TECHNICAL DATASHEET Rev. A JFCW24S5-20 4:1 Input Voltage Range: 9-36VDC 5VDC Single Output at 4A Industry Standard Package and Footprint 20W DC/DC Power Converter FEATURES 20 Watts Maximum Output Power 5VDC Single Output Industry Standard Pin-Out Small Size and Low Profile: 1.0” x 1.0” x 0.39” 4:1 Wide Input Voltage Range: 9-36VDC 89% High Efficiency 1600VDC I/O Isolation Ultra Low Quiescent Current Remote ON/OFF Control APPLICATIONS Wireless Networks Telecom / Datacom Industry Control Systems Measurement Equipment Semiconductor Equipment Adjustable Output Voltage Fixed Switching Frequency No Minimum Load Requirement Input Under Voltage, Over Voltage, Over Current, and Short Circuit Protected Six-Sided Shielding OPTIONS Negative Remote ON/OFF Without Trim Pin Without ON/OFF Pin Heatsink EMI Meets EN55022 Class A Without External Filter CE Mark Meets 2006/95/EC, 93/68/EEC, and 2004/108/EC UL60950-1, EN60950-1, and IEC60950-1 Safety Approvals Compliant to RoHS EU Directive 2002/95/EC DESCRIPTION The JFCW24S5-20 DC/DC power converter provides 20 Watts of output power in an industry standard 1.0” x 1.0” x 0.39” package and footprint. This converter has a 5VDC single output and operates over a 4:1 input voltage range of 9-36VDC. The JFCW24S5-20 is also protected against short circuit, over current, over voltage, and input under voltage conditions. Some features include 89% high efficiency, low quiescent current, adjustable output voltage, and positive (standard) or negative (optional) remote ON/OFF control. This converter is RoHS compliant and has UL60950-1, EN60950-1, and IEC60950-1 safety approvals. (888) 597-WALL www.wallindustries.com Page 1 of 13 TECHNICAL DATASHEET Rev A JFCW24S5-20 TECHNICAL SPECIFICATIONS MODEL NO. JFCW24S5-20 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 SPECIFICATIONS Operating Input Voltage Range Input Voltage TEST CONDITIONS Min Typ Max Unit 9 24 36 36 50 980 VDC Continuous Transient (1 sec max) Input Current Input Standby Current UVLO Turn-On Threshold UVLO Turn-Off Threshold Power Up Remote ON/OFF Input Reflected Ripple Current (See Page 9) Input Filter OUTPUT SPECIFICATIONS Output Voltage Line Regulation Start-Up Time Load Regulation Voltage Adjustability (See Page 5) Output Power Output Current Minimum Load Output Capacitor Load Ripple & Noise (20Hz BW) (See Page 9) Output Voltage Overshoot Temperature Coefficient DYNAMIC LOAD RESPONSE Peak Deviation Setting Time (Vout < 10% peak deviation) REMOTE ON/OFF (See Page 6) DC/DC ON (Open) Positive Logic (standard) DC/DC OFF (Short) DC/DC ON (Short) Negative Logic (optional) DC/DC OFF (Open) Input Current of Remote Control Pin Remote Off State Input Current PROTECTION Over Voltage Protection Over Current Protection Short Circuit Protection GENERAL SPECIFICATIONS Efficiency Switching Frequency Input to Output Isolation Voltage Input to Case Output to Case Isolation Resistance Isolation Capacitance ENVIRONMENTAL SPECIFICATIONS Operating Ambient Temperature (with derating) Operating Case Temperature Storage Temperature Relative Humidity Thermal Shock Vibration Thermal Impedance (See Page 4~5) MTBF (See Page 12) Nominal input and full load Nominal input and no load VDC mA mA VDC VDC 6 9 8 