Data Sheet May 1998 JC050C, JC075C, JC100C Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 15 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: 88% typical Low output noise Constant frequency Industry-standard pinout Metal baseplate 2:1 input voltage range The JC050C, JC075C, JC100C 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 Wireless 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 JC050C, JC075C, JC100C 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 88%. 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. JC050C, JC075C, JC100C Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 15 Vdc Output; 50 W to 100 W Data Sheet May 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): JC050C (See Figure 1) JC075C JC100C (See Figure 2.) Inrush Transient Input Reflected-ripple Current, Peak-to-peak (5 Hz to 20 MHz, 12 H source impedance; see Figure 11.) 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 f use 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. JC050C, JC075C, JC100C Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 15 Vdc Output; 50 W to 100 W Data Sheet May 1998 Electrical Specifications (continued) Table 2. Output Specifications Parameter Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life; see Figure 13.) Output Voltage Set Point (VI = 28 V; IO = IO, max; TC = 25 C) 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 11.): RMS Peak-to-peak (5 Hz to 20 MHz) External Load Capacitance (electrolytic) Output Current (At I O < 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; see Figure 13.) Dynamic Response (IO/t = 1 A/10 s, VI = 28 V, TC = 25 C): Load Change from IO = 50% to 75% of I O, max: Peak Deviation Settling Time (VO < 10% of peak deviation) Load Change from IO = 50% to 25% of I O, max: Peak Deviation Settling Time (VO < 10% of peak deviation) Device All Symbol VO Min 14.55 Typ -- Max 15.45 Unit Vdc All VO, set 14.73 15.0 15.27 Vdc All All All -- -- -- -- -- -- 0.01 0.05 50 0.2 0.4 150 % % mV All All All JC050C JC075C JC100C JC050C JC075C JC100C All JC050C JC075C JC100C -- -- -- IO IO IO IO, cli IO, cli IO, cli -- -- -- 0 0.3 0.3 0.3 -- -- -- -- 86 86 87 -- -- -- -- -- -- 3.8 5.8 7.7 170 88 88 88 60 250 10,000 3.33 5.0 6.7 4.6 7.0 8.7 -- -- -- -- mVrms mVp-p F A A A A A A %IO, max % % % 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 JC050C, JC075C, JC100C Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 15 Vdc Output; 50 W to 100 W Data Sheet May 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 Symbol Remote On/Off Signal Interface (VI = 0 V to 36 V; open collector or equivalent compatible; signal referenced to VI(-) terminal; see Figure 14 and Feature Descriptions.): JCxxxC1 Preferred Logic: Logic Low--Module On Logic High--Module Off JCxxxC Optional Logic Logic Low--Module Off Logic High--Module On Logic Low: Von/off At Ion/off = 1.0 mA At Von/off = 0.0 V Ion/off Logic High: Von/off At Ion/off = 0.0 A Leakage Current Ion/off -- Turn-on Time (See Figure 10) (IO = 80% of I O, 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) -- (Note: Ensure that the combination of remote-sense and trim do not exceed 15.5 V on the output.) Output Overvoltage Clamp VO, clamp Overtemperature Shutdown Tc (100 W only; see Feature Descriptions.) 4 Min Typ Max Unit 0 -- -- -- 1.2 1.0 V mA -- -- -- -- -- 20 15 50 35 V A ms -- 50 -- -- 0.5 103 V %VO, nom 16.5 -- -- 105 20.0 -- V C Tyco Electronics Corp. Data Sheet May 1998 JC050C, JC075C, JC100C Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 15 Vdc Output; 50 W to 100 W Characteristic Curves The following figures provide typical characteristics for the JC050C, JC075C, JC100C power modules. The figures are identical for both on/off configurations. 