Data Sheet October 8, 2004 Document No: DS03-074 ver. 0.9 PDF No: eqw_12-25-ds.pdf EQW012/020/023/025 Series, Eighth-Brick Power Modules: dc-dc Converters; 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output current Features Delivers up to 25A output current High efficiency: 89% at 3.3V full load (Vin = 48Vdc) Industry-Standard Eighth-brick foot print: 57.9 mm x 22.8 mm x 8.52 mm (2.28 in x 0.90 in x 0.335 in) Applications Distributed power architectures Wireless Networks Access and Optical Network Equipment Enterprise Networks Latest generation IC's (DSP, FPGA, ASIC) and Microprocessor powered applications. Options Remote On/Off logic (positive or negative) Surface Mount (-S Suffix) Basic Insulation Approved (-B Suffix) Short Pins Description The EQW series, Eighth-brick power modules are isolated dc-dc converters that can deliver up to 25A of output current and provide a precisely regulated output voltage over a wide range of input voltages (Vi = 36 -75Vdc). The modules achieve full load efficiency of 89% at 3.3V output voltage. The open frame modules construction, available in both surface-mount and through-hole packaging, enable designers to develop cost- and space-efficient solutions. Standard features include remote On/Off, remote sense, output voltage adjustment, over voltage, over current and over temperature protection. Low output ripple and noise Remote Sense Adjustable output voltage ( 10%) Constant switching frequency (285kHz) Output over voltage and over current protection Over temperature protection Input undervoltage lockout Wide operating temperature range (-40C to 85C) UL* 60950 Recognized, CSA C22.2 No. 60950-00 rd Certified, and VDE 0805 (IEC60950, 3 edition) Licensed CE mark meets 73/23/EEC and 93/68/EEC directives ISO** 9001 and ISO14001 certified manufacturing facilities Meets the voltage and current requirements for ETSI 300-132-2 and complies with and licensed for rd Basic insulation rating per IEC60950 3 edition (-B version only) Surface mount or through hole Cost efficient open frame design Remote On/Off positive logic (primary referenced) * UL is a registered trademark of Underwriters Laboratories, Inc. CSA is a registered trademark of Canadian Standards Association. VDE is a trademark of Verband Deutscher Elektrotechniker e.V. This product is intended for integration into end-user equipment. All the required procedures for CE marking of end-user equipment should be followed. (The CE mark is placed on selected products.) ** ISO is a registered trademark of the International Organization of Standards EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Data Sheet October 8, 2004 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 the device reliability. Parameter Device Symbol Min Max Unit EQW VIN -0.3 80 Vdc EQW VIN, trans -0.3 100 Vdc All TA -40 85 C Storage Temperature All Tstg -55 125 C I/O Isolation Voltage All 1500 Vdc Input Voltage Continuous Transient (100ms) Operating Ambient Temperature (see Thermal Considerations section) Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Parameter Device Symbol Min Typ Max Unit 36 48 75 Vdc 3 Adc Operating Input Voltage All VIN Maximum Input Current All IIN,max All IIN,No load 75 mA All IIN,stand-by 3 mA Inrush Transient All It Input Reflected Ripple Current, peak-to-peak (5Hz to 20MHz, 12H source impedance; VIN=0V to 75V, IO= IOmax ; see Test Configuration section) All 13 mAp-p Input Ripple Rejection (120Hz) All 50 dB (VIN=0V to 75V, IO=IO, max) Input No Load Current (Vin = 48Vdc, Io = 0, module enabled) Input Stand-by Current (Vin = 48Vdc, module disabled) EMC, EN55022 2 2 1 As See EMC Considerations section CAUTION: This power module is not internally fused. An input line fuse must always be used. This power module can be used in a wide variety of applications, ranging from simple standalone 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 fast-acting fuse with a maximum rating of 6A (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 sheet for further information. 2 Tyco Electronics Power Systems Data Sheet October 8, 2004 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Electrical Specifications (continued) Parameter Device Symbol Min Typ Max Output Voltage Set-point 1.0Vdc VO, set 0.98 1.0 1.02 Vdc 1.2 Vdc VO, set 1.18 1.2 1.22 Vdc 1.5 Vdc VO, set 1.47 1.5 1.53 Vdc 1.8 Vdc VO, set 1.76 1.8 1.84 Vdc 2.5V dc VO, set 2.45 2.5 2.55 Vdc 3.3 Vdc VO, set 3.25 3.3 3.35 Vdc 5.0 Vdc VO, set 4.90 5.0 5.10 Vdc, Vdc (VIN=VIN,nom, IO=IO, max, Tref=25C) Unit 1.0Vdc VO 0.97 1.03 (Over all operating input voltage, resistive load, 1.2 Vdc VO 1.16 1.24 Vdc and temperature conditions until end of life) 1.5 Vdc VO 1.45 1.55 Vdc 1.8 Vdc VO 1.74 1.86 Vdc 2.5V dc VO 2.42 2.57 Vdc 3.3 Vdc VO 3.2 3.4 Vdc 5.0 Vdc VO 4.85 5.15 Vdc, 1.8Vdc VO -10 +12 % VO, set 2.5Vdc VO -10 +20 % VO, set Output Voltage Adjustment Range Selected by external resistor 3.3Vdc VO -20 +10 % VO, set