Data Sheet October 28, 2002 HW/HC006/010/012 Series Power Modules; dc-dc Converters 18-36 Vdc & 36-75 Vdc Input; 1.0 Vdc to 5 Vdc Output; 6.6A to 12A Features The HW/HC006/010/012 series power modules use advance surface-mount technology to deliver compact, high-quality and efficient dc-dc conversion Applications Distributed Power Architectures Wireless Networks Access and Optical Network Equipment Enterprise Networks Latest generation IC's (DSP, FPGA, ASIC) and Microprocessor-powered applications. Options Delivers up to 12A output current High efficiency: 90% at 3.3V full load (VIN = 48V) Small size and low profile: 47.2 mm x 29.5 mm x 8.50 mm (1.86 in x 1.16 in x 0.335 in) Low output ripple and noise Exceptional thermal performance Cost-efficient open frame design High reliability: MTBF > 4.5M hours at 25 C Remote On/Off positive logic (primary referenced) Constant switching frequency (285 KHz typical) Output overvoltage and overcurrent protection Overtemperature protection Input undervoltage lockout Adjustable output voltage ( 10%) Surface mount or through-hole package Meets the voltage and current requirements for ETSI 300-132-2 and complies with and is approved for Basic Insulation rating per IEC60950 3rd (-B version only) Remote On/Off negative logic Surface-mount package (-S Suffix) Basic Insulation (-B Suffix) UL* 60950 Recognized, CSA C22.2 No. 60950-00 Certified, and VDE 0805 (IEC60950, 3rd edition) Licensed CE mark meets 73/23/EEC and 93/68/EEC directives ISO** 9001 and ISO14001 certified manufacturing facilities Description The HW/HC series power modules are isolated dc-dc converters that can deliver up to 12A of output current and provide a precisely regulated output voltage over a wide range of input voltages (VI = 18 to 36 Vdc for HC modules & 36 V to 75 Vdc for HW modules). The modules achieve full load efficiency of 90% at 3.3 V output voltage. The open frame modules, available in both surface-mount and through-hole packaging, enable designers to develop cost- and space-efficient solutions. Standard features include remote On/Off, output voltage adjustment, overvoltage, overcurrent and overtemperature protection. * ** 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.) ISO is a registered trademark of the Internation Organization of Standards HW/HC006/010/012 Series Power Modules; dc-dc Converters 18-36 Vdc & 36-75 Vdc Input; 1.0 Vdc to 5 Vdc Output; 6.6A to 12A Data Sheet October 28, 2002 Absolute Maximum Ratings Stresses in excess of the absolute maximum ratings can cause permanent damage to the device. These are absolute stress ratings only, functional operation of the device is not implied at these or any other conditions in excess of those given in the operations sections of the data sheet. Exposure to absolute maximum ratings for extended periods can adversely affect the device reliabiltiy. Parameter Device Symbol Min Max Unit HW HC HW VI VI VI, trans -0.3 -0.3 -- 80 50 100 Vdc Vdc Vdc Operating Ambient Temperature (See Thermal Considerations section) All TA -40 85 C Storage Temperature All Tstg -55 125 C Input Voltage:Continuous Transient (100ms) Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Table 1. Input Specifications Parameter Device Symbol Min Typ Max Unit Operating Input Voltage HC HW VIN VIN 18 36 24 48 36 75 Vdc Vdc Maximum Input Current (VI = 0 V to 75 V; IO = IO, max) HC HW II, max II, max 3.2 1.6 Adc Adc Inrush Transient All I2t 1 A 2s Input Reflected Ripple Current, peak-peak (5 Hz to 20 MHz, 12 H source impedance See Test configuration section) All II Input Ripple Rejection (120 Hz) All 3 mAp-p 50 dB Fusing Considerations CAUTION: This power module is not internally fused. An input line fuse must always be used. This power module can be used in a wide variety of applications, ranging from simple 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 time-delay 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 sheet for further information. 