107430324 - Tyco Electronics

Data Sheet

September 2001

FW250H1 and FW300H1 Power Modules; dc-dc Converters:

36 Vdc to 75 Vdc Input, 24 Vdc Output; 250 W to 300 W

The FW250H1 and FW300H1 Power Modules use advanced,

surface-mount technology and deliver high-quality, compact,

dc-dc conversion at an economical price.

Applications

■Redundant and dis tributed power archi tectures

■Computer Equipment

■Communications equipment

Options

■Heat sink available for extended operation

Features

■Size: 61.0 mm x 116.8 mm x 13.5 mm

(2.40 in. x 4.60 in. x 0.53 in.)

■Wide input voltage range

■High efficiency: 89% typical

■Parallel operation with load sharing

■Output voltage set-point adjustment (trim)

■Thermal protection

■Synchronization

■Power good signal

■Current monito r

■Output overvoltage and overcurrent protection

■Constant frequency

■Case ground pin

■Input-to- out put isol atio n

■Remote sense

■Remote on/off

■

ISO*

9001 Certified manufacturing facilities

■

† 60950 Recognized,

CSA

‡ C22.2 No. 60950-00

Certified, and

VDE

§ 0805 (EN60950) Licensed

■CE mark meets 73/23/EEC and 93/68/EEC

directives**

Description

The FW250H1 and FW300H1 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 rat-

ings from 250 W to 300 W at a typical full-load efficiency of 89%.

Two or more modules may be paralleled with f orced load sharing for redundant or enhanced power applications.

The package, which mounts on a printed-circuit board, accommodates a heat sink for high-temperature

applications.

ISO

is a registered trademark of the International Organization for Standardization.

†

is a registered trademark of Underwriters Laboratories, Inc.

‡

CSA

is a registered trademark of Canadian Standards Assn.

VDE

is a trademark of Verband Deutscher Elektrotechniker e.V.

**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.)

2Tyco Electronics Corp.

Data Sheet

September 2001

36 Vdc to 75 Vdc Input, 24 Vdc Output; 250 W to 300 W

FW250H1 and FW300H1 Power Modules; dc-dc Converters:

Absolute Maximum Ratings

Stresses in excess of the absolute maximum ratings can cause permanent damage to the device. These are abso-

lute 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.

Electrical Specifications

Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature

conditions.

Table 1. Input Specifications

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 preserv e maximum flexibility, internal fus-

ing is not included; howe ver, to achie ve 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.

Parameter Symbol Min Max Unit

Input Voltage:

Continuous

Transient (100 ms) VI

VI, trans —

—80

100 Vdc

Vdc

I/O Isolation Voltage — — 1500 V

Operating Case Temperature

(See Thermal Considerations section and

Figure 20.)

TC–40 100 °C

Storage Temperature Tstg –55 125 °C

Parameter Symbol Min Typ Max Unit

Operating Input Voltage VI36 48 75 Vdc

Maximum Input Current (VI = 0 V to 75 V):

FW250H1

FW300H1 II, max

II, max —

——

—12

12 A

Maximum Input Current (VI = 0 V to 75 V):

FW250H1

FW300H1 II, max

II, max —

——

—12

12 A

Inru sh Transient i2t——2.0A

Input Reflected- ripple Current, Peak-to-peak

(5 Hz to 20 MHz, 12 µH source impedance;

see Figure 12.)

II—10—mAp-p

Input Ripple Rejection (120 Hz) — — 60 — dB

Tyco Electronics Corp. 3

Data Sheet

September 2001 36 Vdc to 75 Vdc Input, 24 Vdc Output; 250 W to 300 W

FW250H1 and FW300H1 Power Modules; dc-dc Converters:

Electrical Specifications (continued)

Table 2. Output Specifications

* Consult your sales representativ e or the factory.

†These are manufacturing test limits. In some situations, results may differ.

Parameter Symbol Min Typ Max Unit

Output Voltage

(Over all operating input voltage, resistive load,

and temperature conditions until end of life; see

Figure 14 and Feature Descriptions.)

VO23.15 — 24.85 Vdc

Output Voltage Set Poi nt

(VI = 48 V; IO = IO, max; TC = 25 °C) VO, set 23.45 — 24.55 Vdc

Output Regu la tion :

Line (VI = 36 V to 75 V)

Load (IO = I O, min to IO, max)

Temperature (TC = –40 °C to +100 °C)

—

0.01

0.05

100

0.1

0.2

300

%VO

Output Ripple and Noise Voltage

(See Figures 7, 8, and 13.):

RMS

Peak-to-peak (5 Hz to 20 MHz) —

——

—100

250 mVrms

mVp-p

External Load Capacitance:

FW250H1

FW300H1 —

—330

330 —

—*

*µF

µF

Output Curr ent

(At I O < IO, min, the modules may exceed output

ripple specifications.):

FW250H1

FW300H1 IO

IO0.1

0.1 —

—10.4

12.5 A

Output C urr ent -lim it In ceptio n

(VO = 90% of V O, set; see Feature Descriptions.) IO , cli 103 — 130†% IO, max

Output Sh ort-circuit Curre nt

(VO = 1.0 V; indefinite duration, no hiccup mode;

see Figures 3 and 4.)

