FE050A FE100A FE150A UL-1950 EN60950 FE050A9 FE100A9 FE150A9 TN97-009EPS 9N128 - Datasheet Archive

 

July 1998 FE050A, FE100A, FE150A Power Modules: dc-dc Converters; 38 Vdc to 60 Vdc Input, 5 Vdc Output; 50 W to 150 W Features s

 

Data Sheet July 1998 FE050A FE050A, FE100A FE100A, FE150A FE150A Power Modules: dc-dc Converters; 38 Vdc to 60 Vdc Input, 5 Vdc Output; 50 W to 150 W Features s s Case ground pin s Input-to-output isolation s Remote sense s Remote on/off s Short-circuit protection s Telecommunications Constant frequency s s Within FCC requirements for Telecom s Redundant and distributed power architectures Complete input and output filtering s s Low profile: 12.7 mm (0.5 in.) s Applications Parallel operation with load sharing s The FE050A FE050A, FE100A FE100A, and FE150A FE150A Power Modules use advanced, surface-mount technology and deliver high-quality, compact, dc-dc conversion at an economical price. High efficiency: 82% typical Output overvoltage clamp s UL* Recognized, CSA Certified, TÜV Licensed * UL is a registered trademark of Underwriters Laboratories, Inc. CSA is a registered trademark of Canadian Standards Association. TÜV is a registered trademark of Technischer ÜberwachungsVerein. Options s Output voltage set-point adjustment (trim) Description The FE050A FE050A, FE100A FE100A, and FE150A FE150A Power Modules are dc-dc converters that operate over an input voltage range of 38 Vdc to 60 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 50 W to 150 W at a typical full-load efficiency of 82%. Built-in filtering, for both the input and output of each device, eliminates the need for external filters. Two or more modules may be paralleled with forced load sharing for redundant or enhanced power applications. The package, which mounts on a printed-circuit board, accommodates a heat sink for high-temperature applications. FE050A FE050A, FE100A FE100A, FE150A FE150A Power Modules: dc-dc Converters; 38 Vdc to 60 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1998 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 Input Voltage (continuous) I/O Isolation Voltage Operating Case Temperature (See Thermal Considerations section and Figure 21.) Storage Temperature Symbol VI - TC Min - - 0 Max 60 500 90 Unit Vdc V °C Tstg ­55 125 °C Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Table 1. Input Specifications Parameter Operating Input Voltage Maximum Input Current (VI = 0 V to 60 V): FE050A FE050A FE100A FE100A FE150A FE150A Inrush Transient Input Reflected-ripple Current, Peak-to-peak (5 Hz to 20 MHz, 12 µH source impedance) (See Figure 12.) Input Ripple Rejection (120 Hz) Symbol VI Min 38 Typ 48 Max 60 Unit Vdc II, max II, max II, max i2t - - - - - - - - 2 4 6 1.0 A A A A2s - - 20 - mAp-p - - 60 - dB 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, dc fuse with a maximum rating of 6 A (see Safety Considerations section). Based on the information provided in this data sheet on inrush energy and maximum dc input current, the same type of fuse with a lower rating can be used. Refer to the fuse manufacturer's data for further information. 