Wide input range High efficiency: typical Parallel operation with load
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FC050S6R5 FC150S6R5 Power Modules: dc-dc Converters; Input, Output;
Wide input range High efficiency: typical Parallel operation with load sharing profile: 12.7 (0.5 in.) Complete input output filtering Constant frequency Case ground Input-to-output isolation Remote sense Remote on/off Short-circuit protection Output overvoltage clamp
FC050S6R5 FC150S6R5 Power Modules advanced, surface-mount technology deliver high-quality, compact, dc-dc conversion economical price.
Applications
Recognized, Certified, Licensed
Distributed redundant power architectures Telecommunications
Options
Output voltage set-point adjustment (trim)
Description
FC050S6R5 FC150S6R5 Power Modules dc-dc converters that operate over input voltage range provide precisely regulated output. outputs fully isolated from inputs, allowing versatile polarity configurations grounding connections. modules have maximum power ratings from typical full-load efficiency 84%. Built-in filtering, both input output each device, eliminates need external filters. more modules paralleled with forced load sharing redundant enhanced power applications. package, which mounts printed-circuit board, accommodates heat sink high-temperature applications.
registered trademark Underwriters Laboratories, Inc. registered trademark Canadian Standards Association. registered trademark Technischer
FC050S6R5 FC150S6R5 Power Modules: dc-dc Converters; Input, Output;
Absolute Maximum Ratings
Stresses excess absolute maximum ratings cause permanent damage device. These absolute stress ratings only. Functional operation device implied these other conditions excess those given operations sections data sheet. Exposure absolute maximum ratings extended periods adversely affect device reliability. Parameter Input Voltage (continuous) Isolation Voltage Operating Case Temperature (See Thermal Considerations section Figure 16.) Storage Temperature Symbol Unit
Tstg
Electrical Specifications
Unless otherwise indicated, specifications apply over operating input voltage, resistive load, temperature conditions. Table Input Specifications Parameter Operating Input Voltage Maximum Input Current FC050S6R5 FC150S6R5 Inrush Transient Input Reflected-ripple Current, Peak-to-peak MHz, source impedance; Figure Input Ripple Rejection (120 Fusing Considerations CAUTION: This power module internally fused. input line fuse must always used. This encapsulated power module used wide variety applications, ranging from simple stand-alone operation integrated part sophisticated power architecture. preserve maximum flexibility, internal fusing included; however, achieve maximum safety system protection, always input line fuse. safety agencies require normal-blow, fuse with maximum rating (see Safety Considerations section). Based information provided this data sheet inrush energy maximum input current, same type fuse with lower rating used. Refer fuse manufacturer's data further information. Symbol Unit mAp-p
Tyco Electronics Corp.
FC050S6R5 FC150S6R5 Power Modules: dc-dc Converters; Input, Output;
Electrical Specifications (continued)
Table Output Specifications Parameter Output Voltage (Over operating input voltage, resistive load, temperature conditions until life; Figure Feature Descriptions.) Output Voltage Point max; °C): Unit Operating Parallel PARALLEL Shorted SENSE(-) (See Figure Feature Descriptions.) PARALLEL Open Output Regulation: Line Load max) Temperature Output Ripple Noise Voltage (See Figure Figure 9.): Peak-to-peak MHz) Output Current min, modules exceed output ripple specifications.): FC050S6R5 FC150S6R5 Output Current-limit Inception 5.85 Figure Feature Descriptions.) Output Short-circuit Current Figure External Load Capacitance (electrolytic, total unit multiple paralleled units): FC050S6R5 FC150S6R5 Efficiency max; Figure Figure Dynamic Response (IO/t A/10 Figure Figure 6.): Load Change from max: Peak Deviation Settling Time peak deviation) Load Change from max: Peak Deviation Settling Time peak deviation) Symbol 6.17 6.83 Unit
6.37
6.63
6.37
0.05
6.76
mVrms mVp-p
23.1
2200 5000
Tyco Electronics Corp.
FC050S6R5 FC150S6R5 Power Modules: dc-dc Converters; Input, Output;
Electrical Specifications (continued)
Table Isolation Specifications Parameter Isolation Capacitance Isolation Resistance 1700 Unit
General Specifications
Parameter Calculated MTBF max; Weight 2,000,000 Unit hours (oz.)
