Data Sheet April 2008 JW050F, JW075F, JW100F, JW150F Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 3.3 Vdc Output; 33 W to 99 W Features n The JW050F, JW075F, JW100F, and JW150F Power Modules use advanced, surface-mount technology and deliver highquality, efficient, and compact dc-dc conversion. Applications Small size: 61.0 mm x 57.9 mm x 12.7 mm (2.40 in. x 2.28 in. x 0.50 in.) n High power density n High efficiency: 80% typical n Low output noise n Constant frequency n Industry-standard pinout n Metal baseplate n 2:1 input voltage range n Overtemperature protection (66 W and 99 W only) n Overcurrent and overvoltage protection n Remote sense n Remote on/off n Distributed power architectures n Adjustable output voltage: 60% to 110% of VO, nom n Workstations n Case ground pin n Computer equipment n ISO9001 Certified manufacturing facilities n Communications equipment n Options n Heat sinks available for extended operation n Choice of remote on/off logic configuration Description n UL* 1950 Recognized, CSA † C22.2 No. 950-95 Certified, and VDE 0805 (EN60950, IEC950) Licensed CE mark meets 73/23/EEC and 93/68/EEC directives‡ * UL is a registered trademark of Underwriters Laboratories, Inc. † CSA is a registered trademark of Canadian Standards Assn. ‡ This product is intended for integration into end-use equipment. All the required procedures for CE marking of end-use equipment should be followed. (The CE mark is placed on selected products.) The JW050F, JW075F, JW100F, and JW150F Power Modules are dc-dc converters that operate over an input voltage range of 36 Vdc to 75 Vdc and provide a precisely regulated dc output. The outputs are fully isolated from the inputs, allowing versatile polarity configurations and grounding connections. The modules have maximum power ratings from 33 W to 99 W at a typical full-load efficiency of 80%. The sealed modules offer a metal baseplate for excellent thermal performance. Threaded-through holes are provided to allow easy mounting or addition of a heat sink for high-temperature applications. The standard feature set includes remote sensing, output trim, and remote on/off for convenient flexibility in distributed power applications. JW050F, JW075F, JW100F, JW150F Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 3.3 Vdc Output; 33 W to 99 W Data Sheet April 2008 Absolute Maximum Ratings Stresses in excess of the absolute maximum ratings can cause permanent damage to the device. These are absolute stress ratings only. Functional operation of the device is not implied at these or any other conditions in excess of those given in the operations sections of the data sheet. Exposure to absolute maximum ratings for extended periods can adversely affect device reliability. Parameter Symbol Min Max Unit VI VI VI, trans — — — 75 80 100 Vdc Vdc V I/O Isolation Voltage (for 1 minute) — — 1500 Vdc Operating Case Temperature (See Thermal Considerations section.) TC –40 100 °C Storage Temperature Tstg –55 125 °C Input Voltage: Continuous: JW050F, JW075F JW100F, JW150F Transient (100 ms; JW100F, JW150F only) Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Table 1. Input Specifications Parameter Symbol Min Typ Max Unit VI 36 48 75 Vdc II, max II, max II, max II, max — — — — — — — — 1.2 1.8 2.4 3.7 A A A A Inrush Transient i2 t — — 1.0 A2s Input Reflected-ripple Current, Peak-to-peak (5 Hz to 20 MHz, 12 µH source impedance; see Figure 17.) II — 5 — mAp-p Input Ripple Rejection (120 Hz) — — 60 — dB Operating Input Voltage Maximum Input Current (VI = 0 V to 75 V; IO = IO, max): JW050F (See Figure 1.) JW075F (See Figure 2.) JW100F (See Figure 3.) JW150F (See Figure 4.) Fusing Considerations 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 a sophisticated power architecture. To preserve 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, dc fuse with a maximum rating of 20 A (see Safety Considerations section). Based on the information provided in this data sheet on inrush energy and maximum dc input current, the same type of fuse with a lower rating can be used. Refer to the fuse manufacturer’s data for further information. 