Data Sheet July 1999 JW030-Series Power Modules: 36 Vdc to 75 Vdc Inputs; 30 W Features The JW030-Series Power Modules use advanced, surfacemount technology and deliver high-quality, compact, dc-dc conversion at an economical price. Small size: 61.0 mm x 57.9 mm x 12.7 mm (2.40 in. x 2.28 in. x 0.50 in.) Low output noise Constant frequency Industry-standard pinout Metal case Case ground pin 2:1 input voltage range High efficiency: 83% typical Overcurrent protection Remote on/off Remote sense Adjustable output voltage: 80% to 110% of VO, nom Output overvoltage protection Options Heat sinks available for extended operation Choice of remote on/off logic configuration Short pins: 2.79 mm 0.25 mm (0.110 in. 0.010 in.) Short pins: 3.68 mm 0.25 mm (0.145 in. 0.010 in.) UL* 1950 Recognized, CSA C22.2 No. 950-95 Certified, VDE 0805 (EN60950, IEC950) Licensed CE mark meets 73/23/EEC and 93/68/EEC directives Within FCC Class A radiated limits Applications Distributed power architectures Communications equipment Description The JW030-Series Power Modules are dc-dc converters that operate over an input voltage range of 36 Vdc to 75 Vdc and provide precisely regulated outputs. The outputs are isolated from the inputs, allowing versatile polarity configurations and grounding connections. The modules have maximum power ratings of up to 30 W at a typical full-load efficiency of up to 83%. These power modules feature remote on/off, output sense (both negative and positive leads), and output voltage adjustment, which allows output voltage adjustment from 80% to 110% for the JW030A-M, D-M, F-M, G-M and 60% to 110% for the JW030B-M, C-M of the nominal output voltage. For disk-drive applications, the JW030B-M Power Module provides a motor-start surge current of 3 A. The modules are PC board-mountable and encapsulated in metal cases. The modules are rated to full load at 100 C case temperature. No external filtering is required. * UL is a registered trademark of Underwriters Laboratories, Inc. CSA is a registered trademark of Canadian Standards Association. 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.) JW030-Series Power Modules: 36 Vdc to 75 Vdc Inputs; 30 W Data Sheet July 1999 Absolute Maximum Ratings Stresses in excess of the absolute maximum ratings can cause permanent damage to the device. These are absolute stress ratings only. Functional operation of the device is not implied at these or any other conditions in excess of those given in the operations sections of the data sheet. Exposure to absolute maximum ratings for extended periods can adversely affect device reliability. Parameter Symbol Min Max Unit Input Voltage Continuous VI -- 80 Vdc Operating Case Temperature (See Thermal Considerations section.) TC -40 100 C Storage Temperature Tstg -40 110 C I/O Isolation Voltage: Continuous Transient -- -- -- -- 500 1500 Vdc V 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 VI 36 48 75 Vdc II, max -- -- 1.6 A Inrush Transient i2t -- -- 0.2 A2s Input Reflected-ripple Current, Peak-to-peak (5 Hz to 20 MHz, 12 H source impedance; TC = 25 C; see Figure 20 and Design Considerations section.) II -- 25 -- mAp-p Input Ripple Rejection (120 Hz) -- -- 50 -- dB Operating Input Voltage Maximum Input Current (VI = 0 V to 75 V; IO = IO, max; see Figure 1.) Fusing Considerations CAUTION: This power module is not internally fused. An input line fuse must always be used. This encapsulated power module can be used in a wide variety of applications, ranging from simple stand-alone operation to an integrated part of a sophisticated power architecture. To preserve maximum flexibility, internal fusing is not included; however, to achieve maximum safety and system protection, always use an input line fuse. The safety agencies require a normal-blow fuse with a maximum rating of 5 A (see Safety Considerations section). Based on the information provided in this data sheet on inrush energy and maximum dc input current, the same type of fuse with a lower rating can be used. Refer to the fuse manufacturer's data for further information. 