Data Sheet May 1998 Lucent Technologies Bel! Labs Innovations JWO50H, JW075H, JW100H, JW150H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 150 W Features a Small size: 61.0 mm x 57.9 mm x 12.7 mm (2.40 in. x 2.28 in. x 0.50 in.) m High power density a High efficiency: 89% typical a Low output noise a Constant frequency ws Industry-standard pinout s Metal baseplate a 2:1 input voltage range The JWO50H, JW075H, JW100H, and JW150H Power Modules . use advanced, surface-mount technology and deliver high- Overtemperature protection (100 W, 150 W only) uality, efficient, and compact dc-dc conversion. quality, , P a Remote sense = Remote on/off Applications a Adjustable output voltage: 60% to 110% of Vo, nom = Distributed power architectures = Case ground pin Workstations = UL* Recognized, CSAt Certified, VDE Licensed u EDP equipment a CE mark meets 73/23/EEC and 93/68/EEC directivest s Telecommunications * ULis a registered trademark of Underwriters Laboratories, Inc. Options t CSA is a registered trademark of Canadian Standards Assn. } This product is intended for integration into end-use equipment. . ; ; ; All the required procedures for CE marking of end-use equip- a Choice of remote on/off logic configuration ment should be followed. (The CE mark is placed on selected . ducts. a Heat sink available for extended operation Products.) Description The JWOS0H, JW075H, JW100H, and JW150H 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 iso- lated from the inputs, allowing versatile polarity configurations and grounding connections. The modules have maximum power ratings from 50 W to 150 W at a typical full-load efficiency of 89%. The sealed modules offer a metal baseplate for excellent therma! performance. Threaded-through holes are pro- vided 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. ME 0050026 0033227 3bb a |Data Sheet JWO50H, JW075H, JW100H, JW150H Power Modules: May 1998 dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 150 W 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. Parameter Symbol Min Max Unit Input Voltage: Continuous: JWO50H, JW075H Vi 75 de JW100H, JW150H Vi 80 Vdc Transient (100 ms; JW100H, JW150H only) Vi, trans _ 100 V I/O Isolation Voltage _ _ 1500 Vde Operating Case Temperature Tc 40 100 C (See Thermal Considerations section.) 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 Symbol Min Typ Max Unit Operating Input Voltage Vi 36 48 75 Vde Maximum Input Current (Vi! = 0 V to 75 V; lo = lo, max): JWOS5OH (See Figure 1.) lt, max _ _ 1.7 A JW075H (See Figure 2.) hh, max 2.55 A JW100H (See Figure 3.) ht, max _ _ 3.4 A JW150H (See Figure 4.) li, max _ 5.2 A Inrush Transient i2t 1.0 As Input Reflected-ripple Current, Peak-to-peak _ _ 5 _ mAp-p (5 Hz to 20 MHz, 12 nH source impedance; see Figure 17.) Input Ripple Rejection (120 Hz) _ 60 cB 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 fus- ing is not included; however, to achieve maximum safety and system protection, always use an input line fuse. The safety agencies require a normal-blow, dc fuse with a maximum rating of 20 A (see Safety Considerations section). Based on the information provided in this data sheet on inrush energy and maximum dc input current, the same type of fuse with a lower rating can be used. Refer to the fuse manufacturer's data for further information. 