2 Lineage Power JW050F, JW075F, JW100F, JW150F Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 3.3 Vdc Output; 33 W to 99 W Data Sheet April 2008 Electrical Specifications (continued) Table 2. Output Specifications Device Symbol Min Typ Max Unit Output Voltage Set Point (VI = 48 V; IO = IO, max; TC = 25 °C) Parameter All VO, set 3.25 3.3 3.35 Vdc Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life. See Figure 19.) All VO 3.20 — 3.40 Vdc Output Regulation: Line (VI = 36 V to 75 V) Load (IO = IO, min to IO, max) Temperature (TC = –40 °C to +100 °C) All All All — — — — — — 0.01 0.05 15 0.1 0.2 50 %VO %VO mV Output Ripple and Noise Voltage (See Figure 18.): RMS Peak-to-peak (5 Hz to 20 MHz) All All — — — — — — 40 150 mVrms mVp-p External Load Capacitance All — 0 — * µF Output Current (At IO < IO, min, the modules may exceed output ripple specifications.) JW050F JW075F JW100F JW150F IO IO IO IO 0.5 0.5 0.5 0.5 — — — — 10 15 20 30 A A A A Output Current-limit Inception (VO = 90% of VO, nom) JW050F JW075F JW100F JW150F IO, cli IO, cli IO, cli IO, cli — — — — 12.0 18.0 23.0 34.5 14† 21† 26† 39† A A A A Output Short-circuit Current (VO = 250 mV) Efficiency (VI = 48 V; IO = IO, max; TC = 70 °C) Switching Frequency Dynamic Response (ýIO/ýt = 1 A/10 µs, VI = 48 V, TC = 25 °C; tested with a 10 µF aluminum and a 1.0 µF ceramic capacitor across the load; see Figures 14 and 15): Load Change from IO = 50% to 75% of IO, max: Peak Deviation Settling Time (VO < 10% of peak deviation) Load Change from IO = 50% to 25% of IO, max: Peak Deviation Settling Time (VO < 10% of peak deviation) All — — 170 — %IO, max JW050F JW075F JW100F JW150F η η η η — — — — 80 80 80 80 — — — — % % % % All — — 500 — kHz All All — — — — 3.8 300 — — %VO, set µs All All — — — — 3.8 300 — — %VO, set µs * Consult your sales representative or the factory. † These are manufacturing test limits. In some situations, results may differ. Lineage Power 3 JW050F, JW075F, JW100F, JW150F Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 3.3 Vdc Output; 33 W to 99 W Data Sheet April 2008 Electrical Specifications (continued) Table 3. Isolation Specifications Parameter Min Typ Max Unit Isolation Capacitance — 2500 — pF Isolation Resistance 10 — — M¾ Min Typ Max Unit General Specifications Parameter Calculated MTBF (IO = 80% of IO, max; TC = 40 °C) Weight 2,600,000 — — hr. 100 (3.5) g (oz.) Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See Feature Descriptions for additional information. Parameter Remote On/Off Signal Interface (VI = 0 V to 75 V; open collector or equivalent compatible; signal referenced to VI(–) terminal; see Figure 20 and Feature Descriptions.): JWxxxF1 Preferred Logic: Logic Low—Module On Logic High—Module Off JWxxxF Optional Logic: Logic Low—Module Off Logic High—Module On Logic Low: At Ion/off = 1.0 mA At Von/off = 0.0 V Logic High: At Ion/off = 0.0 µA Leakage Current Turn-on Time (See Figure 16.) (IO = 80% of IO, max; VO within ±1% of steady state) Output Voltage Adjustment (See Feature Descriptions.): Output Voltage Remote-sense Range Output Voltage Set-point Adjustment Range (trim) Output Overvoltage Protection Overtemperature Protection (shutdown) (66 W and 99 W only; see Feature Descriptions.) Symbol Min Typ Max Unit Von/off Ion/off 0 — — — 1.2 1.0 V mA Von/off Ion/off — — — — — — 20 15 50 35 V µA ms — — — 60 — — 0.5 110 V %VO, nom VO, clamp 4.0* — 5.0* V TC — 105 — °C * These are manufacturing test limits. In some situations, results may differ. 4 Lineage Power Data Sheet April 2008 JW050F, JW075F, JW100F, JW150F Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 3.3 Vdc Output; 33 W to 99 W Characteristic Curves The following figures provide typical characteristics for the power modules. The figures are identical for both on/off configurations. 1.4 3.0 1.2 2.5 1.0 2.0 0.8 1.5 0.6 1.0 0.4 0.5 0.2 0.0 0.0 0 4 0 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 INPUT VOLTAGE, V 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 INPUT VOLTAGE, V I (V) I (V 8-1446 (C) Figure 1. Typical JW050F Input Characteristics at Room Temperature ) 8-1448 (C) Figure 3. Typical JW100F Input Characteristics at Room Temperature 2.0 4.0 1.8 3.5 1.6 3.0 1.4 1.2 2.5 1.0 2.0 0.8 1.5 0.6 1.0 0.4 0.2 0.5 0.0 0 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 INPUT VOLTAGE, V I (V) 0 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 INPUT VOLTAGE, V 8-1447 (C) Figure 2. Typical JW075F Input Characteristics at Room Temperature Lineage Power 0.0 I (V) 8-1449 (C) Figure 4. Typical JW150F Input Characteristics at