2 Tyco Electronics Corp. Data Sheet October 28, 2002 HW/HC006/010/012 Series Power Modules; dc-dc Converters 18-36 Vdc & 36-75 Vdc Input; 1.0 Vdc to 5 Vdc Output; 6.6A to 12A Electrical Specifications (continued) Table 2. Output Specifications Parameter Device Symbol Min Typ Max Unit Output Voltage Set Point (VI = 48 Vdc; IO = IO, min to IO, max, TA = 25 C) HW012A0S1R01 HW012A0P1 HW012A0M1 HW012A0Y1 HW010A0G1 HW010A0F1 HW006A6A1 Vo, set Vo, set Vo, set Vo, set Vo, set Vo, set Vo, set 0.975 1.17 1.46 1.75 2.46 3.25 4.92 1.0 1.2 1.5 1.8 2.5 3.3 5.0 1.025 1.23 1.54 1.85 2.54 3.35 5.08 Vdc Vdc Vdc Vdc Vdc Vdc Vdc Output Voltage (Over all operating input voltage, resistive load, and temperature conditions at steady state until end of life.) HW012A0S1R01 HW012A0P1 HW012A0M1 HW012A0Y1 HW010A0G1 HW010A0F1 HW006A6A1 VO VO VO VO VO VO VO 0.96 1.15 1.44 1.73 2.42 3.2 4.85 -- -- -- -- -- -- -- 1.04 1.25 1.56 1.87 2.57 3.4 5.15 Vdc Vdc Vdc Vdc Vdc Vdc Vdc Output Regulation: Line (VI = VI, min to VI, max) Load (IO = IO, min to IO, max) Temperature (TA = TA, min to TA, max) All All All -- -- -- -- -- -- -- -- 0.2 0.1 10 -- %, VO, set mV %, VO, set Output Ripple and Noise Measured across 10F Tantalum, 1F Ceramic, VI = VI, nom TA = 25 C, IO = IO, max See test Configuration section RMS (5 Hz to 20 MHz bandwidth) Peak-to-peak (5 Hz to 20 MHz bandwidth) All All -- -- 8 40 20 75 mVrms mVp-p External Load Capacitance HW006A6A1 All others CO, max CO, max 0 0 -- -- 470 1000 F F Output Current (At Io < Io,min, the output ripple may exceed the maximum specifications. All modules shall operate at no load without damage and without exceeding 110% of VO, set.) HW012A0S1R01 HW012A0P1 HW012A0M1 HW012A0Y1 HW010A0G1 HW010A0F1 HW006A6A1 IO IO IO IO IO IO IO 0.15 0.15 0.15 0.15 0.05 0.05 0.05 -- -- -- -- -- -- -- 12 12 12 12 10 10 6.6 Adc Adc Adc Adc Adc Adc Adc Output Current-limit Inception (VO = 90% of VO, set) HW012A0S1R01 HW012A0P1 HW012A0M1 HW012A0Y1 HW010A0G1 HW010A0F1 HW006A6A1 IO, lim IO, lim IO, lim IO, lim IO, lim IO, lim IO, lim -- -- -- -- -- -- -- 18 18 18 18 12 12 8 -- -- -- -- -- -- -- Adc Adc Adc Adc Adc Adc Adc Output Short-circuit Current (Average) VO = 0.25 V HW012A0S1R01 HW012A0P1 HW012A0M1 HW012A0Y1 HW010A0G1 HW010A0F1 HW006A6A1 IO, s/c IO, s/c IO, s/c IO, s/c IO, s/c IO, s/c IO, s/c -- -- -- -- -- -- -- 20 20 20 20 17 17 13 -- -- -- -- -- -- -- Adc Adc Adc Adc Adc Adc Adc Tyco Electronics Corp. 3 HW/HC006/010/012 Series Power Modules; dc-dc Converters 18-36 Vdc & 36-75 Vdc Input; 1.0 Vdc to 5 Vdc Output; 6.6A to 12A Data Sheet October 28, 2002 Electrical Specifications (continued) Table 2. Output Specifications (continued) Parameter Device Symbol Min Typ Max Unit HW012A0S1R01 HW012A0P1 HW012A0M1 HW012A0Y1 HW010A0G1 HW010A0F1 HW006A6A1 -- -- -- -- -- -- -- 79 82 83 85 89 90 91 -- -- -- -- -- -- -- % % % % % % % Switching Frequency All fSW -- 285 -- kHz Dynamic Load Response (di/dt = 0.1 A/ s, VI = VI, nom, TA = 25 C) 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 Setting Time (VO < 10% peak deviation) All All -- -- -- -- 200 0.2 -- -- mV msec All All -- -- -- -- 200 0.2 -- -- mV msec Efficiency (VI = VIN, nom; IO = IO, max), TA = 25 C Isolation Specifications Parameter Isolation Capacitance Isolation Resistance Isolation Voltage Symbol Min Typ Max Unit Ciso Riso Viso -- 10 -- 1000 -- -- -- -- 1500 PF M Vdc General Specifications Parameter Calculated MTBF (IO = 80% of IO, max TA = 25 C) Tyco RIN (Reliability Infomation Notebook) Method Weight 4 Min Typ Max 4,537,000 -- 13 (0.46) Unit Hours -- g (oz.) Tyco Electronics Corp. Data Sheet October 28, 2002 HW/HC006/010/012 Series Power Modules; dc-dc Converters 18-36 Vdc & 36-75 Vdc Input; 1.0 Vdc to 5 Vdc Output; 6.6A to 12A Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See Feature Descriptions for additional information. Parameter Remote On/Off Signal interface (VI = VI, min to VI, max; Open collector or compatible, signal referenced to VI (-) terminal Negative Logic: Device code with suffix "1" Logic Low--Module On / Logic High--Module Off Positive Logic: If device code suffix "1" is not specified Logic Low--Module Off / Logic High--Module On Module Specifications: On/Off Current--Logic Low On/Off Voltage: Logic Low Logic High Open Collector Specifications: Leakage Current during Logic High (Von/off = 15 V) Output Low Voltage during Logic Low (Ion/Off - 1 mA) Turn-On Delay and Rise Times (IO = 80% of IO, max, VIN = 48 Vdc, TA = 25 C) Case 1: On/Off input is set to Logic high and then input power is applied (delay from instant at which VI = VI, min until VO = 10% of VO, set) Case 2: Input power is applied for at least one second and then the On/Off input is set to logic high (delay from instant at which Von/off = 0.9 V until VO = 10% of VO, set) Output voltage Rise time (time for VO to rise from 10% of VO, set to 90% of VO, set) Output voltage overshoot (IO = 80% of IO, max, VI = 48 Vdc TA = 25 C) Output voltage adjustment (see Feature Description section) Output voltage set-point adjustment range (TRIM) Output Overvoltage Protection (clamp) Overtemperaute Protection (IO = IO, max) See Figure 44 