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MR2502, MR2504, MR2510
MR2504 and MR2510 are Preferred Devices
Medium-Current Silicon Rectifiers
. . . compact, highly efficient silicon rectifiers for medium-current applications requiring:
* High Current Surge -- 400 Amperes @ TJ = 175C * Peak Performance @ Elevated Temperature -- 25 Amperes @ * Low Cost * Compact, Molded Package -- For Optimum Efficiency in a Small
Case Configuration
Mechanical Characteristics:
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TC = 150C
* Case: Epoxy, Molded * Weight: 1.8 grams (approximately) * Finish: All External Surfaces Corrosion Resistant and Terminals are * Lead Temperature for Soldering Purposes: requires a custom * *
temperature soldering profile Polarity: Cathode Polarity Band Shipped 5000 units per box Readily Solderable
MEDIUM-CURRENT SILICON RECTIFIERS 25 AMPERES 200-1000 VOLTS DIFFUSED JUNCTION
MICRODE BUTTON CASE 193
MAXIMUM RATINGS
Please See the Table on the Following Page
MARKING DIAGRAM
MR25xx LYYWW
MR25xx = Device Code xx = 02, 04 or 10 L = Location Code YY = Year WW = Work Week
ORDERING INFORMATION
Device MR2502 MR2504 MR2510 Package Microde Button Microde Button Microde Button Shipping 5000 Units/Box 5000 Units/Box 5000 Units/Box
Preferred devices are recommended choices for future use and best overall value.
(c) Semiconductor Components Industries, LLC, 2000
1
October, 2000 - Rev. 3
Publication Order Number: MR2500/D
MR2502, MR2504, MR2510
MAXIMUM RATINGS
Characteristic Peak Repetitive Reverse Voltage Working Peak Reverse Voltage DC Blocking Voltage Non-Repetitive Peak Reverse Voltage (Halfwave, single phase, 60 Hz peak) Average Rectified Forward Current (Single phase, resistive load, 60 Hz, TC = 150C) Non-Repetitive Peak Surge Current (Surge applied at rated load conditions, halfwave, single phase, 60 Hz) Operating and Storage Junction Temperature Range Symbol VRRM VRWM VR VRSM IO IFSM MR2502 200 MR2504 400 MR2510 1000 Unit Volts
240
480 25 400 (for 1 cycle)
1200
Volts Amps Amps
TJ, Tstg
*65 to +175
C
THERMAL CHARACTERISTICS
Characteristic Thermal Resistance, Junction to Case (Single Side Cooled) Symbol RJC Max 1.0 Unit C/W
ELECTRICAL CHARACTERISTICS
Characteristics and Conditions Maximum Instantaneous Forward Voltage (iF = 78.5 Amps, TC = 25C) Maximum Reverse Current (rated dc voltage) TC = 25C TC = 100C Symbol vF IR 100 500 Max 1.18 Unit Volts A
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MR2502, MR2504, MR2510
IFSM , PEAK HALF WAVE CURRENT (AMP) 700 500 300 200 TJ = 25C TYPICAL MAXIMUM 600 400 300 200 TJ = 175C VRRM MAY BE APPLIED BETWEEN EACH CYCLE OF SURGE. THE TJ NOTED IS TJ PRIOR TO SURGE f = 60 Hz 25C
iF, INSTANTANEOUS FORWARD CURRENT (AMP)
100 70 50 30 20
100 80 60 1.0 2.0
1 CYCLE
5.0
10
20
50
100
NUMBER OF CYCLES
10 7.0 5.0 3.0 2.0 COEFFICIENT (mV/ C) +0.5 0 -0.5
Figure 2. Non-Repetitive Surge Current
1.0 0.7 0.5 0.3 0.2 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6
TYPICAL RANGE -1.0 -1.5 -2.0
0.2
0.5
1.0
2.0
5.0
10
20
50
100
200
vF, INSTANTANEOUS FORWARD VOLTAGE (VOLTS)
iF, INSTANTANEOUS FORWARD CURRENT (AMP)
Figure 1. Forward Voltage
Figure 3. Forward Voltage Temperature Coefficient
PF(AV) , AVERAGE POWER DISSIPATION (WATTS) 50 40 30 20 10 0
I F(AV) , AVERAGE FORWARD CURRENT (AMP)
50 40 30 20 10 0 125
dc
I
(FM) + p (Sine Wave Resistive Load) I (AV)
SINE WAVE CAPACITIVE LOADS
I
(FM) + 20 I (AV)
10
5.0
dc
SQUARE WAVE SINE WAVE RESISTIVE LOAD
Capacitive Loads 130 135
5.0 10 20 145 150 155 160 165 170 175
140
0
10
20
30
40
50
