TECHNICAL DATASHEET Rev. B JFW24S15-1000 9-36VDC Wide Input Voltage Range 15VDC Output at 1A DIP and SMT Type Packages 15W Open Frame DC/DC Power Converter FEATURES 15 Watts Maximum Output Power 15VDC Single Output Cost Efficient Open Frame Design Small Size and Low Profile: 1.10” x 0.94” x 0.34” 86% High Efficiency 9-36VDC Input Voltage Range Fixed Switching Frequency Input to Output Isolation: 2250VDC APPLICATIONS Wireless Networks Telecom / Datacom Industry Control Systems Measurement Equipment Semiconductor Equipment 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 CE Mark Meets 2006/95/EC, 93/68/EEC, and 2004/108/EC UL60950-1, EN60950-1, and IEC60950-1 Licensed DESCRIPTION The JFW24S15-1000 DC/DC power converter provides 15 Watts of output power in a low profile industry standard package and footprint. This converter has a 15VDC single output and operate over a 4:1 input voltage range of 9-36VDC. The JFW24S15-1000 is also protected against short circuit, over current, over voltage, and input under voltage conditions. Some features include 86% 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 17 Rev B TECHNICAL SPECIFICATIONS TECHNICAL DATASHEET JFW24S15-1000 Model No. JFW24S15-1000 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 9 24 36 VDC Input Current Nominal input and full load 763 mA Input Standby Current Nominal input and no load 10 mA Input Surge Voltage (100ms) 50 VDC UVLO Turn-On Threshold 9 VDC UVLO Turn-Off Threshold 8 VDC Power Up 5 30 Start-Up Time Nominal input and constant resistive load ms Remote ON/OFF 5 30 Input Reflected Ripple Current (See Page 9) 5 to 20MHz, 12µH source impedance 30 mAp-p OUTPUT SPECIFICATIONS Output Voltage Nominal input, full load, and 25°C 14.85 15 15.15 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 6) -10 +10 % Output Power 15 W Output Current 1000 mA Output Capacitor Load 660 µF Ripple & Noise (20Hz BW) (See Page 9) Measured with a 1µF M/C and a 10µF T/C 100 125 mVp-p Output Voltage Overshoot Low line to high line at full load and 25°C 3 %Vout Minimum Load 0 % Temperature Coefficient -0.02 +0.02 %/°C DYNAMIC LOAD RESPONSE Peak Deviation 75% to 100% or 100% to 75% of full load 300 mV Setting Time (Vout < 10% peak deviation) 75% to 100% or 100% to 75% of full load 250 µs REMOTE ON/OFF (See Page 5) DC/DC ON (Open) Open or 3V < Vr < 15V Positive Logic (standard) The ON/OFF pin is referenced to -Input DC/DC OFF (Short) Short or 0V < Vr < 1.2V DC/DC ON (Short) Short or 0V < Vr < 1.2V Negative Logic (optional) The ON/OFF pin is referenced to -Input DC/DC OFF (Open) Open or 3V < Vr < 15V Input Current of Remote Control Pin Nominal Input -0.5 1 mA Remote Off State Input Current Nominal Input 2.5 mA PROTECTION Over Voltage Protection Voltage clamped 16.8 20.5 VDC Over Current Protection % of FL at nominal input 150 %FL Short Circuit Protection Hiccup, automatic recovery GENERAL SPECIFICATIONS Efficiency Nominal input and full load 86 % Switching Frequency 360 400 440 KHz Isolation Voltage (Input to Output) For 1 minute 2250 VDC Isolation Resistance 1 GΩ Isolation Capacitance 1500 pF ENVIRONMENTAL SPECIFICATIONS Operating Ambient Temperature 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 1,322,000 hours MTBF (See Page 16) MIL-HDBK-217F 514,700 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 10) EN55022 Class A Radiated Immunity EN61000-4-3 10 V/m Perf. Criteria A Fast Transient (See Note1) EN61000-4-4 ±2KV Perf. Criteria A Surge (See Note1) EN61000-4-5 ±1KV Perf. Criteria A Conducted Immunity EN61000-4-6 3 Vrms Perf. Criteria A Note1: 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 17 Rev B TECHNICAL DATASHEET JFW24S15-1000 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 JFW 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 17 Rev B TECHNICAL DATASHEET JFW24S15-1000 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 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 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 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. 