Feature Specifications
Unless otherwise indicated, specifications apply over operating input voltage, resistive load, temperature conditions. Feature Descriptions further information. Parameter Remote On/Off Signal Interface open collector equivalent compatible; signal referenced terminal; Figure Feature Descriptions.): Logic Low-Module Logic High-Module Logic Low: Ion/off Von/off Logic High: Ion/off Leakage Current Turn-on Time max; within 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 Symbol Unit
Von/off Ion/off Von/off Ion/off
clamp
%VO,
Tyco Electronics Corp.
FC050S6R5 FC150S6R5 Power Modules: dc-dc Converters; Input, Output;
Characteristic Curves
following figures provide typical characteristics FC150S6R5 Power Module. FC050S6R5 characteristics similar FC150S6R5 characteristics provided here, scaled power level where appropriate.
INPUT CURRENT,
INPUT VOLTAGE,
8-2097(C)
EFFICIENCY,
OUTPUT CURRENT,
8-1567(C)
Figure Typical FC150S6R5 Input Characteristics Room Temperature
Figure Typical FC150S6R5 Efficiency Output Current Room Temperature
OUTPUT VOLTAGE,
OUTPUT CURRENT,
8-1566(C)
Figure Typical FC150S6R5 Output Characteristics Room Temperature Input
Tyco Electronics Corp.
FC050S6R5 FC150S6R5 Power Modules: dc-dc Converters; Input, Output;
Characteristic Curves (continued)
OUTPUT VOLTAGE, (100 mV/div) OUTPUT CURRENT, A/div)
17.3 11.5
OUTPUT VOLTAGE, mV/div)
TIME, µs/div)
TIME, (500 ns/div)
8-1568(C) 8-1570(C)
Figure Typical FC150S6R5 Output Ripple Voltage Room Temperature, Input, 23.1 Output
Figure Typical FC150S6R5 Transient Response Step Increase Load from Full Load Room Temperature Input (Waveform Averaged Eliminate Ripple Component.)
OUTPUT CURRENT, A/div)
OUTPUT VOLTAGE, (100 mV/div)
11.5
TIME, µs/div)
8-1569(C)
Figure Typical FC150S6R5 Transient Response Step Decrease Load from Full Load Room Temperature Input (Waveform Averaged Eliminate Ripple Component.)
Tyco Electronics Corp.
FC050S6R5 FC150S6R5 Power Modules: dc-dc Converters; Input, Output;
Test Configurations
OSCILLOSCOPE LTEST CURRENT PROBE
Design Considerations
Input Source Impedance
power module should connected ac-impedance input source. Highly inductive source impedances affect stability power module. test configuration Figure electrolytic capacitor (ESR kHz) mounted close power module helps ensure stability unit. other highly inductive source impedances, consult factory further application guidelines.
BATTERY
8-203(C).l
Note: Measure input reflected-ripple current with simulated source inductance (LTEST) Capacitor offsets possible battery impedance. Measure current shown above.
Safety Considerations
safety-agency approval system which power module used, power module must installed compliance with spacing separation requirements end-use safety agency standard, i.e., UL-1950, 22.2-950, EN60950. converter output considered meeting requirements safety extra-low voltage (SELV), input must meet SELV requirements.
Figure Input Reflected-Ripple Test Setup
PARALLEL SENSE(+) SENSE(-) VO(+) VI(-) VO(-) CONTACT DISTRIBUTION LOSSES
8-683(C).c
VI(+) SUPPLY
LOAD
input meets extra-low voltage (ELV) requirements, then converter's output considered ELV. input these units provided with maximum normal-blow fuse ungrounded lead.
CONTACT RESISTANCE
Note: measurements taken module terminals. When socketing, place Kelvin connections module terminals avoid measurement errors socket contact resistance.
Electrical Descriptions
Current Limit
provide protection fault (output overload) condition, unit equipped with internal current-limiting circuitry endure current limiting unlimited duration. point current-limit inception, unit shifts from voltage control current control. output voltage pulled very during severe fault, current-limit circuit exhibit either foldback tailout characteristics (output-current decrease increase). unit operates normally once output current brought back into specified range.
[VO(+) VO(-)]IO Figure Output Voltage Efficiency Measurement Test Setup
COPPER STRIP SCOPE RESISTIVE LOAD
8-513(C)
Note: ceramic capacitor. Scope measurement should made using socket. Position load between in.) from module.
Figure Peak-to-Peak Output Noise Measurement Test Setup Tyco Electronics Corp.