16 4 14 IO = 3.33 A IO = 1.67 A IO = .33 A 3 2.5 OUTPUT VOLTAGE, VO (V) INPUT CURRENT, II (A) 3.5 2 1.5 1 12 VI = 18 V VI = 28 V VI = 36 V 10 8 6 4 2 0.5 0 0 0 5 10 15 20 25 30 35 0 40 1 2 INPUT VOLTAGE, VI (V) 3 4 5 OUTPUT CURRENT, IO (A) 8-2053 (C) Figure 1. Typical JC050C Input Characteristics at Room Temperature 8-1579 (C) Figure 3. Typical JC050C Input Characteristics at Room Temperature 8 16 7 14 IO = 6.67 A IO = 3.34 A IO = .67 A 6 5 OUTPUT VOLTAGE, VO (V) INPUT CURRENT, II (A) 6 4 3 2 12 VI = 18 V VI = 28 V VI = 36 V 10 8 6 4 2 1 0 0 0 5 10 15 20 25 30 35 40 INPUT VOLTAGE, VI (V) 1 2 3 4 5 6 7 8 9 OUTPUT CURRENT, IO (A) 8-2054 (C) Figure 2. Typical JC100C Input Characteristics at Room Temperature Tyco Electronics Corp. 0 8-1580 (C) Figure 4. Typical JC100C Output Characteristics at Room Temperature 5 JC050C, JC075C, JC100C Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 15 Vdc Output; 50 W to 100 W Data Sheet May 1998 18 V VI = 18 V VI = 28 V VI = 36 V OUTPUT VOLTAGE, VO (V) (50 mV/div) 86.5 86.0 85.5 85.0 84.5 84.0 83.5 83.0 82.5 82.0 81.5 81.0 80.5 80.0 1.0 1.5 2.0 2.5 3.0 3.5 8-1581 (C) 87.0 86.0 EFFICIENCY, (%) 85.0 84.0 83.0 VI = 18 V VI = 28 V VI = 36 V 81.0 80.0 79.0 78.0 77.0 76.0 2 3 4 Figure 7. Typical JC100C Output Ripple Voltage at Room Temperature and 6.7 A Output OUTPUT VOLTAGE, VO (V) (100 mV/div) Figure 5. Typical JC050C Converter Efficiency vs. Output Current at Room Temperature 82.0 TIME, t (1 ms/div) 8-1958 (C) OUTPUT CURRENT, IO (A) 1 28 V 36 V 5 6 7 OUTPUT CURRENT, IO (A) OUTPUT CURRENT, IO (A) (1 A/div) EFFICIENCY, (%) Characteristic Curves (continued) TIME, t (200 ms/div) 8-1956 (C) 8-1582 (C) Figure 6. Typical JC100C Converter Efficiency vs. Output Current at Room Temperature 6 Figure 8. Typical JC100C 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.) Tyco Electronics Corp. Data Sheet May 1998 JC050C, JC075C, JC100C Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 15 Vdc Output; 50 W to 100 W Characteristic Curves (continued) Test Configurations OUTPUT VOLTAGE, VO (V) (100 mV/div) TO OSCILLOSCOPE CURRENT PROBE LTEST VI(+) 12 H CS 220 F ESR < 0.1 @ 20 C, 100 kHz BATTERY 33 F ESR < 0.7 @ 100 kHz OUTPUT CURRENT, IO (A) (1 A/div) VI(-) 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 11. Input Reflected-Ripple Test Setup TIME, t (200 ms/div) 8-1957 (C) Figure 9. Typical JC100C 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.) COPPER STRIP V O (+) 1.0 F 10 F SCOPE RESISTIVE LOAD OUTPUT VOLTAGE, VO (V) (5 V/div) REMOTE ON/OFF, VOLTAGE, VON/OFF (V) V O (-) 9V 8-513 (C).d 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 7 6mm ( 2in .an d 3in.) from the module. 0V Figure 12. Peak-to-Peak Output Noise Measurement Test Setup 15 V SENSE(+) 0V VI (+) CONTACT AND DISTRIBUTION LOSSES VO(+) IO II LOAD SUPPLY VI (- ) TIME, t (5 s/div) 8-2055 (C) Figure 10.Typical Start-Up from Remote On/Off JC100C1; IO = Full Load CONTACT RESISTANCE VO(- ) SENSE(- ) 8-749 (C) 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 Figure 13. Output Voltage and Efficiency Measurement Test Setup Tyco Electronics Corp. 7 JC050C, JC075C, JC100C Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 15 Vdc Output; 50 W to 100 W Design Considerations Input Source Impedance 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 11, 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. 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. The input to these units is to be provided with a maximum 20 A normal-blow fuse in the ungrounded lead. Data Sheet May 1998 ing a logic high and on during a logic low. Negative logic (code suffix "1") is the factory-preferred configuration. 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 14). A logic low is Von/off = 0 V to 1.2V. 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 V on/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. Ion/off + ON/OFF Von/off - SENSE(+) VO(+) LOAD VI(+) VI(-) VO(-) SENSE(-) Electrical Descriptions 8-720 (C).c Current Limit 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. Figure 14. 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(-)] 1.2 V Feature Descriptions Remote On/Off 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 dur8 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 15. 