2 Lucent Technologies Inc. Data Sheet July 1998 FE050A FE050A, FE100A FE100A, FE150A FE150A Power Modules: dc-dc Converters; 38 Vdc to 60 Vdc Input, 5 Vdc Output; 50 W to 150 W Electrical Specifications (continued) Table 2. Output Specifications Parameter Output Voltage Set Point (VI = 48 V; IO = IO, max; TC = 25 °C): Unit Operating in Parallel or PARALLEL Pin Shorted to SENSE(­) (See Figure 13 and Feature Descriptions.) PARALLEL Pin Open Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life; see Figure 13 and Feature Descriptions.) Output Regulation: Line (VI = 36 V to 60 V) Load (IO = IO, min to IO, max) Temperature (TC = 0 °C to 90 °C) Output Ripple and Noise Voltage (See Figure 7 and Figure 14.): RMS Peak-to-peak (5 Hz to 20 MHz) Output Current (At IO < IO, min, the modules may exceed output ripple specifications.): FE050A FE050A FE100A FE100A FE150A FE150A Output Current-limit Inception (VO = 90% of VO, set; see Figure 2 and Feature Descriptions.) Output Short-circuit Current (VO = 250 mV; see Figure 2.) External Load Capacitance (electrolytic, total for one unit or multiple paralleled units): FE050A FE050A FE100A FE100A FE150A FE150A Efficiency (VI = 48 V; IO = IO, max; TC = 25 °C; see Figures 3-6, and Figure 13.) Dynamic Response (IO/t = 1 A/10 µs, VI = 48 V, TC = 25 °C; see Figure 9 and Figure 10.): 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) Lucent Technologies Inc. Symbol Min Typ Max Unit VO, set 4.90 5.00 5.10 Vdc VO, set VO 4.90 4.75 5.00 - 5.20 5.25 Vdc Vdc - - - - - - 0.05 0.2 10 0.2 0.4 50 % % mV - - - - - - 35 100 mVrms mVp-p IO IO IO - 1 1 1 103 - - - - 10 20 30 130 A A A % IO, max - - 135 170 % IO, max - - - 0 0 0 80 - - - 82 4800 14000 17000 - µF µF µF % - - - - 150 300 - - mV µs - - - - 150 300 - - mV µs 3 FE050A FE050A, FE100A FE100A, FE150A FE150A Power Modules: dc-dc Converters; 38 Vdc to 60 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1998 Electrical Specifications (continued) Table 3. Isolation Specifications Parameter Min - 10 Max - - Unit pF M Min Isolation Capacitance Isolation Resistance Typ 1700 - Typ 2,000,000 - Max Unit hours g (oz.) General Specifications Parameter Calculated MTBF (IO = 80% of IO, max; TC = 40 °C) Weight - 200 (7) Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See Feature Descriptions for further information. Parameter Remote On/Off Signal Interface (VI = 0 V to 60 V; open collector or equivalent compatible; signal referenced to VI (­) terminal; see Figure 15 and Feature Descriptions.): 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 µA Leakage Current Turn-on Time (IO = 80% of IO, max; VO within ±1% of steady state) Output Voltage Adjustment (See Feature Descriptions.): Output Voltage Remote-sense Range Output Voltage Set-point Adjustment Range (trim) Parallel Operation Load Sharing (See Feature Descriptions.) Output Overvoltage Clamp 4 Symbol Min Typ Max Unit Von/off Ion/off 0 - - - 1.2 1.0 V mA Von/off Ion/off - - - - - - 5 18 50 10 V µA ms - - - - 90 - - - - 0.6 110 20 V %VO, nom % IO, max VO, clamp 5.6 6.25 7.0 V Lucent Technologies Inc. FE050A FE050A, FE100A FE100A, FE150A FE150A Power Modules: dc-dc Converters; 38 Vdc to 60 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1998 Characteristic Curves The following figures provide typical characteristics for the FE150A FE150A Power Module. The FE050A FE050A and FE100A FE100A characteristics are similar to the FE150A FE150A characteristics provided here, scaled by power level where appropriate. 