Data Sheet February 2001 QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Features The QHW Series Power Modules use advanced, surfacemount technology and deliver high-quality, efficient, and compact dc-dc conversion. Applications Distributed power architectures Communications equipment Computer equipment Options Heat sinks available for extended operation Auto-restart after overtemperature, overvoltage, or overcurrent shutdown Case ground pin Short pins Small size: 36.8 mm x 57.9 mm x 12.7 mm (1.45 in. x 2.28 in. x 0.50 in.) High power density Extra high efficiency: 82% typical Low output noise Constant frequency Industry-standard pinout Metal baseplate 2:1 input voltage range Overvoltage and overcurrent protection Negative remote on/off Remote sense Adjustable output voltage Overtemperature protection ISO* 9001 and ISO 14001 Certified manufacturing facilities UL1950 Recognized, CSA C22.2 No. 950-95 Certified, and VDE 0805 (EN60950, IEC950) Licensed CE mark meets 73/23/EEC and 93/68/EEC directives** * ISO is a registered trademark of the International Organization for Standardization. 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-use equipment. All the required procedures for CE marking of end-use equipment should be followed. (The CE mark is placed on selected products.) Description The QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules are dc-dc converters that operate over an input voltage range of 36 Vdc to 75 Vdc and provide a precisely regulated dc output. The outputs are fully isolated from the inputs, allowing versatile polarity configurations and grounding connections. The modules have maximum power ratings from 18 W to 36 W at a typical full-load efficiency of 82%. The sealed modules offer a metal baseplate for excellent thermal performance. Threaded-through holes are provided to allow easy mounting or addition of a heat sink for high-temperature applications. The standard feature set includes remote sensing, output trim, and remote on/off for convenient flexibility in distributed power applications. QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet February 2001 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 VI VI, trans -- -- 80 100 Vdc V Operating Case Temperature (See Thermal Considerations section.) TC -40 100 C Storage Temperature Tstg -55 125 C I/O Isolation Voltage (for 1 minute) -- -- 1500 Vdc Input Voltage: Continuous Transient (100 ms) 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 II, max II, max -- -- -- -- -- -- 2.5 3.5 4.5 A A A II, max II, max II, max -- -- -- -- -- -- 2.0 2.5 3.0 A A A Inrush Transient i2t -- -- 1.0 A2s Input Reflected-ripple Current, Peak-to-peak (5 Hz to 20 MHz, 12 H source impedance; see Figure 17.) II -- 10 -- mAp-p Input Ripple Rejection (100--120 Hz) -- -- 60 -- dB Operating Input Voltage Maximum Input Current: VI = 0 V to 75 V; IO = IO, max; see Figures 1--3: QHW050Y1 QHW075Y1 QHW100Y1 VI = 36 V to 75 V; I O = IO, max: QHW050Y1 QHW075Y1 QHW100Y1 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 20 A (see Safety Considerations section). Based on the information provided in this data sheet on inrush energy and maximum dc input current, the same type of fuse with a lower rating can be used. Refer to the fuse manufacturer's data for further information. 2 Tyco Electronics Corp. QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet February 2001 Electrical Specifications (continued) Table 2. Output Specifications Parameter Device Symbol Min Typ Max Unit Output Voltage Set Point (VI = 48 V; IO = IO, max; TC = 25 C) All VO, set 1.77 1.8 1.83 Vdc Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life. See Figure 19.) All VO 1.74 -- 1.86 Vdc Output Regulation: Line (VI = 36 V to 75 V) Load (IO = IO, min to IO, max ) Temperature (TC = -40 C to +100 C) All All All -- -- -- -- -- -- 0.01 0.05 8 0.1 0.2 25 %VO %VO mV Output Ripple and Noise Voltage (See Figure 18.): RMS Peak-to-peak (5 Hz to 20 MHz) All All -- -- -- -- -- -- 40 150 mVrms mVp-p All -- 