———150% I

O, max

Efficiency (VI = 48 V; IO = IO, max; TC = 25 °C;

see Figures 5, 6, and 14.):

FW250H1

FW300H1 η

η—

—89

89 —

—%

Switching Frequency — — 475 — kHz

Dyn ami c Res ponse

(∆IO/∆t = 1 A/10 µs, VI = 48 V, TC = 25 °C; see

Figures 9 and 10.):

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)

—

200

—

%VO, set

µs

%VO, set

µs

4Tyco Electronics Corp.

Data Sheet

September 2001

36 Vdc to 75 Vdc Input, 24 Vdc Output; 250 W to 300 W

FW250H1 and FW300H1 Power Modules; dc-dc Converters:

Electrical specifications (continued)

Table 3. Isolation Specifications

General Specifications

Feature Specifications

Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature

conditions. See Feature Descriptions for further information.

Table 4. Feature Specifications

* These are manufacturing test limits. In some situations, results may differ.

Parameter Min Typ Max Unit

Isolation Capacitance — 1700 — pF

Isolation Resistance 10 — — MΩ

Parameter Min Typ Max Unit

Calculated MTBF (IO = 80% of IO, max; TC = 40 °C) 1,350,000 hours

Weight — — 200 (7) g (oz.)

Parameter Symbol Min Typ Max Unit

Remote On/Off Signal Interface

(VI = 0 V to 75 V; open collector or equivalent

compatible; signal referenced to VI(–) terminal; see

Figure 15 and Feature Descriptions.):

Logic Low—Module On

Logic High—Module Off

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

(IO = 80% of I O, max; VO within ±1% of steady state)

Output Voltage Overshoot

Von/off

Ion/off

Von/off

Ion/off

—

1.2

1.0

µA

%VO, set

Output Voltage Adjustment (See Feature Descriptions.):

Output Voltage Remote-sense Range

Output Voltage Set-point Adjustment Range (trim) —

——

60 —

—0.5

110 V

%VO, nom

Output Overvoltage Protection — 29.5* — 34.0* V

Output Current Monitor (IO = IO, max, TC = 70 °C) IO, mon —0.25— V/A

Tyco Electronics Corp. 5

Data Sheet

September 2001 36 Vdc to 75 Vdc Input, 24 Vdc Output; 250 W to 300 W

FW250H1 and FW300H1 Power Modules; dc-dc Converters:

Electrical Specifications (continued)

Table 4. Feature Specifications (continued)

Solder, Cleaning, and Drying Considerations

P ost solder cleaning is usually the final circuit-board assemb ly process prior to electrical testing. The result of inad-

equate 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 Po wer Modules Soldering and Cleaning Application Note (AP01-056EPS)

Parameter Symbol Min Typ Max Unit

Synchronization:

Clock Amplitude

Clock Pulse Width

Fan-out

Capture Frequency Range

—

4.00

0.4

—

425

—

5.00

—

575

µs

—

kHz

Overtemperature Shutdown (See Figure 20.) TC—105— °C

Forced Load Share Accuracy — — 10 — %IO, rated

Power Good Signal Interface

(See Feature Descr ip tions.):

Low Impedance—Module Operating

High Impedance—Module Off

Rpwr/good

Ipwr/good

Rpwr/good

Vpwr/good

—

100

—

Ω

MΩ

66 Tyco Electronics Corp.

Data Sheet

September 200136 Vdc to 75 Vdc Input, 24 Vdc Output; 250 W to 300 W

FW250H1 and FW300H1 Power Modules; dc-dc Converters:

Characteristic Curves

The following figures provide typical characteristics for the power modules.

