over-Current Protection, Auto-Recovery • Output Over Voltage Protection • Under Voltage Lockout • Distributed Power Architectures • Remote On/Off Control • Communication Equipment • Adjustable Output Voltage • Computer Equipment • ISO 9001 Certified Manufacturing Facilities • Test Equipment • UL60950-1 • TUV EN60950-1 Options: • Positive Remote ON/OFF • CB • On/Off Control Function • CE Mark • Trim Function • Input to Output Isolation: 2250VDC, min • Surface Mount • Approved for Basic Insulation Description: JF 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 a wide input range, comprehensively protected against over-current, over-voltage, and input under-voltage protection conditions, and trimmable output voltage. The JF Series converters are especially suited to Network, Data processing, Wireless and Enterprise equipment and microprocessor, intermediate bus voltage power application. (888) 597-WALL www.wallindustries.com 1 of 15 TECHNICAL DATASHEET JF24S15-1000 Technical Specifications Model No. JF24S15-1000 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 Switching Frequency Test at nominal Vin and full load 470 INPUT (Vin) Operating Voltage Range 36 48 75 UVLO Turn-on Threshold 33 UVLO Turn-off Threshold 30.5 Input Surge Voltage (100ms max) -0.3 100 Input Voltage Variation Complies with EST300 132 part 4.4 5 Input Current Full Load 372 Reflected Ripple Current Please see the Test Setup section (pg 9) 30 Test at nominal Vin and full load 88 EFFICIENCY (please see the Test Setup section – pg 9) OUTPUT (Vo) 14.85 15.15 Operating Output Range 15 -1% +1% 13.5 16.5 Voltage Adjustment Please see the External Trim Adjustment section (pg 6) 15 -10% +10% Load Regulation 0% to 100% Full Load 0.2 Line Regulation LL to HL at Full Load 0.2 1uF Ceramic & 10uF Tantalum at 20MHz bandwidth Output Ripple & Noise 100 (please see the Test Setup section - pg 9) Transient Response 50% to 75% to 50% load change, ∆Io / ∆t = 0.1A/µs 300 Output Current 0 1.0 Output Voltage Overshoot 3 Output Capacitor Load 220 Over Current Protection 1.1 1.25 1.4 Over Voltage Protection Control Voltage Clamp 16.8 20.5 Please see the Remote ON/OFF Control section (pg 5) REMOTE ON/OFF Negative Logic DC-DC ON (Short) -0.7 1.2 DC-DC OFF (Open) 3 15 Positive Logic DC-DC ON (Open) 3 15 DC-DC OFF (Short) -0.7 1.2 Test at nominal Vin and constant resistive load START UP TIME Power Up 30 Remote ON/OFF 30 ISOLATION Isolation Voltage (Input-Output) 2250 Isolation Resistance 10 Isolation Capacitance 1000 ENVIRONMENTAL Operating Ambient Temperature -40 85 Storage Temperature -55 125 Temperature Coefficient -0.02 +0.02 Please see the MTBF and Reliability section (pg 14) 2,200,000 MTBF MECHANICAL See Figure 1 Weight 10.5 Dimensions 1.10 x 0.94 x 0.335 (888) 597-WALL www.wallindustries.com Unit kHz Vdc Vdc Vdc Vdc V/ms mA mApk-pk % Vdc Vdc % % mVpk-pk µs A % µF A Vdc Vdc Vdc Vdc Vdc ms ms Vdc MΩ pF o C C % / oC hours o grams inches Page 2 of 15 TECHNICAL DATASHEET JF24S15-1000 Figure 1: Mechanical Dimensions max m ax (0.6) m in stand-off height 0.09(2.3) SM D TYPE SMT TYPE 0.03 (0.75) DIP TYPE TYPE DIP 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 JF48S15-1000 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) (888) 597-WALL www.wallindustries.com Page 3 of 15 TECHNICAL DATASHEET JF24S15-1000 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 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 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 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 overcurrent 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 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. (888) 597-WALL www.wallindustries.com Page 4 of 15 TECHNICAL DATASHEET JF24S15-1000 Remote ON/OFF Two remote ON/OFF controls are available for the JF Series Positive logic remote ON/OFF turns the modules on during a logic-high voltage on the remote ON/OFF pin, and off during logic low. Negative logic remote ON/OFF turns the module off during logic high and on during logic low or when the remote ON/OFF pin is shorted to the -INPUT pin. For negative logic remote ON/OFF control add the suffix “R” for DIP type and “SR” for SMT type. For the positive logic ON/OFF control there is no suffix for DIP type and add the suffix “S” for SMT type. Ex: JF48S15-1000S 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 -INPUT. The switch may be an open collector or equivalent (see figure). A logic low is VON/OFF = -0.7V to 1.2V. The maximum ION/OFF during a logic low is 1mA. The switch should maintain a logic-low voltage while sinking 1mA. During logic high, the maximum VON/OFF generated by the power module is 15V. The maximum allowable leakage current of the switch at Von/off = 15V is 50uA 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. The Figure below details five possible circuits for driving the ON/OFF pin. Figure 3 ON/OFF Control ON/OFF Control ON/OFF Control -INPUT -INPUT Remote Enable Circuit -INPUT Negative Logic (Permanently Enabled) Positive Logic (Permanently Enabled) 5V ON/OFF Control ON/OFF Control TTL/ CMOS -INPUT -INPUT Open Collector Enable Circuit (888) 597-WALL www.wallindustries.com Negative Logic (Permanently Enabled) Page 5 of 15 TECHNICAL DATASHEET JF24S15-1000 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. 