30 30 Nominal input and constant resistive load 5 to 20MHz, 12µH source impedance ms 30 mAp-p Pi type Nominal input, full load, and 25°C Low line to high line at full load 0% to 100% full load 10% to 90% load 4.95 -0.2 -0.2 -0.1 -10 5 5.05 +0.2 +0.2 +0.1 +10 20 4 VDC % % % % W A % µF mVp-p % Vout %/°C 0 Minimum Vin and constant resistive load Measured with a 1µF M/C and a 10µF T/C Low line to high line at full load and 25°C 75 -0.02 Nom.Vin and TA=25°C Nom.Vin and TA=25°C 75% to 100% or 100% to 75% of full load 75% to 100% or 100% to 75% of full load 350 250 3 0 0 3 -0.5 The CTRL pin is referenced to -Input The CTRL pin is referenced to -Input Nominal Input Nominal Input 5000 100 5 +0.02 mV µs 15 1.2 1.2 15 1.0 VDC VDC mA mA 2.0 Voltage clamped % of FL at nominal input 5.6 Nominal input and full load 297 1600 1000 1000 1 For 1 minute 7.0 150 Hiccup, automatic recovery 89 330 VDC % FL % KHz 363 VDC GΩ pF 1500 Vertical direction by natural convection (20LFM) -40 -55 5 Natural Convection Natural Convection with Heatsink BELLCORE TR-NWT-000332, TC=40°C MIL-HDBK-217F PHYSICAL SPECIFICATIONS Case Material Base Material Potting Material Weight Dimensions (L x W x H) SAFETY & EMI CHARACTERISTICS Safety Approvals EMI (See Page 10) EN55022 ESD EN61000-4-2 Radiated Immunity Fast Transient (See Note) Surge (See Note) Conducted Immunity EN61000-4-3 EN61000-4-4 EN61000-4-5 EN61000-4-6 +101 +105 +125 95 MIL-STD-810F MIL-STD-810F 17.6 14.8 1,766,000 hours 553,000 hours °C °C °C % RH °C/Watt Nickel-coated copper FR4 PCB Silicon (UL94V-0) 0.53oz (15g) 1.0 x 1.0 x 0.39 inches (25.4 x 25.4 x 9.9 mm) IEC60950-1, UL60950-1, EN60950-1 Class B Air Contact ±8kV ±6kV 10 V/m ±2KV ±2KV 10 Vrms Perf. Criteria A Perf. Criteria A Perf. Criteria A Perf. Criteria A Perf. Criteria A Note: An external input filter capacitor is required if the module has to meet EN61000-4-4, EN61000-4-5. The filter capacitor we recommend is Nippon Chemi-con KY series, 220µF/100V, ESR 48mΩ (888) 597-WALL www.wallindustries.com Page 2 of 13 Rev A TECHNICAL DATASHEET JFCW24S5-20 MECHANICAL DRAWING 0.39 (9.9) Unit: inches (mm) 0.22 (5.6) DIA. 0.04(1.0) 1.00 (25.4) 3 6 2 0.200 (5.08) 0.10 (2.5) 0.100 (2.54) 0.400 (10.16) 0.400 (10.16) 0.50 (12.7) 1.00 (25.4) 0.800 (20.32) 5 1 4 BOTTOM VIEW PIN CONNECTIONS PIN ASSIGNMENT 1 +INPUT 2 -INPUT 3 CTRL 4 +OUTPUT 5 TRIM 6 -OUTPUT 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) PRODUCT STANDARD TABLE EXTERNAL OUTPUT TRIMMING Option Suffix Positive Remote ON/OFF (standard) No Suffix Negative Remote ON/OFF R Without ON/OFF Pin D Without ON/OFF & Trim Pin G Positive Remote ON/OFF without Trim Pin F Negative Remote ON/OFF without Trim Pin RF Heatsink HS Heatsink with Clamp HC (888) 597-WALL www.wallindustries.com Output can be externally trimmed by using the method shown below. TRIM UP TRIM DOWN 5 6 RD RU 5 4 Page 3 of 13 Rev A TECHNICAL DATASHEET JFCW24S5-20 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 150% of rated current for the JFCW20 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. 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. 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 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, 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. 