8-1698

Figure 1. T ypical FW250H1 Input Characteristics at

Room Temperature

8-1699

Figure 2. T ypical FW300H1 Input Characteristics at

Room Temperature

8-1700

Figure 3. Typical FW250H1 Output Characteristics

at Room Temperature

8-1701

Figure 4. Typical FW300H1 Output Characteristics

at Room Temperature

INPUT VOLTAGE, VI (V)

INPUT CURRENT, II (A)

5 1015202530354045 50

055 60 65 70 75

IO = 10.4 A

IO = 5.2 A

IO = 1.0 A

TURN-OFF TURN-ON

INPUT VOLTAGE, VI (V)

INPUT CURRENT, II (A)

10 20 30 40 50 60 70 80

IO = 12.5 A

IO = 6.25 A

IO = 1.25 A

OUTPUT CURRENT, IO (A)

OUTPUT VOLTAGE, VO (V)

246810 12 14

013579111315

VI = 75 V

VI = 55 V

VI = 36 V

OUTPUT CURRENT, IO (A)

OUTPUT VOLTAGE, VO (V)

246810 12 14

016 18

VI = 36 V

VI = 55 V

VI = 75 V

Tyco Electronics Corp. 7

Data Sheet

September 2001 36 Vdc to 75 Vdc Input, 24 Vdc Output; 250 W to 300 W

FW250H1 and FW300H1 Power Modules; dc-dc Converters:

Characteristic Curves (continued)

8-1702

Figure 5. Typical FW250H1 Efficiency vs. Output

Current at Room Temperature

8-1703

Figure 6. Typical FW300H1 Efficiency vs. Output

Current at Room Temperature

OUTPUT CURRENT, IO (A)

EFFICIENCY, η (%)

12345678910

VI = 36 V

VI = 55 V

VI = 75 V

OUTPUT CURRENT, IO (A)

EFFICIENCY, η (%)

246810 12

VI = 36 V

VI = 55 V

VI = 75 V

8-1704

Note: S ee F igure 14 for test conditions.

Figure 7. Typical FW250H1 Output Ripple Voltage

at Room Temperat ure and 50 A Output

8-1705

Note: S ee F igure 14 for test conditions.

Figure 8. Typical FW300H1 Output Ripple Voltage

at Room Temperat ure and 60 A Output

OUTPUT VO LTAGE, V

(V)

(10 mV/div)

TIME, t (500 ns/div)

VI = 48 V

OUTPUT VOLTAGE, VO (V)

(10 mV/div)

TIME, t (500 ns/div)

VI = 48 V

88 Tyco Electronics Corp.

Data Sheet

September 200136 Vdc to 75 Vdc Input, 24 Vdc Output; 250 W to 300 W

FW250H1 and FW300H1 Power Modules; dc-dc Converters:

Characteristic Curves (contin ued )

8-1706

Note: Tested with a 330 µF aluminum and a 1.0 µF ceramic capacitor

across the load.

Figure 9. Typical FW250H1 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.)

8-1707

Note: Tested with a 330 µF aluminum and a 1.0 µF ceramic capacitor

across the load.

Figure 10. Typical FW250H1 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.)

8-1709 (C)

Figure 11. Typical FW250H1 Start-Up Transient at

Room Temperature, 48 V Input, and Full

Load

OUTPUT VOLT AGE, VO (V)

(200 mV/div)

TIME, t (50 µs/div)

OUTPUT CURRENT, IO (V)

(2 A/div)

5.2

2.6

OUTPUT VOLTAGE, VO (V)

(200 mV/div)

TIME, t (50 µs/div)

OUTPUT CURRENT, IO (V)

(2 A/div)

5.2

OUT P U T VOLT AGE, VO (V)

(5 V/div)

TIME, t (10 ms/div)

REMOTE ON/OFF,

VON/OFF (V)

Tyco Electronics Corp. 9

Data Sheet

September 2001 36 Vdc to 75 Vdc Input, 24 Vdc Output; 250 W to 300 W

FW250H1 and FW300H1 Power Modules; dc-dc Converters:

Test Configurations

8-203

Note: Measure input reflected-ripple current with a simulated source

inductance (LTEST) of 12 µH. Capacitor CS offsets possible bat-

tery impedance. Measure current as shown above.

Figure 12. Input Reflected-Ripple Test Setup

8-513

Note: Use a 0.1 µF ceramic capacitor and a 330 µF aluminum or

tantalum capacitor. The 330 µF capacitor is needed for stabil-

ity, Scope measurement should be made using a BNC socket.

Position the load between 50 mm and 76 mm (2 in. and 3 in.)

from the module.

Figure 13. Peak-to-Peak Output Noise

Measurement Test Setup

8-683

Note: All measurements are taken at the module terminals. When

socketing, place Kelvin connec tions at module term inals to

avoid measurement errors due to socket contact resistance

Figure 14. Output Voltage and Efficiency

Measurement Test Setup

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 mod-

ule. For the test configuration in Figure 12, a 100 µF

electrolytic capacitor (ESR < 0.3 Ω at 100 kHz)

mounted close to the power module helps ensure sta-

bility of the unit. For other highly inductive source

impedances, consult the factory f or 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

requir eme nts of the end-u se sa fety agency stan dard,

i.e.,

60950,

CSA

22.2 No. 60950-00, and

VDE

0805

(EN60950).