6 100 IO = 30 A 80 4 EFFICIENCY, (%) INPUT CURRENT, II (A) 5 3 2 IO = 15 A 1 60 40 20 0 ­1 0 20 10 30 40 50 0 60 0 5 10 15 20 25 OUTPUT CURRENT, IO (A) INPUT VOLTAGE, VI (V) 8-566 (C) 8-560 (C) Figure 1. Typical FE150A FE150A Input Characteristics at Room Temperature and 15 A and 30 A Output Figure 3. Typical FE150A FE150A Efficiency vs. Output Current at Room Temperature and 48 V Input 6 84 5 EFFICIENCY, (%) OUTPUT VOLTAGE, VO (V) 30 4 3 2 83 82 81 1 0 0 5 10 15 20 25 30 35 40 45 OUTPUT CURRENT, IO (A) 0 5 10 15 20 25 30 OUTPUT CURRENT, IO (A) 8-561 (C) Figure 2. Typical FE150A FE150A Output Characteristics at Room Temperature and 48 V Input Lucent Technologies Inc. 80 8-567 (C) Figure 4. Typical FE150A FE150A Efficiency vs. Output Current at Room Temperature and 48 V Input (Enlarged View) 5 FE050A FE050A, FE100A FE100A, FE150A FE150A Power Modules: dc-dc Converters; 38 Vdc to 60 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1998 Characteristic Curves (continued) 84 50 mV 1 µs 83 82 81 80 35 40 45 50 55 60 OUTPUT VOLTAGE, VO (V) (50 mV/div) EFFICIENCY, (%) 5.20 5.10 5.00 4.90 4.80 INPUT VOLTAGE, VI (V) 8-568 (C) Figure 5. Typical FE150A FE150A Efficiency vs. Input Voltage at Room Temperature and 15 A Output TIME, t (1 µs/div) 8-570 (C) Figure 7. Typical FE150A FE150A Output Ripple Voltage at Room Temperature, 48 V Input, and 30 A Output 84 500 mV 1 µs 82 IO = 30 A 81 80 0 20 40 60 80 100 INPUT RIPPLE (V) (500 mV/div) EFFICIENCY, (%) 83 IO = 20 A CASE TEMPERATURE, TC (°C) 8-569 (C) Figure 6. Typical FE150A FE150A Efficiency vs. Case Temperature at 48 V Input and 15 A Output IO = 10 A TIME, t (1 µs/div) 8-571 (C) Figure 8. Typical FE150A FE150A Input Ripple Voltage at Room Temperature, 48 V Input, and 10 A, 20 A, and 30 A Output 6 Lucent Technologies Inc. FE050A FE050A, FE100A FE100A, FE150A FE150A Power Modules: dc-dc Converters; 38 Vdc to 60 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1998 REMOTE ON/OFF PIN, Von/off (V) (5 V/div) 50 mV 50 µs 5.10 OUTPUT VOLTAGE, VO (V) (1 V/div) OUTPUT VOLTAGE, VO (V) (50 mV/div) Characteristic Curves (continued) OUTPUT CURRENT, IO (A) (5 A/div) 5.00 4.90 15 10 7.5 5 TIME, t (50 µs/div) Figure 9. Typical FE150A FE150A Transient Response to Step Decrease in Load from 50% to 25% of Full Load at Room Temperature and 28 V Input (Waveform Averaged to Eliminate Ripple Component.) OUTPUT VOLTAGE, VO (V) (50 mV/div) 5V 10 5 0 5 4 3 2 1 1V 1 ms 0 TIME, t (1 ms/div) 8-573 (C) 50 mV 15 8-574 (C) Figure 11. Typical FE150A FE150A Start-Up Transient at Room Temperature, 48 V Input, and 30 A Output 50 µs 5.10 5.00 OUTPUT CURRENT, IO (A) (5 A/div) 4.90 22.5 15 TIME, t (50 µs/div) 8-572 (C) Figure 10. Typical FE150A FE150A Transient Response to Step Increase in Load from 50% to 75% of Full Load at Room Temperature and 28 V Input (Waveform Averaged to Eliminate Ripple Component.) Lucent Technologies Inc. 7 FE050A FE050A, FE100A FE100A, FE150A FE150A Power Modules: dc-dc Converters; 38 Vdc to 60 Vdc Input, 5 Vdc Output; 50 W to 150 W Test Configurations Data Sheet July 1998 Design Considerations Input Source Impedance TO OSCILLOSCOPE CURRENT PROBE LTEST V I (+) 12 µH CS 220 µF ESR < 0.1 33 µF @ 20 °C, 100 kHz ESR < 0.7 @ 100 kHz BATTERY V I (­) 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 12, a 33 µF 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 (C).l Note: Measure input reflected-ripple current with a simulated source inductance (LTEST) of 12 µH. Capacitor CS offsets possible battery impedance. Measure current as shown above. Figure 12. Input Reflected-Ripple Test