Room Temperature 5 JW050F, JW075F, JW100F, JW150F Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 3.3 Vdc Output; 33 W to 99 W Data Sheet April 2008 Characteristic Curves (continued) 3.5 3.5 3 3.0 2.5 2.5 VI = 36 V VI = 54 V VI = 72 V 2 2.0 1.5 1.5 1 1.0 0.5 0.5 0.0 0 0 2 4 6 8 OUTPUT CURRENT, I O 10 0 12 5 10 15 20 OUTPUT CURRENT, I (A) O 25 30 (A) 8-1452 (C) 8-2159 (C) Figure 5. Typical JW050F Output Characteristics at Room Temperature 3.5 3.5 3.0 3.0 2.5 2.5 2.0 2.0 1.5 1.5 1.0 1.0 0.5 0.5 0.0 0 2 4 6 8 10 12 OUTPUT CURRENT, I 14 O 16 18 20 (A) 0.0 0 5 10 15 20 OUTPUT CURRENT, I 8-1451 (C) Figure 6. Typical JW075F Output Characteristics at Room Temperature 6 Figure 7. Typical JW100F Output Characteristics at Room Temperature 25 30 O 35 40 (A) 8-1453 (C) Figure 8. Typical JW150F Output Characteristics at Room Temperature Lineage Power JW050F, JW075F, JW100F, JW150F Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 3.3 Vdc Output; 33 W to 99 W Data Sheet April 2008 Characteristic Curves (continued) 81 82 81.5 80 81 79 V I = 36 V 80.5 78 80 77 V I = 54 V 79.5 76 79 V I = 36 V V I = 54 V V I = 72 V 75 78.5 78 74 V I = 72 V 77.5 73 77 72 76.5 76 71 2 3 4 5 6 7 OUTPUT CURRENT, I 8 O 9 10 0 2 4 6 8 10 12 OUTPUT CURRENT, I (A) 14 O 16 18 (A) 8-1454 (C) Figure 9. Typical JW050F Converter Efficiency vs. Output Current at Room Temperature 8-1456 (C) Figure 11. Typical JW100F Converter Efficiency vs. Output Current at Room Temperature 78.5 82 78.0 81 77.5 80 77.0 79 76.5 78 76.0 75.0 V I = 36 V 77 V I = 36 V V I = 54 V V I = 72 V 75.5 20 V I = 54 V 76 V I = 72 V 75 74.5 74 74.0 73 73.5 72 3 4 5 6 7 8 9 10 OUTPUT CURRENT, I 11 O 12 13 14 15 (A) 5 10 15 OUTPUT CURRENT, I 8-1455 (C) Figure 10. Typical JW075F Converter Efficiency vs. Output Current at Room Temperature Lineage Power 0 20 O 25 30 (A) 8-1457 (C) Figure 12. Typical JW150F Converter Efficiency vs. Output Current at Room Temperature 7 JW050F, JW075F, JW100F, JW150F Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 3.3 Vdc Output; 33 W to 99 W Data Sheet April 2008 Characteristic Curves (continued) 1.5 A 3.3 V 15.0 A 15.0 A 7.5 A 30.0 A TIME, t (50 µs/div) 8-2001 (C) TIME, t (1 µs/div) 8-2002 (C) Figure 13. Typical JW150F Output Ripple Voltage at Room Temperature, IO = Full Load Note: Tested with a 10 µF aluminum and a 1.0 µF ceramic capacitor across the load. Figure 15. Typical JW150F Transient Response to Step Decrease in Load from 50% to 25% of Full Load at Room Temperature and 48 V Input (Waveform Averaged to Eliminate Ripple Component.) 3.30 V 22.5 A 0 15.0 A TIME, t (50 µs/div) 8-2000 (C) Note: Tested with a 10 µF aluminum and a 1.0 µF ceramic capacitor across the load. Figure 14. Typical JW150F Transient Response to Step Increase in Load from 50% to 75% of Full Load at Room Temperature and 48 V Input (Waveform Averaged to Eliminate Ripple Component.) 8 0 TIME, t (5 ms/div) 8-1458 (C) Note: Tested with a 10 µF aluminum and a 1.0 µF ceramic capacitor across the load. Figure 16. Typical Start-Up from Remote On/Off JW150F1; IO = IO, max Lineage Power JW050F, JW075F, JW100F, JW150F Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 3.3 Vdc Output; 33 W to 99 W Data Sheet April 2008 Test Configurations SENSE(+) V I(+) CONTACT AND DISTRIBUTION LOSSES V O (+) T O O SC ILLO SC O PE SUPPLY LOAD VI ( + ) 12 µ H V I(–) C S 220 µ F ESR < 0.1 • 33 µ F @ 20 °C , 100 kH z ESR < 0.7 • @ 100 kH z BAT T ER Y IO II C U R R EN T PR O BE LT E S T CONTACT RESISTANCE V O (–) SENSE(–) 8-749 (C) V I ( –) 8-203 (C).l Note: Measure input reflected-ripple current with a simulated source inductance (LTEST) of 12 µH. Capacitor CS offsets possible battery impedance. Measure current as shown above. Figure 17. Input Reflected-Ripple Test Setup Note: All measurements are taken at the module terminals. When socketing, place Kelvin connections at module terminals to avoid measurement errors due to socket contact resistance. [ V O (+) – V O (–) ]I O η = ⎛ ------------------------------------------------⎞ x 100 ⎝ [ V I (+) – V I (–) ]I I ⎠ % Figure 19. Output Voltage and Efficiency Measurement Test Setup Design Considerations COPPER STRIP V O (+) Input Source Impedance 1.0 µF 10 µF SCOPE RESISTIVE LOAD V O (–) 8-513 (C).d Note: Use a 1.0 µF ceramic capacitor and a 10 µF aluminum or tantalum capacitor. Scope measurement should be made using a BNC