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), one of the following must be true:

■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 acces-

sible.

■Another SELV reliability test is conducted on the

whole system, as required b y 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 e xtr a-low voltage (ELV) outputs

when all inputs are ELV.

The input to these units is to be provided with a maxi-

mum 20 A normal-blow fuse in the ungrounded lead.

TO OSCILLOSCOPE

CURRENT

PROBE

BATTERY

TEST

220

ESR < 0. 1

Ω

@ 20

C, 100 kHz 33

ESR < 0.3

Ω

@ 100 kHz

(+)

(–)

VO (+)

VO (–)

RESISTIVE

LOAD

SCOPE330 µF

COPPER STRIP

1.0 µF

LOAD

CONTACT AND

SUPPLY II

CONTACT

VI(+)

VI(–)

SENSE(+)

SENSE(–)

VO(+)

VO(–)

DISTRIBUTION LOSSESRESISTANCE

ηVO+()–V

O–()[]IO

VI+()–V

I–()[]II

--------------------------------------------------





x 100=

1010 Tyco Electronics Corp.

Data Sheet

September 200136 Vdc to 75 Vdc Input, 24 Vdc Output; 250 W to 300 W

FW250H1 and FW300H1 Power Modules; dc-dc Converters:

Feature Descriptions

Overcurrent Protection

To provide protection in a f ault (output overload) condi-

tion, the unit is equipped with internal current-limiting

circuitry and can endure current limiting for an unlim-

ited 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 cir cuit 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.

Remote On/Off

To tu rn the p o w er m odu le on an d o ff, the us er m u st

supply a sw itch to contr ol the v oltag e betw een th e on/off

terminal and the VI(–) terminal (V on/off). The s witch can be

an ope n collect or or equivalent (see F ig ure 15). A logic

low is Von/off = 0 V to 1 .2 V, during whi ch the modul e is on.

The maximum Ion/off during a logic low is 1 mA. The s witch

should m ain tai n a lo gic- lo w voltage while sin king 1 mA.

During a logic high, the maximum Von/off generated by

the power module is 15 V. The maximum allowable

leakage cu rren t of the switch at Von/off = 15 V is 50 µA.

If not using the remote on/off feature, short the

ON/OFF pin to VI(–).

8-580

Figure 15. Remot e On/Off Implement ation

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 out-

put voltage sense range given in the Feature Specifica-

tions table, i.e.:

[VO(+) – VO(–)] – [SENSE(+) – SENSE(–)] ≤ 0.5 V

The voltage between the VO(+) and VO(–) termi na l s

must not exceed the minimum value indicated in the

output overvoltage shutdown section of the Feature

Specifications table. This limit includes any incr ease in

v oltage due to remote-sense compensation and output

voltage set-point adjustment (trim), see Figure 16.

If not using the remote-sense feature to regulate the

output at the point of load, connect SENSE(+) to VO(+)

and SENSE(–) to VO(–) at the module.

Although the output voltage can be increased by both

the remote sense and b y the trim, the maximum

increase f or 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 limitati on.

The amount of power delivered by the module is

defined as the v oltage 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.

8-651e

Figure 16. Effective Circ uit Configuration for

Single-Module Remote-Sense Operation

ION/OFF

–

VON/OFF

CASE

ON/OFF

VI (+)

VI (–)

SENSE(+)

SENSE(–)

VO (+)

VO (–)

LOAD

CONTACT AND

SUPPLY II

CONTACT

VI(–)

VI(+)

SENSE(+)

SENSE(–)

VO(–)

VO(+)

DISTRIBUTION LOSSESRESISTANCE

Tyco Electronics Corp. 11

Data Sheet

September 2001 36 Vdc to 75 Vdc Input, 24 Vdc Output; 250 W to 300 W

FW250H1 and FW300H1 Power Modules; dc-dc Converters:

Feature Descriptions (continued)

Output Voltage Set-Point Adjustment

(Trim)

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 17). The following equa-

ti on determines the required external-resistor value to

obtain a percentage output voltage change of ∆%.

With an external resistor connected between the TRIM

and SENSE(+) pins (Radj-up), the output voltage set

point (VO, adj) increas es (see Figure 18).

The following equation determines the required exter-

nal-resistor value to obtain a percentage output v oltage

change of ∆%.

The voltage between the VO(+) and VO(–) terminals

must not exceed the minimum value of the output over-

voltage protection as indicated in the Feature Specifi-

cations table. This limit includes any increase in v oltage

due to remote-sense compensation and output voltage

set-point adjustment (trim). See Figure 16.

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 moudle 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.