2 Lucent Technologies Inc. @@ 00500eb 0033228 2T2Data Sheet May 1998 Electrical Specifications (continued) Table 2. Output Specifications JWO050H, JW075H, JW100H, JW150H Power Modules: dc-de Converters; 36 to 75 Vdc Input, 24 Vde Output; 50 W to 150 W Parameter Device | Symbol Min Typ Max Unit Output Voltage Set Point All Vo, sat 23.55 24.0 24.45 Vdc (Vi = 48 V; lo = lo, max; Tc = 25 C) Output Voltage All Vo 23.28 _- 24.72 Vdc (Over all operating input voltage, resistive load, and temperature conditions until end of life. See Figure 19.) Output Regulation: Line (Vi = 36 V to 75 V) All _ 0.01 0.1 % Load (lo = Io, min to lo, max) All 0.05 0.2 % Temperature (Tc = 40 C to +100 C) All _ _ 100 300 mV Output Ripple and Noise Voltage (See Figure 18.): RMS All _ _ 150 mVrms Peak-to-peak (5 Hz to 20 MHz) All _ 400 mVp-p External Load Capacitance (electrolytic) All _ 0 _ 10,000 LF Output Current: JWO050H lo 0.3 _ 2 A (At lo < lo, min, the modules may exceed output | JW075H lo 0.3 _ 3.1 A ripple specifications.) JW100H lo 0.3 _ 4.2 A JW150H lo 0.3 _ 6.2 A Output Current-limit Inception JWO050H lo, ati 2.2 2.4 2.7 A (Vo = 90% of Vo, nom) JW075H lo, cti 3.3 3.6 4.0 A JW100H lo, efi 4.4 48 5.5 A JW150H lo, cli 6.6 7.3 8.1 A Output Short-circuit Current (Vo = 250 mV) All _ _ 170 _ %lo, max Efficiency JW050H Tl 84.5 86.5 _ % (Vi = 48 V; lo = lo, max; Te = 70 C) JW075H nN 86.5 88.5 % JW100H nN 87.5 89.5 _ % JW150H n 87.5 89.5 % Dynamic Response (Alo/At = 1 A/10 ps, Vi = 48 V, Tc = 25 C): Load Change from lo = 50% to 75% of lo, max: Peak Deviation All _ 3 _ %NVO, set Settling Time (Vo < 10% of peak deviation) All _ 300 _ us Load Change from lo = 50% to 25% of lo, max: Peak Deviation All _ _ 3 _ %VO, sat Settling Time (Vo < 10% of peak deviation) All 300 _ ys Table 3. tsolation Specifications Parameter Min Typ Max Unit Isolation Capacitance _ 2500 _ pF Isolation Resistance 10 _ _ MQ Lucent Technologies Inc. ME 00So02b 09033229 135 3JW050H, JW075H, JW100H, JW150H Power Modules: dc-dc Converters; 36 to 75 Vde Input, 24 Vde Output; 50 W to 150 W May 1998 General Specifications Data Sheet Parameter Min | Typ | Max Unit Calculated MTBF (lo = 80% of lo, max; Tc = 40 C) 2,600,000 hr. Weight | 100(3.5) |g (oz.) Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See Feature Descriptions for additional information. (100 W and 150 W only; see Feature Descriptions.) 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 20 and Feature Descriptions.): JWxxxH1 Preferred Logic: Logic LowModule On Logic HighModule Off JWxxxH Optional Logic: Logic LowModule Off Logic HighModule On Logic Low: At lorott = 1.0 mA Vorvott 0 _ 1.2 Vv At Vornott = 0.0 V lor/off 1.0 mA Logic High: At lonott = 0.0 LA Von/ott _ 15 Vv Leakage Current lornvott _ _ 50 pA Turn-on Time (See Figure 16.) _ 20 35 ms (lo = 80% of lo, max; Vo within +1% of steady state) Output Voltage Adjustment (See Feature Descriptions.): Output Voltage Remote-sense Range _ _ _ 0.5 V Output Voltage Set-point Adjustment Range (trim) 60 _ 110 | %Vo,nom Output Overvoltage Clamp Vo, clamp | 26.5 _ 33.0 V Overtemperature Shutdown Te _ 105 _ C . M8 0050026 0033230 450 Lucent Technologies Inc.Data Sheet JWO050H, JW075H, JW100H, JW150H Power Modules: May 1998 dc-de Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 150 W Characteristic Curves The following figures provide typical characteristics for the JWO50H, JW075H, JW100H, and JW150H power modules. The figures are identical for both on/off configurations. 