FC050S6R5 FC150S6R5 Power Modules: dc-dc Converters; Input, Output;
Feature Descriptions
Remote On/Off
turn power module off, user must supply switch control voltage between on/off terminal VI(-) terminal (Von/off). switch open collector equivalent (see Figure 10). logic Von/off during which module maximum Ion/off during logic switch should maintain logic-low voltage while sinking During logic high, maximum Von/off generated power module maximum allowable leakage current switch Von/off using remote on/off feature, short ON/OFF VI(-).
PARALLEL SENSE(+) SENSE(-) VI(+) SUPPLY VI(-) CONTACT RESISTANCE VO(-) CONTACT DISTRIBUTION LOSSES
8-651(C).e
VO(+)
LOAD
Figure Effective Circuit Configuration Single-Module Remote-Sense Operation
Output Voltage Set-Point Adjustment (Trim)
When using trim feature, leave TRIM open. Adjustment with TRIM Output voltage adjustment allows output voltage point increased decreased adjusting external resistor connected between TRIM either SENSE(+) SENSE(-) pins (see Figure Figure 13). Connecting external resistor (Rtrim-up) between TRIM SENSE(-) pins (VO, adj) increases output voltage point defined following equation: 1.25 5.620 trim-up Connecting external resistor (Rtrim-down) between TRIM SENSE(+) pins (VO, adj) decreases output voltage point defined following equation: 1.25 5.620 trim-down
PARALLEL SENSE(+) CASE Ion/off ON/OFF SENSE(-) VO(+)
Von/off
VI(+) VO(-) VI(-)
8-580(C).b
Figure Remote On/Off Implementation
Remote Sense
Remote sense minimizes effects distribution losses regulating voltage remote-sense connections. single-unit operation, PARALLEL should connected SENSE(-). voltage between remote-sense pins output terminals must exceed output voltage sense range given Feature Specifications table, i.e.: [VO(+) VO(-)] [SENSE(+) SENSE(-)] voltage between VO(+) VO(-) terminals must exceed minimum output overvoltage clamp value shown Feature Specifications table. This limit includes increase voltage remote-sense compensation output voltage setpoint adjustment (trim), Figure using remote-sense feature regulate output point load, connect SENSE(+) VO(+) SENSE(-) VO(-) module.
voltage between VO(+) VO(-) terminals must exceed minimum output overvoltage clamp value shown Feature Specifications table. This limit includes increase voltage remote-sense compensation output voltage setpoint adjustment (trim), Figure
Tyco Electronics Corp.
FC050S6R5 FC150S6R5 Power Modules: dc-dc Converters; Input, Output; Forced Load Sharing (Parallel Operation)
either redundant operation additional power requirements, power modules configured parallel operation with forced load sharing (see Figure 15). typical redundant configuration, Schottky diodes equivalent should used protect against short-circuit conditions. Because remote sense, forward-voltage drops across Schottky diodes affect point voltage applied load. additional power requirements, where multiple units used develop combined power excess rated maximum, Schottky diodes needed. Good layout techniques should observed noise immunity. implement forced load sharing, following connections must made:
Feature Descriptions (continued)
Output Voltage Set-Point Adjustment (Trim) (continued)
Rtrim-up TRIM PARALLEL SENSE(+) SENSE(-) VI(+) SUPPLY VI(-) CONTACT RESISTANCE VO(+) VO(-) CONTACT DISTRIBUTION LOSSES
8-717(C).c
LOAD
Figure Circuit Configuration Trim Output Voltage
Rtrim-down TRIM PARALLEL SENSE(+) SENSE(-) VO(+) VI(-) CONTACT RESISTANCE VO(-) CONTACT DISTRIBUTION LOSSES
8-718(C).c
parallel pins units must connected together. paths these connections should direct possible. remote-sense pins should connected power same point, i.e., connect SENSE(+) pins side power same point SENSE(-) pins side power same point. Close proximity directness necessary good noise immunity.
VI(+) SUPPLY
LOAD
When using parallel feature, short PARALLEL SENSE(-).
PARALLEL SENSE(+) SENSE(-) CASE VO(+) ON/OFF VI(+) VO(-) VI(-)
Figure Circuit Configuration Trim Down Output Voltage Adjustment Without TRIM output voltage adjusted placing external resistor (Radj) between SENSE(+) VO(+) terminals (see Figure 14). adjusting Radj, output voltage increased nominal output voltage. equation below shows resistance required obtain desired output voltage. Radj (VO, nom) 944.3
PARALLEL SENSE(+) SENSE(-) VI(+) SUPPLY VI(-) CONTACT RESISTANCE VO(+) VO(-) CONTACT DISTRIBUTION LOSSES
8-710(C).c
PARALLEL SENSE(+) SENSE(-) CASE VO(+) ON/OFF VI(+) VO(-) VI(-)
8-581(C)
Radj
LOAD
Figure Wiring Configuration Redundant Parallel Operation
Figure Circuit Configuration Adjust Output Voltage Tyco Electronics Corp.
