TECHNICAL DATASHEET Rev B JFCW48S3.3-4000 13.2W DC/DC Converter 18-75 VDC Input 3.3 VDC Single Output at 4000mA Features: Applications: UL TUV CB CE MARK (Pending) Measurement Telecom/Datacom Wireless Networks Industry Control Systems Semiconductor Equipment Options: Trim Function Negative Remote ON/OFF ON/OFF Control Function Heatsinks Available for Extended Operation RoHS Directive Compliant 4A Single Output Current Industry Standard Pin-out No Minimum Load Requirement 15 Watts Output Power Adjustable Output Voltage High Efficiency up to 86% Low Profile: 1.0 x 1.0 x 0.39 Inches Input to Output Isolation: 1600VDC min 4:1 Ultra Wide Input Voltage Range Fixed Switching Frequency Input Under Voltage Protection Output Over Voltage Protection Over Current Protection, Auto-Recovery Output Short Circuit Protection Remote ON/OFF Control Six-Sided Shielding Description: The JFCW48S3.3-4000 is a single output DC/DC converter that provides 13.2 watts of output power in an industry standard package and footprint. The JFCW48S3.3-4000 is specifically designed to meet power needs in a low profile package. This model features a 4:1 wide input voltage range of 18-75VDC as well as positive or negative remote on/off, 1600VDC I/O isolation, and trimmable output voltage. This converter is also protected against over current, over voltage, input under voltage, and short circuit conditions. (888) 597-WALL www.wallindustries.com Page 1 of 14 TECHNICAL DATASHEET JFCW48S3.3-4000 Rev. B Technical Specifications JFCW48S3.3-4000 Model No. 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 INPUT (Vin) Operating Voltage Range UVLO Turn-on Threshold UVLO Turn-off Threshold Input Standby Current Input Current Input Voltage Input Voltage Variation Reflected Ripple Current Start Up Time (Nominal Vin and constant resistive load) OUTPUT (Vo) Output Voltage Range Load Regulation Line Regulation Voltage Adjustability (see page 5) Output Ripple & Noise (20MHz) Output Current Output Voltage Overshoot PROTECTION Over Voltage Protection Over Current Protection Short Circuit Protection DYNAMIC LOAD RESPONSE Peak Deviation Setting Time (Vout < 10% peak deviation) REMOTE ON/OFF Negative Logic (Option) Positive Logic (Standard) Remote OFF Input Current Input Current of Remote Control Pin GENERAL Switching Frequency Efficiency ISOLATION Isolation Voltage (Input-Output) Isolation Voltage (Output to Case) Isolation Voltage (Input to Case) Isolation Resistance Isolation Capacitance ENVIRONMENTAL Operating Ambient Temperature Operating Case Temperature Storage Temperature Temperature Coefficient MTBF Bellcore TR-NWT-000332, TC=40°C MIL-STD-217F MECHANICAL Weight Related condition Nom Max Unit 18 48 75 18 Vdc Vdc Vdc mA mA 16 40 Nominal Vin and No Load Nominal Vin and Full Load Continuous Transient (100ms) Complies with ETS300 132 part 4.4 5 to 20MHz, 12μH source impedance (See the Test Setup section - pg 9) Power Up Remote On/Off Nominal Vin and Full Load; Ta = 25°C 0% to 100% Full Load LL to HL at Full Load All models Measured with a 1μF M/C and a 10μF T/C (See the Test Setup section - pg 9) 336 75 100 5 30 3.267 -0.2 -0.2 -10 3.3 0 LL to HL at Full Load and 25°C voltage clamped All models All models Test at nominal Vin Load step change from 75 to 100% or 100 to 75 % of FL Load step change from 75 to 100% or 100 to 75 % of FL The ON/OFF pin voltage is referenced to -Vin (See the Remote ON/OFF Control section - pg 6) DC/DC ON (Short) DC/DC OFF (Open) DC/DC ON (Open) DC/DC OFF (Short) 0 3.7 ms 3.333 +0.2 +0.2 +10 Vdc % % % 75 mVpk-pk 4000 3 mA % Vout 5.4 Vdc 150 % FL Hiccup, automatic-recovery 0 3 3 0 mV μs 1.2 15 15 1.2 -0.5 1.0 Vdc mA mA kHz 86 % 1000 -55 -0.02 Vdc 400 1600 1000 1000 1 -40 V/ms 30 30 300 250 All models Nominal Vin, and full load; Ta=25°C (See the Test Setup section – pg 9) Vdc mApk-pk 2.5 85 105 125 +0.02 Vdc Vdc Vdc GΩ pF o C C o C % / oC o See the MTBF and Reliability section (pg 13) 1,330,000 hours 563,000 hours See Figure 1 15 grams 1.0 x 1.0 x 0.39 inches 25.4 x 25.4 x 9.9mm Dimensions (888) 597-WALL Min www.wallindustries.com Page 2 of 14 TECHNICAL DATASHEET