2.0 < < B i = = WwW uy oc gC c x 2 2 oO oO - Ee > - ao a z z cobb i Ge it EG oobi i iii iG; iG 0 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 6872 O 4 8 12 16 20 24 28 32 36 40 44 48 52 56 GO 646872 INPUT VOLTAGE, Vi (V) INPUT VOLTAGE, V1(V) 8-4159 (C) 8-1160 (C) Figure 1. Typical JWO50H Input Characteristics at Figure 3. Typical JW100H Input Characteristics at Room Temperature, fo = 2.1 A Room Temperature, lo = 4.2 A 6 =< < EE _ io G oc ac x c 3 3 E bE 2 @ Zz Z INPUT VOLTAGE, Vi (V) INPUT VOLTAGE, V1 (A) 8-1131 (C) 98-1142 (C) Figure 2. Typical JWO75H Input Characteristics at Figure 4. Typical JW150H Input Characteristics at Room Temperature, lo = 3.1 A Room Temperature, lo = 6.2 A Lucent Technologies Inc. M@ ooso02zb 0033231 3897 5JWO50H, JW075H, JW100H, JW150H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 150 W Characteristic Curves (continued) Vout (V) 00 05 10 15 20 25 30 35 40 4.5 OUTPUT CURRENT, Io (A) 8-1286 (C) Figure 5. Typical JWO50H Output Characteristics at Room Temperature, Vin = 48 V Vout (V) OUTPUT CURRENT, Io (A) 8-1287 (C) Figure 6. Typical JW075H Output Characteristics at Room Temperature, Vin = 48 V 6 MM 00500eb 0033232 723 Data Sheet May 1998 Vout (V) 0.00.5 1015 20 25 3.0 3.5 4.0 4.5 5.0 5.5 6.065 OUTPUT CURRENT, lo (A) 8-1288 (C) Figure 7. Typical JW100H Output Characteristics at Room Temperature, Vin = 48 V Vout (V) OUTPUT CURRENT, lo (A) B-1289 (C) Figure 8. Typical JW150H Output Characteristics at Room Temperature, Vin = 48 V Lucent Technologies Inc.Data Sheet May 1998 JWO050H, JW075H, JW100H, JW150H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 150 W Characteristic Curves (continued) 89 88 87 86 85 84 83 82 81 80 79 06 0.8 1.0 1.2 1.4 16 1.8 20 2.2 EFFICIENCY, n (%) OUTPUT CURRENT, lo (A) 8-1290 (C).A Figure 9. Typical JWO50H Converter Efficiency vs. Output Current at Room Temperature EFFICIENCY, 1 (%) 0.8 1.2 1.6 2.0 2.4 2.8 3.2. OUTPUT CURRENT, lo (A) 8-1291 (C) Figure 10. Typical JW075H Converter Efficiency vs. Output Current at Room Temperature Lucent Technologies Inc. 87 85 83 81 EFFICIENCY, n (%) 79 77 75L_i pe 0.004 08 12 16 20 24 28 32 36 4.042 OUTPUT CURRENT, lo (A) 8-1292 (C) Figure 11. Typical JW100H Converter Efficiency vs. Output Current at Room Temperature EFFICIENCY, n (%) OUTPUT CURRENT, Io (A) 8-1293 (C) Figure 12. Typical JW150H Converter Efficiency vs. Output Current at Room Temperature M@ 0050026 0033233 &tETJWO050H, JW075H, JW100H, JW150H Power Modules: Data Sheet dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 150 W May 1998 Characteristic Curves (continued) q = + o > zr u> + Ws + <3 + aE = + Se xt Yo 7 + 4 OS + 5 =? t fortidiodtndaretidiorhud 2 3 VY VV y/ Y/ NT > a as z + rz 5 + ais + cs + s 2 +. on + ke T. + a + E xr = - oO TIME, t (1 ps/div) TIME, t (50 ps/div) 8-2017 (C) 8-2018 (C) Figure 13. Typical JW150H Output Ripple Voltage at = Figure 15. Typical JW150H Transient Response to Room Temperature, 48 V Input, lo = Full Step Increase in Load from 50% to 75% Load of Full Load at Room Temperature and 48 V input (Waveform Averaged to Eliminate Ripple Component.) = g Ee wi > O6 Qs 23 E> > oF Hui >38 oo s< re ae a o 5 > 5 s = = oa E Os oS J ge se 5 a o E 5 3 Oo TIME, t (5 ms/div) TIME, t (50 ps/div) 8-2019 (C) 8-1266 (C).d Figure 14. Typical JW150H Transient Response to Figure 16. Typical Start-Up from Remote On/Off Step Decrease in Load from 50% to 25% JW150H1; lo = Full Load of Full Load at Room Temperature and 48 V Input (Waveform Averaged to Eliminate Ripple Component.) 8 Lucent Technologies Inc. Me 00500eb 0033234 SThData Sheet May 1998 JWO050H, JW075H, JW100H, JW150H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vde Output; 50 W to 150 W Test Configurations TO OSCILLOSCOPE CURRENT 3-H" PROBE @ Vi(+) 12 pH Cs 220 pF BATTERY = ESR <0.19 33 pF rT @ 20C, 100kHz ESR <0.72 @ 100 kHz + > @ Vi(-) 8-203 (C).1 Note: Measure input reflected-ripple current with a simulated source inductance (LresT) of 12 4H. Capacitor Cs offsets possible bat- tery impedance. Measure current as shown above. Figure 17. Input Reflected-Ripple Test Setup COPPER STRIP Vo(+) | @ * +. ero > RESISTIVE SE 1OUF == 10uF SCOPE = Poe Vo(-) | @ 2 8-513 (C).d Note: Use a 1.0 1 F ceramic capacitor