Setup PARALLEL 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 UL-1950, CSA 22.2-950, and EN60950 EN60950. SENSE(+) For the converter output to be considered meeting the requirements of safety extra-low voltage (SELV), the input must meet SELV requirements. SENSE(­) VI(+) SUPPLY II VO(+) VI(­) VO(­) IO LOAD CONTACT AND DISTRIBUTION LOSSES CONTACT RESISTANCE 8-683 (C) If the input meets extra-low voltage (ELV) requirements, then the converter's output is considered ELV. The input to these units is to be provided with a maximum 20 A normal-blow fuse in the ungrounded lead. 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. [VO(+) ­ VO(­)]IO = - x 100 [ V I ( + ) ­ V I ( ­ ) ] I I - Figure 13. Output Voltage and Efficiency Measurement Test Setup COPPER STRIP V O (+) 0.1 µF SCOPE RESISTIVE LOAD V O (­) 8-513 (C) Note: Use a 0.1 µF ceramic capacitor. Scope measurement should be made using a BNC socket. Position the load between 50 mm (2 in.) and 76 mm (3 in.) from the module. Figure 14. Peak-to-Peak Output Noise Measurement Test Setup 8 Lucent Technologies Inc. FE050A FE050A, FE100A FE100A, FE150A FE150A Power Modules: dc-dc Converters; 38 Vdc to 60 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1998 Electrical Descriptions given in the Feature Specifications table, i.e.: [VO(+) ­ VO(­)] ­ [SENSE(+) ­ SENSE(­)] 0.6 V Current Limit 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. The voltage between the VO(+) and VO(­) terminals must not exceed the minimum output overvoltage clamp voltage as indicated in the Feature Specifications table. This limit includes any increase in voltage due to remote-sense compensation and output voltage set-point adjustment (trim), see Figure 16. If not using the remote-sense feature to regulate the output at the point of load, connect SENSE(+) to VO(+) and SENSE(­) to VO(­) at the module. PARALLEL SENSE(+) Feature Descriptions SENSE(­) VI(+) Remote On/Off 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 15). A logic low is Von/off = 0 V to 1.2 V, during which the module is on. 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 µA. If not using the remote on/off feature, short the ON/OFF pin to VI(­). SENSE(+) ON/OFF + Von/off ­ CONTACT RESISTANCE LOAD CONTACT AND DISTRIBUTION LOSSES 8-651 (C) Figure 16. Effective Circuit Configuration for Single-Module Remote-Sense Operation Output Voltage Set-Point Adjustment (Trim) When not using the trim feature, leave the TRIM pin open. Connecting the external resistor (Rtrim-up) between the TRIM and SENSE(­) pins (VO, adj) increases the output voltage set point as defined in the following equation: VO(+) VI(+) VO(­) R trim-up VI(­) 8-580 (C).b Figure 15. Remote On/Off Implementation Remote Sense Remote sense minimizes the effects of distribution losses by regulating the voltage at the remote-sense connections. For single-unit operation, the PARALLEL pin should be connected to SENSE(­). The voltage between the remote-sense pins and the output terminals must not exceed the output voltage sense range Lucent Technologies Inc. IO Output voltage adjustment allows the output voltage set point to be increased or decreased by adjusting an external resistor connected between the TRIM pin and either the SENSE(+) or SENSE(­) pins (see Figure 17 and Figure 18). SENSE(­) Ion/off VO(­) II Adjustment with TRIM Pin PARALLEL CASE VO(+) VI(­) SUPPLY 1.25 × 5.620 = - k