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 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. Measurements shown in inches (mm) 0.5 (12.7) Figure 1 TEMPERATURE MEASURING POINT 0.5 (12.7) (888) 597-WALL www.wallindustries.com Page 4 of 13 TECHNICAL DATASHEET Rev A JFCW24S5-20 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. There are two types of heatsinks to choose from Figure 2: Heatsink with Clamp (Suffix “HC”) Figure 3: Heatsink (Suffix “HS”) 1.0±0.02 (25.4±0.5) 0.65 (16.5) ref. 1.0±0.02 (25.4±0.5) 0.65 (16.5) ref. 1.0±0.02 (25.4±0.5) 1.0±0.02 (25.4±0.5) 1.19 (30.1) ref. All dimensions are in 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 +OUTPUT or -OUTPUT pins. With an external resistor between the TRIM and –OUTPUT pin, the output voltage set point increases. With an external resistor between the TRIM and +OUTPUT pin, the output voltage set point decreases. Trim Up Equation Trim Down Equation 5110 2.5 Rup Vo , up 2.5 2.5 2050 (Vo, down 2.5) 5110 2050 Rdown Vo (Vo, down) -OUTPUT RU -INPUT TRIM Figure 4 +INPUT RD JFCW24S5-20 Trim Trimup Rup Trimdown Rdown 1% 5.050V 253.450 kΩ 4.950V 248.340 kΩ 2% 5.100V 125.700 kΩ 4.900V 120.590 kΩ 3% 5.150V 83.117 kΩ 4.850V 78.007 kΩ 4% 5.200V 61.825 kΩ 4.800V 56.715 kΩ 5% 5.250V 49.050 kΩ 4.750V 43.940 kΩ 6% 5.300V 40.533 kΩ 4.700V 35.423 kΩ 7% 5.350V 34.450 kΩ 4.650V 29.340 kΩ 8% 5.400V 29.888 kΩ 4.600V 24.778 kΩ 9% 5.450V 26.339 kΩ 4.550V 21.229 kΩ 10% 5.500V 23.500 kΩ 4.500V 18.390 kΩ +OUTPUT (888) 597-WALL www.wallindustries.com Page 5 of 13 Rev A TECHNICAL DATASHEET JFCW24S5-20 Remote ON/OFF Control The Remote CTRL pin allows the user to turn the DC/DC power module on and off from a remote switch device. The CTRL input can be switched by a number of switching devices. Figure 5 gives several examples of acceptable configurations. The remote CTRL switch is activated by the voltage difference between the CTRL 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 Circuits 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 (standard) and Negative logic (optional) a. The positive logic structure turned the DC/DC module ON when the CTRL pin is at high-level logic and turned the DC/DC module OFF when the CTRL pin is at low-level logic. Figure 6 When JFCW20 module is turned OFF at Low-level logic When JFCW20 module is turned ON at High-level logic b. The negative logic structure turned the DC/DC module ON when the CTRL pin is at low-level logic and turned the DC/DC module OFF when the CTRL pin is at high-level logic. Figure 7 When JFCW20 module is turned ON at Low-level logic (888) 597-WALL When JFCW20 module is turned OFF at High-level logic www.wallindustries.com Page 6 of 13 TECHNICAL DATASHEET Rev A JFCW24S5-20 Graph 1: Efficiency vs. Output Current Graph 2: Efficiency vs. Input Voltage (Full Load) Graph 3: Output Power vs. Ambient Temperature with Airflow (Nominal Vin) Graph 4: Output Power vs. Ambient Temperature with Heatsink & Airflow (Nominal Vin) Graph 5: Power Dissipation Vs. Output Current (888) 597-WALL www.wallindustries.com Page 7 of 13 TECHNICAL DATASHEET Rev A JFCW24S5-20 Graph 6: Typical Output Ripple and Noise (Nominal Vin and Full Load) Graph 