socket. Position the load between 51 mm and 76 mm (2 in. and 3 in.) from the module. The power module should be connected to a low ac-impedance input source. Highly inductive source impedances can affect the stability of the power module. For the test configuration in Figure 17, a 33 µF electrolytic capacitor (ESR < 0.7 ¾ at 100 kHz) mounted close to the power module helps ensure stability of the unit. For other highly inductive source impedances, consult the factory for further application guidelines. Figure 18. Peak-to-Peak Output Noise Measurement Test Setup Lineage Power 9 JW050F, JW075F, JW100F, JW150F Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 3.3 Vdc Output; 33 W to 99 W Data Sheet April 2008 Safety Considerations Remote On/Off For safety-agency approval of the system in which the power module is used, the power module must be installed in compliance with the spacing and separation requirements of the end-use safety agency standard, i.e., UL1950, CSA C22.2 No. 950-95, and VDE 0805 (EN60950, IEC950). Two remote on/off options are available. Positive logic remote on/off turns the module on during a logic-high voltage on the ON/OFF pin, and off during a logic low. Negative logic remote on/off turns the module off during a logic high and on during a logic low. Negative logic (code suffix 1) is the factory-preferred configuration. If the input source is non-SELV (ELV or a hazardous voltage greater than 60 Vdc and less than or equal to 75 Vdc), for the module’s output to be considered meeting the requirements of safety extra-low voltage (SELV), all of the following must be true: n n n n The input source is to be provided with reinforced insulation from any hazardous voltages, including the ac mains. One VI pin and one VO pin are to be grounded or both the input and output pins are to be kept floating. The input pins of the module are not operator accessible. Another SELV reliability test is conducted on the whole system, as required by the safety agencies, on the combination of supply source and the subject module to verify that under a single fault, hazardous voltages do not appear at the module’s output. Note: Do not ground either of the input pins of the module without grounding one of the output pins. This may allow a non-SELV voltage to appear between the output pin and ground. The power module has extra-low voltage (ELV) outputs when all inputs are ELV. The input to these units is to be provided with a maximum 20 A normal-blow fuse in the ungrounded lead. Feature Descriptions Overcurrent Protection To turn the power module on and off, the user must supply a switch to control the voltage between the on/off terminal and the VI(–) terminal (Von/off). The switch can be an open collector or equivalent (see Figure 20). A logic low is Von/off = 0 V to 1.2 V. The maximum Ion/off during a logic low is 1 mA. The switch should maintain a logic-low voltage while sinking 1 mA. During a logic high, the maximum Von/off generated by the power module is 15 V. The maximum allowable leakage current of the switch at Von/off = 15 V is 50 µA. If not using the remote on/off feature, do one of the following: n For negative logic, short ON/OFF pin to VI(–). n For positive logic, leave ON/OFF pin open. Ion/off ON/OFF V on/off SENSE(+) V O (+) LOAD V I (+) V I (–) V O (–) SENSE(–) 8-720 (C).c Figure 20. Remote On/Off Implementation To provide protection in a fault (output overload) condition, the unit is equipped with internal current-limiting circuitry and can endure current limiting for an unlimited duration. At the point of current-limit inception, the unit shifts from voltage control to current control. If the output voltage is pulled very low during a severe fault, the current-limit circuit can exhibit either foldback or tailout characteristics (output current decrease or increase). The unit operates normally once the output current is brought back into its specified range. 