2 Tyco Electronics Corp. JW030-Series Power Modules: 36 Vdc to 75 Vdc Inputs; 30 W Data Sheet July 1999 Electrical Specifications (continued) Table 2. Output Specifications Device Code or Code Suffix Symbol Min Typ Max Unit Output Voltage Set Point (VI = 48 V; IO = IO, max; TC = 25 C) JW030D-M JW030G-M JW030F-M JW030A-M JW030B-M JW030C-M VO, set VO, set VO, set VO, set VO, set VO, set 1.97 2.46 3.25 4.95 11.82 14.77 2.0 2.5 3.3 5.0 12.0 15.0 2.03 2.54 3.35 5.05 12.18 15.23 Vdc Vdc Vdc Vdc Vdc Vdc Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life. See Figure 22.) JW030D-M JW030G-M JW030F-M JW030A-M JW030B-M JW030C-M VO VO VO VO VO VO 1.94 2.42 3.20 4.85 11.64 14.55 -- -- -- -- -- -- 2.06 2.57 3.40 5.15 12.36 15.45 Vdc Vdc Vdc Vdc Vdc Vdc All All A-M, B-M, C-M D-M, F-M, G-M -- -- -- -- -- -- -- -- 0.01 0.05 0.5 0.75 0.1 0.2 1.5 1.5 %VO %VO %VO %VO A-M, D-M, F-M, G-M B-M, C-M A-M, D-M, F-M, G-M B-M, C-M -- -- -- -- -- -- -- -- -- -- -- -- 20 25 150 200 mVrms mVrms mVp-p mVp-p Output Current (At IO < IO, min, the modules may exceed output ripple specifications; see Figures 3 through 8.) JW030D-M, F-M, G-M JW030A-M JW030B-M JW030B-M JW030C-M IO IO IO IO, trans IO 0.6 0.6 0.3 -- 0.2 -- -- -- -- -- 6.5 6.0 2.5 3.0 2.0 A A A A A Output Current-limit Inception (VO = 90% of VO, nom) JW030D-M, F-M, G-M JW030A-M JW030B-M JW030C-M IO IO IO IO -- -- -- -- 7.5 6.9 3.6 2.5 -- -- -- -- A A A A Output Short-circuit Current (VO = 250 mV) JW030D-M, F-M, G-M JW030A-M JW030B-M JW030C-M -- -- -- -- -- -- -- -- 8.0 8.0 4.0 3.0 10.0 9.5 5.5 4.5 A A A A JW030D-M JW030G-M JW030F-M JW030A-M JW030B-M, C-M 64 70 72 79 80 69 72 75 81 83 -- -- -- -- -- % % % % % All -- -- 250 -- kHz Parameter Output Regulation: Line (VI = 36 V to 75 V) Load (IO = IO, min to IO, max) Temperature (TC = -40 C to +100 C) Output Ripple and Noise Voltage (See Figure 21.): RMS Peak-to-peak (5 Hz to 20 MHz) Efficiency (VI = 48 V; IO = IO, max; TC = 25 C; see Figures 9 through 14 and 22.) Switching Frequency (secondary circuit) Tyco Electronics Corp. 3 JW030-Series Power Modules: 36 Vdc to 75 Vdc Inputs; 30 W Electrical Specifications Data Sheet July 1999 (continued) Table 2. Output Specifications (continued) Parameter Dynamic Response (yIO/yt = 1 A/10 s, VI = 48 V, TC = 25 C; see Figures 15 and 18.): Load Change from IO = 50% to 75% of IO, max: Peak Deviation Settling Time (VO < 10% peak deviation) Load Change from IO = 50% to 25% of IO, max: Peak Deviation Settling Time (VO < 10% of peak deviation) Device Code or Code Suffix Symbol Min Typ Max Unit JW030D-M, F-M, G-M JW030A-M, B-M, C-M All -- -- -- -- -- -- 5 2 0.5 -- -- -- %VO, set %VO, set ms JW030D-M, F-M, G-M JW030A-M, B-M, C-M All -- -- -- -- -- -- 5 2 0.5 -- -- -- %VO, set %VO, set ms Table 3. Isolation Specifications Min Typ Max Unit Isolation Capacitance Parameter -- 0.02 -- pF Isolation Resistance 10 -- -- M3/4 Min Typ Max Unit General Specifications Parameter Calculated MTBF (IO = 80% of IO, max; TC = 40 C) Weight 4 3,000,000 -- -- hours 113 (4.0) g (oz.) Tyco Electronics Corp. JW030-Series Power Modules: 36 Vdc to 75 Vdc Inputs; 30 W Data Sheet July 1999 Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See Feature Descriptions and Design Considerations for further information. Parameter Device Code or Code Suffix Symbol Min Typ Max Unit Remote On/Off (VI = 36 V to 75 V; open collector or equivalent compatible; signal referenced to VI(-) terminal. See Figure 23 and Feature Descriptions.): JW030x1-M Negative Logic: Logic Low--Module On Logic High--Module Off JW030x-M Positive Logic: Logic Low--Module Off Logic High--Module On Module Specifications: On/Off Current--Logic Low On/Off Voltage: Logic Low Logic High (Ion/off = 0) Open Collector Switch Specifications: Leakage Current During Logic High (Von/off = 10 V) Output Low Voltage During Logic Low (Ion/off = 1 mA) Turn-on Time (@ 80% of IO, max; TA = 25 C; VO within 1% of steady state; see Figure 19.) Output Voltage Overshoot All Ion/off -- -- 1.0 mA All All Von/off Von/off -0.7 -- -- -- 1.2 6 V V All Ion/off -- -- 50 A All Von/off -- -- 1.2 V All -- -- 80 150 ms All -- -- 0 5 % Output Voltage Sense Range All -- -- -- 10 %VO, nom D-M, G-M, F-M, A-M B-M, C-M -- -- 80 60 -- -- 110 110 %VO, nom %VO, nom JW030D-M JW030G-M JW030F-M JW030A-M JW030B-M JW030C-M VO, clamp VO, clamp VO, clamp VO, clamp VO, clamp VO, clamp 2.5 2.9 4.0 5.6 13.5 17.0 -- -- -- -- -- -- 4.0 3.8 5.7 7.0 16.0 20.0 V V V V V V Output Voltage Set-point Adjustment Range (See Feature Descriptions.) Output Overvoltage Protection (clamp) Tyco Electronics Corp. 5 JW030-Series Power Modules: 36 Vdc to 75 Vdc Inputs; 30 W Data Sheet July 1999 OUTPUT VOLTAGE, V O (V) Characteristic Curves 1.6 INPUT CURRENT, II (A) 1.4 1.2 1.0 2.5 2.0 1.5 VI = 36 V 1.0 VI = 72 V VI = 54 V 0.5 0 0.8 0 1 2 3 4 6 5 7 8 9 0.6 OUTPUT CURRENT, I O(A) 0.4 8-1331(C) 0.2 0.0 0 10 20 30 40 50 60 70 80 Figure 3. JW030D-M Typical Output Characteristics INPUT VOLTAGE, V I (V) 8-740(C) 1.002 1.001 1.000 0.999 3.0 OUTPUT VOLTAGE, VO (V) NORMALIZED OUTPUT VOLTAGE, V O (V) Figure 1. JW030-Series Typical Input Characteristics 2.5 2.0 VI = 36 V VI = 48 V VI = 75 V 1.5 1.0 0.5 0.998 0.997 0.0 0 0.996 1 2 3 4 5 6 7 8 9 10 0.995 OUTPUT CURRENT, IO (A) 0.994 8-2557(C) 0.993 0.992 -40 -20 0 20 40 60 80 100 CASE TEMPERATURE, T (C) 8-852(C).a Figure 4. JW030G-M Typical Output Characteristics Figure 2. JW030 Family Typical Output Voltage Variation over Ambient Temperature Range 6 Tyco Electronics Corp. Data Sheet July 1999 JW030-Series Power Modules: 36 Vdc to 75 Vdc Inputs; 30 W Characteristic Curves (continued) OUTPUT VOLTAGE, V O (V) 12 3.5 OUTPUT VOLTAGE, V O (V) 3.0 VI = 72 V 2.5 VI = 54 V 2.0 VI = 36 V 1.5 10 8 6 2 0 0.0 1.0 VI = 36 V VI = 54 V VI = 72 V 4 0.5 1.0 0.5 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 OUTPUT CURRENT, I O(A) 8-738(C) 0 0 1 2 3 4 5 6 7 8 9 10 OUTPUT CURRENT, IO (A) 8-1194(C) Figure 7. JW030B-M Typical Output Characteristics Figure 5. JW030F-M Typical Output Characteristics 16 OUTPUT VOLTAGE, V O (V) 14 OUTPUT VOLTAGE, V O (V) 5 4 3 VI = 36 V VI = 54 V VI = 72 V 2 12 10 8 6 VI = 36 V VI = 54 V 4 VI = 72 V 2 0 0.0 1 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 OUTPUT CURRENT, I O (A) 0 1 2 3 4 5 6 7 8 9 10 8-739(C) OUTPUT CURRENT, I O (A) 8-737(C) Figure 8. JW030C-M Typical Output Characteristics Figure 6. JW030A-M Typical Output Characteristics Tyco Electronics Corp. 7 JW030-Series Power Modules: 36 Vdc to 75 Vdc Inputs; 30 W Data Sheet July 1999 Characteristic Curves (continued) 80 75 EFFICIENCY, (%) 80 75 VI = 54 V EFFICIENCY, (%) 70 65 VI = 54 V 70 VI = 36 V 65 VI = 72 V 60 55 60 VI = 36 V 50 55 0 1 VI = 72 V 50 2 3 4 5 6 OUTPUT CURRENT, I O (A) 8-1193(C) 45 40 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 Figure 11. JW030F-M Typical Converter Efficiency vs. Output Current OUTPUT CURRENT, I O (A) 8-1330(C) 90 74 EFFICIENCY, (%) 72 80 EFFICIENCY, (%) Figure 9. JW030D-M Typical Converter Efficiency vs. Output Current 70 VI = 36 V VI = 54 V VI = 72 V 60 50 70 40 68 0 2 3 4 5 6 OUTPUT CURRENT, I O (A) 66 VI = 36 V VI = 48 V VI = 75 V 64 8-742(C) Figure 12. JW030A-M Typical Converter Efficiency vs. Output Current 62 60 0.6 1 1.6 2.6 3.6 4.6 5.6 6.6 OUTPUT CURRENT, IO (A) 8-2558(C) Figure 10. JW030G-M Typical Converter Efficiency vs. Output Current 8 Tyco Electronics Corp. Data Sheet July 1999 JW030-Series Power Modules: 36 Vdc to 75 Vdc Inputs; 30 W OUTPUT CURRENT, OUTPUT VOLTAGE, IO (%I O, max) VO (%VO, set) Characteristic Curves (continued) 90 EFFICIENCY, (%) 80 70 VI = 36 V VI = 54 V VI = 72 V 60 50 40 0.0 0.5 1.0 1.5 2.0 2.5 105 100 95 75 50 l o = 1 A/10 s t 25 500 s 3.0 TIME, t (500 s/div) OUTPUT CURRENT, I O (A) 8-731(C).a 8-741(C) Figure 