7: Transient Response to Dynamic Load Change from 100% to 75% to 100% of Full Load at Nominal Vin Graph 8: Typical Input Start-Up and Output Rise Characteristic (Nominal Vin and Full Load) Graph 9: 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) Graph 11: Conducted Emission of EN55022 Class B (Nominal Vin and Full Load) (888) 597-WALL www.wallindustries.com Page 8 of 13 TECHNICAL DATASHEET Rev A JFCW24S5-20 TEST SETUP The JFCW24S5-20 specifications are tested with the following configurations: Input Reflected-Ripple Current Measurement Test Setup CURRENT PROBE MEASURE POINT +Vin L Figure 8 + 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 9 Figure 10 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 13 TECHNICAL DATASHEET Rev A JFCW24S5-20 EMI Considerations Suggested Schematic for EN55022 Class B Limits Recommended Layout with Input Filter C5 L1 +INPUT C1 +Vin C2 C3 +Vout DC/DC CONVERTER -Vin -INPUT LOAD -Vout C4 Figure 12 Figure 13 To meet EN55022 CLASS B the following components are needed: Component C1 C2 & C3 C4 & C5 L1 JFCW24S5-20 Voltage 50V ---2KV ---- Value 4.7µF ---470pF 325μH Reference 1812 MLCC ---1808 MLCC Common Choke, P/N: PMT-050 COMMON CHOKE: PMT-050 Unit: inches (mm) 0.43 (11.0) ref. L: 325mH±35% 0.43 (11.0) ref. 0.30±0.008 (7.5±0.2) DCR: 35Ω, max. Test Conditions: 100KHz / 100mV Recommended Through Hole: Ø0.04 in (Ø0.8 mm) Ø0.02±0.004 (Ø0.6±0.1) N1 3 2 0.1 (2.5) 1 N2 0.35 (8.8) ref. 4 0.30±0.008 (7.62±0.2) Figure 14 (888) 597-WALL www.wallindustries.com Page 10 of 13 TECHNICAL DATASHEET Rev A JFCW24S5-20 Recommended Pad Layout Figure 15 NOTES: 1. All dimensions in inches [mm] 2. Tolerance: X.XXX±0.010 [XX.XX±0.25] Pad Size (Lead Free Recommended) Pin Through Hole: Ø0.047 in (Ø1.20 mm) Top View Pad: Ø0.079 in (Ø2.00 mm) Bottom View Pad: Ø0.118 in (Ø3.00 mm) Soldering Considerations Lead Free Wave Solder Profile for JFCW20 Series 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 Reference Solder: Sn-Ag-Cu; Sn-Cu Hand Welding: Soldering Iron: Power 90W Welding Time: 2~4 sec Temp: 380~400°C Packaging Information 10 PCS per Tube All dimensions are in inches (mm) (888) 597-WALL www.wallindustries.com Page 11 of 13 TECHNICAL DATASHEET Rev A JFCW24S5-20 SAFETY & 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 4A for JFCW24Sxx-20 and 2A for JFCW48Sxx-20 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 for the JFCW20 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 1,766,000 hours. MIL-HDBK 217F NOTICE2 FULL LOAD, Operating Temperature at 25°C. The resulting figure for MTBF is 553,000 hours. ORDERING INFORMATION Part Number Example: JFCW 24 S 5 - 20 R HS Series Designation Nominal Input Voltage Single Output Nominal Output Voltage Output Power PRODUCT STANDARD TABLE Option Suffix No Heatsink No Suffix Heatsink HS Heatsink with Clamp HC PRODUCT STANDARD TABLE Option Positive Remote ON/OFF (standard) Negative Remote ON/OFF Without ON/OFF Pin Without ON/OFF & Trim Pin Positive Remote ON/OFF without Trim Pin Negative Remote ON/OFF without Trim Pin (888) 597-WALL www.wallindustries.com Suffix No Suffix R D G F RF Page 12 of 13 Rev A TECHNICAL DATASHEET JFCW24S5-20 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 13 of 13