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. Tyco Electronics Corp. Data Sheet May 1998 JC050C, JC075C, JC100C Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 15 Vdc Output; 50 W to 100 W Feature descriptions (continued) The test results for this configuration are displayed in Figure 17. For applications requiring voltage between 15 V and 24 V, consider using the JC050H, JC075H, JC100H (24 V) trimmed down. Remote Sense (continued) SENSE(+) SENSE(-) SUPPLY VI(+) VO(+) VI(-) VO(-) IO II CONTACT RESISTANCE LOAD The voltage between the VO(+) and VO(-) terminals must not exceed 16.5 V. This limit includes any increase in voltage due to remote-sense compensation and output voltage set-point adjustment (trim). See Figure 15. If not using the trim feature, leave the TRIM pin open. CONTACT AND DISTRIBUTION LOSSES 8-651 (C).h Figure 15. Effective Circuit Configuration for Single-Module Remote-Sense Operation ON/OFF Output Voltage Set-Point Adjustment (Trim) 100 R adj-down = ---------- - 2 k % The test results for this configuration are displayed in Figure 17. This figure applies to all output voltages. With an external resistor connected between the TRIM and SENSE(+) pins (R adj-up), the output voltage set point (VO, adj) increases (see Figure 18). Note: The output voltage of this module may be increased to a maximum of 0.5 V. The 0.5 V is the combination of both the remotesense and the output voltage set-point adjustment (trim). Do not exceed 15.5 V between the V O(+) and VO(-) terminals. The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. V O ( 100 + % ) ( 100 + 2% ) R adj-up = ------------------------------------- - k 1.225% - --------------------------------% SENSE(+) CASE RLOAD TRIM Radj-down VI (-) SENSE(-) VO(-) 8-748 (C).c Figure 16. Circuit Configuration to Decrease Output Voltage 100 k ADJUSTMENT RESISTOR VALUE (1/2) 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 16). The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. VO (+) VI (+) 10 k 1k 100 10 1 0 10 20 30 40 50 % CHANGE IN OUTPUT VOLTAGE 8-1237 (C).a Figure 17. Resistor Selection for Decreased Output Voltage Only trim up to 0.5 V maximum. See note above. Tyco Electronics Corp. 9 JC050C, JC075C, JC100C Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 15 Vdc Output; 50 W to 100 W Data Sheet May 1998 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. VI(+) ON/OFF VO(+) Thermal Considerations SENSE(+) Introduction Radj-up CASE VI(-) TRIM RLOAD SENSE(-) VO(-) 8-715 (C).d Figure 18. 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 20. ADJUSTMENT RESISTOR VALUE () 100M 38.0 (1.50) MEASURE CASE TEMPERATURE HERE 7.6 (0.3) 10M VI(+) ON/OFF 1M VO(+) + SEN TRIM CASE 100k 0 2 4 6 8 % CHANGE IN OUTPUT VOLTAGE (%) 10 VI(-) - SEN VO(-) 8-716 (C).f 8-2056 (C) Figure 19. 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. 10 Note: Top view, pin locations are for reference. Measurements shown in millimeters and (inches). Figure 20. 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. Tyco Electronics Corp. Data Sheet May 1998 JC050C, JC075C, JC100C Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 15 Vdc Output; 50 W to 100 W Thermal Considerations (continued) 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). POWER DISSIPATION, PD (W) 35 Introduction (continued) 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 Heat Transfer Without Heat Sinks 10 20 30 40 50 60 70 90 100 80 LOCAL AMBIENT TEMPERATURE, TA (C) 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 Figur e21 is shown in the following example. Example What is the minimum airflow necessary for a JC100C operating at nominal line, an output current of 6 A, and a maximum ambient temperature of 40 C? 8-1150 (C).a Figure 21. Forced Convection Power Derating with No Heat Sink; Either Orientation 10 9 POWER DISSIPATION, PD (W) Increasing airflow over the module enhances the heat transfer via convection. Figure 21 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.). 