13. JW030B-M Typical Converter Efficiency vs. Output Current Figure 15. JW030D-M, F-M, G-M Typical Output Voltage for a Step Load Change from 50% to 75% EFFICIENCY, (%) 80 70 VI = 36 V VI = 54 V VI = 72 V 60 50 40 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 OUTPUT CURRENT, I O (A) 8-743(C) OUTPUT CURRENT, OUTPUT VOLTAGE, IO (%I O, max) VO (%VO, set) 90 102 100 98 75 50 l o = 1 A/10 s t 25 500 s TIME, t (500 s/div) Figure 14. JW030C-M Typical Converter Efficiency vs. Output Current 8-731(C) Figure 16. JW030A-M, B-M, C-M Typical Output Voltage for a Step Load Change from 50% to 75% Tyco Electronics Corp. 9 JW030-Series Power Modules: 36 Vdc to 75 Vdc Inputs; 30 W Data Sheet July 1999 OUTPUT VOLTAGE VO (%VO, set) 102 100 98 REMOTE ON/OFF, Von/off (2 V/div) OUTPUT CURRENT, OUTPUT VOLTAGE, IO (%IO, max) VO (%VO, set) Characteristic Curves (continued) 75 50 25 l o = 1 A/10 s t 100 50 0 4 2 0 1 ms TIME, t (20 ms/div) 500 s 8-733(C).a TIME, t (500 s/div) 8-732(C).a Figure 19. Typical Output Voltage Start-Up when Signal Applied to Remote On/Off OUTPUT CURRENT, OUTPUT VOLTAGE, IO (%IO, max) VO (%VO, set ) Figure 17. JW030D-M, F-M, G-M Typical Output Voltage for a Step Load Change from 50% to 25% 102 100 98 75 50 25 IO = 1 A/10 s t 500 s TIME, t (500 s/div) 8-732(C) Figure 18. JW030A-M, B-M, C-M Typical Output Voltage for a Step Load Change from 50% to 25% 10 Tyco Electronics Corp. JW030-Series Power Modules: 36 Vdc to 75 Vdc Inputs; 30 W Data Sheet July 1999 Test Configurations Design Considerations Grounding Considerations TO OSCILLOSCOPE CURRENT PROBE LTEST The case is not connected internally allowing the user flexibility in grounding. V I (+) 12 H CS 220 F IMPEDANCE < 0.1 @ 20 C, 100 kHz BATTERY Input Source Impedance VI (-) 8-489(C) Note: Input reflected-ripple current is measured with a simulated source impedance of 12 H. Capacitor CS offsets possible battery impedance. Current is measured at the input of the module. The power module should be connected to a low acimpedance input source. Highly inductive source impedances can affect the stability of the power module. A 33 F electrolytic capacitor (ESR < 0.7 3/4 at 100 kHz) mounted close to the power module helps ensure stability of the unit. (See Figure 20.) Figure 20. Input Reflected-Ripple Test Setup 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 C22.2 No. 950-95, and VDE 0805 (EN60950, IEC950). COPPER STRIP V O (+) 0.1 F RESISTIVE LOAD SCOPE V O (-) 8-513(C) Note: Use a 0.1 F ceramic capacitor. Scope measurement should be made using a BNC socket. Position the load between 50 mm and 75 mm (2 in. and 3 in.) from the module. Figure 21. Peak-to-Peak Output Noise Measurement Test Setup SENSE(+) VI (+)/CASE CONTACT AND DISTRIBUTION LOSSES IO II LOAD VI(-) The input source is to be provided with reinforced insulation from any other 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 accessible. 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. VO (+) SUPPLY CONTACT RESISTANCE 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), all of the following must be true: VO (-) SENSE(-) 8-749(C).a Note: All measurements are taken at the module terminals. When socketing, place Kelvin connections at module terminals to avoid measurement errors due to socket contact resistance. [ V O (+) - V O (-) ] I O = ----------------------------------------------------- x 100 [ V I (+) - V I (-) ] II Figure 22. Output Voltage and Efficiency Measurement Test Setup Tyco Electronics Corp. % 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 pins and ground. The power module has extra-low voltage (ELV) outputs when all inputs are ELV. The input to these units is to be provided with a maximum 5 A normal-blow fuse in the ungrounded lead. 11 JW030-Series Power Modules: 36 Vdc to 75 Vdc Inputs; 30 W Data Sheet July 1999 Feature Descriptions VI(+) Overcurrent Protection To provide protection in a fault (output