8-748

Figure 17. Circuit Configuration to Decrease

Output Voltage

8-715

Figure 18. Circuit Configuration to Increase

Output Voltage

Output Overvoltage Protection

The output voltage is monitored at the VO(+) and V O(–)

pins of the module. If the voltage at these pins exceeds

the value indicated in the Feature Specifications table,

the m o du l e will shut down and la t ch of f. Re covery fr om

latched shutdown is accomplished by cycling the dc

input power off for at least 1.0 second or toggling the

primary referenced on/off signal for at least 1.0 second.

Radj-down 205

∆%

----------2.255–





kΩ=

Radj-up VO, nom 1∆%

100

----------

+()

1.225

–()

1.225∆%

()

------------------------------------------------------------------------- 205 2.255

–







kΩ=

RLOAD

Radj-down

VI(+)

ON/OFF

CASE

SENSE (+)

VI(–)

VO(+)

TRIM

SENSE (–)

VO(–)

RLOAD

Radj-up

VI(+)

ON/OFF

CASE

SENSE (+)

VI(–)

VO(+)

TRIM

SENSE (–)

VO(–)

1212 Tyco Electronics Corp.

Data Sheet

September 200136 Vdc to 75 Vdc Input, 24 Vdc Output; 250 W to 300 W

FW250H1 and FW300H1 Power Modules; dc-dc Converters:

Feature Descriptions (continued)

Output Current Monitor

The CURRENT MON pin provides a dc voltage propor-

tional to the dc output current of the module given in

the Feature Specifications table. For exampl e, on the

FW250H1, the V/A ratio is set at 250 mV/A ± 10% @

70 °C case. At a full load current of 12.5 A, the voltage

on the CURRENT MON pin is 3.13 V. The current mon-

itor signal is referenced to the SENSE(–) pin on the

secondary and is supplied from a source impedance of

approximately 2 kΩ. It is recommended that the CUR-

RENT MON pin be left open when not in use, although

no damage will result if the CURRENT MON pin is

shorted to secondary ground. Directly driving the CUR-

RENT MON pin with an external source will detrimen-

tally affect operation of the module and should be

avoided.

Synchronization

Any module can be synchronized to any other module

or to an external clock using the SYNC IN or SYNC

OUT pins. The modules are not designed to operate in

a master/slav e configuration; that is, if one module fails,

the other modules will continue to operate.

SYNC IN Pin

This pin can be connected either to an e xternal clock or

directly to the SYNC OUT pin of another FW250x or

FW300x module.

If an external clock signal is applied to the SYNC IN

pin, the signal must be a 500 kHz (±50 kHz) square

wave with a 4 Vp-p amplitude. Operation outside this

frequency band will detrimentally affect the perfor-

mance of the module and must be avoided.

If the SYNC IN pin is connected to the SYNC OUT pin

of another module, the connection should be as direct

as possible , and the VI(–) pins of the modules must be

shorted together.

Unused SYNC IN pins should be tied to VI(–). If the

SYNC IN pin is unused, the module will operate from

its own internal clock.

SYNC OUT Pin

This pin contains a clock signal referenced to the VI(–)

pin. The frequency of this signal will equal either the

module’ s internal clock frequency or the frequency estab-

lished by an external clock applied to the SYNC IN pin.

When synchronizing several modules together, the

modules can be connected in a daisy-chain fashion

where the SYNC OUT pin of one module is connected

to the SYNC IN pin of another module. Each module in

the chain will synchronize to the frequency of the first

module in the chain.

To avoid loading effects, ensure that the SYNC OUT

pin of any one module is connected to the SYNC IN pin

of only one module. Any number of modules can be

synchronized in this daisy-chain fashion.

Overtemperature Protection

To provide protection in a fault condition, the unit is

equipped with an overtemperature shutdown circuit.

The shutdown circuit will not engage unless the unit is

operated above the maximum case temperature.

Recovery from overtemperature shutdown is

accomplished by cycling the dc input power off for at

least 1.0 second or toggling the primary referenced on/

off signal for at least 1.0 second.

Forced Load Sharing (Parallel Operation)

For either redundant operation or additional power

requirements, the power modules can be configured for

parallel operation with forced load sharing (see

Figure 19). For a typical redundant configuration,

Schottky diodes or an equivalent should be used to

protect against short-circuit conditions. Because of the

remote sense, the forw ard-voltage drops across the

Schottky diodes do not affect the set point of the

voltage applied to the load. For additional power

requirements, where multiple units are used to dev elop

combined power in excess of the rated maximum, the

Schottky diodes are not needed.

Good layout techniques should be observed for noise

immunity. To implement forced load sharing, the follow-

ing connections must be made:

Tyco Electronics Corp. 13

Data Sheet

September 2001 36 Vdc to 75 Vdc Input, 24 Vdc Output; 250 W to 300 W

FW250H1 and FW300H1 Power Modules; dc-dc Converters:

Feature Descriptions (continued)

Forced Load Sharing (Parallel Operation)

(continued)

■The parallel pins of all units must be connected

together. The paths of these connections should be

as direct as poss ible.