All others VO -10.0 +10 % VO, set % VO, set Output Regulation Line (VIN=VIN, min to VIN, max) All 0.1 Load (IO=IO, min to IO, max) All 10 mV Temperature (Tref=TA, min to TA, max) All 0.2 % VO, set RMS (5Hz to 20MHz bandwidth) 5.0 Vdc 18 35 mVrms Peak-to-Peak (5Hz to 20MHz bandwidth) 5.0 Vdc 50 90 mVpk-pk RMS (5Hz to 20MHz bandwidth) All others 8 20 mVrms Peak-to-Peak (5Hz to 20MHz bandwidth) All others 40 75 mVpk-pk F Output Ripple and Noise on nominal output measured with 10F Tantalum, 1F ceramic (VIN=VIN, nom and IO=IO, min to IO, max) External Capacitance* Output Current Output Current Limit Inception (Vo = 90% of VO, set) Hiccup mode Tyco Electronics Power Systems 5.0 Vdc CO, max 0 3000 All others CO, max 0 5000 F 1.0Vdc Io 0 25.0 Adc 1.2 Vdc Io 0 25.0 Adc 1.5 Vdc Io 0 25.0 Adc 1.8 Vdc Io 0 25.0 Adc 2.5V dc Io 0 23.0 Adc 3.3 Vdc Io 0 20.0 Adc 5.0 Vdc Io 0 12.0 Adc 1.0Vdc IO, lim 35 Adc 1.2 Vdc 1.5 Vdc 1.8 Vdc 2.5V dc 3.3 Vdc 5.0 Vdc IO, lim IO, lim IO, lim IO, lim IO, lim IO, lim 35 35 35 30 25 15 Adc Adc Adc Adc Adc Adc 3 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Data Sheet October 8, 2004 Electrical Specifications (continued) Parameter Device Symbol Min Typ Max Unit Output Short-circuit Current (Average) 1.0Vdc Io,sc 3 Adc 1.2 Vdc Io,sc 3 Adc 1.5 Vdc Io,sc 3 Adc 1.8 Vdc Io,sc 3 Adc 2.5V dc Io,sc 3 Adc 3.3 Vdc Io,sc 3 Adc 5.0 Vdc Io,sc 3 Adc (Vo = 0.25V) 1.0Vdc 80.0 % VIN=VIN, nom, TA=25C 1.2 Vdc 81.0 % IO=IO, max , VO= VO,set 1.5 Vdc 81.0 % 1.8 Vdc 84.0 % 2.5V dc 87.0 % 3.3 Vdc 89.0 % 5.0 Vdc 91.0 % All fsw 300 kHz (Io/t=0.1A/s; Vin=Vin,set; TA=25C) Load Change from Io= 50% to 75% of Io,max; 10F Tantalum, 1F ceramic external capacitance Peak Deviation All Vpk 200 mV Settling Time (Vo<10% peak deviation) All ts 200 s (Io/t=0.1A/s; Vin=Vin,set; TA=25C) Load Change from Io= 50% to 25% of Io,max; 10F Tantalum, 1F ceramic external capacitance Peak Deviation All Vpk 200 mV Settling Time (Vo<10% peak deviation) All ts 200 s Unit Efficiency Switching Frequency Dynamic Load Response Isolation Specifications Parameter Symbol Min Typ Max Isolation Capacitance Ciso 1000 pF Isolation Resistance Riso 10 M General Specifications Parameter Min Calculated MTBF (IO=IO, max, TA=25C) Typ Max 2,686,000 Unit Hours Tyco RIN (Reliability Information Notebook) Method Weight 4 15.2 (0.6) g (oz.) Tyco Electronics Power Systems Data Sheet October 8, 2004 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See Feature Descriptions for additional information. Parameter Device Symbol Min Typ Max Unit All Ion/off 0.15 1.0 mA Remote On/Off Signal Interface (VIN=VIN, min to VIN, max ; open collector or equivalent, Signal referenced to VIN- terminal) Negative Logic: device code suffix "1" Logic Low = module On, Logic High = module Off Positive Logic: No device code suffix required Logic Low = module Off, Logic High = module On Logic Low Specification Remote On/Off Current - Logic Low On/Off Voltage: Logic Low All Von/off -0.7 1.2 V Logic High - (Typ = Open Collector) All Von/off 15 V Logic High maximum allowable leakage current All Ion/off 10 A All Tdelay 20 msec All Tdelay 12 msec All Trise Turn-On Delay and Rise Times (VI =48Vdc, IO=IO, max , VO to within 1% of steady state) Case 1: On/Off input is set to Logic high and then input power is applied (delay from instant at which VI = VI,min until Vo = 10% of Vo, set) Case 2: Input power is applied for at least one second and then the On/Off input is set to logic high (delay from instant at which Von/Off = 0.9V until Vo = 10% of Vo, set) Output voltage Rise time (time for Vo to rise from 10% of Vo, set to 90% of Vo, set) Output voltage overshoot (Io = 80% of Io,max, VI = 48Vdc TA=25C) Output Voltage Remote Sense Output Overvoltage Protectionn (Clamp) Overtemperature Protection All 0.9 msec 5 %VO, set 0.25 Vdc 10 %VO, set 1.0, 1.2, 1.5, 1.8Vdc 2.5, 3.3, 5.0 Vdc 1.0Vdc VO, limit 2.0 2.8 Vdc 1.2 Vdc VO, limit 2.0 2.8 Vdc 1.5 Vdc VO, limit 2.3 3.2 Vdc 1.8 Vdc VO, limit 2.3 3.2 Vdc 2.5V dc VO, limit 3.1 3.7 Vdc 3.3 Vdc VO, limit 4.0 4.6 Vdc 5.0 Vdc VO, limit 6.1 7.0 Vdc All Tref 125 C (See thermal section) Input Undervoltage Lockout Turn-on Threshold All 32 36 V Turn-off Threshold All 25 27 V Tyco Electronics Power Systems 5 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Data Sheet October 8, 2004 Characteristic Curves The following figures provide typical characteristics for theEQW025A0P1 (1.2V, 25A) at 25C (except derating curve). The figures are identical for either positive or negative Remote On/Off logic. 27 84 24 OUTPUT CURRENT, Io (A) 86 80 78 Vin=75V 74 Vin=48V 72 Vin=36V 70 5 10 15 20 OUTPUT CURRENT, IO (A) 15 12 9 6 3 0 NC 100 LFM 200 LFM 300 LFM 400 LFM 30 40 50 60 70 80 90 O AMBIENT TEMPERATURE, TA C Figure 4. Derating Output Current versus Local Ambient Temperature and Airflow Figure 3. Transient Response to Dynamic Load Change from 50% to 75% to 50% of full load (Vin =48Vdc). 