VO, adj ­ 5 - Connecting the external resistor (Rtrim-down) between the TRIM and SENSE(+) pins (VO, adj) decreases the output voltage set point as defined in the following equation: ( V O, adj ­ 1.25 ) × 5.620 R trim-down = -5 ­ V O, adj k 9 FE050A FE050A, FE100A FE100A, FE150A FE150A Power Modules: dc-dc Converters; 38 Vdc to 60 Vdc Input, 5 Vdc Output; 50 W to 150 W Feature Descriptions (conitnued) Data Sheet July 1998 Adjustment Without TRIM Pin Output Voltage Set-Point Adjustment (Trim) (continued) Adjustment with TRIM Pin (continued) The voltage between the VO(+) and VO(­) terminals must not exceed the minimum output overvoltage clamp voltage as indicated in the Feature Specifications table. This limit includes any increase in voltage due to remote-sense compensation and output voltage set-point adjustment (trim), see Figure 16. The output voltage can be adjusted by placing an external resistor (Radj) between the SENSE(+) and VO(+) terminals (see Figure 19). By adjusting Radj, the output voltage can be increased by 10% of the nominal output voltage. The equation below shows the resistance required to obtain the desired output voltage. For FE050A FE050A, FE100A FE100A, FE150A FE150A: Radj = (VO, adj ­ VO, nom) 944.3 For FE050A9 FE050A9, FE100A9 FE100A9, FE150A9 FE150A9: Radj = (VO, adj ­ VO, nom) 1007 PARALLEL Rtrim-up Radj SENSE(+) TRIM SENSE(­) PARALLEL SENSE(+) VI(+) SUPPLY VI(+) SUPPLY VO(+) IO II VO(­) VI(­) 8-717 (C).c Figure 17. Circuit Configuration to Trim Up Output Voltage Rtrim-down TRIM PARALLEL SENSE(+) SENSE(­) VI(+) VO(+) VI(­) SUPPLY VO(­) IO II CONTACT RESISTANCE IO LOAD CONTACT AND DISTRIBUTION LOSSES 8-710 (C).c CONTACT AND DISTRIBUTION LOSSES CONTACT RESISTANCE VO(­) II CONTACT RESISTANCE LOAD VO(+) VI(­) SENSE(­) LOAD CONTACT AND DISTRIBUTION LOSSES 8-718 (C).c Figure 18. Circuit Configuration to Trim Down Output Voltage Figure 19. Circuit Configuration to Adjust Output Voltage Forced Load Sharing (Parallel Operation) For either redundant operation or additional power requirements, the power modules can be configured for parallel operation with forced load sharing (see Figure 20). For a typical redundant configuration, Schottky diodes or an equivalent should be used to protect against short-circuit conditions. Because of the remote sense, the forward-voltage drops across the Schottky diodes do not affect the set point of the voltage applied to the load. For additional power requirements, where multiple units are used to develop combined power in excess of the rated maximum, the Schottky diodes are not needed. Good layout techniques should be observed for noise immunity. To implement forced load sharing, the following connections must be made: s s 10 The parallel pins of all units must be connected together. The paths of these connections should be as direct as possible. All remote-sense pins should be connected to the power bus at the same point, i.e., connect all SENSE(+) pins to the (+) side of the power bus at the same point and all SENSE(­) pins to the (­) side of the power bus at the same point. Close proximity and directness are necessary for good noise immunity. Lucent Technologies Inc. FE050A FE050A, FE100A FE100A, FE150A FE150A Power Modules: dc-dc Converters; 38 Vdc to 60 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1998 Feature Descriptions (continued) MEASURE CASE TEMPERATURE HERE 76 (3.0) Forced