Rev. B JFCW48S3.3-4000 Figure 1: Mechanical Dimensions Unit: inches (mm) PIN CONNECTION PIN SINGLE OUTPUT 1 + INPUT 2 - INPUT 3 ON/OFF 4 +VOUT 5 TRIM 6 -VOUT 1. Tolerance: X.XX±0.02 (X.X±0.5) X.XXX±0.01 (X.XX±0.25) 2. Pin pitch tolerance: ±0.01 (0.25) 3. Pin dimension tolerance: ±0.004 (0.1) EXTERNAL OUTPUT TRIMMING PRODUCT STANDARD TABLE Option Negative Remote ON/OFF Positive Remote ON/OFF Without ON/OFF pin Without ON/OFF & TRIM pin Negative Remote ON/OFF without TRIM pin Positive Remote ON/OFF without TRIM pin (888) 597-WALL Suffix R No Suffix D G RF F www.wallindustries.com Output can be externally trimmed by using the method shown below. Page 3 of 14 TECHNICAL DATASHEET JFCW48S3.3-4000 Rev. B 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 JFCW single output 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 an output 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 IC to limit the output voltage. Short Circuit Protection Continuous, hiccup, and auto-recovery mode. The average current during this condition will be very low and the device is still safe in this condition. 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 10μF/100V and 10μF/100V. The capacitor must be connected as close as possible to the input terminals of the power module for lower impedance. 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 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. Figure 2 TOP VIEW Measurement shown in inches (mm) TEMPERATURE MEASURING POINT (888) 597-WALL www.wallindustries.com Page 4 of 14 TECHNICAL DATASHEET Rev. B JFCW48S3.3-4000 Heatsink Consideration Equip heatsink for lower temperature and higher reliability of the module. Considering space and airflow is the way to choose which heatsink is needed. Figure 3 Unit: inches (mm) Output Voltage 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 increases. With an external resistor between the TRIM and +Vout pin, the output voltage set point decreases. JFCW48S3.3-4000 Trim Up Equation Figure 4 5110 2.5 Rup Vo , up 2.5 0.8 2050 Trim Down Equation (Vo, down 2.5) 5110 2050 Rdown Vo (Vo, down) (888) 597-WALL www.wallindustries.com Trim Trimup Rup 1% 3.333V 385.071 kΩ Trimdown 3.267V 116.719 kΩ Rdown 2% 3.366V 191.511 kΩ 3.234V 3% 3.399V 126.990 kΩ 3.201V 34.133 kΩ 4% 3.432V 94.730 kΩ 3.168V 23.810 kΩ 5% 3.465V 75.374 kΩ 3.135V 17.616 kΩ 6% 3.498V 62.470 kΩ 3.102V 13.486 kΩ 7% 3.531V 53.253 kΩ 3.069V 10.537 kΩ 8% 3.564V 46.340 kΩ 3.036V 8.325 kΩ 9% 3.597V 40.963 kΩ 3.003V 6.604 kΩ 10% 3.630V 36.662 kΩ 2.970V 5.228 kΩ 54.779 kΩ Page 5 of 14 TECHNICAL DATASHEET Rev. B JFCW48S3.3-4000 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 5 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. Remote ON/OFF Implementation Figure 5 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 6 When JFCW module is turned OFF at Low-level logic When JFCW 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 7 When JFCW module is turned ON at Low-level logic (888) 597-WALL When JFCW module is turned OFF at High-level logic www.wallindustries.com Page 6 of 14 TECHNICAL DATASHEET JFCW48S3.3-4000 Rev. B JFCW48S3.3-4000 Graphs. All test conditions are at 25°C Graph 2: Efficiency vs. Input Voltage (Full Load) Efficiency (%) Efficiency (%) Graph 1: Efficiency vs. Output Current Input Voltage (V) % Of Full Load Graph 4: Output Power vs. Ambient Temperature with Heatsink & Airflow (Nominal Vin) Output Power (%) Output Power (%) Graph 3: Output Power vs. Ambient Temperature & Airflow (Nominal Vin) Ambient Temperature, Ta (°C) Ambient Temperature, Ta (°C) Graph 6: Typical Output Ripple and Noise (Nominal Vin and Full Load) Power Dissipation (W) Graph 5: Power Dissipation Vs. Output Current % Of Full Load (888) 597-WALL www.wallindustries.com Page 7 of 14 TECHNICAL DATASHEET JFCW48S3.3-4000 Rev. B JFCW48S3.3-4000 Graphs (Continued). All test conditions are at 25°C Graph 7: Typical Input Start-Up and Output Rise Characteristic (Nominal Vin and Full Load) Graph 9: Transient Response to Dynamic Load Change from 100% to 75% to 100% of Full Load at Nominal Vin Graph 8: Using ON/OFF Voltage Start-Up