6 VON/OFF(V) (5V/div) IO (A) (10A/div) TIME, t (100s/div) VO (V) (1/div) Figure 5. Typical Start-Up with application of Vin (Vin = 48Vdc, Io = 25A). VO (V) (100mV/div) Figure 2. Typical Output Ripple and Noise (Vin =48Vdc, Io = 25A). On/Off VOLTAGE OUTPUT VOLTAGE TIME, t (5msec/div) OUTPUT CURRENT, OUTPUT VOLTAGE TIME, t (1s/div) 18 20 OUTPUT VOLTAGE VO (V) (20mV/div) OUTPUT VOLTAGE, Figure 1. Converter Efficiency versus Output Current 25 INPUT VOLTAGE , 0 21 VO (V) (1V/div) 76 V IN (A) (20V/div) EFFICIENCY, (%) 82 TIME, t (5ms/div) Figure 6. Typical Start-Up Using Remote On/Off, negative logic version shown (Vin = 48Vdc, Io = 25A). Tyco Electronics Power Systems Data Sheet October 8, 2004 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Characteristic Curves (continued) The following figures provide typical characteristics for the EQW025A0M (1.5V, 25A) at 25C (except derating curve). The figures are identical for either positive or negative Remote On/Off logic. 27 86 24 OUTPUT CURRENT, Io (A) 88 EFFICIENCY, (%) 84 82 80 78 76 Vin=75V 74 Vin=48V 72 Vin=36V 70 0 5 10 15 20 25 Tyco Electronics Power Systems 6 3 0 200 LFM 300 LFM 400 LFM 30 40 50 60 70 80 90 VO (V) (1V/div) V IN (A) (20V/div) INPUT VOLTAGE , OUTPUT VOLTAGE Figure 9. Transient Response to Dynamic Load Change from 50% to 75% to 50% of full load (Vin =48Vdc). 9 NC 100 LFM Figure 10. Derating Output Current versus Local Ambient Temperature and Airflow TIME, t (5ms/div) VO (V) (1V/div) Figure 11. Typical Start-Up with application of Vin (Vin = 48Vdc, Io = 25A). OUTPUT VOLTAGE TIME, t (100s/div) 12 O VON/OFF(V) (5V/div) VO (V) (200mV/div) IO (A) (5A/div) OUTPUT CURRENT, OUTPUT VOLTAGE Figure 8. Typical Output Ripple and Noise (Vin =48Vdc, Io = 25A). 15 AMBIENT TEMPERATURE, TA C On/Off VOLTAGE VO (V) (20mV/div) OUTPUT VOLTAGE, TIME, t (1s/div) 18 20 OUTPUT CURRENT, IO (A) Figure 7. Converter Efficiency versus Output Current 21 TIME, t (5ms/div) Figure 12. Typical Start-Up Using Remote On/Off, negative logic version shown (Vin = 48Vdc, Io = 25A). 7 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Data Sheet October 8, 2004 Characteristic Curves (continued) The following figures provide typical characteristics for the EQW025A0Y (1.8V, 25A) at 25C (except derating curve). The figures are identical for either positive or negative Remote On/Off logic. 27 88 24 OUTPUT CURRENT, Io (A) 90 EFFICIENCY, (%) 86 84 82 80 Vin=75V 78 Vin=48V 76 Vin=36V 74 72 0 5 10 15 20 25 8 9 6 3 0 NC 100 LFM 200 LFM 300 LFM 400 LFM 30 40 50 60 70 80 90 AMBIENT TEMPERATURE, TA C OUTPUT VOLTAGE VO (V) (1V/div) INPUT VOLTAGE , V IN (A) (20V/div) TIME, t (5ms/div) VO (V) (1V/div) Figure 17. Typical Start-Up with application of Vin (Vin = 48Vdc, Io = 25A). On/Off VOLTAGE, TIME, t (100s/div) Figure 15. Transient Response to Dynamic Load Change from 50% to 75% to 50% of full load (Vin =48Vdc). 12 Figure 16. Derating Output Current versus Local Ambient Temperature and Airflow OUTPUT VOLTAGE VO (V) (100mV/div) IO (A) (10A/div) OUTPUT CURRENT, OUTPUT VOLTAGE Figure 14. Typical Output Ripple and Noise (Vin =48Vdc, Io = 25A).. 15 O VON/OFF(V) (5V/div) VO (V) (20mV/div) OUTPUT VOLTAGE, TIME, t (1s/div) 18 20 OUTPUT CURRENT, IO (A) Figure 13. Converter Efficiency versus Output Current 21 TIME, t (5ms/div) Figure 18. Typical Start-Up Using Remote On/Off, negative logic version shown (Vin = 48Vdc, Io = 25A). Tyco Electronics Power Systems Data Sheet October 8, 2004 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Characteristic Curves (continued) The following figures provide typical characteristics for the EQW023A0G (2.5V, 23A) at 25C (except derating curve). The figures are identical for either positive or negative Remote On/Off logic. 24 90 21 OUTPUT CURRENT, Io (A) 92 EFFICIENCY, (%) 88 86 84 82 Vin=75V 80 Vin=48V 78 Vin=36V 76 74 0 5 10 15 20 Tyco Electronics Power Systems 9 200 LFM 6 300 LFM 3 400 LFM 0 30 40 50 60 70 80 90 AMBIENT TEMPERATURE, TA C OUTPUT VOLTAGE VO (V) (1V/div) INPUT VOLTAGE , V IN (A) (20V/div) TIME, t (100s/div) OUTPUT VOLTAGE VO (V) (1V/div) Figure 23. Typical Start-Up with application of Vin (Vin = 48Vdc, Io = 23A). VON/OFF(V) (5V/div) VO (V) (100mV/div) IO (A) (10A/div) OUTPUT CURRENT, OUTPUT VOLTAGE TIME, t (100s/div) Figure 21. Transient Response to Dynamic Load Change from 50% to 75% to 50% of full load (Vin =48Vdc). 100 LFM Figure 22. Derating Output Current versus Local Ambient Temperature and Airflow On/Off VOLTAGE, VO (V) (20mV/div) OUTPUT VOLTAGE, TIME, t (1s/div) NC 12 O OUTPUT CURRENT, IO (A) Figure 20. Typical Output Ripple and Noise (Vin =48Vdc, Io = 23A). 15 20 25 Figure 19. Converter Efficiency versus Output Current 18 TIME, t (5ms/div) Figure 24. Typical Start-Up Using Remote On/Off, negative logic version shown (Vin = 48Vdc, Io = 23A). 9 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Data Sheet October 8, 2004 Characteristic Curves (continued) The following figures provide typical characteristics for the EQW020A0F (3.3V, 20A) at 25C (except derating curve). The figures are identical for either positive or negative Remote On/Off logic. 