and a 10 LF aluminum or tan- talum capacitor. Scope measurement should be made using a BNC socket. Position the load between 51 mm and 76 mm (2 in. and 3 in.) from the module. Figure 18. Peak-to-Peak Output Noise Measurement Test Setup Lucent Technologies Inc. SENSE(+) CONTACT AND DISTRIBUTION LOSSES @ Vi(+) Vo(+) == SUPPLY LOAD | Vi) Vot-) SENSE(-) [ 8-749 (C) Note: Ail measurements are taken at the module terminals. When socketing, place Kelvin connections at module terminals to avoid measurement errors due to socket contact resistance. CONTACT RESISTANCE (Wol+) - Te) n= ( [ViG) -ViC_) * 100 Figure 19. 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 17, a 33 uF electrolytic capacitor (ESR < 0.7 Q 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 for further application guidelines. M@ 0050026 0033235 432JWO50H, JW075H, JW100H, JW150H Power Modules: dc-de Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 150 W Design Considerations (continued) 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), one of the following must be true: = All inputs are SELV and floating, with the output also floating. a All inputs are SELV and grounded, with the output also grounded. e Any non-SELv input must be provided with rein- forced insulation from any other hazardous voltages, including the ac mains, and must have a SELV reli- ability test performed on it in combination with the converters. Inputs must meet SELV requirements. If the input meets extra-low voltage (ELV) require- ments, then the converters output is considered ELV. The input to these units is to be provided with a maxi- mum 20 A normal-blow fuse in the ungrounded lead. Electrical Descriptions Current Limit To provide protection in a fault (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 circuit can exhibit either foldback or tai- lout characteristics (output current decrease or increase). The unit operates normally once the output current is brought back into its specified range. 10 M@@ 0050026 Data Sheet May 1998 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 dur- ing a logic high and on during a logic low. Negative logic (code suffix 1) is the factory-preferred configura- tion. 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 (Vorot). The switch can be an open collector or equivalent (see Figure 20). A logic low is Vonott = 0 V to 1.2 V. The maximum lorvoft 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/o# generated by the power module is 15 V. The maximum allowable leakage current of the switch at Voror = 15 V is 50 pA. if not using the remote on/off feature, do one of the following: a For negative logic, short ON/OFF pin to Vi(). = For positive logic, leave ON/OFF pin open. lon/ott -@ ON/OFF We + Vonvott SENSE(+) @ Vo(+) z LOAD < @ Vi(+) Vo(-) e- >= SENSE(-) @ tL @ Vi(-) O 8-720 (C).c Figure 20. Remote On/Off implementation Lucent Technologies Inc. 0033236 379Data Sheet May 1998 JWO050H, JW075H, JW100H, JW150H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vde Output; 50 W to 150 W Feature Descriptions (continued) 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(-) terminals must not exceed 26.4 V. This limit includes any increase in voltage due to remote-sense compensation and out- put voltage set-point adjustment (trim). See Figure 21. If not using the remote-sense feature to regulate the output at the point of load, then connect SENSE(+) to Vo(+) and SENSE(-) to Vo(-) at the module. SENSE(+)e SENSE(-)e ow Vi(+) Vo(+) Li} vww AMY = SUPPLY >" lo LOAD reVii-) Vo(-)E } www CONTACT CONTACT AND RESISTANCE DISTRIBUTION LOSSES 8-651 (C).m Figure 21. Effective Circuit Configuration for Single-Module Remote-Sense Operation 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. With an external resistor between the TRIM and SENSE(-) pins (Ragj-down), the output voltage set point (Vo, adj) decreases (see Figure 22). The follow- ing equation determines the required external-resistor value to obtain a percentage output voltage change of A%. 