overload) condition, the unit is equipped with internal current-limiting circuitry and can endure current limiting for an unlimited duration. At the point of current-limit inception, the unit shifts from voltage control to current control. If the output voltage is pulled very low during a severe fault, the current-limit circuit can exhibit either foldback or tailout characteristics (output current decrease or increase). The unit operates normally once the output current is brought back into its specified range. VI(-) - SENSE(+) Von/off VO(+) + Ion/off LOAD REMOTE ON/OFF VO(-) SENSE(-) 8-720(C).h Figure 23. Remote On/Off Implementation Remote On/Off Remote Sense Two remote on/off options are available. Positive logic remote on/off turns the module on during a logic-high voltage on the REMOTE ON/OFF pin, and off during a logic low. Negative logic remote on/off turns the module off during a logic high and on during a logic low. Negative logic, device code suffix "1," is the factory-preferred configuration. Remote sense minimizes the effects of distribution losses by regulating the voltage at the remote-sense connections. The voltage between the remote-sense pins and the output terminals must not exceed the output voltage sense range given in the Feature Specifications table, i.e.: To turn the power module on and off, the user must supply a switch to control the voltage between the on/off terminal and the VI(-) terminal (Von/off). The switch can be an open collector or equivalent (see Figure 23). A logic low is Von/off = -0.7 V to 1.2 V, during which the module is off. The maximum Ion/off during a logic low is 1 mA. The switch should maintain a logiclow voltage while sinking 1 mA. During a logic high, the maximum Von/off generated by the power module is 6 V. The maximum allowable leakage current of the switch at Von/off = 6 V is 50 A. [VO(+) - VO(-)] - [SENSE(+) - SENSE(-)] 0.2 V The voltage between the VO(+) and VO(-) terminals must not exceed the minimum output overvoltage shutdown voltage as indicated in the Feature Specifications table. This limit includes any increase in voltage due to remote-sense compensation and output voltage setpoint adjustment (trim). See Figure 24. 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. The module has internal capacitance to reduce noise at the ON/OFF pin. Additional capacitance is not generally needed and may degrade the start-up characteristics of the module. CAUTION: To avoid damaging the power module or external on/off circuit, the connection between the VI(-) pin and the input source must be made before or simultaneously to making a connection between the ON/OFF pin and the input source (either directly or through the external on/off circuit.) 12 SENSE(+) SENSE(-) VI(+) SUPPLY VO(+) II VI(-) CONTACT RESISTANCE IO LOAD VO(-) CONTACT AND DISTRIBUTION LOSSES 8-651(C).m Figure 24. Effective Circuit Configuration for Single-Module Remote-Sense Operation Tyco Electronics Corp. JW030-Series Power Modules: 36 Vdc to 75 Vdc Inputs; 30 W Data Sheet July 1999 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. With an external resistor between the TRIM and SENSE(-) pins (Radj-down), the output voltage set point (VO, adj) decreases (see Figure 25). The following equation determines the required external-resistor value to obtain an output voltage change of %y. 1 - %y R adj-down = ----------------- 10 k %y For example, to lower the output voltage by 30%, the external resistor value must be: 1 - 0.3 R adj-down = ----------------- 10 k = 23.33 k 0.3 With an external resistor connected between the TRIM and SENSE(+) pins (Radj-up), the output voltage set point (VO, adj) increases (see Figure 26). The following equations determine the required external-resistor value to obtain an output voltage change of %y. The combination of the output voltage adjustment and sense range and the output voltage given in the Feature Specifications table cannot