Data Sheet August 1998 JC050A, JC075A, JC100A Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W to 100 W Features Small size: 61.0 mm x 57.9 mm x 12.7 mm (2.40 in. x 2.28 in. x 0.50 in.) High power density High efficiency: 85% typical Low output noise Constant frequency Industry-standard pinout Metal baseplate 2:1 input voltage range The JC050A, JC075A, JC100A Power Modules use advanced, surface-mount technology and deliver high-quality, efficient, compact dc-dc conversion. Overtemperature protection (100 W only) Remote sense Applications Remote on/off Adjustable output voltage Case ground pin UL* Recognized, CSA Certified, VDE Licensed Distributed power architectures Workstations EDP equipment Telecommunications Options Choice of remote on/off logic configuration Heat sink available for extended operation * UL is a registered trademark of Underwriters Laboratories, Inc. CSA is a registered trademark of Canadian Standards Assn. Description The JC050A, JC075A, JC100A Power Modules are dc-dc converters that operate over an input voltage range of 18 Vdc to 36 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 50 W to 100 W at typical full-load efficiency of 85%. The sealed modules offer 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. JC050A, JC075A, JC100A Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 1998 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. Symbol Min Max Unit Input Voltage Continuous Parameter VI -- 50 Vdc I/O Isolation Voltage -- -- 1500 Vdc Operating Case Temperature (See Thermal Considerations section.) TC -40 100 C Storage Temperature Tstg -55 125 C Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Table 1. Input Specifications Parameter Operating Input Voltage Maximum Input Current (VI = 0 V to 36 V; IO = IO, max): JC050A (See Figure 1) JC075A (See Figure 2) JC100A (See Figure 3.) Inrush Transient Input Reflected-ripple Current, Peak-to-peak (5 Hz to 20 MHz, 12 H source impedance; see Figure 20.) Input Ripple Rejection (120 Hz) Symbol VI Min 18 Typ 28 Max 36 Unit Vdc II, max II, max II, max i2t -- -- -- -- -- -- -- -- -- -- 5 3.5 5.2 6.9 1.0 -- A A A A2s mAp-p -- -- 60 -- dB 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 Tyco Electronics Corp. JC050A, JC075A, JC100A Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 1998 Electrical Specifications (continued) Table 2. Output Specifications Parameter Output Voltage Set Point (VI = 28 V; IO = IO, max; TC = 25 C) Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life; see Figure 16.) Output Regulation: Line (VI = 18 V to 36 V) Load (IO = IO, min to IO, max) Temperature (TC = -40 C to +100 C) Output Ripple and Noise Voltage (See Figure 14.): RMS Peak-to-peak (5 Hz to 20 MHz) External Load Capacitance (electrolytic) Output Current (At IO < IO, min, the module may exceed output ripple specifications.) Output Current-limit Inception (VO = 90% of VO, nom) Output Short-circuit Current (VO = 250 mV) Efficiency (VI = 28 V; IO = IO, max; TC = 70 C) Switching Frequency Dynamic Response (IO/t = 1 A/10 s, VI = 28 V, TC = 25 C): 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) Device All Symbol VO, set Min 4.92 Typ 5.0 Max 5.08 Unit Vdc All VO 4.85 -- 5.15 Vdc All All All -- -- -- -- -- -- 0.01 0.05 15 0.1 0.2 50 % % mV All All All JC050A JC075A JC100A JC050A JC075A JC100A All JC050A JC075A JC100A All -- -- -- IO IO IO IO, cli IO, cli IO, cli -- -- -- -- 0 0.5 0.5 0.5 -- -- -- -- 83 83 83 -- -- -- -- -- -- -- 12.0 18.0 23.0 170 84 85 85 500 40 150 10,000 10 15 20 14 21 26 -- -- -- -- -- mVrms mVp-p F A A A A A A %IO, max % % % kHz All All -- -- -- -- 2 300 -- -- %VO, set s All All -- -- -- -- 2 300 -- -- %VO, set s Table 3. Isolation Specifications Parameter Isolation Capacitance Isolation Resistance Tyco Electronics Corp. Min -- 10 Typ 2500 -- Max -- -- Unit pF M 3 JC050A, JC075A, JC100A Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 1998 General Specifications Parameter Calculated MTBF (IO = 80% of IO, max; TC = 40 C) Weight Min -- Typ 2,600,000 -- Max 100 (3.5) Unit hr. 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 36 V; open collector or equivalent compatible; signal referenced to VI(-) terminal; see Figure 17 and Feature Descriptions.): JCxxxA1 Preferred Logic: Logic Low--Module On Logic High--Module Off JCxxxA 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 A Leakage Current Turn-on Time (See Figure 13) (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 Clamp Overtemperature Shutdown (100 W only; see Feature Descriptions.) 4 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 A ms -- -- -- 60 5.9 -- -- -- -- 105 0.5 110 7.0 -- V %VO, nom V C VO, clamp Tc Tyco Electronics Corp. Data Sheet August 1998 JC050A, JC075A, JC100A Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W to 100 W Characteristic Curves 4.0 9 3.5 8 INPUT CURRENT, II (A) INPUT CURRENT, II (V) The following figures provide typical characteristics for the JC050A, JC075A, JC100A power modules. The figures are identical for both on/off configurations. 3.0 IO = 10 A 2.5 2.0 IO = 5 A 1.5 1.0 IO = 1 A 0.5 7 IO = 20 A 6 5 4 IO = 10 A 3 2 IO = 1 A 1 0.0 0 5 10 15 20 25 30 35 0 40 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 INPUT VOLTAGE, V I (A) INPUT VOLTAGE, V I (V) 8-2218 (C) Figure 1. Typical JC050A Input Characteristics at Room Temperature 8-1914 (C) Figure 3. Typical JC100A Input Characteristics at Room Temperature 6 6 OUTPUT VOLTAGE, VO (V) INPUT CURRENT, II (A) 5 IO = 15 A 4 3 IO = 7.5 A 2 1 IO = 0.7 A 5 4 VI = 36 V 3 VI = 27 V VI = 18 V 2 1 0 0 0 4 8 12 16 20 24 28 32 36 40 INPUT VOLTAGE, V I (V) 2 4 6 8 10 12 14 16 OUTPUT CURRENT, IO (A) 8-1597 (C) Figure 2. Typical JC075A Input Characteristics at Room Temperature Tyco Electronics Corp. 0 8-2219 (C) Figure 4. Typical JC050A Output Characteristics at Room Temperature 5 JC050A, JC075A, JC100A Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 1998 Characteristic Curves (continued) 84 83 6 EFFICIENCY, (%) OUTPUT VOLTAGE, VO (V) 82 5 VIN = 18 V 4 VIN = 28 V VIN = 36 V 3 2 VI = 18 V 81 VI = 27 V 80 79 78 77 VI = 36 V 76 75 1 74 0 1 2 3 4 5 6 7 9 9 10 0 0 2 4 6 8 10 12 14 16 18 20 OUTPUT CURRENT, IO (A) 8-1600 (C) OUTPUT CURRENT, IO (A) 8-1598 (C) Figure 5. Typical JC075A Output Characteristics at Room Temperature. Figure 7. Typical JC050A Converter Efficiency vs. Output Current at Room Temperature 83 6 81 4 EFFICIENCY, (%) OUTPUT VOLTAGE, VO (V) 82 5 VIN = 18 V VIN = 28 V 3 VIN = 36 V 2 80 79 VI = 36 V VI = 28 V VI = 18 V 78 77 76 1 75 74 0 0 5 10 15 20 25 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 OUTPUT CURRENT, IO (A) OUTPUT CURRENT, IO (A) 8-1601 (C) 8-1599 (C) Figure 6. Typical JC100A Output Characteristics at Room Temperature. 