100 _ A% Radj-down = ( 2) kQ The test results for this configuration are displayed in Figure 23. This figure applies to all output voltages. With an external resistor connected between the TRIM and SENSE(+) pins (Radj-up), the output voltage set point (Vo, agi) increases (see Figure 24). Lucent Technologies tnc. Mm ogosdogcL The following equation determines the required exter- nal-resistor value to obtain a percentage output voltage change of A%. _ (Vo(100+A%) (100+ 24%) Rladtup = ( 1.225% A% ka The test results for this configuration are displayed in Figure 25. The voltage between the Vo(+) and Vo() terminats must not exceed 26.4 V. This limit includes any increase in voltage due to remote-sense compensation and out- put voltage set-point adjustment (trim). See Figure 21. If not using the trim feature, leave the TRIM pin open. Vi{+) Vo(+) o o ON/OFF SENSE(+) TRIM oF 3 Radj-down SENSE(-) o CASE $ RLoAD Vi(-) Vo(-) o 8-748 (C).b Figure 22. Circuit Configuration to Decrease Output Voltage 1M 100k we nn de ee ee en nn ede ene eee 10k TOT ik ADJUSTMENT RESISTOR VALUE (2) TOP TTT 100 i i 0 10 20 30 40 % CHANGE IN OUTPUT VOLTAGE (A%) 2.879 (C) Figure 23. Resistor Selection for Decreased Output Voltage 11 0O0332e37? 2cOSJWO50H, JW075H, JW100H, JW150H Power Modules: dc-de Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 150 W Feature Descriptions (continued) Output Voltage Set-Point Adjustment (Trim) (continued) o Vi(+) Vo(+) o o ON/OFF SENSE(+) o : Radj-up 4 CASE TRIM > = RLoaD o Vi(-) SENSE(-) o Vo(-) o 8-715 (C).b Figure 24. Circuit Configuration to Increase Output Voltage 100M 10M ADJUSTMENT RESISTOR VALUE (Q) z= g 0 2 4 6 8 10 % CHANGE IN OUTPUT VOLTAGE (A%) 8-2093 (C) Figure 25. Resistor Selection for Increased Output Voltage Output Overvoltage Clamp The output overvoltage clamp consists of control cir- cuitry, independent of the primary regulation loop, that monitors the voltage on the output terminals. The con- trol 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. 12 Mi 00500264 Data Sheet May 1998 Overtemperature Protection (Shutdown) The 100 W and 150 W modules feature an overtemper- ature protection circuit to safeguard against thermal damage. The circuit shuts down the module when the maximum case temperature is exceeded. The module restarts automatically after cooling. Thermal Considerations 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 (Tc) occurs at the position indicated in Figure 26. j~a 38.0 (1.50) r} MEASURE CASE | /- TEMPERATURE HERE 76(0.3) | Gg Ng Oo | @Vi(s) Vo (+) @ @ ON/OFF +SENe TRIM @ @ CASE -SEN evi) Vo(-)@ QO oO 8-716 (C).f Note: Top view, pin locations are for reference. Measurements shown in millimeters and (inches). Figure 26. Case Temperature Measurement Location The temperature at this location should not exceed 100 C. The output power of the module should not exceed the rated power for the module as listed in the Ordering Information table. Lucent Technologies Inc. 0033238 14,Data Sheet May 1998 JWO050H, JW075H, JW100H, JW150H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 150 W Therma! Considerations (continued) introduction (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 Lucent Technologies Thermal Management JC-, JFC-, JW-, and JFW-Series 50 W to 150 W Boara- Mounted Power Modules Technical Note (TN97-008EPS). Heat Transfer