22 94 20 OUTPUT CURRENT, Io (A) 91 EFFICIENCY, (%) 88 85 82 Vin=75V 79 Vin=48V 76 Vin=36V 73 70 0 4 8 12 16 Figure 27. Transient Response to Dynamic Load Change from 50% to 75% to 50% of full load (Vin =48Vdc). 10 10 8 6 4 2 0 NC 100 LFM 200 LFM 300 LFM 400 LFM 30 40 50 60 70 80 90 OUTPUT VOLTAGE VO (V) (1V/div) INPUT VOLTAGE , V IN (A) (20V/div) Figure 28. Derating Output Current versus Local Ambient Temperature and Airflow TIME, t (5ms/div) OUTPUT VOLTAGE VO (V) (1V/div) Figure 29. Typical Start-Up with application of Vin (Vin = 48Vdc, Io = 20A). VON/OFF(V) (5V/div) VO (V) (100mV/div) IO (A) (10A/div) OUTPUT CURRENT, OUTPUT VOLTAGE TIME, t (100s/div) 12 AMBIENT TEMPERATURE, TA C On/Off VOLTAGE, VO (V) (20mV/div) OUTPUT VOLTAGE, TIME, t (1s/div) 14 O OUTPUT CURRENT, IO (A) Figure 26. Typical Output Ripple and Noise (Vin =48Vdc, Io = 20A). 16 20 20 Figure 25. Converter Efficiency versus Output Current 18 TIME, t (5ms/div) Figure 30. Typical Start-Up Using Remote On/Off, negative logic version shown (Vin = 48Vdc, Io = 20A). Tyco Electronics Power Systems Data Sheet October 8, 2004 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Characteristic Curves (continued) The following figures provide typical characteristics for the EQW012A0A (5.0V, 12A) at 25C (except derating curve). The figures are identical for either positive or negative Remote On/Off logic. 14 91 12 OUTPUT CURRENT, Io (A) 94 EFFICIENCY, (%) 88 85 82 Vin=75V 79 Vin=48V 76 Vin=36V 73 70 0 3 6 9 4 2 100 LFM 200 LFM 300 LFM 400 LFM 0 30 40 50 60 70 80 90 AMBIENT TEMPERATURE, TA C Figure 33. Transient Response to Dynamic Load Change from 50% to 75% to 50% of full load (Vin =48Vdc). Tyco Electronics Power Systems OUTPUT VOLTAGE VO (V) (2V/div) VO (V) (2V/div) OUTPUT VOLTAGE TIME, t (100s/div) VON/OFF(V) (5V/div) IO (A) (5A/div) VO (V) (100mV/div) Figure 35. Typical Start-Up with application of Vin (Vin = 48Vdc, Io = 12A). On/Off VOLTAGE, TIME, t (5ms/div) Figure 32. Typical Output Ripple and Noise (Vin =48Vdc, Io = 12A). OUTPUT CURRENT, OUTPUT VOLTAGE V IN (A) (20V/div) Figure 34. Derating Output Current versus Local Ambient Temperature and Airflow INPUT VOLTAGE , VO (V) (20mV/div) OUTPUT VOLTAGE, 6 O OUTPUT CURRENT, IO (A) TIME, t (1s/div) 8 20 12 Figure 31. Converter Efficiency versus Output Current NC 10 TIME, t (5ms/div) Figure 36. Typical Start-Up Using Remote On/Off, negative logic version shown (Vin = 48Vdc, Io = 12A). 11 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Safety Considerations Test Configurations CURRENT PROBE TO OSCILLOSCOPE LTEST VIN(+) BATTERY 12H CS 220F 33F E.S.R.<0.1 E.S.R. <0.1 @ 100kHz @ 20C 100kHz VIN(-) NOTE: Measure input reflected ripple current with a simulated source inductance (LTEST) of 12H. Capacitor CS offsets possible battery impedance. Measure current as shown above. Figure 37. Input Reflected Ripple Current Test Setup COPPER STRIP VO (+) RESISTIVE LOAD 1uF . 10uF 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., UL60950, CSA C22.2 No. 60950-00 and VDE 0805:2001-12 (IEC60950, 3rd Ed). These converters have been evaluated to the spacing requirements for Basic Insulation, per the above safety standards. For Basic Insulation models ("-B" Suffix), 1500 Vdc is applied from Vi to Vo to 100% of outgoing production. For end products connected to -48V dc, or -60Vdc nominal DC MAINS (i.e. central office dc battery plant), no further fault testing is required. *Note: -60V dc nominal battery plants are not available in the U.S. or Canada. For all input voltages, other than DC MAINS, where the input voltage is less than 60V dc, if the input meets all of the requirements for SELV, then: * SCOPE V O (- ) GROUND PLANE NOTE: All voltage measurements to be taken at the module terminals, as shown above. If sockets are used then Kelvin connections are required at the module terminals to avoid measurement errors due to socket contact resistance. Figure 38. Output Ripple and Noise Test Setup Rdistribution Rcontact Rcontact VIN(+) Rdistribution Rcontact Rcontact VO. IO = VIN. IIN x 100 % Figure 39. Output Voltage and Efficiency Test Setup 12 * The input source is to be provided with reinforced insulation from any hazardous voltage, including the AC mains. * One Vi pin and one Vo pin are to be reliably earthed, or both the input and output pins are to be kept floating. * NOTE: All voltage measurements to be taken at the module terminals, as shown above. If sockets are used then Kelvin connections are required at the module terminals to avoid measurement errors due to socket contact resistance. Efficiency One pole of the input and one pole of the output are to be grounded, or both circuits are to be kept floating, to maintain the output voltage to ground voltage within ELV or SELV limits. For all input sources, other