Input Undervoltage Lockout Turn-on Threshold Turn-off Threshold Tyco Electronics Corp. Device Symbol Min Typ Max Unit All Ion/off -- -- 1.0 mA All All Von/off Von/off -0.7 -- -- -- 1.2 15 V V All Ion/off -- -- 50 A All Von/off -- -- 1.2 V All Tdelay -- 25 -- msec All Tdelay -- 25 -- msec All Trise -- 0.9 -- msec All -- -- 5 %VO, set ALL HW012A0S1R01 HW012A0P1 HW012A0M1 HW012A0Y1 HW010A0G1 HW010A0F1 HW006A6A1 All 90 -- -- -- -- -- -- -- -- -- 2.0 2.0 2.3 2.3 3.1 4.0 6.1 125 110 2.8 2.8 3.2 3.2 3.7 4.6 7.0 -- %VO, set V V V V V V V C -- 25 32 27 36 -- V V All All VO, ovsd VO, ovsd VO, ovsd VO, ovsd VO, ovsd VO, ovsd VO, ovsd TQ203 5 HW/HC006/010/012 Series Power Modules; dc-dc Converters 18-36 Vdc & 36-75 Vdc Input; 1.0 Vdc to 5 Vdc Output; 6.6A to 12A Data Sheet October 28, 2002 Characteristic Curves The following figures provide typical characteristics curves for the HW012A0P1 (VO = 1.2 V) module at room temperature (TA = 25 C) OUTPUT VOLTAGE, VO (V) (200 mV/div) 0.7 0.5 IO = 12A 0.4 OUTPUT CURRENT, IO (A) (2 A/div) INPUT CURRENT, II (A) 0.6 0.3 IO = 6A 0.2 0.1 IO = 0.15A 0 25 30 35 40 45 50 55 60 INPUT VOLTAGE, VI (V) 65 70 75 TIME, t (200 s/div) 1-0903 Figure 1. Input Voltage and Current Characteristics VI = 36V VI = 48V 80 78 OUTPUT CURRENT, IO (A) (5 A/div) EFFICIENCY, (%) 82 OUTPUT VOLTAGE, VO (V) (200 mV/div) 86 84 76 74 72 VI = 75V 70 0 2 1-0929 Figure 4. Transient Response to Step Decrease in Load from 50% to 25% of Full Load (VI = 48 Vdc) 4 6 8 OUTPUT CURRENT, IO (A) 10 12 TIME, t (200 s/div) 1-0904 REMOTE ON/OFF, VON/OFF (V) (5 V/div) OUTPUT VOLTAGE, VO (V) (10 mV/div) TIME, t (1 s/div) TIME, t (10 ms/div) 1-0905 Figure 3. Output Ripple Voltage (IO = IO, max) 6 Figure 5. Transient Response to Step Increase in Load from 50% to 75% of Full Load (VI = 48 Vdc) OUTPUT VOLTAGE, VO (V) (1 V/div) Figure 2. Converter Efficiency vs. Output Current 1-0928 1-0954 Figure 6. Start-up from Remote On/Off (IO = IO, max) Tyco Electronics Corp. HW/HC006/010/012 Series Power Modules; dc-dc Converters 18-36 Vdc & 36-75 Vdc Input; 1.0 Vdc to 5 Vdc Output; 6.6A to 12A Data Sheet October 28, 2002 Characteristic Curves The following figures provide typical characteristics curves for the HW012A0M1 (VO = 1.5 V) module at room temperature (TA = 25 C) OUTPUT VOLTAGE, VO (V) (100 mV/div) 0.9 0.7 0.6 0.5 IO = 12A 0.4 0.3 OUTPUT CURRENT, IO (A) (2 A/div) INPUT CURRENT, II (A) 0.8 IO = 6A 0.2 0.1 0 IO = 0.15A 25 30 35 40 45 50 55 60 INPUT VOLTAGE, VI (V) 65 70 75 TIME, t (200 ms/div) 1-0906 Figure 7. Input Voltage and Current Characteristics Figure 10. Transient Response to Step Decrease in Load from 50% to 25% of Full Load (VI = 48 Vdc) OUTPUT VOLTAGE, VO (V) (100 mV/div) 90 88 84 82 80 78 OUTPUT CURRENT, IO (A) (5 A/div) EFFICIENCY, (%) 86 VI = 36V VI = 48V VI = 75V 76 74 72 70 1-0955 0 2 4 6 8 10 12 OUTPUT CURRENT, IO (A) TIME, t (200 ms/div) 1-0907 Figure 11. Transient Response to Step Increase in Load from 50% to 75% of Full Load (VI = 48 Vdc) REMOTE ON/OFF, VON/OFF (V) (5 V/div) OUTPUT VOLTAGE, VO (V) (10 mV/div) OUTPUT VOLTAGE, VO (V) (0.5 V/div) Figure 8. Converter Efficiency vs. Output Current 1-0956 TIME, t (1 s/div) TIME, t (10 ms/div) 1-0908 Figure 9. Output Ripple Voltage (IO = IO, max) Tyco Electronics Corp. 1-0984 Figure 12. Start-up from Remote On/Off (IO = IO, max) 7 HW/HC006/010/012 Series Power Modules; dc-dc Converters 18-36 Vdc & 36-75 Vdc Input; 1.0 Vdc to 5 Vdc Output; 6.6A to 12A Data Sheet October 28, 2002 Characteristic Curves The following figures provide typical characteristics curves for the HW012A0Y1 (VO = 1.8 V) module at room temperature (TA = 25 C) OUTPUT VOLTAGE, VO (V) (100 mV/div) 1 0.8 IO = 12A 0.6 0.4 OUTPUT CURRENT, IO (A) (2 A/div) INPUT CURRENT, II (A) 1.2 IO = 6A 0.2 IO = 0.15A 0 25 30 35 40 45 50 55 60 INPUT VOLTAGE, VI (V) 65 70 75 TIME, t (200 ms/div) 1-0909 Figure 13. Input Voltage and Current Characteristics OUTPUT VOLTAGE, VO (V) (100 mV/div) 90 88 84 82 80 78 OUTPUT CURRENT, IO (A) (5 A/div) EFFICIENCY, (%) 86 VI = 36V VI = 48V VI = 75V 76 74 72 70 1-0957 Figure 16. Transient Response to Step Decrease in Load from 50% to 25% of Full Load (VI = 48 Vdc) 0 2 4 6 8 OUTPUT CURRENT, IO (A) 10 12 TIME, t (200 ms/div) 1-0910 REMOTE ON/OFF, VON/OFF (V) (5 V/div) OUTPUT VOLTAGE, VO (V) (10 mV/div) TIME, t (1 s/div) TIME, t (10 ms/div) 1-0911 Figure 15. Output Ripple Voltage (IO = IO, max) 8 Figure 17. Transient Response to Step Increase in Load from 50% to 75% of Full Load (VI = 48 Vdc) OUTPUT VOLTAGE, VO (V) (1 V/div) Figure 14. Converter Efficiency