Without Heat Sinks Increasing airflow over the module enhances the heat transfer via convection. Figure 27 shows the maximum power that can be dissipated by the module without exceeding the maximum case temperature versus local ambient temperature (Ta) for natural convection through 4 m/s (800 ft./min.). Note that the natural convection condition was mea- sured 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 dissipat- ing components in the system. The use of Figure 27 is shown in the following example. Example What is the minimum airflow necessary for a JW100H operating at nominal line, an output current of 4.2 A, and a maximum ambient temperature of 40 C? Solution Given: Vi=54V lo=4.2A Ta = 40 C Determine Pp (Use Figure 30): Po=12W Determine airflow (v) (Use Figure 27): Vv = 1.0 m/s (200 ft./min.) Lucent Technologies Inc. 1 4.0 mis (800 ft-/min.) 7-3-5 m/s (700 ft./min.) = * 3.0 m/s (600 ft/min.) = 1 2.5 m/s (500 ft./min.) a _f,-2.0 ms (400 ft/min.) z -1.5 m/s (300 ft./min.) 1.0 m/s (200 ft./min.) qe %-0.5 m/s (100 ft./min.) Qa, . ' : . i a : : ' Z g 10 ses es o i : a 5-09.41 m/s (NAT. CONV.) (20 ft./min.) : . 0 j I ! l l l l I Oo 10 20 30 40 50 60 70 80 LOCAL AMBIENT TEMPERATURE, Ta (C) 8-1150 (C).a Figure 27. Forced Convection Power Derating with No Heat Sink; Either Orientation POWER DISSIPATION, Pp (W) os NWA UD N DO OD So So o on = o _ a ho Oo OUTPUT CURRENT, lo (A) Figure 28. JW050H Power Dissipation vs. Output Current 8-1295 (C) 13 M@ 0050026 0033239 068JWO50H, JW075H, JW100H, JW150H Power Modules: dce-de Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 150 W Data Sheet May 1998 Thermal Considerations (continued) Heat Transfer Without Heat Sinks (continued) 14 12 z oa & 10 z 2 8 < o. B 6 Q ' G 4 5 a 2 : 0 i r t r i 0.0 0.5 1.0 1.5 2.0 2.5 3.0 OUTPUT CURRENT, lo (A) 8-1296 (C) Figure 29. JW075H Power Dissipation vs. Output Current ae ew oe DONO t POWER DISSIPATION, Po (W) om NWOAONANED T pei ac 16 20 24 28 3.2 3.6 4.042 0.0 04 08 1.2 OUTPUT CURRENT, Io (A) 8-1297 (C) Figure 30. JW100H Power Dissipation vs. Output Current 14 25 = a a z QO < o w 2 a oc = t oO : a : 0 i i { { f 0 1 2 3 4 5 6 OUTPUT CURRENT, Io (A) 8-1298 (C) Figure 31. JW150H 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 customers 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-Ibs.). Thermal derating with heat sinks is expressed by using the overall thermal resistance of the module. Total mod- ule thermal resistance (@ca) is defined as the maximum case temperature rise (ATc, max) divided by the module power dissipation (Pp): Oca = [a] - [a] Lucent Technologies Inc. M@@ 0050026 0033240 &TTData Sheet May 1998 Thermal Considerations (continued) Heat Transfer with Heat Sinks (continued) The location to measure case temperature (Tc) is shown in Figure 26. Case-to-ambient thermal resis- tance vs. airflow is shown, for various heat sink config- urations and heights, in Figure 32. These curves were obtained by experimental testing of heat sinks, which are offered in the product catalog. 8 ; : BT Reese beceeeeeebeceeeeeeetes 11/2 in. HEAT SINK-.-.J = 1 in. HEAT SINK = 6 1/2 in. HEAT SINK -----+ rs 1/4 in. HEAT SINK Peg SRS NOHEATSINK 9 77777] zo : : Way 4P-------e.