10 Lineage Power JW050F, JW075F, JW100F, JW150F Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 3.3 Vdc Output; 33 W to 99 W Data Sheet April 2008 Feature Descriptions (continued) Output Voltage Set-Point Adjustment (Trim) Remote Sense Remote sense minimizes the effects of distribution losses by regulating the voltage at the remote-sense connections. The voltage between the remote-sense pins and the output terminals must not exceed the output voltage sense range given in the Feature Specifications table, i.e.: [VO(+) – VO(–)] – [SENSE(+) – SENSE(–)] ð 0.5 V The voltage between the VO(+) and VO(–) terminals must not exceed the minimum value of the output overvoltage protection. This limit includes any increase in voltage due to remote-sense compensation and output voltage set-point adjustment (trim). See Figure 21. If not using the remote-sense feature to regulate the output at the point of load, then connect SENSE(+) to VO(+) and SENSE(–) to VO(–) at the module. Although the output voltage can be increased by both the remote sense and by the trim, the maximum increase for the output voltage is not the sum of both. The maximum increase is the larger of either the remote sense or the trim. Consult the factory if you need to increase the output voltage more than the above limitation. The amount of power delivered by the module is defined as the voltage at the output terminals multiplied by the output current. When using remote sense and trim, the output voltage of the module can be increased, which at the same output current would increase the power output of the module. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power. SENSE(+) SENSE(–) SUPPLY II CONTACT RESISTANCE V I (+) V O (+) V I (–) V O (–) IO LOAD CONTACT AND DISTRIBUTION LOSSES 8-651 (C).m Figure 21. Effective Circuit Configuration for Single-Module Remote-Sense Operation Lineage Power Output voltage trim 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 SENSE(+) or SENSE(–) pins. The trim resistor should be positioned close to the module. If not using the trim feature, leave the TRIM pin open. With an external resistor between the TRIM and SENSE(–) pins (Radj-down), the output voltage set point (VO, adj) decreases (see Figure 22). The following equation determines the required external-resistor value to obtain a percentage output voltage change of ý%. 100 R adj-down = ⎛ ---------- – 2⎞ kΩ ⎝ Δ% ⎠ The test results for this configuration are displayed in Figure 23. This figure applies to all output voltages. With an external resistor connected between the TRIM and SENSE(+) pins (Radj-up), the output voltage set point (VO, adj) increases (see Figure 24). The following equation determines the required external-resistor value to obtain a percentage output voltage change of ý%. 100 + 2Δ% )⎞ V O ( 100 + Δ% -) – (--------------------------------- kΩ R adj-up = ⎛ ------------------------------------⎝ 1.225Δ% ⎠ Δ% The test results for this configuration are displayed in Figure 25. The voltage between the VO(+) and VO(–) terminals must not exceed the minimum value of the output overvoltage protection. This limit includes any increase in voltage due to remote-sense compensation and output voltage set-point adjustment (trim). See Figure 21. Although the output voltage can be increased by both the remote sense and by the trim, the maximum increase for the output voltage is not the sum of both. The maximum increase is the larger of either the remote sense or the trim. Consult the factory if you need to increase the output voltage more than the above limitation. The amount of power delivered by the module is defined as the voltage at the output terminals multiplied by the output current. When using remote sense and trim, the output voltage of the module can be increased, which at the same output current would increase the power output of the module. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power. 11 JW050F, JW075F, JW100F, JW150F Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 3.3 Vdc Output; 33 W to 99 W Data Sheet April 2008 Feature Descriptions (continued) Output Voltage Set-Point Adjustment (Trim) (continued) 10M 1M V I (+) ON/OFF V O (+) SENSE(+) CASE R LOAD TRIM 100k R adj-down V I (–) SENSE(–) 10k V O (–) 0 8-748 (C).b Figure 22. Circuit Configuration to Decrease Output Voltage 2 4 6 8 10 % CHANGE IN OUTPUT VOLTAGE (•%) 8-2090 (C) Figure 25. Resistor Selection for Increased Output Voltage Output Overvoltage Protection 1M The output overvoltage clamp consists of control circuitry, independent of the primary regulation loop, that monitors the voltage on the output terminals. The control loop of the clamp has a higher voltage set point than the primary loop (see Feature Specifications table). This provides a redundant voltage control that reduces the risk of output overvoltage. 