vs. Output Current 1-0958 1-0959 Figure 18. Start-up from Remote On/Off (IO = IO, max) Tyco Electronics Corp. HW/HC006/010/012 Series Power Modules; dc-dc Converters 18-36 Vdc & 36-75 Vdc Input; 1.0 Vdc to 5 Vdc Output; 6.6A to 12A Data Sheet October 28, 2002 Characteristic Curves The following figures provide typical characteristics curves for the HW010A0G1 (VO = 2.5 V) module at room temperature (TA = 25 C) OUTPUT VOLTAGE, VO (V) (100 mV/div) 1 0.8 IO = 10A 0.6 0.4 OUTPUT CURRENT, IO (A) (5 A/div) INPUT CURRENT, II (A) 1.2 IO = 5A 0.2 IO = 0.05A 0 25 30 35 40 45 50 55 60 INPUT VOLTAGE, VI (V) 65 70 75 TIME, t (100 s/div) 1-0912 Figure 19. Input Voltage and Current Characteristics Figure 22. Transient Response to Step Decrease in Load from 50% to 25% of Full Load (VI = 48 Vdc) OUTPUT VOLTAGE, VO (V) (100 mV/div) 95 85 80 OUTPUT CURRENT, IO (A) (5 A/div) EFFICIENCY, (%) 90 VI = 36V VI = 48V VI = 75V 75 70 0 1-0915 1 2 3 4 5 6 7 OUTPUT CURRENT, IO (A) 8 9 10 TIME, t (100 s/div) 1-0913 Figure 23. Transient Response to Step Increase in Load from 50% to 75% of Full Load (VI = 48 Vdc) REMOTE ON/OFF, VON/OFF (V) (5 V/div) OUTPUT VOLTAGE, VO (V) (10 mV/div) OUTPUT VOLTAGE, VO (V) (500 mV/div) Figure 20. Converter Efficiency vs. Output Current 1-0916 TIME, t (1 s/div) TIME, t (5 ms/div) 1-0914 Figure 21. Output Ripple Voltage (IO = IO, max) Tyco Electronics Corp. 1-017 Figure 24. Start-up from Remote On/Off (IO = IO, max) 9 HW/HC006/010/012 Series Power Modules; dc-dc Converters 18-36 Vdc & 36-75 Vdc Input; 1.0 Vdc to 5 Vdc Output; 6.6A to 12A Data Sheet October 28, 2002 Characteristic Curves The following figures provide typical characteristics curves for the HW010A0F1 (VO = 3.3 V) module at room temperature (TA = 25 C) OUTPUT VOLTAGE, VO (V) (200 mV/div) 1.6 1.2 1 IO = 10A 0.8 OUTPUT CURRENT, IO (A) (5 A/div) INPUT CURRENT, II (A) 1.4 0.6 IO = 5A 0.4 0.2 0 25 IO = 0.05A 30 35 40 45 50 55 60 INPUT VOLTAGE, VI (V) 65 70 75 TIME, t (100 s/div) 1-0918 Figure 25. Input Voltage and Current Characteristics OUTPUT VOLTAGE, VO (V) (200 mV/div) 95 85 OUTPUT CURRENT, IO (A) (5 A/div) EFFICIENCY, (%) 90 80 VI = 36V VI = 48V VI = 75V 75 70 1-0920 Figure 28. Transient Response to Step Decrease in Load from 50% to 25% of Full Load (VI = 48 Vdc) 0 1 2 3 4 5 6 7 OUTPUT CURRENT, IO (A) 8 9 10 TIME, t (100 s/div) 1-0919 REMOTE ON/OFF, VON/OFF (V) (5 V/div) OUTPUT VOLTAGE, VO (V) (20 mV/div) TIME, t (1 s/div) TIME, t (5 ms/div) 1-0960 Figure 27. Output Ripple Voltage (IO = IO, max) 10 Figure 29. Transient Response to Step Increase in Load from 50% to 75% of Full Load (VI = 48 Vdc) OUTPUT VOLTAGE, VO (V) (1 V/div) Figure 26. Converter Efficiency vs. Output Current 1-0921 1-0961 Figure 30. Start-up from Remote On/Off (IO = IO, max) Tyco Electronics Corp. HW/HC006/010/012 Series Power Modules; dc-dc Converters 18-36 Vdc & 36-75 Vdc Input; 1.0 Vdc to 5 Vdc Output; 6.6A to 12A Data Sheet October 28, 2002 Characteristic Curves The following figures provide typical characteristics curves for the HW006A6A1 (VO = 5.0 V) module at room temperature (TA = 25 C) OUTPUT VOLTAGE, VO (V) (200 mV/div) 1.4 1 IO = 6.6A 0.8 OUTPUT CURRENT, IO (A) (2 A/div) INPUT CURRENT, II (A) 1.2 0.6 IO = 3.3A 0.4 0.2 IO = 0.05A 0 25 30 35 40 45 50 55 60 INPUT VOLTAGE, VI (V) 65 70 75 TIME, t (100 s/div) 1-0922 Figure 31. Input Voltage and Current Characteristics Figure 34. Transient Response to Step Decrease in Load from 50% to 25% of Full Load (VI = 48 Vdc) OUTPUT VOLTAGE, VO (V) (200 mV/div) 95 85 OUTPUT CURRENT, IO (A) (2 A/div) EFFICIENCY, (%) 90 80 VI = 36V VI = 48V VI = 75V 75 70 0 1-0924 1 2 3 4 5 OUTPUT CURRENT, IO (A) 6 7 TIME, t (100 s/div) 1-0923 Figure 35. Transient Response to Step Increase in Load from 50% to 75% of Full Load (VI = 48 Vdc) REMOTE ON/OFF, VON/OFF (V) (5 V/div) OUTPUT VOLTAGE, VO (V) (10m V/div) OUTPUT VOLTAGE, VO (V) (2 V/div) Figure 32. Converter Efficiency vs. Output Current 1-0925 TIME, t (1 s/div) TIME, t (5 ms/div) 1-0962 Figure 33. Output Ripple Voltage (IO = IO, max) Tyco Electronics Corp. 1-0963 Figure 36. Start-up from Remote On/Off (IO = IO, max) 11 HW/HC006/010/012 Series Power Modules; dc-dc Converters 18-36 Vdc & 36-75 Vdc Input; 1.0 Vdc to 5 Vdc Output; 6.6A to 12A Safety Considerations Test Configurations For safety-agency approval of the system in which the power module is used, the power module must be installed in compliance with the spacing and separation requirements of the end-use safety agency standard, i.e., UL60950, CSA C22.2 No. 60950-00, and VDE 0805:2001-12 (IEC60950, 3rd Ed). 