0 -- * F Output Current External Load Capacitance QHW050Y1 QHW075Y1 QHW100Y1 IO IO IO 0 0 0 -- -- -- A A A Output Current-limit Inception (VO = 90% of VO, nom) QHW050Y1 QHW075Y1 QHW100Y1 IO, cli IO, cli IO, cli -- -- -- 12 18 24 10 15 20 20 25 30 Efficiency (VI = 48 V; IO = IO, max ; TC = 70 C; see Figure 19.) QHW050Y1 QHW075Y1 QHW100Y1 -- -- -- 81 82 82 -- -- -- % % % All -- -- 380 -- kHz All All -- -- -- -- 80 300 -- -- mV s All All -- -- -- -- 80 300 -- -- mV s Switching Frequency Dynamic Response (IO/t = 1 A/10 s, VI = 48 V, TC = 25 C; tested with a 1000 F aluminum and a 1.0 F ceramic capacitor across the load): Load Change from IO = 50% to 75% of IO, max: Peak Deviation Settling Time (VO < 10% of peak deviation) Load Change from IO = 50% to 25% of IO, max: Peak Deviation Settling Time (VO < 10% of peak deviation) A A A * Consult your sales representative or the factory. These are manufacturing test limits. In some situations, results may differ. Table 3. Isolation Specifications Parameter Min Typ Isolation Capacitance -- 2500 -- pF Isolation Resistance 10 -- -- M Tyco Electronics Corp. Max Unit 3 QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet February 2001 General Specifications Parameter Min Calculated MTBF (I O = 80% of I O, max; TC = 40 C) Weight Typ Max 2,245,000 -- Unit hours -- 75 (2.7) g (oz.) Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See the Feature Descriptions section for additional information. Parameter Remote On/Off Signal Interface (VI = 0 V to 75 V; open collector or equivalent compatible; signal referenced to VI(-) terminal): Logic Low--Module On Logic High--Module Off Logic Low: At Ion/off = 1.0 mA At Von/off = 0.0 V Logic High: At Ion/off = 0.0 A Leakage Current Turn-on Time (See Figure 16.) (IO = 80% of I O, max; VO within 1% of steady state) Output Voltage Adjustment: Output Voltage Remote-sense Range Output Voltage Set-point Adjustment Range (trim) Output Overvoltage Protection (measured at the V O(+) and VO(-) output terminals) Overtemperature Protection Note: If auto-restart option is chosen, the unit will continually attempt restart in "hiccup" mode. Symbol Min Typ Max Unit Von/off Ion/off 0 -- -- -- 1.2 1.0 V mA Von/off Ion/off -- -- -- -- -- -- 20 15 50 35 V A ms -- -- -- 90 -- -- 0.5 110 V %VO, nom VO, sd 2.2* -- 2.8* V TC -- 105 -- C * These are manufacturing test limits. In some situations, results may differ. Solder, Cleaning, and Drying Considerations Post solder cleaning is usually the final circuit-board assembly process prior to electrical testing. The result of inadequate circuit-board cleaning and drying can affect both the reliability of a power module and the testability of the finished circuit-board assembly. For guidance on appropriate soldering, cleaning, and drying procedures, refer to Tyco Electronics Board-Mounted Power Modules Soldering and Cleaning Application Note (AP97-021EPS). 4 Tyco Electronics Corp. QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet February 2001 Characteristic Curves The following figures provide typical characteristics for the power modules. 1.6 0.6 1.4 IO = 10 A INPUT CURRENT, II (A) INPUT CURRENT, II (A) 0.7 0.5 0.4 IO = 5 A 0.3 0.2 IO = 1 A 0.1 0 25 30 35 40 45 50 55 60 65 70 IO = 20 A IO = 10 A IO = 2 A 1.2 1 0.8 0.6 0.4 0.2 75 0 INPUT VOLTAGE, VI (V) 0 10 20 1-0021 Figure 1. Typical QHW050Y1 Input Characteristics at Room Temperature 30 40 50 60 70 80 INPUT VOLTAGE, VI (V) 8-3461(F) Figure 3. Typical QHW100Y1 Input Characteristics at Room Temperature 90 1.0 VI = 36 V IO = 15 A 0.8 EFFICIENCY, (%) INPUT CURRENT, II (A) 1.2 0.6 IO = 7.5 A 0.4 0.2 0 25 IO = 1.5 A 80 VI = 48 V 70 VI = 75 V 60 50 40 30 35 40 45 50 55 60 65 70 75 30 INPUT VOLTAGE, VI (V) 0 1-0022 Figure 2. Typical QHW075Y1 Input Characteristics at Room Temperature Tyco Electronics Corp. 1 2 3 4 5 6 7 8 OUTPUT CURRENT, IO (A) 9 10 1-0023 Figure 4. Typical QHW050Y1 Converter Efficiency vs. Output Current at Room Temperature 5 QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet February 2001 Characteristic Curves (continued) VI = 75 V OUTPUT VOLTAGE, VO (V) (50 mV/div) 85 EFFICIENCY, (%) VI = 36 V VI = 48 V 80 VI = 75 V 75 70 65 60 2 3 4 5 VI = 48 V VI = 36 V 6 7 8 9 10 11 12 13 14 15 OUTPUT CURRENT, IO (A) TIME, t (1 s/div) 1-0024 1-0025 Figure 5. Typical QHW075Y1 Converter Efficiency vs. Output Current at Room Temperature Note: See Figure 18 for test conditions. Figure 7. Typical QHW050Y1, Output Ripple Voltage at Room Temperature; I O = IO, max 85 VI = 75 V 75 70 65 VI = 36 V VI = 48 V VI = 75 V 60 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 OUTPUT VOLTAGE, VO (V) (50 mV/div) EFFICIENCY, (%) 80 VI = 48 V VI = 36 V OUTPUT CURRENT, IO (A) 8-3462(F) TIME, t (1 s/div) Figure 6. Typical QHW100Y1 Converter Efficiency vs. Output Current at Room Temperature 1-0026 Note: See Figure 18 for test conditions. Figure 8. Typical QHW075Y1, Output Ripple Voltage at Room Temperature; I O = IO, max 6 Tyco Electronics Corp. Data Sheet February 2001 QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W OUTPUT VOLTAGE, VO (V) (50 mV/div) Characteristic Curves (continued) VI = 48 V OUTPUT CURRENT, IO (A) (2 A/div) OUTPUT VOLTAGE, VO (V) (50 mV/div) VI = 75 V 11.25 A VI = 36 V 7.50 A TIME, t (100 s/div) TIME, t (1 s/div) 1-0083 1-0027 Note: Tested with a 1000 F aluminum and a 1.0 F ceramic capacitor across the load. Note: See Figure 18 for test conditions. Figure 11. Typical QHW075Y1 Transient Response to Step Increase in Load from 50% to 75% of Full Load at Room Temperature and 48 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) OUTPUT VOLTAGE, VO (V) (50 mV/div) OUTPUT VOLTAGE, VO (V) (50 mV/div) Figure 9. Typical QHW100Y1, Output Ripple Voltage at Room Temperature; I O = IO, max OUTPUT CURRENT, IO (A) (2 A/div) 7.5 A 5.0 A OUTPUT CURRENT, IO (A) (5 A/div) 15 A 10 A TIME, t (200 s/div) 1-0082 Note: Tested with a 1000 F aluminum and a 1.0 F ceramic capacitor across the load. Figure 10. Typical QHW050Y1 Transient Response to Step Increase in Load from 50% to 75% of Full Load at Room Temperature and 48 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) Tyco Electronics Corp. TIME, t (200 s/div) 1-0084 Note: Tested with a 1000 F aluminum and a 1.0 F ceramic capacitor across the load. Figure 12. Typical QHW100Y1 Transient Response to Step Increase in Load from 50% to 75% of Full Load at Room Temperature and 48 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) 7 QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet February 2001 OUTPUT CURRENT, IO (A) (5 A/div) OUTPUT VOLTAGE, VO (V) (50 mV/div) OUTPUT VOLTAGE, VO (V) (50 mV/div) Characteristic Curves (continued) 10 A OUTPUT CURRENT, IO (A) (2 A/div) 5.0 A 2.5 A 5A TIME, t (200 s/div) 1-0087 Note: Tested with a 1000 F aluminum and a 1.0 F ceramic capacitor across the load. 1-0085 Note: Tested with a 1000 F aluminum and a 1.0 F ceramic capacitor across the load. OUTPUT CURRENT, IO (A) (2 A/div) OUTPUT VOLTAGE, VO (V) (1 V/div) OUTPUT VOLTAGE, VO (V) (50 mV/div) Figure 13. Typical QHW050Y1 Transient Response to Step Decrease in Load from 50% to 25% of Full Load at Room Temperature and 48 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) Figure 15. Typical QHW100Y1 Transient Response to Step Decrease in Load from 50% to 25% of Full Load at Room Temperature and 48 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) REMOTE ON/OFF, VON/OFF (V) TIME, t (100 s/div) TIME, t (20 ms/div) 1-0033 TIME, t (100 s/div) 1-0086 Note: Tested with a 1000 F aluminum and a 1.0 F ceramic capacitor across the load. Figure 14. Typical QHW075Y1 Transient Response to Step Decrease in Load from 50% to 25% of Full Load at Room Temperature and 48 Vdc Input (Waveform Averaged to Eliminate Ripple Component.) 