100k 10k 1k Overtemperature Protection 100 0 10 20 30 40 % CHANGE IN OUTPUT VOLTAGE (•%) 8-879 (C) Figure 23. Resistor Selection for Decreased Output Voltage The 100 W and 150 W modules feature an overtemperature protection circuit to safeguard against thermal damage. The circuit shuts down the module when the maximum case temperature is exceeded. The module restarts automatically after cooling. Thermal Considerations V I (+) ON/OFF V O (+) Introduction SENSE(+) R adj-up CASE V I (–) TRIM R LOAD SENSE (–) V O (–) 8-715 (C).b Figure 24. Circuit Configuration to Increase Output Voltage 12 The power modules operate in a variety of thermal environments; however, sufficient cooling should be provided to help ensure reliable operation of the unit. Heat-dissipating components inside the unit are thermally coupled to the case. Heat is removed by conduction, convection, and radiation to the surrounding environment. Proper cooling can be verified by measuring the case temperature. Peak temperature (TC) occurs at the position indicated in Figure 26. Lineage Power JW050F, JW075F, JW100F, JW150F Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 3.3 Vdc Output; 33 W to 99 W Data Sheet April 2008 Thermal Considerations (continued) Introduction (continued) 38.0 (1.50) MEASURE CASE TEMPERATURE HERE Note that the natural convection condition was measured at 0.05 m/s to 0.1 m/s (10 ft./min. to 20 ft./min.); however, systems in which these power modules may be used typically generate natural convection airflow rates of 0.3 m/s (60 ft./min.) due to other heat dissipating components in the system. The use of Figure 31 is shown in the following example. Example 7.6 (0.3) V I (+) What is the minimum airflow necessary for a JW100F operating at VI = 54 V, an output current of 20 A, and a maximum ambient temperature of 40 °C? V O (+) ON/OFF + SEN CASE – SEN V I (–) V O (–) Solution TRIM Given: VI = 54 V IO = 20 A TA = 40 °C Determine PD (Use Figure 29.): 8-716 (C).f Note: Top view, pin locations are for reference only. Measurements shown in millimeters and (inches). PD = 15.8 W Determine airflow (v) (Use Figure 31.): Figure 26. Case Temperature Measurement Location The temperature at this location should not exceed 100 °C. The output power of the module should not exceed the rated power for the module as listed in the Ordering Information table. Although the maximum case temperature of the power modules is 100 °C, you can limit this temperature to a lower value for extremely high reliability. For additional information on these modules, refer to the Thermal Management JC-, JFC-, JW-, and JFWSeries 50 W to 150 W Board-Mounted Power Modules Technical Note (TN97-008EPS). Heat Transfer Without Heat Sinks v = 1.7 m/s (340 ft./min.) 9 8 7 V I = 75 V 6 V I = 54 V 5 V I = 36 V 4 3 2 0 1 2 3 4 5 6 OUTPUT CURRENT, I 7 O 8 9 10 (A) 8-1459 (C) Figure 27. JW050F Power Dissipation vs. Output Current Increasing airflow over the module enhances the heat transfer via convection. Figure 31 shows the maximum power that can be dissipated by the module without exceeding the maximum case temperature versus local ambient temperature (TA) for natural convection through 4 m/s (800 ft./min.). Lineage Power 13 JW050F, JW075F, JW100F, JW150F Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 3.3 Vdc Output; 33 W to 99 W Data Sheet April 2008 Thermal Considerations (continued) Heat Transfer Without Heat Sinks (continued) 30 25 20 16 15 14 12 10 10 V I = 36 V V I = 54 V V I = 75 36 V 5 8 V I = 36 V V I = 54 V V I = 75 36 V 6 0 0 5 10 4 15 20 OUTPUT CURRENT, I O 25 30 (A) 8-1462 (C) 2 Figure 30. JW150F Power Dissipation vs. Output Current 0 0 2 4 6 8 10 OUTPUT CURRENT, I O 12 14 (A) 8-1460 (C) Figure 28. JW075F Power Dissipation vs. Output Current 35 4.0 m/s 3.5 m/s 3.0 m/s 2.5 m/s 2.0 m/s 1.5 m/s 1.0 m/s 0.5 m/s 30 25 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 20 (800 ft./min.) (700 ft./min.) (600 ft./min.) (500 ft./min.) (400 ft./min.) (300 ft./min.) (200 ft./min.) (100 ft./min.) 15 10 V I = 36 V V I = 54 V V I = 75 36 V 5 0.1 m/s (NAT. CONV.) (20 ft./min.) 0 0 10 20 30 40 50 60 LOCAL AMBIENT TEMPERATURE, T 0 2 4 6 8 10 12 OUTPUT CURRENT, I 14 O 16 18 20 (A) 70 80 A 90 100 (°C) 8-1150 (C).a Figure 31. Forced Convection Power Derating with No Heat Sink; Either Orientation 8-1461 (C) Figure 29. JW100F Power Dissipation vs. Output Current Heat Transfer with Heat Sinks The power modules have through-threaded, M3 x 0.5 mounting holes, which enable heat sinks or cold plates to attach to the module. The mounting torque must not exceed 0.56 N-m (5 in.