Load Sharing (Parallel Operation) 18 (0.7) (continued) Lucent TRIM PARALLEL When not using the parallel feature, short the PARALLEL pin to SENSE(­). CASE ON/OFF + IN ­ PARALLEL SENSE(+) SENSE(­) FE150A9 FE150A9 DC-DC Power Module IN:DC 48V, 3.7A + SENSE ­ ­ OUT:DC 5V, 30A OUT 150W MADE IN USA Protected by U.S. Patents: 5,036,452 5,179,365 TUV Rheinland + 8-582 (C).q Note: Top view, measurements shown in millimeters and (inches). CASE VO(+) ON/OFF VI(+) VO(­) VI(­) Figure 21. Case Temperature Measurement Location The temperature at this location should not exceed 95 °C. The maximum case temperature can be limited to a lower value for extremely high reliability. The output power of the module should not exceed the rated power for the module as listed in the Ordering Information table. PARALLEL SENSE(+) SENSE(­) CASE VO(+) ON/OFF VI(+) VO(­) VI(­) 8-581 (C) For additional information about these modules, refer to the Lucent Technologies Thermal Management for High-Power Board-Mounted Power Modules Technical Note (TN97-009EPS TN97-009EPS). Figure 20. Wiring Configuration for Redundant Parallel Operation Heat Transfer Without Heat Sinks 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. Thermal Considerations Introduction The power modules operate in a variety of thermal environments; however, sufficient cooling should be provided to help ensure reliable operation of the unit. Heat-dissipating components inside the unit are 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 occurs at the position indicated in Figure 21. Lucent Technologies Inc. Derating curves for forced-air cooling without a heat sink are shown in Figure 22. These curves can be used to determine the appropriate airflow for a given set of operating conditions. For example, if the unit dissipates 20 W of heat, the correct airflow in a 40 °C environment is 1.0 m/s (200 ft./min.). 40 POWER DISSIPATION, PD (W) Output Overvoltage Clamp 0.5 m/s (100 ft./min.) 1.0 m/s (200 ft./min.) 1.5 m/s (300 ft./min.) 2.0 m/s (400 ft./min.) 2.5 m/s (500 ft./min.) 3.0 m/s (600 ft./min.) 3.5 m/s (700 ft./min.) 4.0 m/s (800 ft./min.) 30 20 10 0.1 m/s (20 ft./min.) NATURAL CONVECTION 0 0 20 40 60 80 100 LOCAL AMBIENT TEMPERATURE, TA (°C) 8-587 (C) Figure 22. Power Derating vs. Local Ambient Temperature and Air Velocity 11 FE050A FE050A, FE100A FE100A, FE150A FE150A Power Modules: dc-dc Converters; 38 Vdc to 60 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1998 Heat Transfer with Heat Sinks The power modules have threaded #4-40 fasteners, which enable heat sinks or cold plates to be attached to the module. The mounting torque must not exceed 0.56 N-m (5 in.-lb.). 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): THERMAL RESISTANCE, (°C/W) The location to measure case temperature (TC) is shown in Figure 21. Case-to-ambient thermal resistance vs. airflow for various heat sink configurations is shown in Figure 23 and Figure 24. These curves were obtained by experimental testing of heat sinks, which are offered in the product catalog. 