■All remote-sense pins should be connected to the

power bus at the same point, i.e., connect all

SENSE(+) pins to the (+) side of the power bus at the

same point and all SENSE(–) pins to the (–) side of

the power b us at the same point. Close pro ximity and

directness are necessary for good noise immunity.

When not using the parallel feature, leave the

PARALLEL pin open.

8-581

Figure 19. Wiring Configura tion for Redundant

Parallel Operation

Power Good Signal

The PWR GOOD pin provides an open-drain signal

(referenced to the SENSE(–) pin) that indicates the

operating state of the module. A low impedance

(<100 Ω) between PWR GOOD and SENSE(–) indi-

cates that the module is operating. A high impedance

(>1 MΩ) between PWR GOOD and SENSE(–) indi-

cates that the module is off or has failed. The PWR

GOOD pin can be pulled up through a resistor to an

external voltage to facilitate sensing. This external volt-

age lev el must not exceed 40 V, and the current into the

PWR GOOD pin during the low-impedance state

should be limited to 1 mA maximum.

Thermal Considerations

Introduction

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 ther-

mally coupled to the case. Heat is removed by conduc-

tion, convection, and radiation to the surrounding

environment. Proper cooling can be verified by mea-

suring the case temperature. Peak temperature occurs

at the position indicated in Figure 20.

8-1303

Note: Top view, measurements shown in millimeters and (inches).

Pin locations are for reference only.

Figure 20. Case Temperature Measurement

Location

VO(+)

PARALLEL

SENSE(+)

SENSE(–)

VO(–)

CASE

VI(+)

ON/OFF

VI(–)

VO(+)

PARALLEL

SENSE(+)

SENSE(–)

VO(–)

CASE

VI(+)

ON/OFF

VI(–)

CASE

SYNC IN

SYNC OUT

MEASURE CASE

TEMPERATURE HERE

ON/OFF

82.6

(3.25)

30.5

(1.20)

(+)

(–)V

(+)

(–)

Tyco Electronics Corp. 14

Data Sheet

September 2001 36 Vdc to 75 Vdc Input, 24 Vdc Output; 250 W to 300 W

FW250H1 and FW300H1 Power Modules; dc-dc Converters:

Thermal Considerations (continued)

Introduction (continued)

The t emp er a t ure at t hi s lo ca ti on sh ou ld no t exceed

100 °C. The maximum case temperature can be limited

to a lower value for extremely high reliability. The output

po w e r of the mo du le shou ld no t exceed the ra t ed power

for the module as listed in the Ordering Information table.

F or additional inf ormation about these modules, ref er to

the

Thermal Management for FC- and FW-Series 250

W—300 W Board-Mounted Power Modu les

Technica l

Note (TN96-009EPS).

Heat Transfer Without Heat Sinks

Derating curves for forced-air cooling without a heat

sink are shown in Figures 21 and 22. These curv es can

be used to determine the appropriate airflow f or a given

set of operating conditions. F or example, if the unit with

airflow along its length dissipates 20 W of heat, the

correct airflow in a 40 °C environment is 1.0 m/s

(200 ft./min.).

8-1315

Figure 21. Con vection P ower Derating with No Heat

Sink; Airflow Along Width (Transverse)

8-1314

Figure 22. Con vection P ower Dera ting with No Heat

Sink; Airflow Along Length

(Longitudinal)

Heat Tran sfer with Hea t Sinks

The power modules have through-threaded, M3 x 0.5

mounting holes, which enable heat sinks or cold plates

to be attached to the module. The mounting torque

must not exceed 0.56 N-m (5 in.-lb.). For the 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 (θca) is defined as the max-

imum case temperature rise (∆TC, max) divided by the

module power dissipation (PD):

The location to measure case temperature (TC) is

shown in Figure 20. Case-to-ambient thermal resis-

tance vs. airflow for various heat sink configurations is

shown in Figure 23 and Figure 24. These curves were

obtained by experimental testing of heat sinks, which

are offered in the product catalog.

010203040 100

9080706050

LOCAL AMBIEN T TEMPERATURE, TA (°C)

POWER DISSIPATION, PD (W)

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.)

0.1 m/s (20 ft./min.) NAT. CONV.

010203040 100

9080706050

LOCAL AMBIENT TEMPERATURE, TA (°C)

POWER DISSIPATION, PD (W)

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.)

0.1 m/s (20 ft./min.) NAT. CONV.