than DC MAINS, where the input voltage is between 60 and 75V dc (Classified as TNV-2 in Europe), the following must be adhered to, if the converter's output is to be evaluated for SELV: Rdistribution COM The output may be considered SELV. Output voltages will remain within SELV limits even with internally-generated non-SELV voltages. Single component failure and fault tests were performed in the power converters. * RLOAD VO VIN(-) Rdistribution VO VIN Data Sheet October 8, 2004 Another SELV reliability test is conducted on the whole system, as required by the safety agencies, on the combination of supply source and the subject module to verify that under a single fault, hazardous voltages do not appear at the module's output. The power module has ELV (extra-low voltage) outputs when all inputs are ELV. All flammable materials used in the manufacturing of these modules are rated 94V-0, and UL60950 A.2 for reduced thickness. The input to these units is to be provided with a maximum 6A time- delay in the unearthed lead. Tyco Electronics Power Systems Data Sheet October 8, 2004 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Design Considerations Input Source Impedance Remote Sense The power module should be connected to a low ac-impedance source. A highly inductive source impedance can affect the stability of the power module. For the test configuration in Figure 37, a 33F electrolytic capacitor (ESR<0.7 at 100kHz), mounted close to the power module helps ensure the stability of the unit. Consult the factory for further application guidelines. Remote sense minimizes the effects of distribution losses by regulating the voltage at the remote-sense connections (See Figure 41). 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: Feature Descriptions Remote On/Off Two remote on/off options are available. Positive logic 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, device code suffix "1", turns the module off during a logic high and on during a logic low. VIN(+) [VO(+) - VO(-)] - [SENSE(+) - SENSE(-)] 0.5 V 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. The amount of power delivered by the module is defined as the voltage at the output terminals multiplied by the output current. When using remote sense and trim, the output voltage of the module can be increased, which at the same output current would increase the power output of the module. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power (Maximum rated power = Vo,set x Io,max). VO Ion/off ON/OFF SENSE(+) Von/off SENSE(-) COM VIN(-) Figure 40. Remote On/Off Implementation To turn the power module on and off, the user must supply a switch (open collector or equivalent) to control the voltage (Von/off) between the ON/OFF terminal and the VIN(-) terminal (Figure 40). Logic low is -0.7V Von/off 1.2V. The maximum Ion/off during a logic low is 1mA, the switch should be maintain a logic low level while sinking this current. During a logic high, the typical Von/off generated by the module is 15V, and the maximum allowable leakage current at Von/off = 15V is 10A. If not using the remote on/off feature: For positive logic, leave the ON/OFF pin open. For negative logic, short the ON/OFF pin to VIN(-). Tyco Electronics Power Systems SUPPLY VI(+) VO(+) VI(-) VO(-) II CONTACT RESISTANCE IO LOAD CONTACT AND DISTRIBUTION LOSSES Figure 41. Effective Circuit Configuration for remote sense operation 13 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Feature Descriptions (continued) Output Voltage Set-Point Adjustment (Trim) Trimming allows the output voltage set point to be increased or decreased, this is accomplished by connecting an external resistor between the TRIM pin and either the VO(+) pin or the VO(-) pin (COM pin) . VIN(+) ON/OFF LOAD VOTRIM 5.1x Vo, set x (100 + %) 510 Rtrim - up = - - 10.2 1.225 x % % 5.1x Vo, set x (100 + %) 510 Rtrim - up = - - 10.2 0 . 6 x % % Where Rtrim-down VO(-) Figure 42. Circuit Configuration to Trim Output Voltage Connecting an external resistor (Rtrim-down) between the TRIM pin and the Vo(-) (or Sense(-)) pin decreases the output voltage set point. To maintain set point accuracy, the trim resistor tolerance should be 0.1%. The following equation determines the required external resistor value to obtain a percentage output voltage change of % For output voltage: 1.2 V to 12V 510 Rtrim - down = - 10.2 % Where Vo, set - Vdesired % = x 100 Vo, set For example, to trim-down the output voltage of 2.5V module (EQW023A0G1) by 8% to 2.3V, Rtrim-down is calculated as follows: % = 8 510 Rtrim - down = - 10.2 8 Rtrim - down = 53.55 14 Connecting an external resistor (Rtrim-up) between the TRIM pin and the VO(+) (or Sense (+)) pin increases the output voltage set point. The following equations determine the required external resistor value to obtain a percentage output voltage change of %: For output voltage: 1.5 V to 12V For output voltage: 1.2 VO(+) Rtrim-up VIN(-) Data Sheet October 8, 2004 Vdesired - Vo, set % = x 100 Vo, set For example, to trim-up the output voltage of 1.5V module (EQW025A0M1) by 6% to 1.59V, Rtrim-up is calculated is as follows: % = 6 5.1 x 1.5 x (100 + 6) 510 Rtrim - up = - - 10.2 1 . 