FC050S6R5 FC150S6R5 Power Modules: dc-dc Converters; Input, Output;
Feature Descriptions (continued)
Output Overvoltage Clamp
output overvoltage clamp consists control circuitry, independent primary regulation loop, that monitors voltage output terminals. control loop clamp higher voltage point than primary loop (see Feature Specifications table). This provides redundant voltage-control that reduces risk output overvoltage.
Heat Transfer Without Heat Sinks
Derating curves forced-air cooling without heat sink shown Figure These curves used determine appropriate airflow given operating conditions. example, unit dissipates heat, correct airflow environment (200 ft./min.).
POWER DISSIPATION,
(100 ft./min.) (200 ft./min.) (300 ft./min.) (400 ft./min.) (500 ft./min.) (600 ft./min.) (700 ft./min.) (800 ft./min.)
Thermal Considerations
Introduction
power modules operate variety thermal environments; however, sufficient cooling should provided help ensure reliable operation unit. Heat-dissipating components inside unit thermally coupled case. Heat removed conduction, convection, radiation surrounding environment. Proper cooling verified measuring case temperature. Peak temperature occurs position indicated Figure
(3.0) MEASURE CASE TEMPERATURE HERE
ft./min.) NATURAL CONVECTION
8-587(C)
LOCAL AMBIENT TEMPERATURE, (°C)
Figure Power Derating Local Ambient Temperature Velocity
Heat Transfer with Heat Sinks
power modules have threaded #4-40 fasteners, which enable heat sinks cold plates attached module. mounting torque must exceed 0.56 in.-lb.). Thermal derating with heat sinks expressed using overall thermal resistance module. Total module thermal resistance (ca) defined maximum case temperature rise (TC, max) divided module power dissipation (PD): location measure case temperature (TC) shown Figure Case-to-ambient thermal resistance airflow various heat sink configurations shown Figure Figure These curves were obtained experimental testing heat sinks, which offered product catalog.
(0.7)
Lucent
CASE ON/OFF
TRIM PARALLEL
FC150S6R59 DC-DC Power Module
IN:DC 28V, 6.5A MADE
SENSE
Rheinland
OUT:DC 6.5V, 23.1A 150W
Protected U.S. Paterts: 5,036,452 5,179,365
8-582(C).v
Note: view, measurements shown millimeters (inches). locations reference only.
Figure Case Temperature Measurement Location temperature this location should exceed maximum case temperature limited lower value extremely high reliability. output power module should exceed rated power module listed Ordering Information table. additional information about these modules, refer Thermal Management High-Power BoardMounted Power Modules Technical Note (TN97-009EPS).
Tyco Electronics Corp.
FC050S6R5 FC150S6R5 Power Modules: dc-dc Converters; Input, Output;
Thermal Considerations (continued)
Heat Transfer with Heat Sinks (continued)
(°C/W)
HEAT SINK CONV 0.25 HEAT SINK HEAT SINK HEAT SINK
POWER DISSIPATION,
OUTPUT CURRENT,
THERMAL RESISTANCE,
(100)
(200)
(300)
(400)
(500)
8-1571(C)
VELOCITY, (ft./min.)
8-696(C)
Figure Power Dissipation Heat Output Current Example case temperature desired, what minimum airflow necessary? Assume FC150S6R5 module operating nominal line output current maximum ambient temperature heat sink inch. Solution Given: Heat sink inch. Determine using Figure Then solve following equation:
Figure Heat Sink Resistance Curves; Fins Oriented Along Width
(°C/W)
HEAT SINK CONV 0.25 HEAT SINK HEAT SINK HEAT SINK
THERMAL RESISTANCE,
(100)
(200)
(300)
(400)
(500)
VELOCITY, (ft./min.)