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 These converters have been evaluated to the spacing requirements for Basic Insulation, per the above safety standards. VI(-) 8-203 Note: Measure input reflected ripple current with a simulated source inductance (LTEST) of 12H. Capacitor CS offsets possible battery impedance. Measure current as shown above. Figure 37. Input Reflected Ripple Current Test Setup For Basic Insulation models ("-B" Suffix), 1500 Vdc is applied from VI to VO to 100% of outgoing production. For end products connected to -48 Vdc, or -60 Vdc nomianl DC MAINS (i.e. central office dc battery plant), no further fault testing is required. Note: -60 V dc nominal bettery plants are not available in the U.S. or Canada. COPPER STRIP For all input voltages, other than DC MAINS, where the input voltage is less than 60 Vdc, if the input meets all of the requirements for SELV, then: V O (+) 1.0 F 10 F RESISTIVE LOAD SCOPE The output may be considered SELV. Output voltages will remain withing SELV limits even with internally-generated non-SELV voltages. Single component failure and fault tests were performed in the power converters. One pole of the input and one pole of the output are to be grounded, or both circuits are to be kept floating, to maintain the output voltage to ground voltage within ELV or SELV limits. V O (-) GROUND PLANE 8-513 Note: Scope measurements should be made using a BNC socket, with a 10 F tantalum capacitor and a 1 F ceramic capcitor. Position the load between 51 mm and 76 mm (2 in and 3 in) from the module Figure 38. Peak-to-Peak Output Ripple Measurement Test Setup For all input sources, other than DC MAINS, where the input voltage is between 60 and 75 Vdc (Classified as TNV-2 in Europe), the following must be adhered to, if the converter's output is to be evaluated for SELV: The input source is to be provided with reinforced insulation from any hazardous voltage, including the AC mains. One VI pin and one VO pin are to be reliably earthed, or both the input and output pins are to be kept floating. 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. CONTACT AND DISTRIBUTION LOSSES VI(+) VO(+) IO II LOAD SUPPLY VI(-) VO(-) CONTACT RESISTANCE 8-749 Note: All voltage measurements to be taken at the module terminals, as shown above. If sockets are used then Kelvin connections are required at the module terminals to avoid measurement errors due to socket contact resistance. Figure 39. Output Voltage and Efficiency Test Setup [ V O(+) - V O(-) ] x I O = ------------------------------------------------ x 100 [ V I(+) - V I(-) ] x I I 12 Data Sheet October 28, 2002 The power module has ELV (extra-low voltage) outputs when all inputs are ELV. All flammable materials used in the manufacturing of these modules are rated 94V-0, and UL60950A.2 for reduced thicknesses. The input to these units is to be provided with a maximum 5A time-delay in the unearthed lead. Tyco Electronics Corp. Data Sheet October 28, 2002 HW/HC006/010/012 Series Power Modules; dc-dc Converters 18-36 Vdc & 36-75 Vdc Input; 1.0 Vdc to 5 Vdc Output; 6.6A to 12A Design Considerations Output Voltage Set-Point Adjustment (Trim) Input Source Impedance The power module should be connected to a low ac-impedance source. A highly inductive source impedance can affect the stability of the power module. For the test configuration in Figure 37, a 33F electrolytic capacitor (ESR<0.7 at 100kHz), mounted close to the power module helps ensure the stability of the unit. Consult the factory for further application guidelines. 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 remote ON/OFF pin, and off during a logic low. Negative logic remote On/Off, device code suffix "1", turns the module off during logic-high voltage 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 pin and the VI(-) terminal. The switch may be an open collector or equivalent (see Figure 40). A logic low is Von/off = -0.7 V to 1.2 V. The maximum Ion/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 Von/off generated by the power module is 15 V. The maximum allowable leakage current of the switch at Von/off = 15 V is 50 A. If not using the remote on/off feature, do one of the following: For negative logic, short the ON/OFF pin to VI(-). A R trim-down = --------- - B k % Rtrim-down is the external resistor in k % is the % change in output voltage A & B are defined in Table 3 for various models Table 3 Output Voltage (V) A B 1.0 1.2 1.5 1.8 2.5 3.3 5.0 TBD 1089 1089 1089 1690 1690 1690 TBD 62.0 