6 Figure 8. Typical JC075A Converter Efficiency vs. Output Current at Room Temperature Tyco Electronics Corp. Data Sheet August 1998 JC050A, JC075A, JC100A Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W to 100 W OUTPUT VOLTAGE, VO (V) (100 mV/div) Characteristic Curves (continued) 83 82 80 VI = 18 V VI = 28 V VI = 36 V 79 78 OUTPUT CURRENT, IO (A) (2 A/div) EFFICIENCY, (%) 81 77 76 75 74 73 0 4 6 8 10 12 14 16 18 OUTPUT CURRENT, IO (A) 8-1602 (C) 18 V OUTPUT VOLTAGE, VO (V) (50 mV/div) 8-1916 (C) Figure 11.Typical JC100A Transient Response to Step Decrease in Load from 50% to 25% of Full Load at Room Temperature and 28 V Input (Waveform Averaged to Eliminate Ripple Component.) OUTPUT VOLTAGE, VO (V) (100 mV/div) Figure 9. Typical JC100A Converter Efficiency vs. Output Current at Room Temperature OUTPUT CURRENT, IO (A) (2 A/div) 28 V 36 V TIME, t (1 s/div) TIME, t (200 s/div) 8-1915 (C) Figure 10.Typical JC100A Output Ripple Voltage at Room Temperature and 20 A Output Tyco Electronics Corp. TIME, t (200 s/div) 20 8-1917 (C) Figure 12.Typical JC100A Transient Response to Step Increase in Load from 50% to 75% of Full Load at Room Temperature and 28 V Input (Waveform Averaged to Eliminate Ripple Component.) 7 JC050A, JC075A, JC100A Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 1998 Characteristic Curves (continued) COPPER STRIP V O (+) REMOTE ON/OFF VOLTAGE, V ON/OFF (V) 1.0 F 10 F SCOPE RESISTIVE LOAD V O (-) 8-513 (C).d OUTPUT VOLTAGE, Vo (V) (1 V/div) Note: Use a 1.0 F ceramic capacitor and a 10 F 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. Figure 15. Peak-to-Peak Output Noise Measurement Test Setup SENSE(+) TIME, t (5 ms/div) 8-1603 (C) Figure 13.Typical Start-Up from Remote On/Off JC100A1; IO = Full Load VI (+) VO(+) IO II LOAD SUPPLY VI (- ) Test Configurations CONTACT AND DISTRIBUTION LOSSES CONTACT RESISTANCE VO(- ) SENSE(- ) 8-749 (C) TO OSCILLOSCOPE LTEST CURRENT PROBE VI(+) 12 H BATTERY CS 220 F ESR < 0.1 @ 20 C, 100 kHz 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. [Vo(+) - Vo(-)]Io = ------------------------------------------- x 100 [Vi(+) - Vi(-)]Ii 33 F ESR < 0.7 @ 100 kHz VI(-) Figure 16. Output Voltage and Efficiency Measurement Test Setup 8-203 (C).l Note: Measure input reflected-ripple current with a simulated source inductance (LTEST) of 12 H. Capacitor CS offsets possible battery impedance. Measure current as shown above. Figure 14. Input Reflected-Ripple Test Setup 8 Tyco Electronics Corp. Data Sheet August 1998 JC050A, JC075A, JC100A Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W to 100 W Design Considerations Feature Descriptions Input Source Impedance Remote On/Off 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 14, a 33 F electrolytic capacitor (ESR < 0.7 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. 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. Safety Considerations 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., UL-1950, CSA 22.2-950, and EN60950. For the converter output to be considered meeting the requirements of safety extra-low voltage (SELV), the input must meet SELV requirements. If the input meets extra-low voltage (ELV) requirements, then the converter's output is considered ELV. 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 17). 