5.0 NO HEAT SINK 0.25 in. HEAT SINK 0.5 in. HEAT SINK 3.0 1 in. HEAT SINK 0.25 in. HEAT SINK 0.5 in. HEAT SINK 3.0 1 in. HEAT SINK 2.0 1.0 0.0 NAT CONV 0.5 (100) 1.0 (200) 1.5 (300) 2.0 (400) 2.5 (500) Figure 24. Heat Sink Resistance Curves; Fins Oriented Along Length 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 23 and Figure 24 had a thermal-conductive dry pad between the case and the heat sink to minimize contact resistance. To choose a heat sink, determine the power dissipated as heat by the unit for the particular application. Figure 25, Figure 26, and Figure 27 show typical heat dissipation for a range of output currents and three voltages for the FE050A FE050A, FE100A FE100A, and FE150A FE150A. 2.0 1.0 0.0 NAT CONV NO HEAT SINK 4.0 8-697 (C).a PD 4.0 5.0 AIR VELOCITY MEASURED IN m/s (ft./min.) (TC ­ TA) ca = T C, max = -PD THERMAL RESISTANCE, (°C/W) Thermal Considerations (continued) 0.5 (100) 1.0 (200) 1.5 (300) 2.0 (400) 2.5 (500) AIR VELOCITY MEASURED IN m/s (ft./min.) 8-696 (C).a Figure 23. Heat Sink Resistance Curves; Fins Oriented Along Width 12 Lucent Technologies Inc. FE050A FE050A, FE100A FE100A, FE150A FE150A Power Modules: dc-dc Converters; 38 Vdc to 60 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1998 Thermal Considerations (continued) Heat Transfer with Heat Sinks (continued) POWER DISSIPATION, PD (W) 40 POWER DISSIPATION (W) 20 15 VI = 60 V VI = 50 V 10 VI = 60 V 30 VI = 50 V VI = 40 V 20 10 5 0 VI = 40 V 0 5 10 15 20 25 30 OUTPUT CURRENT, IO (A) 0 0 2 4 6 8 10 5-583 (C) OUTPUT CURRENT, IO (A) 8-585 (C) Figure 25. FE050A FE050A Power Dissipation as Heat vs. Output Current Example If an 85 °C case temperature is desired, what is the minimum airflow necessary? Assume the FE150A FE150A module is operating at nominal line and an output current of 22 A, maximum ambient air temperature of 40 °C, and the heat sink is 0.5 inch. 30 POWER DISSIPATION (W) Figure 27. FE150A FE150A Power Dissipation as Heat vs. Output Current VI = 60 V 20 VI = 50 V Solution Given: VI = 50 V IO = 22 A TA = 40 °C TC = 85 °C Heat sink = 0.5 inch. 10 VI = 40 V 0 0 4 8 12 16 20 Determine PD by using Figure 27: OUTPUT CURRENT, IO (A) 5-584 (C) Figure 26. FE100A FE100A Power Dissipation as Heat vs. Output Current PD = 24 W Then solve the following equation: (TC ­ TA) ca = -PD ca = ( 85 ­ 40 ) -24 ca = 1.88 °C/W Lucent Technologies Inc. 13 FE050A FE050A, FE100A FE100A, FE150A FE150A Power Modules: dc-dc Converters; 38 Vdc to 60 Vdc Input, 5 Vdc Output; 50 W to 150 W Thermal Considerations (continued) Heat Transfer with Heat Sinks (continued) Use Figure 23 and Figure 24 to determine air velocity for the 0.5 inch heat sink. The minimum airflow necessary for the FE150A FE150A module depends on heat sink fin orientation and is shown below: s 0.4 m/s (80 ft./min.) (oriented along width) s 0.45 m/s (90 ft./min.) (oriented along length) Data Sheet July 1998 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. Custom Heat Sinks A more detailed model can be used to determine the required thermal resistance of a heat sink to provide necessary cooling. The total module resistance can be separated into a resistance from case-to-sink (cs) and sink-to-ambient (sa) shown below (Figure 28.): PD TC TS cs Layout Considerations Copper paths must not be routed beneath the power module standoffs. TA sa 8-1304 (C) Figure 28. Resistance from Case-to-Sink and Sinkto-Ambient 14 Lucent Technologies Inc. FE050A FE050A, FE100A FE100A, FE150A FE150A Power Modules: dc-dc Converters; 38 Vdc to 60 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1998 Outline Diagram Dimensions are in millimeters and (inches). Tolerances: x.x mm ± 0.5 mm (x.xx in. ± 0.02 in.), x.xx mm ± 0.25 mm (x.xxx in. ± 0.010 in.) Top View 121.9 (4.80) 5.3 (0.21) Lucent TRIM TRIM OPTION ONLY PARALLEL FE150A9 FE150A9 DC-DC Power Module 52.83 (2.080) 63.5 (2.50) CASE ON/OFF + IN ­ 5.3 (0.21) + SENSE ­ IN:DC 48V, 3.7A OUT:DC 5V, 30A 150W ­ OUT MADE IN USA Protected by U.S. Patents: 5,036,452 5,179,365 + TUV Rheinland 55.63 (2.190) 55.63 (2.190) FOR OPTIONAL HEAT SINK MOUNTING #4-40 THD 4.6 (0.18) DEEP 6 PLCS Side View SIDE MARKING 1.0 (0.04) 12.7 (0.50) 4.1 ± 0.076 (0.16 ± 0.030) 1.57 (0.062) ± 0.05 (0.002) DIA TIN-PLATED BRASS TYP 12 PLCS 3.8 (0.15) TYP 8 PLCS Bottom View 4.3 (0.17) 5.08 (0.200) 10.16 (0.400) 113.54 (4.470) 12.2 (0.48) 20.32 (0.800) 25.40 (1.000) 30.48 (1.200) 35.56 (1.400) 15.24 (0.600) TRIM OPTION ONLY 8-719 (C).o Lucent Technologies Inc. 15 FE050A FE050A, FE100A FE100A, FE150A FE150A Power Modules: dc-dc 38 Vdc to 60 Vdc Input, 5 Vdc Output; 50 W to 150 W Data Sheet July 1998 Recommended Hole Pattern Component-side footprint. Dimensions are in millimeters and (inches). TRIM OPTION ONLY TRIM 15.24 (0.600) PARALLEL + SENSE ­ CASE ­ ON/OFF 10.16 (0.400) OUT + IN ­ 35.56 30.48 (1.400) 25.40 (1.200) 20.32 (1.000) (0.800) + 12.2 (0.48) 5.08 (0.200) 4.3 (0.17) 113.54 (4.470) 8-719 (C).o Ordering Information This family of modules is not recommended for new designs. For new designs we recommend the JFW family of power modules. Please refer to the Lucent Technologies Power Systems Selection Guide or to individual data sheets. For further assistance you may call the Lucent Technologies Power Systems Technical Hotline (1-800-526-7819 or 972-284-2626). Optional TRIM pin is designated by the ending 9 in device code name. Input Voltage 48 V 48 V 48 V 48 V 48 V 48 V Output Voltage 5V 5V 5V 5V 5V 5V Output Power 50 W 100 W 150 W 50 W 100 W 150 W Trim Yes Yes Yes No No No Device Code FE050A9 FE050A9 FE100A9 FE100A9 FE150A9 FE150A9 FE050A FE050A FE100A FE100A FE150A FE150A Comcode Not Available 106865694 106659873 106258296 106258346 105775498 For additional information, contact your Lucent Technologies Account Manager or the following: POWER SYSTEMS UNIT: Network Products Group, Lucent Technologies Inc., 3000 Skyline Drive, Mesquite, TX 75149, USA +1-800-526-7819 (Outside U.S.A.: +1-972-284-2626, FAX +1-972-329-8202) (product-related questions or technical assistance) INTERNET: http://www.lucent.com E-MAIL: techsupport@lucent.com ASIA PACIFIC: Lucent Technologies Singapore Pte. Ltd., 750A Chai Chee Road #05-01, Chai Chee Industrial Park, Singapore 469001 Tel. (65) 240 8041, FAX (65) 240 8053 JAPAN: Lucent Technologies Japan Ltd., 7-18, Higashi-Gotanda 2-chome, Shinagawa-ku, Tokyo 141-0022, Japan Tel. (81) 3 5421 1600, FAX (81) 3 5421 1700 LATIN AMERICA: Lucent Technologies Inc., Room 9N128 9N128, One Alhambra Plaza, Coral Gables, FL 33134, USA Tel. +1-305-569-4722, FAX +1-305-569-3820 EUROPE: Data Requests: DATALINE: Tel. (44) 1189 324 299, FAX (44) 1189 328 148 Technical Inquiries:GERMANY: (49) 89 95086 0 (Munich), UNITED KINGDOM: (44) 1344 865 900 (Bracknell), FRANCE: (33) 1 48 83 68 00 (Paris), SWEDEN: (46) 8 600 7070 (Stockholm), FINLAND: (358) 9 4354 2800 (Helsinki), ITALY: (39) 2 6608131 (Milan), SPAIN: (34) 1 807 1441 (Madrid) Lucent Technologies Inc. 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. Copyright © 1998 Lucent Technologies Inc. All Rights Reserved Printed in U.S.A. July 1998 DS97-473EPS DS97-473EPS (Replaces DS93-159EPS DS93-159EPS) Printed On Recycled Paper