-lb.). For a screw attachment from the pin side, the recommended hole size on the customer’s PWB around the mounting holes is 0.130 ± 0.005 inches. If a larger hole is used, the mounting torque from the pin side must not exceed 0.25 N-m (2.2 in.-lb.). 14 Lineage Power JW050F, JW075F, JW100F, JW150F Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 3.3 Vdc Output; 33 W to 99 W Data Sheet April 2008 Thermal Considerations (continued) Example Heat Transfer with Heat Sinks (continued) Thermal derating with heat sinks is expressed by using the overall thermal resistance of the module. Total module thermal resistance (θca) is defined as the maximum case temperature rise (ΔTC, max) divided by the module power dissipation (PD): ( TC – TA) C, max θ ca = ΔT --------------------- = -----------------------PD PD The location to measure case temperature (TC) is shown in Figure 26. Case-to-ambient thermal resistance vs. airflow is shown, for various heat sink configurations and heights, in Figure 32. These curves were obtained by experimental testing of heat sinks, which are offered in the product catalog. 1 1/2 IN. HEAT SINK 6 1 IN. HEAT SINK 1/2 IN. HEAT SINK 1/4 IN. HEAT SINK 5 Solution Given: VI = 54 V IO = 20 A TA = 40 °C TC = 85 °C Heat sink = 1/2 in. Determine PD by using Figure 29: PD = 15.8 W Then solve the following equation: ( TC – TA) θ ca = ----------------------- 8 7 If an 85 °C case temperature is desired, what is the minimum airflow necessary? Assume the JW100F module is operating at VI = 54 V and an output current of 20 A, maximum ambient air temperature of 40 °C, and the heat sink is 1/2 inch. PD 85 – 40 ) θ ca = (----------------------15.8 NO HEAT SINK 4 θ ca = 2.8 °C/W 3 Use Figure 32 to determine air velocity for the 1/2 inch heat sink. 2 1 0 0 0.5 (100) 1.0 (200) 1.5 (300) 2.0 (400) 2.5 (500) 3.0 (600) AIR VELOCITY, m/s (ft./min.) 8-1153 (C) Figure 32. Case-to-Ambient Thermal Resistance Curves; Either Orientation These measured resistances are from heat transfer from the sides and bottom of the module as well as the top side with the attached heat sink; therefore, the case-to-ambient thermal resistances shown are generally lower than the resistance of the heat sink by itself. The module used to collect the data in Figure 32 had a thermal-conductive dry pad between the case and the heat sink to minimize contact resistance. The use of Figure 32 is shown in the following example. Lineage Power The minimum airflow necessary for the JW100F module is 1.1 m/s (220 ft./min.). Custom Heat Sinks A more detailed model can be used to determine the required thermal resistance of a heat sink to provide necessary cooling. The total module resistance can be separated into a resistance from case-to-sink (θcs) and sink-to-ambient (θsa) shown below (Figure 33). PD ∅ TC TS θ cs TA θ sa 8-1304 (C) Figure 33. Resistance from Case-to-Sink and Sink-to-Ambient 15 JW050F, JW075F, JW100F, JW150F Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 3.3 Vdc Output; 33 W to 99 W Thermal Considerations (continued) Custom Heat Sinks (continued) For a managed interface using thermal grease or foils, a value of θcs = 0.1 °C/W to 0.3 °C/W is typical. The solution for heat sink resistance is: (TC – TA) PD θ sa = ------------------------- – θ cs This equation assumes that all dissipated power must be shed by the heat sink. Depending on the userdefined application environment, a more accurate model, including heat transfer from the sides and bottom of the module, can be used. This equation provides a conservative estimate for such instances. Data Sheet April 2008 Solder, Cleaning, and Drying Considerations Post solder cleaning is usually the final circuit-board assembly process prior to electrical testing. The result of inadequate circuit-board cleaning and drying can affect both the reliability of a power module and the testability of the finished circuit-board assembly. For guidance on appropriate soldering, cleaning, and drying procedures, refer to the Board-Mounted Power Modules Soldering and Cleaning Application Note (AP97-021EPS). EMC Considerations For assistance with designing for EMC compliance, please refer to the FLTR100V10 data sheet (DS98-152EPS). Layout Considerations Copper paths must not be routed beneath the power module mounting inserts. For additional layout guidelines, refer to the FLTR100V10 data sheet (DS98-152EPS). 