θca ∆TCmax,

---------------------TCTA

–()

------------------------

1515 Tyco Electronics Corp.

Data Sheet

September 2001

36 Vdc to 75 Vdc Input, 24 Vdc Output; 250 W to 300 W

FW250H1 and FW300H1 Power Modules; dc-dc Converters:

Thermal Considerations (continued )

Heat Transfer with Heat Sinks (continued)

8-1321

Figure 23. Case-to-Ambient Thermal Resistance

Curves; Transverse Orientation

8-1320

Figure 24. Case-to-Ambient Thermal Resistance

Curves; Longitudinal 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 gener-

ally lower than the resistance of the heat sink by itself.

The module used to collect the data in Figures 23 and

24 had a thermal-conductive dry pad between the case

and the heat sink to minimize contact resistance.

To choose a heat sink, determine the power dissipated

as heat by the unit for the particular application.

Figures 25 and 26 show typical heat dissipation for a

range of output currents and three voltages for the

FW250H1 and FW300H1.

8-1711

Figure 25. FW250H1 Power Dissipation vs. Output

Current

8-1712

Figure 26. FW300H1 Power Dissipation vs. Output

Current

00.5

(100) 1.0

(200) 1.5

(300) 2.0

(400) 2.5

(500) 3.0

(600)

0.0

0.5

3.0

3.5

4.0

4.5

2.5

2.0

1.0

CASE-TO-AMBIENT THERMAL

1.5

AIR VELOCITY, m/s (ft./min.)

RESISTANCE, θCA (°C/W)

1 1/2 IN. HEAT SINK

1 IN. HEAT SINK

1/2 IN. HEAT SINK

1/4 IN. HEAT SINK

NO HEAT SINK

00.5

(100) 1.0

(200) 1.5

(300) 2.0

(400) 2.5

(500) 3.0

(600)

0.0

0.5

3.0

3.5

4.0

4.5

2.5

2.0

1.0

CASE-TO-AMBIENT THERMAL

1.5

AIR VELOCITY, m/s (ft./min.)

RESISTANCE, θCA (°C/W)

1 1/2 IN. HEAT SINK

1 IN. HEAT SINK

1/2 IN. HEAT SINK

1/4 IN. HEAT SINK

NO HEAT SINK

OUTPUT CURRENT, IO (A)

POWER DISSIPATION, PD (W)

1234567

08910

VI = 75 V

VI = 55 V

VI = 36 V

OUTPUT CURRENT, IO (A)

POWER DISSIPATION, PD (W)

246810 12

VI = 75 V

VI = 55 V

VI = 36 V

Tyco Electronics Corp. 16

Data Sheet

September 2001 36 Vdc to 75 Vdc Input, 24 Vdc Output; 250 W to 300 W

FW250H1 and FW300H1 Power Modules; dc-dc Converters:

Thermal Considerations (continued)

Heat Transfer with Heat Sinks (continued)

Example

If an 85 °C case temperature is desired, what is the

minimum airflow necessary? Assume the FW250H1

module is operating at nominal line and an output cur-

rent of 10 A, maximum ambient air temperature of

40 °C, and the heat sink is 1/2 inch.

Solution

Given: VI = 55 V

IO = 10 A

TA = 40 °C

TC = 85 °C

Heat sink = 1/2 inch.

Determine PD by using Figure 25:

PD = 28 W

Then solve the following equation:

Use Figures 23 and 24 to determine air velocity for the

1/2 inch heat sink. The minimum airflow necessary for

the FW250H1 module depends on heat sink fin orienta-

tion and is shown below:

■1.25 m/s (250 ft./min.) (oriented along width)

■1.5 m/s (300 ft./min. ) (or ien ted alo ng len gth )

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) as shown in Figure 27.

8-1304

Figure 27. Resistance from Case-to-Sink and Sink-

to-Ambient

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

solut ion for heat sink resistance is:

This equation assumes that all dissipated power must

be shed by the heat sink. Depending on the user-

defined application environment, a more accurate

model, including heat transfer from the sides and bot-

tom of the module, can be used. This equation pro-

vides a conservative estimate for such instances.

EMC Considerations

For assistance with designing for EMC compliance,

please refer to the FLTR100V10 data sheet

(FDS01-043EPS)

Layout Considerations

Copper paths must not be routed beneath the power

module mounting inserts. For additional layout guide-

lines, refer to the FLTR100V10 data sheet

(FDS01-043EPS)

θca TCTA–()

------------------------

θca 85 40–()

------------------------

θca 1.61 °C/W=

PDTCTSTA

θcs θsa

θsa TCTA–()

-------------------------θcs–=

17 Tyco Electronics Corp.

Data Sheet

September 2001

36 Vdc to 75 Vdc Input, 24 Vdc Output; 250 W to 300 W

FW250H1 and FW300H1 Power Modules; dc-dc Converters:

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.)