8 Note: Tested with a 1000 F aluminum and a 1.0 F ceramic capacitor across the load. Figure 16. QHW100Y1 Typical Start-Up from Remote On/Off; IO = IO, max Tyco Electronics Corp. QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet February 2001 Test Configurations Design Considerations Input Source Impedance TO OSCILLOSCOPE CURRENT PROBE LTEST VI(+) 12 H CS 220 F ESR < 0.1 @ 20 C, 100 kHz BATTERY 33 F ESR < 0.7 @ 100 kHz VI(-) The power module should be connected to a low ac-impedance input source. Highly inductive source impedances can affect the stability of the power module. For the test configuration in Figure 17, a 33 F electrolytic capacitor (ESR < 0.7 at 100 kHz) mounted close to the power module helps ensure stability of the unit. For other highly inductive source impedances, consult the factory for further application guidelines. 8-203(F).l Note: Measure input reflected-ripple current with a simulated source inductance (LTEST) of 12 H. Capacitor CS offsets possible battery impedance. Measure current as shown above. Figure 17. Input Reflected-Ripple Test Setup COPPER STRIP VO(+) 1.0 F 10 F RESISTIVE LOAD SCOPE VO(-) 8-513(F).d Note: Use a 1.0 F ceramic capacitor and a 10 F aluminum or tantalum capacitor. Scope measurement should be made using a BNC socket. Position the load between 51 mm and 76 mm (2 in. and 3 in.) from the module. Figure 18. Peak-to-Peak Output Noise Measurement Test Setup SENSE(+) VI(+) CONTACT AND DISTRIBUTION LOSSES VO(+) II IO LOAD SUPPLY VI(-) VO(-) CONTACT RESISTANCE SENSE(-) 8-749(F) 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 (-) ]I I % Figure 19. Output Voltage and Efficiency Measurement Test Setup Tyco Electronics Corp. 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., UL1950, CSA C22.2 No. 950-95, and VDE 0805 (EN60950, IEC950). 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: The input source is to be provided with reinforced insulation from any hazardous voltages, including the ac mains. One VI pin and one V O 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. Note: Do not ground either of the input pins of the module without grounding one of the output pins. This may allow a non-SELV voltage to appear between the output pin and ground. The power module has extra-low voltage (ELV) outputs when all inputs are ELV. The input to these units is to be provided with a maximum 20 A normal-blow fuse in the ungrounded lead. 9 QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet February 2001 Feature Descriptions Overcurrent Protection Ion/off + To provide protection in a fault (output overload) condition, the unit is equipped with internal current-limiting circuitry and can endure current limiting for up to one second. If overcurrent exists for more than one second, the unit will shut down. 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 currentlimit circuit can exhibit either foldback or tailout characteristics (output current decrease or increase). The module is available in two overcurrent configurations. In one configuration, when the unit shuts down it will latch off. The overcurrent latch is reset by either cycling the input power or by toggling the ON/OFF pin for one second. In the other configuration, the unit will try to restart after shutdown. If the output overload condition still exists when the unit restarts, it will shut down again. This operation will continue indefinitely until the overcurrent condition is corrected. Remote On/Off Negative logic remote on/off turns the module off during a logic high and on during a logic low. 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 20). A logic low is Von/off = 0 V to 1.2 V. The maximum I on/off during a logic low is 1 mA. The switch should maintain a logic-low voltage while sinking 1 mA. During a logic high, the maximum V on/off generated by the power module is 15 V. The maximum allowable leakage current of the switch at V on/off = 15 V is 50 A. If not using the remote on/off feature, short the ON/OFF pin to VI(-). 