225 x 6 6 Rtrim - up = 15.12 At 48Vin (+/- 2.5V), EQW series modules can be trim down to 20% over the entire temperature range. This allows for margining the unit during manufacturing process if the set point voltage is lower than the standard output voltage. Please consult your local Tyco field application engineer for additional details. The voltage between the Vo(+) and Vo(-) terminals must not exceed the minimum output overvoltage protection value shown in the Feature Specifications table. This limit includes any increase in voltage due to remotesense compensation and output voltage set-point adjustment trim. 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. The amount of power delivered by the module is defined as the voltage at the output terminals multiplied by the output current. When using remote sense and trim, the output voltage of the module can be increased, which at the same output current would increase the power output of the module. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power (Maximum rated power = Vo,set x Io,max). Tyco Electronics Power Systems Data Sheet October 8, 2004 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Feature Descriptions (continued) Over current Protection Thermal Considerations To provide protection in a fault (output overload) condition, the module is equipped with internal current-limiting circuitry, and can endure current limiting continuously. At the instance of current-limit inception, the module enters a hiccup mode of operation, whereby it shuts down and automatically attempts to restart. Typical delay before a module shuts down in current limit is 30 ms and typical turn-off period in over current condition is 300 ms before module attempts to restart. While the fault condition exists, the module will remain in this hiccup mode, and can remain in this mode until the fault is cleared. The unit operates normally once the output current is reduced back into its specified range. The power modules operate in a variety of thermal environments; however, sufficient cooling should be provided to help ensure reliable operation. Considerations include ambient temperature, airflow, module power dissipation, and the need for increased reliability. A reduction in the operating temperature of the module will result in an increase in reliability. The thermal data presented here is based on physical measurements taken in a wind tunnel. The thermal reference point, Tref used in the specifications is shown in Figure 43. For reliable operation this temperature should not exceed 115 oC. The output power of the module should not exceed the rated power for the module (Vo, set x Io, max). Output Over voltage Protection Tref The output over voltage protection clamp consists of control circuitry, independent of the primary regulation loop, that monitors the voltage on the output terminals. This control loop has a higher voltage set point than the primary loop (See the over voltage clamp values in the Feature Specifications Table). In a fault condition, the over voltage clamp ensures that the output voltage does not exceed Vo,ovsd, max. This provides a redundant voltage-control that reduces the risk of output overvoltage. Air Flow Over temperature Protection To provide protection under certain fault conditions, the unit is equipped with a thermal shutdown circuit. The unit will shutdown if the thermal reference point Tref (Figure 43), exceeds 125oC (typical), but the thermal shutdown is not intended as a guarantee that the unit will survive temperatures beyond its rating. The module will automatically restarts after it cools down. Input Undervoltage Lockout At input voltages below the input undervoltage lockout limit, the module operation is disabled. The module will begin to operate at an input voltage between the undervoltage lockout limit and the minimum operating input voltage. Tyco Electronics Power Systems Figure 43. Tref Temperature Measurement Location Heat Transfer via Convection Increased airflow over the module enhances the heat transfer via convection. Derating figures showing the maximum output current that can be delivered by each module versus local ambient temperature (TA) for natural convection and up to 2m/s (400 ft./min) are shown in the respective Characteristics Curves section. 