1.0 4 ∗ 2.5 Rup = + − 5110 (in Ω) Vo − 2.5 − 12.5 Rdown = Vo+ is the desired up output voltage (Vo − − 2.5) ∗ 1.0 4 − 5110 (in Ω) Vout − (Vo − ) Vo- is the desired down output voltage Table 3 Trim Resistor Values Figure 4 Trim -Vout -Vin +Vin (888) 597-WALL RT1 Trim RT2 +Vout 1% 2% 3% 4% 5% 6% 7% 8% 9% 10% www.wallindustries.com Vo+ Rup 15.15V 161.557 kΩ 15.3V 78.223 kΩ 15.45V 50.446 kΩ 15.6V 36.557 kΩ 15.75V 28.223 kΩ 15.9V 22.668 kΩ 16.05V 18.7 kΩ 16.2V 15.723 kΩ 16.35V 13.409 kΩ 16.5V 11.557 kΩ – Vo Rdown 14.85V 14.7V 14.55V 14.4V 14.25V 14.1V 13.95V 13.8V 13.65V 13.5V 818.223 kΩ 401.557 kΩ 262.668 kΩ 193.223 kΩ 151.557 kΩ 123.779 kΩ 103.938 kΩ 89.057 kΩ 77.483 kΩ 68.223 kΩ Page 6 of 15 TECHNICAL DATASHEET JF24S15-1000 Graph 1: Efficiency vs. Output Current Graph 2: Efficiency vs. Input Voltage (Io=Full Load) 90 85 Efficiency (%) Efficiency (%) 80 75 75Vin 48Vin 36Vin 70 65 60 55 50 100 200 300 400 500 600 700 800 900 90 89.5 89 88.5 88 87.5 87 86.5 86 85.5 85 1000 36 40 44 48 52 56 60 64 68 75 Input Voltage, Vin (V) Output Current, Iout (mA) Graph 4: Conducted Emission of EN55022 Class B (Nominal Vin, Io = Full Load) Graph 3: Output Current vs. Ambient Temperature & Airflow 1.20 Output Current (A) 1.00 0.80 Natural convection 1.0m/s(200LFM) 2.0m/s(400LFM) 3.0m/s(600LFM) 0.60 0.40 0.20 0.00 -40 -20 0 20 40 60 80 100 Frequency (MHz) Ambient Temperature, Ta (°C) Graph 6: Typical Output Ripple and Noise (Nominal Vin, Io = Full Load) Output Voltage Output Voltage Input Voltage Graph 5: Typical Input Start-Up and Output Rise Characteristic (888) 597-WALL www.wallindustries.com Page 7 of 15 TECHNICAL DATASHEET JF24S15-1000 (888) 597-WALL Output Current Graph 8: Transient Response to Dynamic Load Change from 70% to 50% to 75% of Full Load Output Voltage Output Voltage ON/ OFF Voltage Graph 7: Using ON/OFF Voltage Start-Up and Output Rise Characteristic www.wallindustries.com Page 8 of 15 TECHNICAL DATASHEET JF24S15-1000 TEST SETUP: The JF48S15-1000 specifications are tested with the following configurations: Input Reflected-Ripple Current Measurement Test Setup Figure 5 Peak-to-Peak Output Ripple & Noise Measurement Setup Figure 6 Output Voltage and Efficiency Measurement Setup Figure 7 NOTE: All measurements are taken at the module terminals Vout × Iout Efficiency = × 100% Vin × Iin (888) 597-WALL www.wallindustries.com Page 9 of 15 TECHNICAL DATASHEET JF24S15-1000 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 8 Temperature Measure Point EMC Considerations Figure 9 Figure 10 Recommended Layout with Input To meet conducted emissions EN55022 Class B needed the following components: C2, C3, C4: 2.2uF/100V MLCC C5, C6: 470pF/3KV MLCC L1: Pulse Engineering type P0354, 1.17mH L2: Inductor 10uH ψ0.35mm (888) 597-WALL www.wallindustries.com Page 10 of 15 TECHNICAL DATASHEET JF24S15-1000 Recommended Pad Layout for DIP Type Figure 11 Recommended Pad Layout for SMT Type Figure 12 (888) 597-WALL www.wallindustries.com Page 11 of 15 TECHNICAL DATASHEET JF24S15-1000 Soldering and Reflow Considerations: Lead Free Wave Solder Profile for DIP Type Figure 13 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 14 Zone Preheat Zone Actual Heating Cooling (888) 597-WALL 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 www.wallindustries.com Page 12 of 15 TECHNICAL DATASHEET JF24S15-1000 Packaging Information: DIP Type DIP Type Figure 15 NOTES: 1. Material: PS (thick=1.2mm) SMT Type Figure 16 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. (888) 597-WALL www.wallindustries.com Page 13 of 15 TECHNICAL DATASHEET JF24S15-1000 Safety and Installation Instruction: Isolation Consideration The JF Series features 2250 Volt DC isolation from input to output. The input to output resistance is greater than 10MΩ. 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 UL609501, 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. 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. (888) 597-WALL www.wallindustries.com Page 14 of 15 TECHNICAL DATASHEET JF24S15-1000 Ordering Information: Part Number Example: JF 48 S 15 – 1000 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] www.wallindustries.com 5 Watson Brook Rd. Exeter, NH 03833 www.wallindustries.com Page 15 of 15