10 ON/OFF Von/off - SENSE(+) VO(+) LOAD VI(+) VI(-) VO(-) SENSE(-) 8-720(F).c Figure 20. Remote On/Off Implementation Remote Sense Remote sense minimizes the effects of distribution losses by regulating the voltage at the remote-sense connections. The voltage between the remote-sense pins and the output terminals must not exceed the output voltage sense range given in the Feature Specifications table, i.e.: [VO(+) - VO(-)] - [SENSE(+) - SENSE(-)] 0.5 V 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 remote-sense compensation and output voltage setpoint 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. Although the output voltage can be increased by both the remote sense and by the trim, the maximum increase for the output voltage is not the sum of both. The maximum increase is the larger of either the remote sense or the trim. Consult the factory if you need to increase the output voltage more than the above limitation. Tyco Electronics Corp. QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet February 2001 Feature Descriptions (continued) The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. Remote Sense (continued) 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. SENSE(+) SENSE(-) SUPPLY VI(+) VO (+) VI(-) VO(-) IO II CONTACT RESISTANCE LOAD CONTACT AND DISTRIBUTION LOSSES 8-651(F).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. The trim resistor should be positioned close to the module. 5.11V O ( 100 + % ) 511 R adj-up = ------------------------------------------------- - ---------- - 10.22 k % 1.225% 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 remote-sense compensation and output voltage setpoint adjustment (trim). See Figure 21. Although the output voltage can be increased by both the remote sense and by the trim, the maximum increase for the output voltage is not the sum of both. The maximum increase is the larger of either the remote sense or the trim. Consult the factory if you need to increase the output voltage more than the above limitation. The amount of power delivered by the 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. VI(+) ON/OFF CASE VO(+) SENSE(+) TRIM RLOAD Radj-down VI(-) SENSE(-) If not using the trim feature, leave the TRIM pin open. VO(-) With an external resistor between the TRIM and SENSE(-) pins (Radj-down), the output voltage set point (VO, adj) decreases (see Figure 22). The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. 8-748(F).b Figure 22. Circuit Configuration to Decrease Output Voltage 511 R adj-down = ---------- - 10.22 k % With an external resistor connected between the TRIM and SENSE(+) pins (R adj-up), the output voltage set point (VO, adj) increases (see Figure 23). Tyco Electronics Corp. 11 QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet February 2001 Feature Descriptions (continued) Thermal Considerations Output Voltage Set-Point Adjustment (Trim) Introduction (continued) VI(+) ON/OFF VO(+) SENSE(+) Radj-up CASE VI(-) TRIM RLOAD SENSE(-) The power modules operate in a variety of thermal environments; however, sufficient cooling should be provided to help ensure reliable operation of the unit. Heat-dissipating components inside the unit are thermally coupled to the case. Heat is removed by conduction, convection, and radiation to the surrounding environment. Proper cooling can be verified by measuring the case temperature. Peak temperature (T C) occurs at the position indicated in Figure 24. VO(-) 33 (1.30) 8-715(F).b Figure 23. Circuit Configuration to Increase Output Voltage Note: The output voltage of this module may be increased by a maximum of 0.5 V. The 0.5 V is the combination of both the remote-sense and the output voltage set-point adjustment (trim). Do not exceed 2.3 V between the V O(+) and VO(-) terminals. Output Overvoltage Protection 14 (0.55) V I (+) ON/OFF VI (-) V O (+) (+)SENSE TRIM (-)SENSE VO (-) 8-2104(F) Note: Top view, pin locations are for reference only. Measurements shown in millimeters and (inches). Figure 24. Case Temperature Measurement Location The output overvoltage protection consists of circuitry that monitors the voltage on the output terminals. If the voltage on the output terminals exceeds the overvoltage protection threshold, then the module will shut down and latch off. The overvoltage latch is reset by either cycling the input power for one second or by toggling the on/off signal for one second. If the auto-restart option is chosen, the unit will "hiccup" until the temperature is within specification. 