15 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Data Sheet October 8, 2004 EMC Considerations The figure 44 shows a suggested configuration to meet the conducted emission limits of EN55022 Class B. Level [dBV] 80 70 EN55022 Class B Conducted Average dBuV 60 50 + Ld1 40 CY1 Vin+ Vout+ 30 CX1 CX5 CX3 CX4 CX2 20 EQW 10 CY2 Vin- Vout- 0 150k 300k 500k 1M 2M 3M 4M 5M Frequency [Hz] 7M 10M 30M LC1 Cim Figure 44. Suggested Input Filter Configuration for EN55022 Class B Filter components: Cx1: 47uF aluminum electrolytic, 100V (Nichicon PW series) Cx2: 2x1uF ceramic, 100V (TDK C4532X7R2A105M) Cx3: 2x1uF ceramic, 100V (TDK C4532X7R2A105M) Cx4: 2x1uF ceramic, 100V (TDK C4532X7R2A105M) Cx5: 100uF aluminum electrolytic, 100V (Nichicon PW series) Cy3, Cy4: 3300pF ceramic, 1500V (AVX 1812SC332MAT1A) Cim: 3300pF ceramic, 1500V (AVX 1812SC332MAT1A) Lc1: 768 uH, 4.7A (Pulse Engineering P0422) Figure 45. EMC signature using recommended filter For further information on 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. Recommended SMT layout shown in the mechanical section are for reference only. SMT layout depends on the end PCB configuration and the location of the load. For additional layout guide-lines, refer to FLTR100V10 data sheet or contact your local Tyco Power field application engineer. Ld1: 4.7 uH, 5.5A (Vishay IHLP-2525CZ) 16 Tyco Electronics Power Systems Data Sheet October 8, 2004 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Mechanical Outline for EQW Through-Hole Module Dimensions are in millimeters and (inches). Tolerances: x.x mm 0.5 mm ( x.xx in. 0.02 in.) [unless otherwise indicated] x.xx mm 0.25 mm ( x.xxx in 0.010 in.) Top View Side View Bottom View Pin Function 1 VI(+) 2 On/Off 3 VI(-) 4 Vo(-) 5 Sense(-) 6 Trim 7 Sense(+) 8 Vo(+) Note: Location of pins are from true position Tyco Electronics Power Systems 17 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Data Sheet October 8, 2004 Mechanical Outline for EQW Surface Mount Module Dimensions are in millimeters and (inches). Tolerances: x.x mm 0.5 mm ( x.xx in. 0.02 in.) [unless otherwise indicated] x.xx mm 0.25 mm ( x.xxx in 0.010 in.) Top View Side View Bottom View Pin Function 1 VI(+) 2 On/Off 3 VI(-) 4 Vo(-) 5 Sense(-) 6 Trim 7 Sense(+) 8 Vo(+) 18 Tyco Electronics Power Systems Data Sheet October 8, 2004 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Recommended Pad Layout for Surface-Mount Modules Dimensions are in millimeters and (inches). Tolerances: x.x mm 0.5 mm ( x.xx in. 0.02 in.) [unless otherwise indicated] x.xx mm 0.25 mm ( x.xxx in 0.010 in.) Low Current High Current 1 . 0 Tyco Electronics Power Systems 19 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Data Sheet October 8, 2004 Recommended Pad Layout for Through-Hole Modules Dimensions are in millimeters and (inches). Tolerances: x.x mm 0.5 mm ( x.xx in. 0.02 in.) [unless otherwise indicated] x.xx mm 0.25 mm ( x.xxx in 0.010 in.) Component side view 20 Tyco Electronics Power Systems Data Sheet October 8, 2004 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Surface Mount Information Pick and Place Packaging Details The surface mount versions of the EQW surface mount modules (suffix -S) are supplied as standard in the plastic tray shown in Figure 69. The tray has external dimensions of 136mm (W) x 322.6mm (L) x 17.2mm (H) or 5.35in (W) x 12.7in (L) x 0.68in (H). The SMT versions of the EQW series of DC-to-DC power converters use an open-frame construction and are designed for surface mount assembly within a fully automated manufacturing process. The EQW-S series modules are fitted with a label designed to provide a large flat surface for pick and placing. The label is located covering the center of gravity of the power module. The label meets all the requirements for surface-mount processing, as well as meeting UL safety agency standards. The label will withstand reflow temperatures up to 300C. The label also carries product information such as product code, date and location of manufacture. Note: All dimensions in mm [inches]. Figure 47. Pick and Place Location Z Plane Height The `Z' plane height of the pick and place label is 9.15 mm (0.360 in) nominal with an RSS tolerance of +/0.25 mm. Figure 46. Surface Mount Packaging Tray Tray Specification Material Max temperature Antistatic coated PVC 65oC Max surface resistivity Colour Capacity Min order quantity 1012/sq Clear 12 power modules 36 pcs (1box of 3 full trays) Each tray contains a total of 12 power modules. The trays are self-stacking and each shipping box will contain 3 full trays plus one empty hold down tray giving a total number of 36 power modules. Tyco Electronics Power Systems Nozzle Recommendations The module weight has been kept to a minimum by using open frame construction. Even so, they have a relatively large mass when compared with conventional smt components. Variables such as nozzle size, tip style, vacuum pressure and placement speed should be considered to optimize this process. The minimum recommended nozzle diameter for reliable operation is 6mm. The maximum nozzle outer diameter, which will safely fit within the allowable component spacing, is 9 mm. Oblong or oval nozzles up to 11 x 9 mm may also be used within the space available. For further information please contact your local Tyco Electronics Power Systems Technical Sales Representative. 