exceed 110% of the nominal output voltage between the VO(+) and VO(-) terminals. The JW030-Series Power Modules have a fixed current-limit set point. Therefore, as the output voltage is adjusted down, the available output power is reduced. In addition, the minimum output current is a function of the output voltage. As the output voltage is adjusted down, the minimum required output current can increase. VI (+) ON/OFF CASE VO (+) SENSE(+) TRIM RLOAD Radj-down VI (-) SENSE(-) VO(-) 8-748(C)b Figure 25. Circuit Configuration to Decrease Output Voltage JW030A-M, B-M, C-M: 1 + % V O, nom R adj-up = ------------------ - 1 ------------------- 10 k 2.5 %y For example, to increase the output voltage of the JW030B-M by 5%, the external resistor value must be: VI(+) ON/OFF R adj-up SENSE(+) Radj-up CASE 1 + 0.05 12.0 = ----------- - 1 --------------------- 10 k = 798 k 0.05 2.5 VO(+) VI(-) TRIM RLOAD SENSE(-) VO(-) JW030D-M, F-M, G-M: 8-715(C)b 1 + % V O, nom R adj-up = ------------------- - 1 ------------------- 10 k 1.235 % For example, to increase the output voltage of the JW030D-M by 5%, the external resistor must be: 1 + 0.05 2 R adj-up = --------------- - 1 --------------------- 10 k = 130 k 1.235 0.05 Tyco Electronics Corp. Figure 26. Circuit Configuration to Increase Output Voltage Output Overvoltage Protection The output overvoltage clamp consists of control circuitry, independent of the primary regulation loop, that monitors the voltage on the output terminals. The control loop of the clamp has a higher voltage set point than the primary loop (see Feature Specifications table). This provides a redundant voltage-control that reduces the risk of output overvoltage. 13 JW030-Series Power Modules: 36 Vdc to 75 Vdc Inputs; 30 W Data Sheet July 1999 Thermal Considerations The JW030-Series Power Modules are designed to operate in a variety of thermal environments. As with any electronic component, sufficient cooling must be provided to help ensure reliable operation. Heat-dissipating components inside the module are thermally coupled to the case to enable heat removal by conduction, convection, and radiation to the surrounding environment. The thermal data presented is based on measurements taken in a wind tunnel. The test setup shown in Figure 27 was used to collect data for Figure 34. The graphs in Figures 28 through 33 provide general guidelines for use. Actual performance can vary depending on the particular application environment. The maximum case temperature of 100 C must not be exceeded. 12.7 (0.50) WIND TUNNEL WALL MEASURE CASE TEMPERATURE (TC) AT CENTER OF UNIT AIRFLOW CONNECTORS TO LOADS, POWER SUPPLIES, AND DATALOGGER, 6.35 (0.25) TALL 203.2 (8.00) AIRFLOW 101.6 (4.00) 76.2 (3.00) AIR VELOCITY AND AMBIENT TEMPERATURE MEASURED BELOW THE MODULE 203.2 (8.00) 19.1 (0.75) 8-1046(C) Note: Dimensions are in millimeters and (inches). Figure 27. Thermal Test Setup Basic Thermal Performance The JW030-Series Power Modules are constructed with a specially designed, heat spreading enclosure. As a result, full-load operation in natural convection at 50 C can be achieved without the use of an external heat sink. Higher ambient temperatures can be sustained by increasing the airflow or by adding a heat sink. As stated, this data is based on a maximum case temperature of 100 C and measured in the test configuration shown in Figure 27. 