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. Overtemperature Protection Heat Transfer Without Heat Sinks These modules feature an overtemperature protection circuit to safeguard against thermal damage. The circuit shuts down and latches off the module when the maximum case temperature is exceeded. The module can be restarted by cycling the dc input power for at least one second or by toggling the remote on/off signal for at least one second. If the auto-restart option is chosen, the unit will "hiccup" until the temperature is within specification. Increasing airflow over the module enhances the heat transfer via convection. Figures 25 and 26 show 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 3 m/s (600 ft./min.). 12 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. Note that the natural convection condition was measured at 0.05 m/s to 0.1 m/s (10 ft./min. to 20 ft./min.); however, systems in which these power modules may be used typically generate natural convection airflow rates of 0.3 m/s (60 ft./min.) due to other heat dissipating components in the system. The use of Figure 25 is shown in the following example. Tyco Electronics Corp. Data Sheet February 2001 QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Thermal Considerations (continued) Heat Transfer Without Heat Sinks (continued) Example What is the minimum airflow necessary for a QHW100Y1 operating at VI = 48 V, an output current of 20 A, transverse orientation, and a maximum ambient temperature of 40 C? Solution POWER DISSIPATION, PD (W) 20 Given: VI = 48 V IO = 20 A TA = 40 C 3.0 m/s (600 ft./min.) 2.0 m/s (400 ft./min.) 1.0 m/s (200 ft./min.) 0.1 m/s (20 ft./min.) NATURAL CONVECTION 15 10 5 0 0 10 20 30 40 50 60 70 90 100 80 LOCAL AMBIEMT TEMPERATURE, TA (C) 8-2318(F).a Determine PD (Use Figure 29): PD = 8.0 W Figure 26. Forced Convection Power Derating with No Heat Sink; Longitudinal Orientation Determine airflow (v) (Use Figure 25): v = 0.5 m/s (100 ft./min.) POWER DISSIPATION, PD (W) 3.0 m/s (600 ft./min.) 2.0 m/s (400 ft./min.) 1.0 m/s (200 ft./min.) 0.1 m/s (20 ft./min.) NATURAL CONVECTION 15 10 5 POWER DISSIPATION, PD (W) 6.5 20 6.0 5.0 4.5 4.0 VI = 48 V 3.5 3.0 VI = 36 V 2.5 2.0 1 0 0 VI = 75 V 5.5 2 3 4 5 6 7 8 9 10 OUTPUT CURRENT, IO (A) 10 20 30 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (C) 8-2321(F) 1-0034 Figure 27. QHW050Y1 Power Dissipation vs. Output Current at 25 C Figure 25. Forced Convection Power Derating with No Heat Sink; Transverse Orientation Tyco Electronics Corp. 13 QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet February 2001 Thermal Considerations (continued) Heat Transfer with Heat Sinks Heat Transfer Without Heat Sinks (continued) 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 ( 5in.-lb.). For a screw attachment from the pin side, the recommended hole size on the customer's PWB around the mounting holes is 0.130 0.005 inches. If a larger hole is used, the mounting torque from the pin side must not exceed 0. 25N-m (2.2 in.-lbs.). 7 VI = 75 V 6 5 VI = 48 V VI = 36 V 4 3 2 1 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 OUTPUT CURRENT, IO (A) 1-0035 POWER DISSIPATION, PD (W) Figure 28. QHW075Y1 Power Dissipation vs. Output Current at 25 C 10 9 8 7 VI = 75 V VI = 48 V VI = 36 V 6 Thermal derating with heat sinks is expressed by using the overall thermal resistance of the module. Total module thermal resistance (ca) is defined as the maximum case temperature rise (TC, max) divided by the module power dissipation (PD): ( T C - TA ) C, max -------------------- = ----------------------- ca = T PD PD The location to measure case temperature (T C) is shown in Figure 24. Case-to-ambient thermal resistance vs. airflow is shown, for various heat sink configurations, heights, and orientations, as shown in Figures 30 and 31. Longitudinal orientation is defined as when the long axis of the module is parallel to the airflow direction, whereas in the transverse orientation, the long axis is perpendicular to the airflow. These curves were obtained by experimental testing of heat sinks, which are offered in the product catalog. 