21 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Data Sheet October 8, 2004 300 Surface Mount Information (cont) The following instructions must be observed when SMT soldering these units. Failure to observe these instructions may result in the failure of or cause damage to the modules, and can adversely affect long-term reliability. The surface mountable modules in the EQW family use our newest SMT technology called "Column Pin" (CP) connectors. Figure 48 shows the new CP connector before and after reflow soldering onto the end-board assembly. REFLOW TEMP (C) Reflow Soldering Information P eak Temp 235oC 250 Co o ling zo ne 1-4oCs -1 Heat zo ne max 4oCs -1 200 150 So ak zo ne 30-240s 100 Tlim above 205oC P reheat zo ne max 4oCs -1 50 0 REFLOW TIME (S) Figure 49. Recommended Reflow Profile EQW Board 240 Insulator Solder Ball End assembly PCB Figure 48. Column Pin Connector Before and After Reflow Soldering MAX TEMP SOLDER (C) 235 230 225 220 215 210 205 200 0 The CP is constructed from a solid copper pin with an integral solder ball attached, which is composed of tin/lead (Sn/Pb-63/37) solder. The CP connector design is able to compensate for large amounts of coplanarity and still ensure a reliable SMT solder joint. o Typically, the eutectic solder melts at 183 C, wets the land, and subsequently wicks the device connection. Sufficient time must be allowed to fuse the plating on the connection to ensure a reliable solder joint. There are several types of SMT reflow technologies currently used in the industry. These surface mount power modules can be reliably soldered using natural forced convection, IR (radiant infrared), or a combination of convection/IR. For reliable soldering the solder reflow profile should be established by accurately measuring the modules CP connector temperatures. 22 10 20 30 40 50 60 TIME LIMIT (S) Figure 50. Time Limit Curve Above 205oC Reflow Post Solder Cleaning and Drying Considerations Post solder cleaning is usually the final circuit-board assembly process prior to electrical board testing. The result of inadequate 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 Tyco Electronics Board Mounted Power Modules: Soldering and Cleaning Application Note (AP01-056EPS). Tyco Electronics Power Systems Data Sheet October 8, 2004 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Ordering Information Please contact your Tyco Electronics' Sales Representative for pricing, availability and optional features. Table 1. Device Codes Input Voltage Output Voltage(s) Output Current Efficiency Connector Type Comcodes EQW025A0S1R01 48V (36-75Vdc) 1.0 V 25 A 80.0 % Through hole 108980863 EQW025A0P1 48V (36-75Vdc) 1.2 V 25 A 81.0 % Through hole 108981960 EQW025A0M1 48V (36-75Vdc) 1.5 V 25 A 81.0 % Through hole 108980632 EQW025A0Y1 48V (36-75Vdc) 1.8 V 25 A 84.0 % Through hole 108981978 EQW023A0G1 48V (36-75Vdc) 2.5V 23 A 87.0 % Through hole 108980624 Product codes EQW020A0F1 48V (36-75Vdc) 3.3 V 20 A 89.0 % Through hole 108981952 EQW012A0A1 48V (36-75Vdc) 5.0 V 12 A 91.0 % Through hole 108984444 EQW025A0S1R01-S 48V (36-75Vdc) 1.0 V 25 A 80.0 % SMT 108980996 EQW025A0P1-S 48V (36-75Vdc) 1.2 V 25 A 81.0 % SMT 108980970 EQW025A0M1-S 48V (36-75Vdc) 1.5 V 25 A 81.0 % SMT 108980723 EQW025A0Y1-S 48V (36-75Vdc) 1.8 V 25 A 84.0 % SMT 108980947 EQW023A0G1-S 48V (36-75Vdc) 2.5V 23 A 87.0 % SMT 108980921 EQW020A0F1-S 48V (36-75Vdc) 3.3 V 20 A 89.0 % SMT 108980905 EQW012A0A1-S 48V (36-75Vdc) 5.0 V 12 A 91.0 % SMT 108980889 Table 2. Device Options Option* Suffix** Negative remote on/off logic 1 Surface mount connections -S Approved for Basic Insulation -B Short Pins: 3.68 mm 0.25mm (0.145 in 0.010 in) 6 * Please contact Tyco Electronics Sales Representative for availability of these options, samples, minimum order quantity and lead times ** When adding multiple options to the product code, add suffix numbers in the descending order Tyco Electronics Power Systems 23 EQW012/020/023/025 Series, Eighth-Brick Power Modules: 36 - 75Vdc Input; 1.0Vdc to 5Vdc Output; 12A to 25A Output Data Sheet October 8, 2004 Europe, Middle-East and Africa Headquarters Tyco Electronics (UK) Ltd Tel: +44 (0) 1344 469 300 Latin America, Brazil, Caribbean Headquarters Tyco Electronics Power Systems Tel: +56 2 209 8211 World Wide Headquarters Tyco Electronics Power Systems, Inc. 3000 Skyline Drive, Mesquite, TX 75149, USA +1-800-526-7819 (Outside U.S.A.: +1-972-284-2626 www.tycopower.com e-mail: techsupport1@tycoelectronics.com Asia Pacific Region Tyco Electronics Systems india Pte. Ltd. Tel: +91 80 841 1633 x3001 Asia-Pacific Headquarters Tyco Electronics Singapore Pte. Ltd. Tel: +65 6416 4283 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) 2003 Tyco Electronics Corporation, Harrisburg, PA. All International Rights Reserved. Document No: DS03-074 ver. 0.9 PDF No: eqw_2-25-ds.pdf