14 Tyco Electronics Corp. Data Sheet July 1999 JW030-Series Power Modules: 36 Vdc to 75 Vdc Inputs; 30 W Thermal Considerations (continued) Forced Convection Cooling To determine the necessary airflow, determine the power dissipated by the unit for the particular application. Figures 28 through 33 show typical power dissipation for these power modules over a range of output currents. With the known power dissipation and a given local ambient temperature, the appropriate airflow can be chosen from the derating curves in Figure 34. For example, if the JW030A-M dissipates 6.2 W, the minimum airflow in a 80 C environment is 1 ms-1 (200 ft./min.). POWER DISSIPATION, PD (W) 8 7 6 VI = 36 V 5 VI = 72 V 4 VI = 54 V 3 2 1 0 0 1 2 3 4 5 6 OUTPUT CURRENT, I O (A) 8-1195(C) 8 POWER DISSIPATION, PD (W) 7 Figure 30. JW030F-M Power Dissipation vs. Output Current 6 5 VI = 72 V VI = 54 V VI = 36 V 4 9 3 VI = 72 V VI = 54 V VI = 36 V 2 1 0 0 1 2 3 4 5 6 OUTPUT CURRENT, I O (A) 8-1050(C) Figure 28. JW030D-M Power Dissipation vs. Output Current POWER DISSIPATION, PD (W) 8 7 6 5 4 3 2 1 0 0 1 2 3 4 5 6 OUTPUT CURRENT, I O (A) 8-1047(C) POWER DISSIPATION, PD (W) 8 7 6 5 Figure 31. JW030A-M Power Dissipation vs. Output Current VI = 75 V VI = 48 V VI = 36V 4 3 2 1 0 0.6 1.6 2.6 3.6 4.6 5.6 6.6 OUTPUT CURRENT, IO (A) 8-2556(C) Figure 29. JW030G-M Power Dissipation vs. Output Current Tyco Electronics Corp. 15 JW030-Series Power Modules: 36 Vdc to 75 Vdc Inputs; 30 W Data Sheet July 1999 Thermal Considerations (continued) 9 8 POWER DISSIPATION, PD (W) 8 POWER DISSIPATION, PD (W) Forced Convection Cooling (continued) VI = 72 V VI = 54 V VI = 36 V 7 6 5 4 7 6 5 2.0 ms -1(400 ft./min.) 1.0 ms -1(200 ft./min.) 0.5 ms -1(100 ft./min.) NATURAL CONVECTION 4 3 2 1 0 3 30 40 50 60 70 80 90 100 2 LOCAL AMBIENT TEMPERATURE, TA (C) 1 0 0.0 8-1051(C) 0.5 1.0 1.5 2.0 2.5 OUTPUT CURRENT, I O (A) Figure 34. Forced Convection Power Derating with No Heat Sink; Either Orientation 8-1048(C) Figure 32. JW030B-M Power Dissipation vs. Output Current POWER DISSIPATION, PD (W) 8 7 Several heat sinks are available for these modules. The case includes through-threaded mounting holes allowing attachment of heat sinks or cold plates from either side of the module. The mounting torque must not exceed 0.56 N-m (5 in./lb.). Figure 35 shows the case-to-ambient thermal resistance, (C/W), for these modules. These curves can be used to predict which heat sink will be needed for a particular environment. For example, if the JW030A-M dissipates 7 W of heat in an 80 C environment with an airflow of 0.7 ms-1 (130 ft./min.), the minimum heat sink required can be determined as follows: 6 5 Heat Sink Selection VI = 72 V VI = 54 V VI = 36 V 4 3 2 ( T C, max - T A ) P D 1 0 0.0 0.5 1.0 1.5 2.0 OUTPUT CURRENT, I O (A) 8-1049(C) Figure 33. JW030C-M Power Dissipation vs. Output Current where: = module's total thermal resistance TC, max = case temperature (See Figure 27.) TA = inlet ambient temperature (See Figure 27.) PD = power dissipation (100 - 80)/7 2.9 C/W From Figure 35, the 1/2 in. high heat sink or greater is required. 16 Tyco Electronics Corp. JW030-Series Power Modules: 36 Vdc to 75 Vdc Inputs; 30 W Data Sheet July 1999 Thermal Considerations (continued) Although the previous example uses 100 C as the maximum case temperature, for extremely high reliability applications, one can use a lower temperature for TC, max. Heat Sink Selection (continued) It is important to point out that the thermal resistances shown in Figure 35 are for 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 will generally be lower than the resistance of the heat sink by itself. The data in Figure 35 was taken with a thermally conductive dry pad between the case and the heat sink to minimize contact resistance (typically 0.1 C/W to 0.3 C/W). CASE-TO-AMBIENT THERMAL RESISTANCE, CA (C/W) 8 7 NO HEAT SINK 1/4 in. HEAT SINK 1/2 in. HEAT SINK 1 in. HEAT SINK 1 1/2 in. HEAT SINK 6 5 4 3 2 1 0 0 0.25 (50) 0.51 0.76 (100) (150) 1.02 1.27 (200) (250) 1.52 1.78 2.03 (300) (350) (400) AIR VELOCITY, ms -1(ft./min.) For a more detailed explanation of thermal energy management for this series of power modules as well as more details on available heat sinks, please request the following technical note: Thermal Energy Management for JC- and JW-Series 30 Watt Board-Mounted Power Modules (TN97-016EPS). 