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 A. If not using the remote on/off feature, do one of the following: For negative logic, short ON/OFF pin to VI(-) For positive logic, leave ON/OFF pin open. The input to these units is to be provided with a maximum 20 A normal-blow fuse in the ungrounded lead. Ion/off Electrical Descriptions Current Limit + ON/OFF Von/off - SENSE(+) VO(+) 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 coutput 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. LOAD VI(+) VI(-) VO(-) SENSE(-) 8-720 (C).c Figure 17. Remote On/Off Implementation 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(-)] 0.5 V Tyco Electronics Corp. 9 JC050A, JC075A, JC100A Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 1998 Feature Descriptions (continued) The test results for this configuration are displayed in Figure 22. Remote Sense (continued) The voltage between the VO(+) and VO(-) terminals must not exceed 5.9 V. This limit includes any increase in voltage due to remote-sense compensation and output voltage set-point adjustment (trim). See Figure 18. The voltage between the VO(+) and VO(-) terminals must not exceed 5.9 V. This limit includes any increase in voltage due to remote-sense compensation and output voltage set-point adjustment (trim), see Figure 18. If not using the trim feature, leave the TRIM pin open. 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. VI (+) ON/OFF CASE SENSE(+) VO (+) SENSE(+) RLOAD TRIM Radj-down SENSE(-) VI(+) SUPPLY VI (-) VO(+) IO II VI(-) VO(-) VO(-) CONTACT RESISTANCE SENSE(-) LOAD CONTACT AND DISTRIBUTION LOSSES 8-748 (C).c 8-651 (C).h Figure 18. Effective Circuit Configuration for Single-Module Remote-Sense Operation Figure 19. Circuit Configuration to Decrease Output Voltage Output Voltage Set-Point Adjustment (Trim) 100 R adj-down = ---------- - 2 k % The test results for this configuration are displayed in Figure 20. 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 21). ADJUSTMENT RESISTOR VALUE () 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. With an external resistor between the TRIM and SENSE(-) pins (Radj-down), the output voltage set point (Vo, adj) decreases (see Figure 19). The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. 1M 100k 10k 1k 100 0 10 20 30 % CHANGE IN OUTPUT VOLTAGE (%) 8-879 (C) Figure 20. Resistor Selection for Decreased Output Voltage The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. V O ( 100 + % ) - ( 100 + 2% ) k R adj-up = ------------------------------------- 1.225% - --------------------------------% 10 40 Tyco Electronics Corp. Data Sheet August 1998 JC050A, JC075A, JC100A Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W to 100 W Feature Descriptions (continued) Overtermperature Protection (Shutdown) Output Voltage Set-Point Adjustment (Trim) (continued) The 100 W module features 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 VO(+) VI(+) ON/OFF Introduction SENSE(+) Radj-up CASE RLOAD TRIM SENSE(-) VI(-) VO(-) 8-715 (C).d Figure 21. Circuit Configuration to Increase Output Voltage 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,a nd 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 23. ADJUSTMENT RESISTOR VALUE () 10M 38.0 (1.50) MEASURE CASE TEMPERATURE HERE 7.6 (0.3) 1M VI(+) ON/OFF 100k VO(+) + SEN TRIM CASE VI(-) 10k 0 2 4 6 8 - SEN VO(-) 10 % CHANGE IN OUTPUT VOLTAGE (%) 8-880a Figure 22. Resistor Selection for Increased Output Voltage Output Overvoltage Clamp The ouput 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. Tyco Electronics Corp. 8-716 (C).f Note: Top view, pin locations are for reference. Measurements shown in millimeters and (inches). Figure 23. 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 JFW-Series 50 W to 150 W Board-Mounted Power Modules Technical Note (TN97-008EPS). 