and Vo Rise Characteristic (Nominal Vin and Full Load) Graph 10: Conducted Emission of EN55022 Class A (Nominal Vin and Full Load) Frequency (MHz) Graph 11: Conducted Emission of EN55022 Class B (Nominal Vin and Full Load) Frequency (MHz) (888) 597-WALL www.wallindustries.com Page 8 of 14 TECHNICAL DATASHEET JFCW48S3.3-4000 Rev. B TEST SETUP: The JFCW48S3.3-4000 specifications are tested with the following configurations: Input Reflected-Ripple Current Measurement Test Setup CURRENT PROBE MEASURE POINT Figure 8 +Vin L + BATTERY + C2 C1 -Vin Component L C1 C2 Value 12μH 10μF 10μF Voltage ---100V 100V Reference ---Aluminum Electrolytic Capacitor Aluminum Electrolytic Capacitor Peak-to-Peak Output Ripple & Noise Measurement Setup Figure 10 Figure 9 Output Voltage and Efficiency Measurement Setup Figure 11 Vout Iout Efficiency 100% Vin Iin NOTE: All measurements are taken at the module terminals (888) 597-WALL www.wallindustries.com Page 9 of 14 TECHNICAL DATASHEET JFCW48S3.3-4000 Rev. B EMC Considerations Suggested Schematic for EN55022 Conducted Emission Class A Limits C3 Figure 12 ＋INPUT +Vin C1 +Vout C2 －INPUT LOAD -Vin -Vout D/D Converter C4 Recommended Layout with Input Filter Figure 13 The following components are needed to meet conducted emissions EN55022 Class A JFCW24Sxx-xxxx Component C1 C2 C3, C4 Value 6.8μF 6.8μF 470pF Voltage 50V 50V 2KV Reference 1812 MLCC 1812 MLCC 1808 MLCC JFCW48Sxx-xxxx Component C1 C2 C3, C4 (888) 597-WALL Value 2.2μF 2.2μF 470pF Voltage 100V 100V 2KV www.wallindustries.com Reference 1812 MLCC 1812 MLCC 1808 MLCC Page 10 of 14 TECHNICAL DATASHEET Rev. B JFCW48S3.3-4000 EMC Considerations (Continued) Suggested Schematic for EN55022 Conducted Emission Class B limits Figure 14 Recommended Layout with Input Filter Figure 15 The following components are needed to meet conducted emissions EN55022 Class B Figure 16: Common Choke (L1) JFCW24Sxx-xxxx Component C1, C3 C2 C4, C5 L1 Value 6.8μF --470pF 325μH Voltage 50V --2KV --- Reference 1812 MLCC --1808 MLCC Common Choke JFCW48Sxx-xxxx Component C1, C3 C2 C4, C5 L1 Value 2.2μF 2.2μF 1000pF 325μH Voltage 100V 100V 2KV --- Reference 1812 MLCC 1812 MLCC 1808 MLCC Common Choke Dimensions: mm L: 325μH±35% / DCR: 35Ω, max Height: 8.8mm, max. Test conditions: 100KHz / 100mV Recommended through hole: Φ0.8mm (888) 597-WALL www.wallindustries.com Page 11 of 14 TECHNICAL DATASHEET JFCW48S3.3-4000 Rev. B Recommended Pad Layout Figure 17 1. All dimensions in inches [mm] 2. Tolerance: x.xxx±0.010 inches xx.xx±0.25 mm Pad Size (Lead Free Recommended) Pin Through Hole: Ø 0.047 in (1.2mm) Top View Pad: Ø 0.079 in (2.0mm) Bottom View Pad: Ø 0.118 in (3.0mm) Soldering and Reflow Considerations: Lead Free Wave Solder Profile for JFCW-Single Output Models Figure 18 TEMPERATURE (°C) 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 Reference Solder: Sn-Ag-Cu; Sn-Cu Hand Welding: Soldering Iron: Power 90W Welding Time: 2~4 sec Temp: 380~400°C TIME (SEC) Packaging Information: Figure 19 300 Unit: mm 26.5 19 10 PCS per Tube 6 (888) 597-WALL www.wallindustries.com Page 12 of 14 TECHNICAL DATASHEET JFCW48S3.3-4000 Rev. B Safety and Installation Instructions: 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. For 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 JFCW24Sxx-xxx modules and 1.5A for JFCW48Sxx-xxx. 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 JFCW single output 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 1,330,000 hours. MIL-HDBK 217F NOTICE2 FULL LOAD, Operating Temperature at 25°C. The resulting figure for MTBF is 563,000 hours. Ordering Information: Part Number Example: JFCW 48 S 3.3 - 4000 R Series Designation Nominal Input Voltage Single Output Nominal Output Voltage Output Current Suffix R No Suffix D G RF F (888) 597-WALL www.wallindustries.com Option Negative Remote ON/OFF Positive Remote ON/OFF Without ON/OFF pin Without ON/OFF & TRIM pin Negative Remote ON/OFF without TRIM pin Positive Remote ON/OFF without TRIM pin Page 13 of 14 TECHNICAL DATASHEET Rev. B JFCW48S3.3-4000 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 14 of 14