8-1052(C).a Figure 35. Case-to-Ambient Thermal Resistance vs. Air Velocity Curves; Either Orientation Tyco Electronics Corp. Layout Considerations Copper paths must not be routed beneath the power module standoffs. 17 JW030-Series Power Modules: 36 Vdc to 75 Vdc Inputs; 30 W Data Sheet July 1999 Outline Diagram Dimensions are in millimeters and (inches). Tolerances: x.x 0.5 mm (0.02 in.), x.xx 0.25 mm (0.010 in.). Top View 57.9 (2.28) M X 61.0 (2.40) MAX VI(+) VO(+) ON/ OFF + SEN JW030A-M TRIM DC-DC Power Module CASE 36-75V 0.95A IN 5V 6A OUT MADE IN USA - SEN M3 VO(-) VI(-) Side View 0.51 (0.020) 12.7 (0.50) MAX 1.02 (0.040) DIA SOLDER-PLATED BRASS,ALL PINS 5.1 (0.20) MIN Bottom View STANDOFF, 4 PLACES 12.7 (0.50) 7.1 (0.28) MOUNTING INSERTS M3 x 0.5 THROUGH, 4 PLACES 5.1 (0.20) 7.1 (0.28) 10.16 (0.400) 50.8 (2.00) 25.40 (1.000) 35.56 (1.400) 4 5 3 6 7 2 1 4.8 (0 19) 18 8 48.26 (1.900) TERMINALS 48.3 (1.90) MOUNTING HOLE 10.16 (0.400) 17.78 (0.700) 25.40 (1.000) 35.56 (1.400) 9 8-716(C) Tyco Electronics Corp. JW030-Series Power Modules: 36 Vdc to 75 Vdc Inputs; 30 W Data Sheet July 1999 Recommended Hole Pattern Component-side footprint. Dimensions are in millimeters and (inches). 4.8 (0.19) 48.3 (1.90) 48.26 (1.900) TERMINALS 1 35.56 (1.400) 2 9 35.56 (1.400) 8 7 50.8 (2.00) 25.40 (1.000) 10.16 (0.400) 3 6 4 5 25.40 (1.000) 17.78 10.16 (0.700) (0.400) 5.1 (0.20) 12.7 (0.50) MODULE OUTLINE M3 x 0.5 CLEARANCE HOLE, 4 PLACES (OPTIONAL) 8-716(C) Ordering Information Please contact your Tyco Electronics' Account Manager or Field Application Engineer for pricing and availability. Table 4. Device Codes Input Voltage 48 V 48 V 48 V 48 V 48 V 48 V 48 V 48 V 48 V 48 V 48 V 48 V Output Voltage 2V 2.5 V 3.3 V 5V 12 V 15 V 2V 2.5 V 3.3 V 5V 12 V 15 V Output Power 13 W 30 W 21.5 W 30 W 30 W 30 W 13 W 30 W 21.5 W 30 W 30 W 30 W Remote On/ Off Logic Negative Negative Negative Negative Negative Negative Positive Positive Positive Positive Positive Positive Device Code JW030D1-M JW030G1-M JW030F1-M JW030A1-M JW030B1-M JW030C1-M JW030D-M JW030G-M JW030F-M JW030A-M JW030B-M JW030C-M Comcode 107670259 108448259 107587859 107587776 107587818 107587834 107587842 TBD 107600546 107584278 107587800 107587826 Table 5. Device Options Option Device Code Suffix Short pins: 3.68 mm 0.25 mm (0.145 in. 0.010 in.) Short pins: 2.79 mm 0.25 mm (0.110 in. 0.010 in.) 6 Tyco Electronics Corp. 8 19 JW030-Series Power Modules: 36 Vdc to 75 Vdc Inputs; 30 W Data Sheet July 1999 Ordering Information (continued) Table 6. Device Accessories Accessory Comcode 1/4 in. transverse kit (heat sink, thermal pad, and screws) 1/4 in. longitudinal kit (heat sink, thermal pad, and screws) 1/2 in. transverse kit (heat sink, thermal pad, and screws) 1/2 in. longitudinal kit (heat sink, thermal pad, and screws) 1 in. transverse kit (heat sink, thermal pad, and screws) 1 in. longitudinal kit (heat sink, thermal pad, and screws) 1 1/2 in. transverse kit (heat sink, thermal pad, and screws) 1 1/2 in. longitudinal kit (heat sink, thermal pad, and screws) 407243989 407243997 407244706 407244714 407244722 407244730 407244748 407244755 Note: Dimensions are in millimeters and (inches). 1/4 IN. 1/4 IN. 1/2 IN. 1/2 IN. 1 IN. 1 IN. 61 (2.4) 57.9 (2.28) 1 1/2 IN. 1 1/2 IN. 57.9 (2.28) 61 (2.4) D000-d.cvs D000-c.cvs Figure 36. Longitudinal Heat Sink Figure 37. Transverse Heat Sink Tyco Electronics Power Systems, Inc. 3000 Skyline Drive, Mesquite, TX 75149, USA +1-800-526-7819 FAX: +1-888-315-5182 (Outside U.S.A.: +1-972-284-2626, FAX: +1-972-284-2900) http://power.tycoelectronics.com Tyco Electronics Corporation reserves the right to make changes to the product(s) or information contained herein without notice. No liability is assumed as a result of their use or application. No rights under any patent accompany the sale of any such product(s) or information. (c) 2001 Tyco Electronics Corporation, Harrisburg, PA. All International Rights Reserved. Printed in U.S.A. July 1999 DS98-265EPS (Replaces DS97-135EPS) Printed on Recycled Paper