------ PRS A A deen eee eee nee eee ca : 22 3 ; Oo | wi 2 Qe : <x G6 1 be eeeeenneegeceeeeeneen eee ama === 0 i l i | j 0 1.0 1.5 0.5 2.0 2.5 3.0 (100) (200) (300) (400) (500) (600) AIR VELOCITY MEASURED IN ms (ft./min.) 8-1153 (C) Figure 32. Case-to-Ambient Thermal Resistance Curves; Either Orientation These measured resistances are from heat transfer from the sides and bottom of the module as well as the top side with the attached heat sink; therefore, the case-to-ambient thermal resistances shown are gener- ally lower than the resistance of the heat sink by itself. The module used to collect the data in Figure 32 had a thermal-conductive dry pad between the case and the heat sink to minimize contact resistance. The use of Figure 32 is shown in the following example. Example If an 85 C case temperature is desired, what is the minimum airflow necessary? Assume the JW100H module is operating at nominal line and an output cur- rent of 4.2 A, maximum ambient air temperature of 40 C, and the heat sink is 0.5 in. Solution Given: Vi=54V lo=4.2A Ta = 40 C Te = 85C Heat sink = 0.5 in. Lucent Technologies Inc. JWO50H, JW075H, JW100H, JW150H Power Modules: dc-dc Converters; 36 to 75 Vdc Input, 24 Vdc Output; 50 W to 150 W Determine Po by using Figure 30: Po = 12W Then solve the following equation: Oca = [) Oca jes - oy 12 Oca = 3.75 C/W Use Figure 32 to determine air velocity for the 0.5 inch heat sink. The minimum airflow necessary for the JW100H module is 0.6 m/s (125 ft./min.). Custom Heat Sinks A more detailed model can be used to determine the required thermal resistance of a heat sink to provide necessary cooling. The total module resistance can be separated into a resistance from case-to-sink (@cs) and sink-to-ambient (@sa) shown below (Figure 33). Tc Ts Ta Wwe Ocs Osa Po > 8-1304 (C) Figure 33. Resistance from Case-to-Sink and Sink-to-Ambient For a managed interface using thermal grease or foils, a value of 6cs = 0.1 C/W to 0.3 C/W is typical. The solution for heat sink resistance is: Qsa = [S| -~Ocs 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 provides a conservative estimate for such instances. Layout Considerations Copper paths must not be routed beneath the power module mounting inserts. M@ OOSO0eb 0033241 736 mm 15JWO50H, JW075H, JW100H, JW150H Power Modules: Data Sheet dc-dc Converters; 36 to 75 Vdc Input, 24 Vde Output; 50 W to 150 W 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. in. + 0.010 in.) Top View [* 57.9 (2.28) MAX | 4 oO Oo 61 o 2.4 Gar y Side View } SIDE LABELS 12.70 0.5 (0.500 + 0.020) ' 2.06 (0.081) DIA 5.1 (0.20) MIN 1.02 (0.040) DIA [x SOLDER-PLATED BRASS t [_- SOLDER-PLATED U 2 PLCS (-OUTPUT AND f BRASS 7 PLCS +OUTPUT) Bottom View MOUNTING INSERTS t 12.7 (0.50) / M3 x0.5 THROUGH 5.1 (0.20) . 4PLCS +0 oO t [ vit) Vo (-)-0 t 10.16 10.16 4 | | (0.400) (0.400) 17.78 (0.700) 50.8 25.40 T CASE ~ SEN TF (2.00) | (1.000) ram o } 25.40 (1.000) 35.56 { t (1.400) 7 ON/OFF + SEN o Grice) yr o Vi(+) Vo (+) | | 48.26 i 6 (1.900) O oie k 48.3 (1.90) w| 8-1945 (C).a * Side labels include Lucent logo, product designation, safety agency markings, input/output voltage and current ratings, and bar code. 16 me 0050026 00393242 672 om Lucent Technologies inc.Data Sheet JW050H, JW075H, JW100H, JW150H Power Modules: May 1998 dc-de Converters; 36 to 75 Vde Input, 24 Vde Output; 50 W to 150 W Recommended Hole Pattern Component-side footprint. Dimensions are in millimeters and (inches). 48.26 (1.900) 35.56 +SEN o OF (1.400) ! 50. TRIM o Gt00) : . I 61.0 ~SEN tH, (0-700) (2.49) . 1(0.400) MA $ Vo (-)o ' F | 5.1 (020) Tie Me 12.7 (0.50) \ MOUNTING INSERTS MODULE OUTLINE 8-1945 (C).a Ordering Information Input Output Output Remote On/ Device Comcode Voltage Voltage Power Off Logic Code 48V 24.0 V 50 W negative JWOS50H1 107430258 48V 24.0V 75W negative JW075H1 107477283 48V 24.0V 100 W negative JW100H1 107430282 48V 24.0V 150 W negative JW150H1 107253197 48V 24.0V 50 W positive JWO050H 107477358 48V 24.0V 75W positive JW075H 107430266 48V 24.0V 100 W positive JW100H 107477572 48V 24.0V 150 W positive JW150H 107477432 Lucent Technologies Inc. MB 0050026 0033243 505 a 17