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 (888) 597-WALL www.wallindustries.com Page 4 of 17 Rev B TECHNICAL DATASHEET JFW24S15-1000 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. 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 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 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 JFW module is turned ON at Low-level logic (888) 597-WALL When JFW module is turned OFF at High-level logic www.wallindustries.com Page 5 of 17 TECHNICAL DATASHEET Rev B JFW24S15-1000 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. The external TRIM resistor needs to be at least 1/16W. 10,000 2.5 5110 Rup (Vout , up 2.5 12.5) (Vout , down 2.5) 10,000 5110 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% 15.150V 15.300V 15.450V 15.600V 15.750V 15.900V 16.050V 16.200V 16.350V 16.500V 161.557 kΩ 78.223 kΩ 50.446 kΩ 36.557 kΩ 28.223 kΩ 22.668 kΩ 18.700 kΩ 15.723 kΩ 13.409 kΩ 11.557 kΩ 14.850V 14.700V 14.550V 14.400V 14.250V 14.100V 13.950V 13.800V 13.650V 13.500V 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 www.wallindustries.com Page 6 of 17 TECHNICAL DATASHEET Rev B JFW24S15-1000 Graph 1: Efficiency vs. Output Current Graph 2: Efficiency vs. Input Voltage (Full Load) Graph 3: Output Power vs. Ambient Temperature & Airflow (Nominal Vin) Graph 4: Power Dissipation Vs. Output Current 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) (888) 597-WALL www.wallindustries.com Page 7 of 17 Rev B Graph 7: Typical Input Start-Up and Output Rise Characteristic (Nominal Vin and Full Load) Graph 9: Typical Output Ripple and Noise (Nominal Vin and Full Load) (888) 597-WALL TECHNICAL DATASHEET JFW24S15-1000 Graph 8: Using ON/OFF Voltage Start-Up and Vo 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 www.wallindustries.com Page 8 of 17 TECHNICAL DATASHEET Rev B JFW24S15-1000 TEST SETUP: The JFW24S15-1000 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 9 of 17 TECHNICAL DATASHEET Rev B JFW24S15-1000 EMI Considerations: Suggested Schematic for EN55022 Conducted Emission Class A Limits C3 L1 +INPUT Figure 10 +Vin +Vout -Vin Trim CTRL -Vout C1 -INPUT Load DC/DC CONVERTER C2 To meet conducted emissions EN55022 CLASS A the following components are needed: JFW24S15-1000 Component Value Voltage L1 10µH ---- C1 C2, C3 6.8µF 470pF 50V 3KV Reference 2.6A 0.04Ω 0705 SMD Inductor P/N: PMT-070 1812 MLCC 1808 MLCC Recommended Layout with Input Filter Figure 11 (888) 597-WALL www.wallindustries.com Page 10 of 17 TECHNICAL DATASHEET Rev B JFW24S15-1000 EMI Considerations (Continued): Suggested Schematic for EN55022 Conducted Emission Class B Limits C6 L1 L2 +Vin +INPUT C1 C2 C3 +Vout C4 LOAD Figure 12 -Vin -INPUT -Vout DC/DC CONVERTER C5 To meet conducted emissions EN55022 CLASS B the following components are needed: JFW24S15-1000 Component L1 Value 145µF Voltage ---- L2 10µF ---- C1 C2, C3, C4 C5, C6 ---6.8µF 470pF ---50V 3KV Reference Common Choke, P/N: PMT-051 2.6A 0.04Ω 0705 SMD Inductor P/N: PMT-070 ---1812 MLCC 1808 MLCC Recommended Layout with Input Filter Figure 13 (888) 597-WALL www.wallindustries.com Page 11 of 17 Rev B TECHNICAL DATASHEET JFW24S15-1000 Recommended Pad Layout for DIP Type Figure 14 Recommended Pad Layout for SMT Type Figure 15 (888) 597-WALL www.wallindustries.com Page 12 of 17 TECHNICAL DATASHEET Rev B JFW24S15-1000 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 13 of 17 Rev B TECHNICAL DATASHEET JFW24S15-1000 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 14 of 17 Rev B TECHNICAL DATASHEET JFW24S15-1000 Packaging Information: DIP Type Figure 18 SMT Type Figure 19 (888) 597-WALL www.wallindustries.com Page 15 of 17 TECHNICAL DATASHEET Rev B JFW24S15-1000 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. 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. Ordering Information Part Number Example: JFW 24 S 15 – 1000 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 16 of 17 Rev B TECHNICAL DATASHEET JFW24S15-1000 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 17 of 17