11 JC050A, JC075A, JC100A Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W to 100 W Thermal considerations (continued) Data Sheet August 1998 Heat Transfer Without Heat Sinks Increasing airflow over the module enhances the heat transfer via convection. Figure 24 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.). 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 24 is shown in the following example. POWER DISSIPATION, PD (W) 12 Given: VI = 28 V IO = 20 A TA = 40 C Determine PD (Use Figure 27.): 9 VI = 36 V VI = 27 V VI = 18 V 8 7 6 5 1 2 3 4 5 6 7 8 9 10 OUTPUT CURRENT, IO (A) 8-2220 Figure 25. JC050A Power Dissipation vs. Output Current 20 18 POWER DISSIPATION, PD (W) Solution 10 4 Example What is the minimum airflow necessary for a JC100A operating at nominal line, an output current of 20 A, and a maximum ambient temperature of 40 C? 11 16 VI = 18 V VI = 28 V VI = 36 V 14 12 10 8 6 4 2 0 PD = 22.8 W 0 1 2 3 Determine airflow (v) (Use Figure 24.): 4 5 6 7 8 9 10 11 12 13 14 15 OUTPUT CURRENT, IO (A) 8-1604 v = 2.7 m/s (540 ft./min.) Figure 26. JC075A Power Dissipation vs. Output Current 4.0 m/s (800 ft./min.) 3.5 m/s (700 ft./min.) 3.0 m/s (600 ft./min.) 2.5 m/s(500 ft./min.) 2.0 m/s(400 ft./min.) 1.5 m/s (300 ft./min.) 1.0 m/s (200 ft./min.) 0.5 m/s (100 ft./min.) 30 25 20 15 10 5 0.1 m/s (NAT. CONV.) (20 ft./min.) 0 0 10 20 30 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (C) 24 22 POWER DISSIPATION, PD (W) POWER DISSIPATION, PD (W) 35 20 VI = 36 V VI = 28 V VI = 18 V 18 16 14 12 10 8 6 4 2 0 0 2 4 6 8 10 12 14 16 18 20 8-1150 (C).a Figure 24. Forced Convection Power Derating with No Heat Sink; Either Orientation 12 OUTPUT CURRENT, IO (A) 8-1605 Figure 27. JC100A Power Dissipation vs. Output Current Tyco Electronics Corp. Data Sheet August 1998 JC050A, JC075A, JC100A Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W to 100 W Thermal Considerations (continued) thermal-conductive dry pad between the case and the heat sink to minimize contact resistance. The use of Figure 28 is shown in the following example 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.). Thermal derating with heat sinks is expressed by using the overall thermal resistance of the module. Total module thermal resistance (ca) is defined as the maximum case temperature rise (TC, max) divided by the module power dissipation (PD): (TC - TA) C, max ca = T --------------------- = -----------------------PD PD The location to measure case temperature (TC) is shown in Figure 23. Case-to-ambient thermal resistance vs. airflow is shown, for various heat sink configurations and heights, in Figure 28. These curves were obtained by experimental testing of heat sinks, which are offered in the product catalog. Example If an 85 C case temperature is desired, what is the minimum airflow necessary? Assume the JC100A module is operating at nominal line and an output current of 20 A, maximum ambient air temperature of 40 C, and the heat sink is 0.5 in. Solution Given: VI = 28 V IO = 20 A TA = 40 C TC = 85 C Heat sink = 0.5 in. Determine PD by using Figure 27: PD = 22.8 W Then solve the following equation: (TC - TA ) ca = ----------------------PD ( 85 - 40 ) ca = ----------------------17 ca = CASE-TO-AMBIENT THERMAL RESISTANCE, RCA (C/W) 8 1.97 C/W 7 Use Figure 28 to determine air velocity for the 0.5 inch heat sink. 1 1/2 IN HEAT SINK 1 IN HEAT SINK 1/2 IN HEAT SINK 1/4 IN HEAT SINK NO HEAT SINK 6 5 The minimum airflow necessary for the JC100A module is 2.0 m/s (400 ft./min.). 