5 4 10 9 3 2 1 0 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 OUTPUT CURRENT, IO (A) 8-3465(F) Figure 29. QHW100Y1 Power Dissipation vs. Output Current at 25 C CASE-TO-ANBIENT THERMAL RESISTANCE, CA (C/W) POWER DISSIPATION, PD (W) 8 8 NO HEAT SINK 1/4 IN. HEAT SINK 1/2 IN. HEAT SINK 1 IN. HEAT SINK 7 6 5 4 3 2 1 0 0 0.5 (100) 1.0 1.5 2.0 (200) (300) (400) VELOCITY, m/s (ft./min.) 2.5 (500) 3.0 (600) 8-2323(F) Figure 30. Case-to-Ambient Thermal Resistance Curves; Transverse Orientation 14 Tyco Electronics Corp. QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet February 2001 Thermal Considerations (continued) CASE-TO-ANBIENT THERMAL RESISTANCE, CA (C/W) 11 10 9 NO HEAT SINK 1/4 IN. HEAT SINK 1/2 IN. HEAT SINK 1 IN. HEAT SINK 8 7 6 5 POWER DISSIPATION, PD (W) 20 Heat Transfer with Heat Sinks (continued) 4 10 5 0 0 3 2 1 0 1 IN. HEAT SINK 1/2 IN. HEAT SINK 1/4 IN. HEAT SINK NO HEAT SINK 15 10 20 30 40 50 60 70 80 90 100 LOCAL AMBIEMT TEMPERATURE, TA (C) 8-2890(F) 0.5 (100) 0 1.0 1.5 2.0 (200) (300) (400) VELOCITY, m/s (ft./min.) 2.5 (500) 3.0 (600) 8-2324(F) Figure 33. Heat Sink Power Derating Curves; Natural Convection; Longitudinal Orientation Figure 31. Case-to-Ambient Thermal Resistance Curves; Longitudinal Orientation POWER DISSIPATION, PD (W) 20 1 IN. HEAT SINK 1/2 IN. HEAT SINK 1/4 IN. HEAT SINK NO HEAT SINK 15 10 POWER DISSIPATION, PD (W) 20 15 10 5 0 0 5 1 IN. HEAT SINK 1/2 IN. HEAT SINK 1/4 IN. HEAT SINK NO HEAT SINK 10 20 30 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (C) 8-2891(F) 0 0 10 20 30 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (C) 8-2889(F) Figure 34. Heat Sink Power Derating Curves; 1.0 m/s (200 lfm); Transverse Orientation Figure 32. Heat Sink Power Derating Curves; Natural Convection; Transverse Orientation Tyco Electronics Corp. 15 QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Thermal Considerations (continued) Example Heat Transfer with Heat Sinks (continued) POWER DISSIPATION, P D (W) 20 Given: VI = 48 V IO = 20 A TA = 40 C TC = 85 C Heat sink = 1/2 inch 10 0 0 1 IN. HEAT SINK 1/2 IN. HEAT SINK 1/4 IN. HEAT SINK NO HEAT SINK 10 20 30 40 Determine PD by using Figure 29: 50 60 70 80 90 100 PD = 8.0 W Then solve the following equation: LOCAL AMBIENT TEMPERATURE, TA (C) 8-2892(F) Figure 35. Heat Sink Power Derating Curves; 1.0 m/s (200 lfm); Longitudinal Orientation These measured resistances are from heat transfer from the sides and bottom of the module as well as the top side with the attached heat sink; therefore, the case-to-ambient thermal resistances shown are generally lower than the resistance of the heat sink by itself. The module used to collect the data in Figure 30 had a thermal-conductive dry pad between the case and the heat sink to minimize contact resistance. The use of Figure 30 is shown in the following example. 16 If an 85 C case temperature is desired, what is the minimum airflow necessary? Assume the QHW100Y1 module is operating at VI = 48 V and an output current of 20 A, maximum ambient air temperature of 4 0C, and the heat sink is 1/2 inch. The module is oriented in the transverse direction. Solution 15 5 Data Sheet February 2001 ( T C - T A) ca = ----------------------PD 85 - 40 ) ca = (----------------------8.0 ca = 5.63 C/W Use Figure 30 to determine air velocity for the 1/2 inch heat sink. The minimum airflow necessary for this module is 0.4 m/s (80 ft./min.). Tyco Electronics Corp. QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet February 2001 Custom Heat Sinks EMC Considerations 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) as shown in Figure 36. For