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. (888) 597-WALL www.wallindustries.com 1 of 16 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 (888) 597-WALL www.wallindustries.com Page 2 of 16 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) (888) 597-WALL www.wallindustries.com Page 3 of 16 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 (888) 597-WALL www.wallindustries.com Page 4 of 16 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 (888) 597-WALL When JFW module is turned off at High-level logic www.wallindustries.com Page 5 of 16 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 (888) 597-WALL 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 www.wallindustries.com Page 6 of 16 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) (888) 597-WALL www.wallindustries.com Page 7 of 16 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) (888) 597-WALL www.wallindustries.com Page 8 of 16 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 (888) 597-WALL www.wallindustries.com Page 9 of 16 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 (888) 597-WALL 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 www.wallindustries.com Page 10 of 16 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 (888) 597-WALL 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 www.wallindustries.com Page 11 of 16 TECHNICAL DATASHEET JFW48S5-3000 Recommended Pad Layout for DIP Type Figure 15 Recommended Pad Layout for SMT Type Figure 16 (888) 597-WALL www.wallindustries.com Page 12 of 16 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 (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 13 of 16 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. (888) 597-WALL www.wallindustries.com Page 14 of 16 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. (888) 597-WALL www.wallindustries.com Page 15 of 16 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] www.wallindustries.com 5 Watson Brook Rd. Exeter, NH 03833 www.wallindustries.com Page 16 of 16