104 104 73.1 73.1 73.1 % = 8 A = 1690 B = 73.1 Ion/off ON/OFF Von/off - 1690 R trim-down = ------------ - 73.1 k 8 VO(+) LOAD VI(+) With an external resistor Trim-down between the TRIM and VO(-) pins, the output voltage set point VO, set decreases (see Figure 41. The following equation determines the required external-resistor value to trimdown the output voltage from VO, set to VO: For example, to trim-down the output voltge of 2.5 V module (HW010A0G) by 8% to 2.3 V, Rtrim-down is calculated as follows: For positive logic, leave the ON/OFF pin open. + 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 VO(+) or VO(-) pins. The trim resistor should be positioned close to the module. If not using the trim feature, leave the TRIM pin open. VO(-) VI(-) R trim - do wn = 138.15k 8-720 Figure 40. Remote On/Off Implementation Tyco Electronics Corp. 13 HW/HC006/010/012 Series Power Modules; dc-dc Converters 18-36 Vdc & 36-75 Vdc Input; 1.0 Vdc to 5 Vdc Output; 6.6A to 12A Data Sheet October 28, 2002 Feature Descriptions (continued) 19.8 ( 100 + 8 ) - 1089 R trim-up = ---------------------------------------------------- - 104 k 8 Output Voltage Set-Point Adjustment (Trim) (continued) R trim-up = 27.175k VO(+) VI(+) VI(+) VO(+) ON/OFF Rtrim-up ON/OFF TRIM RLOAD VI(-) TRIM Rtrim-down RLOAD VI(-) VO(-) 8-748 Figure 41. Circuit Configuration to Decrease Output Voltage 8-715 With an external resistor Rtrim-up, connected between the TRIM and VO(+) pins, the output voltage set point VO, set increases (see Figure 42). The following equation determines the required external-resistor value to trim-up the output voltage from VO, set to VO: A ( 100 + % ) - B R trim-up = ------------------------------------------- - C k % Rtrim-up is the external resistor in k % is the % change in output voltage A, B and C are defined in Table 4 Output Voltage (V) A B C 1.0 1.2 1.5 1.8 2.5 3.3 5.0 TBD 15.9 19.8 23.8 34.5 45.5 69.0 TBD 1089 1089 1089 1690 1690 1690 TBD 62.0 104 104 73.1 73.1 73.1 For example, to trim-up the output voltage of 1.5 V module (HW012A0M) by 8% to 1.62 V, Rtrim-up is calculated is as follows: 14 Figure 42. Circuit Configuration to Increase Output Voltage The amount of power delivered by the module is defined as the voltage at the output terminals multiplied by the output current. When using trim, the output voltage of the module can be increased, which at the same output current would increase the power output of the module. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power (maximum rated power = VO, set x IO, max). Overcurrent Protection Table 4 % = 8 A = 19.8 B = 1089 C = 104 VO(-) To provide protection in a fault (output overload) condition, the module is equipped with internal current limiting circuitry, and can endure current limiting continuously. At the instance of current-limit inception, the output current begins to tail-out. When an overcurrent condition exists beyond a few seconds, the module enters a "hiccup" mode of operation, whereby it shuts down and automatically attempts to restart upon cooling. While the fault condition exists, the module will remain in the hiccup mode, and can remain in this mode until the fault is cleared. The unit operates normally once the output current is reduced back into its specified range. Output Overvoltage Protection The output overvoltage protection clamp consists of control circuitry, independent of the primary regulation loop, that monitors the voltage on the output terminals. This control loop has a higher voltage set point than the primary loop (See the overvoltage clamp values in the Feature Specifications Table). In a fault condition, the overvoltage clamp ensures that the output voltage Tyco Electronics Corp. Data Sheet October 28, 2002 HW/HC006/010/012 Series Power Modules; dc-dc Converters 18-36 Vdc & 36-75 Vdc Input; 1.0 Vdc to 5 Vdc Output; 6.6A to 12A Feature Descriptions (continued) Heat Transfer via Convection does not exceed VO, ovsd, max. This provides a redundant voltage-control that reduces the risk of output overvoltage. Increasing airflow over the module enhances the heat transfer via convection. Figures 44--48 show the maximum current that can be delivered by various modules versus local ambient temperature (TA) for natural convection through 2 m/s (400 ft./min.). Overtemperature Protection To provide protection under certain fault conditios, the unit is equipped with a thermal shutdown circuit. The unit will shudown if the overtemperature threshold is exceeded, but the thermal shut down is not intended