4 3 2 1 0 0 0.5 (100) 1.0 (200) 1.5 (300) 2.0 (400) 2.5 3.0 (500) (600) AIR VELOCITY MEASURED IN m/s (ft./min.) 8-1153 Figure 28. 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 28 had a Tyco Electronics Corp. 13 JC050A, JC075A, JC100A Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W to 100 W Thermal Considerations (continued) For a managed interface using thermal grease or foils, a value of cs = 0.1 C/W to 0.3 C/W is typical. The solution for heat sink resistance is: 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 (cs) and sink-to-ambient (sa) shown below (Figure 29). PD TC TS cs TA TC - TA) sa = (------------------------ - cs PD 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. sa 8-1304 Figure 29. Resistance from Case-to-Sink and Sink-to-Ambient 14 Data Sheet August 1998 Layout Considerations Copper paths must not be routed beneath the power module mounting inserts. Tyco Electronics Corp. JC050A, JC075A, JC100A Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 1998 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 PLCS Bottom View MOUNTING INSERTS M3 x 0.5 THROUGH, 4 PLACES 12.7 (0.50) 5.1 (0.20) VI (-) VO (-) CASE -SEN 10.16 (0.400) 50.8 (2.00) 25.40 (1.000) TRIM 35.56 (1.400) ON/OFF VI (+) 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) VO (+) 48.3 (1.90) 8-1945 * Side labels include Tyco name, product designation, safety agency markings, input/output voltage and current ratings, and bar code. 15 Tyco Electronics Corp. JC050A, JC075A, JC100A Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 5 Vdc Output; 50 W to 100 W Data Sheet August 1998 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) VI (+) 35.56 (1.400) 50.8 (2.00) 48.26 (1.900) ON/OFF VO (+) 35.56 (1.400) +SEN 25.40 (1.000) TRIM 25.40 (1.000) CASE -SEN VI (-) VO (-) 10.16 (0.400) 17.78 10.16 (0.700) (0.400) 61.0 (2.40) MAX 5.1 (0.20) 12.7 (0.50) MODULE OUTLINE MOUNTING INSERTS 3.30 0.15 (0.130 0.005) 8-1945 Ordering Information Input Voltage 28 V 28 V 28 V 28 V 28 V 28 V Output Voltage 5.0 V 5.0 V 5.0 V 5.0 V 5.0 V 5.0 V Output Power 50 W 75 W 100 W 50 W 75 W 100 W Remote On/ Off Logic negative negative negative positive positive positive Device Code JC050A1 JC075A1 JC100A1 JC050A JC075A JC100A Comcode 107201634 107309999 107201675 107309858 107430340 107309924 Europe, Middle-East and Africa Headquarters Tyco Electronics (UK) Ltd Tel: +44 (0) 1344 469 300, Fax: +44 (0) 1344 469 301 World Wide Headquarters Tyco Electronics Power Systems, Inc. 3000 Skyline Drive, Mesquite, TX 75149, USA +1-800-526-7819 FAX: +1-888-315-5182 (Outside U.S.A.: +1-972-284-2626, FAX: +1-972-284-2900) www.power.tycoelectronics.com e-mail: techsupport1@tycoelectronics.com Central America-Latin America Headquarters Tyco Electronics Power Systems Tel: +54 11 4316 2866, Fax: +54 11 4312 9508 Asia-Pacific Headquarters Tyco Electronics Singapore Pte Ltd Tel: +65 482 0311, Fax: 65 480 9299 Tyco Electronics Corporation reserves the right to make changes to the product(s) or information contained herein without notice. No liability is assumed as a result of their use or application. No rights under any patent accompany the sale of any such product(s) or information. (c) 2001 Tyco Electronics Power Systems, Inc. (Mesquite, Texas) All International Rights Reserved. Printed in U.S.A. August 1998 DS97-550EPS Printed on Recycled Paper