8-1650c

* Side label includes Tyco name, product designation, safety agency markings, input/output voltage and current ratings, and bar code.

CASE

SYNC IN

ON/OFF

VI -

VI+

2.54 (0.100) TYP

VO-

VO+

SYNC OUT

5.1 (0.20)

10.16

(0.400)

MOUNTING INSERTS

M3 x 0.5 THROUGH,

4 PLACES

5.1 (0.20)

2.54 (0.100) TYP

SENSE-

SENSE+

TRIM

PARALLEL

CURRENT MON

PWR GOOD

50.8

(2.00)

30.48

(1.200)

22.86

(0.900)

12.7

(0.50)

5.08

(0.200)

15.24

(0.600)

20.32

(0.800)

25.40

(1.000)

30.48

(1.200)

35.56

(1.400)

66.04 (2.600)

106.7 (4.20)

7.62

(0.300)

17.78

(0.700)

12.70

(0.500)

13.5

(0.53)

5.1 (0.20) MIN 1.57 (0.062) DIA

SOLDER-PLATED,

11 PLACES

SIDE LABEL*

1.02 (0.040) DIA

SOLDER-PLATED,

9 PLACES

116.8 (4.60)

61.0

(2.40)

Top View

Side View

Bottom View

Tyco Electronics Corp. 18

Data Sheet

September 2001 36 Vdc to 75 Vdc Input, 24 Vdc Output; 250 W to 300 W

FW250H1 and FW300H1 Power Modules; dc-dc Converters:

Recommended Hole Pattern

Component-side footprint.

Dimensions are in millimeters and (inches).

8-1650c

Ordering Information

Please contact your Tyco Electronics’ Account Manager or Field Application engineer for pricing and availabilty.

Input Voltage Output Voltage Output Power Device Code Comcode

48 V 24 V 250 W FW250H1 108026840

48 V 24 V 300 W FW300H1 107430324

5.1 (0.20)

MOUNTING INSERTS

5.1 (0.20)

2.54 (0.100) TYP

5.08

(0.200)

15.24

(0.600)

20.32

(0.800)

25.40

(1.000)

30.48

(1.200)

35.56

(1.400)

106.68 (4.200)

66.04 (2.600)

50.8

(2.00)

30.48

(1.200)

22.86

(0.900)

17.78

(0.700)

12.70

(0.500)

12.7

(0.50)

7.62

(0.300)

CASE

SYNC IN

ON/OFF

SENSE-

SENSE+

TRIM

PARALLEL

CURRENT MON

PWR GOOD

SYNC OUT

7.62

(0.300) 7.62

(0.300)

10.16

(0.400)

19 Tyco Electronics Corp.

Data Sheet

September 2001

36 Vdc to 75 Vdc Input, 24 Vdc Output; 250 W to 300 W

FW250H1 and FW300H1 Power Modules; dc-dc Converters:

Ordering Information (continued)

Table 6. Device Accessories

Dimension are in millimeters and (inches).

Accessory Comcode

1/4 in. transverse kit (heat sink, thermal pad, and screws) 847308335

1/4 in. longitudinal kit (heat sink, thermal pad, and screws) 847308327

1/2 in. transverse kit (heat sink, thermal pad, and screws) 847308350

1/2 in. longitudinal kit (heat sink, thermal pad, and screws) 847308343

1 in. transverse kit (heat sink, thermal pad, and screws) 847308376

1 in. longitudinal kit (heat sink, thermal pad, and screws) 847308368

1 1/2 in. transverse kit (heat sink, thermal pad, and screws) 847308392

1 1/2 in. longitudinal kit (heat sink, thermal pad, and screws) 847308384

8-2830

Figure 28. Longitudinal Heat Sink

8-2831

Figure 29. Transverse Heat Sink

1/4 IN.

1/2 IN.

1 IN.

1 1/2 IN.

60.45

115.82

(4.56)

(2.38)

1/4 IN.

1/2 IN.

1 IN.

1 1/2 IN.

115.82

(4.56)

59.94

(2.36)

Data Sheet

September 200136 Vdc to 75 Vdc Input, 24 Vdc Output; 250 W to 300 W

FW250H1 and FW300H1 Power Modules; dc-dc Converters:

Printed on

Recycled Paper

Tyco Electroni cs Power Systems, Inc.

3000 Skyline Drive, Mesquite, TX 75149, USA

+1-800-526-7819 FAX: + 1-888 -315-5182

(Outs ide U.S.A.: +1-972-284-2626, FAX: +1-972-284-2900

http://power.tycoeleectronics.com

Tyco Electronics Corportation reserv es the right to make changes to the pro duct(s) or inf ormation cont ained her ei n 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.

Printed in U.S.A.

September 2001

DS00-158EPS