as a guarantee that the unit will survive temperatures beyond its rating. The module will automatically restart after it cools down. Systems in which these power modules may be used typically generate natural convection airflow rates of 0.3 ms-1 (60 ft./min.) due to other heat-dissipating components in the system. Therefore, the natural convection condition represents airflow rates of up to 0.3 ms-1 (60 ft./min.). Use of Figure 44 is shown in the following example. Example Input Undervoltage Lockout At input voltages below the input undervoltage lockout limit, the module operation is disabled. The module will begin to operate at an input voltage above the undervoltage lockout turn-on threshold. Thermal Considerations What is the minimum airflow necessary for a HW010A0F1 operating at VIN = 48 V, an output current of 10 A, and a maximum ambient temperature of 75 C. Solution Given: VIN = 48V IO = 12 A TA = 75 C Determine airflow (v) (Use Figure 44.): Introduction v = 0.5 m/s (100 ft./min.) The temperature at Q203 drain pins should not exceed 115 C. The output power of the module should not exceed the rated power for the module (VO, set x IO, max). Although the maximum operating ambient temperature of the power modules is 85 C, you can limit this temperature to a lower value for extremely high reliability. 12 10 Output Current IO (A) 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 is removed by conduction, convection, and radiation to the surrounding environment. Proper cooling can be verified by measuring drain pin Q203 at the position indicated in Figure 43. 8 2.0 m/s (400 ft./min.) 1.0 m/s (200 ft./min.) 0.5 m/s (100 ft./min.) NATURAL CONVECTION 6 4 2 0 20 30 40 50 60 70 Ambient Temperature TA (C) 80 90 1-0770 Figure 44. Derating Curves for HW010A0F1 (VO = 3.3 V) in Transvere Orientation (VI = 48 Vdc) Q203 Attach thermocouple to drain lead. AIRFLOW 1-0765 Figure 43. HW/HC 6.6A-12A-Series Temperature Measurement Location (Top View) Tyco Electronics Corp. 15 Data Sheet October 28, 2002 HW/HC006/010/012 Series Power Modules; dc-dc Converters 18-36 Vdc & 36-75 Vdc Input; 1.0 Vdc to 5 Vdc Output; 6.6A to 12A Thermal Consideration (Continued) 14 OUTPUT CURRENT, I O (A) 12 8 OUTPUT CURRENT, IO (A) 7 6 2.0 m/s (400 ft./min.) 1.0 m/s (200 ft./min.) 0.5 m/s (100 ft./min.) NATURAL CONVECTION 5 4 3 2.0 m/s (400 ft./min.) 1.0 m/s (200 ft./min.) 0.5 m/s (100 ft./min.) NATURAL CONVECTION 6 4 2 30 40 50 60 70 AMBIENT TEMPERATURE, T A (C) 80 90 1 20 30 40 50 60 70 AMBIENT TEMPERATURE, TA (C) 80 90 1-0953 Figure 45. Derating Curves for HW006A6A1 (VO = 5.0 V) in Transvere Orientation (VI = 48 Vdc) Figure 48. Derating Curves for HW012A0P1 (VO = 1.2 V) in Transvere Orientation (VI = 48 Vdc) Layout Considerations Copper paths must not be routed beneath the power module. For additional layout guidelines, refer to the FLTR100V10 or FLTR100V20 data sheet. 14 12 OUTPUT CURRENT, I O (A) 8 0 20 2 0 EMC Considerations 10 8 For assistance with designing for EMC compliance, please refer to the FLTR100V10 data sheet (FDS01-043EPS) 2.0 m/s (400 ft./min.) 1.0 m/s (200 ft./min.) 0.5 m/s (100 ft./min.) NATURAL CONVECTION 6 4 Pick and Place Area 2 0 20 30 40 50 60 70 AMBIENT TEMPERATURE, T A (C) 80 90 Figure 46. Derating Curves for HW010A0G1 (VO = 2.5 V) in Transvere Orientation (VI = 48 Vdc) 14 12 OUTPUT CURRENT, IO (A) 10 Although the module weight is minimized by using open-frame construction, the modules have a relatively large mass compared to conventional surface-mount components. To optimize the pick-and-place process, automated vacuum equipment variables such as nozzle size, tip style, vacuum pressure, and placement speed should be considered. Surface-mount versions of this family have a flat surface which serves as a pick-and-place location for automated vacuum equipment. The module's pick-and-place location is identified in Figure 49. 