8-697(C)
Figure Heat Sink Resistance Curves; Fins Oriented Along Length These measured resistances from heat transfer from sides bottom module well side with attached heat sink; therefore, case-to-ambient thermal resistances shown generally lower than resistance heat sink itself. module used collect data Figure Figure thermal-conductive between case heat sink minimize contact resistance. choose heat sink, determine power dissipated heat unit particular application. Figure shows typical heat dissipation range output currents three voltages FC050S6R5 FC150S6R5. Tyco Electronics Corp.
1.88 °C/W
Figure Figure determine velocity inch heat sink. minimum airflow necessary FC150S6R5 module depends heat sink orientation shown below:
ft./min.) (oriented along width) 0.45 ft./min.) (oriented along length)
FC050S6R5 FC150S6R5 Power Modules: dc-dc Converters; Input, Output;
Thermal Considerations (continued)
Custom Heat Sinks
more detailed model used determine required thermal resistance heat sink provide necessary cooling. total module resistance separated into resistance from case-to-sink (cs) sink-to-ambient (sa) shown Figure
managed interface using thermal grease foils, value °C/W °C/W typical. solution heat sink resistance This equation assumes that dissipated power must shed heat sink. Depending userdefined application environment, more accurate model, including heat transfer from sides bottom module, used. This equation provides conservative estimate such instances.
8-1304(C)
Layout Considerations
Copper paths must routed beneath power module standoffs.
Figure Resistance from Case-to-Sink Sinkto-Ambient
Tyco Electronics Corp.
FC050S6R5 FC150S6R5 Power Modules: dc-dc Converters; Input, Output;
Outline Diagram
Dimensions millimeters (inches). Tolerances: (x.xx 0.02 in.), x.xx 0.25 (x.xxx 0.010 in.) View
(0.21)
121.9 (4.80)
Lucent
52.83 (2.080) 63.5 (2.50)
CASE ON/OFF
TRIM PARALLEL
TRIM OPTION ONLY
FC150S6R59 DC-DC Power Module
IN:DC 28V, 6.5A OUT:DC 6.5V, 23.1A 150W
SENSE
MADE Protected U.S. Patents: 5,036,452 5,179,365
Rheinland
(0.21)
55.63 (2.190)
55.63 (2.190)
OPTIONAL HEAT SINK MOUNTING #4-40 (0.18) DEEP PLCS
Side View
12.7 (0.50) 1.57 (0.062) 0.05 (0.002) TIN-PLATED BRASS PLCS
(0.04)
(0.16
(0.15) PLCS
Bottom View
(0.17) 5.08 (0.200) 10.16 (0.400) 113.54 (4.470) 12.2 (0.48) 20.32 (0.800) 25.40 30.48 (1.000) (1.200) 35.56 (1.400)
15.24 (0.600)
TRIM OPTION ONLY
8-719(C).v
Tyco Electronics Corp.
FC050S6R5 FC150S6R5 Power Modules: dc-dc Converters; Input, Output;
Recommended Hole Pattern
Component-side footprint. Dimensions millimeters (inches).
TRIM OPTION ONLY
15.24 (0.600)
TRIM PARALLEL SENSE CASE
10.16 (0.400) 5.08 (0.200) (0.17)
ON/OFF
35.56 30.48 (1.400) 25.40 (1.200) 20.32 (1.000) (0.800) 12.2 (0.48)
113.54 (4.470)
8-719(C).v
Ordering Information
This family modules recommended designs. designs, recommend family power modules. Please refer Power Systems Selection Guide individual data sheets. Please contact your Tyco Electronics' Account Manager Field Application Engineer pricing availability. Optional TRIM designated ending device code name. Input Voltage Output Voltage Output Power Trim Device Code FC050S6R59 FC150S6R59 FC050S6R5 FC150S6R5 Comcode Available Available 106949837 106793987
Tyco Electronics Corp.
FC050S6R5 FC150S6R5 Power Modules: dc-dc Converters; Input, Output;
Notes
Tyco Electronics Corp.
FC050S6R5 FC150S6R5 Power Modules: dc-dc Converters; Input, Output;
Tyco Electronics Power Systems, Inc. 3000 Skyline Drive, Mesquite, 75149, +1-800-526-7819 FAX: +1-888-315-5182 (Outside U.S.A.: +1-972-284-2626, FAX: +1-972-284-2900
Tyco Electronics Corportation reserves right make changes product(s) information contained herein without notice. liability assumed result their application. rights under patent accompany sale such product(s) information. 2001 Tyco Electronics Corporation, Harrisburg, International Rights Reserved. Printed U.S.A.
1998 DS97-523EPS
Printed Recycled Paper
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