16 Lineage Power JW050F, JW075F, JW100F, JW150F Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 3.3 Vdc Output; 33 W to 99 W Data Sheet April 2008 Outline Diagram Dimensions are in millimeters and (inches). Tolerances: x.x mm ± 0.5 mm (x.xx in. ± 0.02 in.) x.xx mm ± 0.25 mm (x.xxx in. ± 0.010 in.) Top View 57.9 (2.28) MAX 61.0 (2.40) MAX Side View SIDE LABEL* 12.70 ± 0.5 (0.500 ± 0.020) 5.1 (0.20) MIN 2.06 (0.081) DIA SOLDER-PLATED BRASS, 2 PLACES (–OUTPUT AND +OUTPUT) 1.02 (0.040) DIA SOLDER-PLATED BRASS, 7 PLACES Bottom View MOUNTING INSERTS M3 x 0.5 THROUGH, 4 PLACES 12.7 (0.50) 5.1 (0.20) 10.16 (0.400) 50.8 (2.00) 25.40 (1.000) 35.56 (1.400) V I (–) V O (–) CASE –SEN TRIM ON/OFF V I (+) 4.8 (0.19) +SEN 48.26 (1.900) 10.16 (0.400) 17.78 (0.700) 25.40 (1.000) 35.56 (1.400) V O (+) 48.3 (1.90) 8-1945 (C).c * Side label includes Lineage name, product designation, safety agency markings, input/output voltage and current ratings, and bar code. Lineage Power 17 JW050F, JW075F, JW100F, JW150F Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 3.3 Vdc Output; 33 W to 99 W Data Sheet April 2008 Recommended Hole Pattern Component-side footprint. Dimensions are in millimeters and (inches). 57.9 (2.28) MAX 4.8 (0.19) 48.3 (1.90) V I (+) 35.56 (1.400) 50.8 (2.00) ON/OFF 48.26 (1.900) V O (+) 35.56 (1.400) +SEN 25.40 (1.000) TRIM 25.40 (1.000) 10.16 (0.400) CASE –SEN V I (–) V O (–) 61.0 (2.40) MAX 17.78 10.16 (0.700) (0.400) 5.1 (0.20) 12.7 (0.50) MOUNTING INSERTS MODULE OUTLINE 8-1945 (C).c Ordering Information Table 4. Device Codes 18 Input Voltage Output Voltage Output Power Remote On/Off Logic Device Code Comcode 48 V 3.3 V 33 W Negative JW050F1 107253171 48 V 3.3 V 49.5 W Negative JW075F1 107431256 48 V 3.3 V 66 W Negative JW100F1 107253189 48 V 3.3 V 99 W Negative JW150F1 107361461 48 V 3.3 V 33 W Positive JW050F 107309775 48 V 3.3 V 49.5 W Positive JW075F 107477374 48 V 3.3 V 66 W Positive JW100F 107309791 48 V 3.3 V 99 W Positive JW150F 107018962 Lineage Power Data Sheet April 2008 JW050F, JW075F, JW100F, JW150F Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 3.3 Vdc Output; 33 W to 99 W Ordering Information (continued) Table 5. Device Accessories Accessory Comcode 1/4 in. transverse kit (heat sink, thermal pad, and screws) 1/4 in. longitudinal kit (heat sink, thermal pad, and screws) 1/2 in. transverse kit (heat sink, thermal pad, and screws) 1/2 in. longitudinal kit (heat sink, thermal pad, and screws) 1 in. transverse kit (heat sink, thermal pad, and screws) 1 in. longitudinal kit (heat sink, thermal pad, and screws) 1 1/2 in. transverse kit (heat sink, thermal pad, and screws) 1 1/2 in. longitudinal kit (heat sink, thermal pad, and screws) 407243989 407243997 407244706 407244714 407244722 407244730 407244748 407244755 Dimensions are in millimeters and (inches). 1/4 IN. 1/4 IN. 1/2 IN. 1/2 IN. 1 IN. 1 IN. 61 (2.4) 57.9 (2.28) 1 1/2 IN. 1 1/2 IN. 57.9 (2.28) 61 (2.4) D000-c.cvs D000-d.cvs Figure 34. Longitudinal Heat Sink Figure 35. Transverse Heat Sink Lineage Power 19 JW050F, JW075F, JW100F, JW150F Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 3.3 Vdc Output; 33 W to 99 W Data Sheet April 2008 A sia-Pacific Head qu art ers T el: +65 6 41 6 4283 World W ide Headq u arters Lin eag e Po wer Co rp oratio n 30 00 Sk yline D rive, Mesquite, T X 75149, U SA +1-800-526-7819 (Outs id e U .S.A .: +1- 97 2-2 84 -2626) www.line ag ep ower.co m e-m ail: tech sup port1@ lin ea gep ower.co m Eu ro pe, M id dle-East an d Afric a He ad qu arters T el: +49 8 9 6089 286 Ind ia Head qu arters T el: +91 8 0 28411633 Lineage Power reserves the right to make changes to the produc t(s) or information contained herein without notice. No liability is ass umed as a res ult of their use or applic ation. No rights under any patent acc ompany the sale of any s uc h pr oduct(s ) or information. © 2008 Lineage Power Corpor ation, (Mesquite, Texas ) All International Rights Res er ved. April 2008 DS99-289EPS (Replaces DS99-288EPS)