10 8 2.0 m/s (400 ft./min.) 1.0 m/s (200 ft./min.) 0.5 m/s (100 ft./min.) NATURAL CONVECTION 6 X 4 2 0 20 14mm (0.57in) 30 40 50 60 70 AMBIENT TEMPERATURE, TA (C) 80 90 21mm (0.84in) Figure 47. Derating Curves for HW012A0Y1 (VO = 1.8 V) in Transvere Orientation (VI = 48 Vdc) Tyco Electronics Corp. 1-0766 Figure 49. Pick and Place Location 16 HW/HC006/010/012 Series Power Modules; dc-dc Converters 18-36 Vdc & 36-75 Vdc Input; 1.0 Vdc to 5 Vdc Output; 6.6A to 12A Data Sheet October 28, 2002 Outline Diagram for Surface-Mount Module Dimensions are in millimeters and (inches). Tolerances: x.x mm 0.5 mm (x.xx in. 0.02 in.) [unless otherwise indicated] x.xx mm 0.25 mm (x.xxx in. 0.010 in.) Pin Function 1 Vo(+) 2 Vo(-) 9 Trim 11 On/Off 17 VI(-) 18 VI(+) 47.2 (1.86) Top View 18 17 11 29.5 (1.16) 0.06 x 0.06 chamffer 1 9 2 8.50 (0.335) MAX 2.5 (0.10) min stand-off height Side View 0.5 (.020) max compliance 1.7 (0.07) 3.6 (0.14) TRIM Bottom View VO+ VO- 26.16 (1.030) On/Off VI+ VI5.00 (0.197) 35.00 (1.375) 40.00 (1.575) 1-0767 2 17 Tyco Electronics Corp. HW/HC006/010/012 Series Power Modules; dc-dc Converters 18-36 Vdc & 36-75 Vdc Input; 1.0 Vdc to 5 Vdc Output; 6.6A to 12A Data Sheet October 28, 2002 Outline Diagram for Through-Hole Module Dimensions are in millimeters and (inches). Tolerances: x.x mm 0.5 mm (x.xx in. 0.02 in.) [unless otherwise indicated] x.xx mm 0.25 mm (x.xxx in. 0.010 in.) 47.2 (1.86) Top View 17 47.2 (1.86) 18 Top View 11 17 11 18 Pin 1 Pin 2 91 2 11 9 17 11 18 17 18 29.5 (1.16) 29.5 (1.16) VI(-) VI(+) 0.06 x 0.06 chamffer 1 0.06 x 0.06 chamffer 9 2 1 2.5 (0.10) MIN Function Vo(+) Function Vo(-) Vo(+) Trim Vo(-) On/Off Trim VI(-) On/Off VI(+) 9 2 8.50 (0.335) 8.50 MAX (0.335) 2.5 (0.10) MIN MAX Side View Side View 1.001.00 (0.040) (0.040) Pin Pin DIADIA 9.0 9.0 (0.35) (0.35) MIN MIN 3.6 3.6 1.7 1.7 (0.14) (0.14) (0.07) (0.07) TRIM Bottom View TRIM VO+ VO- Bottom View VO+ VO26.16 26.16 (1.030) (1.030) On/Off VI+ VI- On/Off VI+ VI- 5.00 (0.197) 5.00 (0.197) 35.00 (1.375) 35.00 (1.375) 40.00 (1.575) 40.00 (1.575) Tyco Electronics Corp. 1-0768 2 18 HW/HC006/010/012 Series Power Modules; dc-dc Converters 18-36 Vdc & 36-75 Vdc Input; 1.0 Vdc to 5 Vdc Output; 6.6A to 12A Data Sheet October 28, 2002 Recommended Pad Layout for Surface-Mount Module and Recommended Hole Layout for Through-Hole Module Component-side footprint. 47.24 (1.860) 43.64 (1.718) 38.63 (1.521) 8.64 (0.340) 3.63 (0.143) 0 (0) Dimensions are in millimeters and (inches), unless otherwise noted. 29.46 (1.160) 27.84 (1.096) 20.73 (0.816) KEEP-OUT AREA: Besides trace to ON/OFF pin, do not route other traces on the PWB top layer closest to the power module in this keep-out area. 1.68 (0.066) 0 (0) NOTES: 32.56 (1.282) 0 (0) 0 (0) 1. FOR CGA SURFACE MOUNT PIN USE THE FOLLOWING PAD 0.022" DIA VIA 0.032" DIA SOLDER MASK OPENING 4 PLACES FOR OUTPUT PINS 2 PLACES FOR INPUT PINS 0.025" SPACING VIA TO PAD 0.015" MIN SOLDER MASK WALL 0.105" PASTE MASK OPENING 0.110" SOLDER MASK OPENING 1-0769 19 Tyco Electronics Corp. HW/HC006/010/012 Series Power Modules; dc-dc Converters 18-36 Vdc & 36-75 Vdc Input; 1.0 Vdc to 5 Vdc Output; 6.6A to 12A Data Sheet October 28, 2002 Ordering Information Please contact your Tyco Electronics' Sales Representative for pricing, availability and optional features. Table 5. Device Codes Input Voltage Output Voltage Output Current Efficiency Connector Type Device Code Comcodes 36 - 75 Vdc 36 - 75 Vdc 36 - 75 Vdc 36 - 75 Vdc 36 - 75 Vdc 36 - 75 Vdc 36 - 75 Vdc 36 - 75 Vdc 36 - 75 Vdc 36 - 75 Vdc 36 - 75 Vdc 36 - 75 Vdc 36 - 75 Vdc 36 - 75 Vdc 1.0 V 1.2 V 1.5 V 1.8 V 2.5 V 3.3 V 5.0 V 1.0 V 1.2 V 1.5 V 1.8 V 2.5 V 3.3 V 5.0 V 12 A 12 A 12 A 12 A 10 A 10 A 6A 12 A 12 A 12 A 12 A 10 A 10 A 6A TBD 82 83 85 89 90 91 TBD 82 83 85 89 90 91 Through-Hole Through-Hole Through-Hole Through-Hole Through-Hole Through-Hole Through-Hole SMT SMT SMT SMT SMT SMT SMT HW012A0S1R01 HW012A0P1 HW012A0M1 HW012A0Y1 HW010A0G1 HW010A0F1 HW006A6A1 HW012A0S1R01-S HW012A0P1-S HW012A0M1-S HW012A0Y1-S HW010A0G1-S HW010A0F1-S HW006A6A1-S TBD 108965617 108968371 108968397 108968413 108967985 108968355 TBD 108965591 108968389 108968405 108968421 108965625 108968363 Optional features can be ordered using the suffixes shown below. The suffixes follow the last letter of the Product Code and are placed in descending alphanumerical order. Table 6. Device Options Option Negative remote on/off logic Approved for Basic Insulation Surface mount interconnections Suffix 1 -B -S Europe, Middle-East and Africa Headquarters Tyco Electronics (UK) Ltd Tel: +44 (0) 1344 469 300, Fax: +44 (0) 1344 469 301 World Wide Headquarters 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) www.power.tycoelectronics.com e-mail: techsupport1@tycoelectronics.com Central America-Latin America Headquarters Tyco Electronics Power Systems Tel: +54 11 4316 2866, Fax: +54 11 4312 9508 Asia-Pacific Headquarters Tyco Electronics Singapore Pte Ltd Tel: +65 482 0311, Fax: 65 480 9299 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 Power Systems, Inc. (Mesquite, Texas) All International Rights Reserved. Printed in U.S.A. October 28, 2002 FDS03-003 (Replaces ADS02-006EPS) Printed on Recycled Paper