8 7 6 5 VI = 18 V VI = 28 V VI = 36 V 4 3 2 1 0 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 OUTPUT CURRENT, IO (A) Solution Given: VI = 28 V IO = 6 A TA = 40 C 8-1583 (C) Figure 22. JC050C Power Dissipation vs. Output Current Determine PD (Use Figure 23.): PD = 14.0 W Determine airflow (v) (Use Figure 21.): v = 1.5 m/s (300 ft./min.) Tyco Electronics Corp. 11 JC050C, JC075C, JC100C Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 15 Vdc Output; 50 W to 100 W Data Sheet May 1998 Thermal considerations (continued) Heat Transfer Without Heat Sinks (continued) POWER DISSIPATION, PD (W) 18 16 14 VI = 18 V VI = 28 V VI = 36 V 12 10 8 6 CASE-TO-AMBIENT THERMAL RESISTANCE, RCA (C/W) 8 7 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 4 3 2 1 0 4 0 2 0 0 1 2 3 4 5 6 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.) 7 8-1153 OUTPUT CURRENT, IO (A) 8-1584 (C) Figure 23. JC100C 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.-lbs.). 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 (P D): (TC - TA ) C, max ca = T --------------------- = -----------------------PD PD The location to measure case temperature (TC) is shown in Figure 20. Case-to-ambient thermal resistance vs. airflow is shown, for various heat sink configurations and heights, in Figure 24. These curves were obtained by experimental testing of heat sinks, which are offered in the product catalog. 12 Figure 24. 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 Figur e24 had a thermal-conductive dry pad between the case and the heat sink to minimize contact resistance. The use of Figure 24 is shown in the following example Example If an 8 5C case temperature is desired, what is the minimum airflow necessary? Assume the JC100C module is operating at nominal line and an output current of 6 A, maximum ambient air temperature of 40 C, and the heat sink is 0.5 in. Tyco Electronics Corp. Data Sheet May 1998 JC050C, JC075C, JC100C Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 15 Vdc Output; 50 W to 100 W Thermal considerations (continued) Custom Heat Sinks Heat Transfer with Heat Sinks (continued) 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 25). Solution Given: VI = 28 V IO = 6 A TA = 40 C TC = 85 C Heat sink = 0.5 in. PD TC TS cs Determine PD by using Figure 23: TA sa 8-1304 PD = 14.0 W Then solve the following equation: TC - TA) ca = (----------------------PD 85 - 40 ) ca = (----------------------14.0 ca = 3.2 C/W Use Figure 24 to determine air velocity for the0.5 inch heat sink. The minimum airflow necessary for the JC100C module is 1.0 m/s (200 ft./min.). Figure 25. Resistance from Case-to-Sink and Sink-to-Ambient 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: TC - TA ) - - cs sa = (-----------------------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. Layout Considerations Copper paths must not be routed beneath the power module mounting inserts. Tyco Electronics Corp. 13 JC050C, JC075C, JC100C Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 15 Vdc Output; 50 W to 100 W Data Sheet May 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 LABELS* 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 (C).b * Side labels include Tyco name, product designation, safety agency markings, input/output voltage and current ratings, and bar code. 14 Tyco Electronics Corp. JC050C, JC075C, JC100C Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 15 Vdc Output; 50 W to 100 W Data Sheet May 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) ON/OFF 48.26 (1.900) VO (+) 35.56 (1.400) +SEN 25.40 (1.000) TRIM 25.40 (1.000) CASE -SEN VI (-) VO (-) 10.16 (0.400) 10.16 (0.400) 17.78 (0.700) 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) 4 PLCS 8-1945 (C).b Ordering Information Input Voltage 28 V 28 V 28 V 28 V 28 V 28 V 15 Output Voltage 15.0 V 15.0 V 15.0 V 15.0 V 15.0 V 15.0 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 JC050C1 JC075C1 JC100C1 JC050C JC075C JC100C Comcode 107314676 TBD 107314692 107309874 TBD 107309965 Tyco Electronics Corp. JC050C, JC075C, JC100C Power Modules: dc-dc Converters; 18 Vdc to 36 Vdc Input, 15 Vdc Output; 50 W to 100 W Data Sheet May 1998 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. May 1998 DS97-551EPS Printed on Recycled Paper