assistance with designing for EMC compliance, please refer to the FLTR100V10 Filter Module Data Sheet (DS99-294EPS). Layout Considerations PD TC TS cs TA sa 8-1304(F).e Copper paths must not be routed beneath the power module mounting inserts. For additional layout guidelines, refer to the FLTR100V10 Filter Module Data Sheet (DS99-294EPS). Figure 36. Resistance from Case-to-Sink and Sink-to-Ambient For a managed interface using thermal grease or foils, a value of cs = 0.1 C/W to 0.3 C/W is typical. The solution for heat sink resistance is: (TC - TA) sa = ------------------------- - cs PD This equation assumes that all dissipated power must be shed by the heat sink. Depending on the userdefined application environment, a more accurate model, including heat transfer from the sides and bottom of the module, can be used. This equation provides a conservative estimate for such instances. Tyco Electronics Corp. 17 QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet February 2001 Outline Diagram Dimensions are in millimeters and (inches). Tolerances: x.x mm 0.5 mm (x.xx in. 0.02 in.) x.xx mm 0.25 mm (x.xxx in. 0.010 in.) Top View 36.8 (1.45) 57.9 (2.28) Side View 12.7 (0.50) 0.51 (0.020) 4.1 (0.16) MIN, 2 PLACES 4.1 (0.16) MIN, 6 PLACES 3.5 (0.14) MIN 1.57 (0.062) DIA SOLDER-PLATED BRASS, 2 PLACES 1.02 (0.040) DIA SOLDER-PLATED BRASS, 6 PLACES Bottom View RIVETED CASE PIN (OPTIONAL) 1.09 x 0.76 (0.043 x 0.030) 50.80 (2.000) 3.6 (0.14) 5.3 (0.21) 10.9 (0.43) 11.2 (0.44) VO(-) VI(-) 15.24 (0.600) 26.16 (1.030) - SENSE TRIM ON/OFF MOUNTING INSERTS M3 x 0.5 THROUGH, 4 PLACES 3.81 11.43 (0.150) (0.450) 12.7 (0.50) 7.62 (0.300) 15.24 (0.600) + SENSE VI(+) 7.62 (0.300) 5.3 (0.21) VO(+) 47.2 (1.86) SIDE LABEL* 8-1769(F).b * Side label includes Tyco name, product designation, safety agency markings, input/output voltage and current ratings, and bar code. 18 Tyco Electronics Corp. QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet February 2001 Recommended Hole Pattern Component-side footprint. Dimensions are in millimeters and (inches). 5.3 (0.21) 7.62 (0.300) 26.16 (1.030) 15.24 (0.600) 47.2 (1.86) VI(+) VO(+) + SENSE TRIM ON/OFF 7.62 (0.300) - SENSE VI(-) 15.24 (0.600) VO(-) 3.81 (0.150) 10.9 (0.43) 5.3 3.6 (0.21) (0.14) 11.2 (0.44) 50.80 (2.000) 11.43 (0.450) MOUNTING INSERTS M3 x 0.5 THROUGH, 4 PLACES 12.7 (0.50) CASE PIN (OPTIONAL) 8-1769(F).b Ordering Information Please contact your Tyco Electronics Account Manager or Field Application Engineer for pricing and availability. Table 4. Device Codes Input Voltage Output Voltage Output Power Output Current Remote On/Off Logic Device Code Comcode 48 Vdc 1.8 Vdc 18 W 10 A Negative QHW050Y1 108844333 48 Vdc 1.8 Vdc 27 W 15 A Negative QHW075Y1 108448176 48 Vdc 1.8 Vdc 36 W 20 A Negative QHW100Y1 108448218 Optional features can be ordered using the suffixes shown in Table 5. To order more than one option, list device codes suffixes in numerically descending order. For example, the device code for a QHW100Y1 module with the following option is shown below: Negative logic and auto-restart after overtemperature, overvoltage, or overcurrent shutdown QHW100Y41 Table 5. Device Options Option Case ground pin Short pins: 3.68 mm 0.25 mm (0.145 in. 0.010 in.) Auto-restart after overtemperature, overvoltage, or overcurrent shutdown Tyco Electronics Corp. Device Code Suffix 7 6 4 19 QHW050Y1, QHW075Y1, and QHW100Y1 Power Modules; dc-dc Converters: 36 to 75 Vdc Input, 1.8 Vdc Output; 18 W to 36 W Data Sheet February 2001 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) 848060992 848061008 848061016 848061024 848061032 848061040 Dimensions are in millimeters and (inches). 1/4 IN. 57.91 0.38 (2.280 0.015) 36.83 0.38 (1.450 0.015) 1/2 IN. 1/4 IN. 1/2 IN. 1 IN. 1 IN. 47.24 0.13 (1.850 0.005) 26.16 0.13 (1.030 0.005) 8-2472(F) 8-2473(F) Figure 37. Longitudinal Heat Sink Figure 38. 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. February 2001 DS99-214EPS (Replaces PB00-002EPS) Printed on Recycled Paper