TC, CASE TEMPERATURE (C)
IF(AV), AVERAGE FORWARD CURRENT (AMP)
Figure 4. Current Derating
Figure 5. Forward Power Dissipation
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MR2502, MR2504, MR2510
r(t), TRANSIENT THERMAL RESISTANCE (NORMALIZED) 1.0 0.7 0.5 0.3 0.2 0.1 0.07 0.05 0.03 0.02 0.01 0.05 0.07 0.1 0.2 0.3 0.5 0.7 1.0 2.0 3.0 5.0 7.0 10 20 30 50 70 100 200 300 500 RqJC(t) = RqJC * r(t) NOTE 1
t, TIME (ms)
Figure 6. Thermal Response
Ppk tp t1 Ppk DUTY CYCLE, D = tp/t1 PEAK POWER, Ppk, is peak of an equivalent square power pulse. TIME
500 300 C, CAPACITANCE (pF) 200 ALL DEVICES ALL DEVICES EXCEPT MR2500 TJ = 25C
To determine maximum junction temperature of the diode in a given situation, the following procedure is recommended: The temperature of the case should be measured using a thermocouple placed on the case at the temperature reference point (see the outline drawing on page 1). The thermal mass connected to the case is normally large enough so that it will not significantly respond to heat surges generated in the diode as a result of pulsed operation once steady-state conditions are achieved. Using the measured value of T C , the junction temperature may be determined by: TJ = TC + n TJC where n TJC is the increase in junction temperature above the case temperature, it may be determined by: n TJC = Ppk@RJC [D + (1 * D)@r(t1 + tp) + r(tp) *r(t1)] where r(t) = normalized value of transient thermal resistance at time, t, from Figure 6, i.e.: r (t1 + tp) = normalized value of transient thermal resistance at time t1 + tp. 1.0 t fr , FORWARD RECOVERY TIME ( m s) 0.7 0.5 tfr 0.3 0.2 2.0 V 0.1
100 70 50 0.1 0.2
0.5
1.0
2.0
5.0
10
20
50
100
VR, REVERSE VOLTAGE (VOLTS)
Figure 7. Capacitance
TJ = 25C uf ufr t rr , REVERSE RECOVERY TIME ( m s) ufr = 1.0 V
20 IF 0 IF = 10 A IR trr
TJ = 25C
10 7.0 5.0 3.0 2.0
0.25 IR
1.0 A 5.0 A
1.0
2.0
3.0
5.0
7.0
10
1.0
0.1
0.2
0.3
0.5 0.7 1.0
2.0
3.0
5.0 7.0 10
IF, FORWARD CURRENT (AMP)
IR/IF, RATIO OF REVERSE TO FORWARD CURRENT
Figure 8. Forward Recovery Time
Figure 9. Reverse Recovery Time
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MR2502, MR2504, MR2510
60 40 s, EFFICIENCY FACTOR TJ = 25C
20
CURRENT INPUT WAVEFORM
10 8.0 6.0 1.0 2.0 3.0 5.0 7.0 10 20 30 50 70 100
f, FREQUENCY (kHz)
Figure 10. Rectification Waveform Efficiency
RECTIFICATION EFFICIENCY NOTE
RS RL VO
Figure 11. Single-Phase Half-Wave Rectifier Circuit
The rectification efficiency factor shown in Figure 10 was calculated using the formula:
V2o(dc) RL RL (1) V 2o (dc) .100% 2o (ac) ) V 2o (dc) V
For a square wave input of amplitude Vm, the efficiency factor becomes:
V 2m 2R L (square) + V 2m .100% + 50% RL
+
P (dc) P (rms)
+ V2o(rms) .100% +
(3)
For a sine wave input Vm sin (t) to the diode, assume lossless, the maximum theoretical efficiency factor becomes:
V2m p 2R L (sine) + V2m .100% + 4 .100% + 40.6% 2 4R L
(2)
(A full wave circuit has twice these efficiencies) As the frequency of the input signal is increased, the reverse recovery time of the diode (Figure 9) becomes significant, resulting in an increasing ac voltage component across RL which is opposite in polarity to the forward current, thereby reducing the value of the efficiency factor , as shown on Figure 10. It should be emphasized that Figure 10 shows waveform efficiency only; it does not provide a measure of diode losses. Data was obtained by measuring the ac component of VO with a true rms ac voltmeter and the dc component with a dc voltmeter. The data was used in Equation 1 to obtain points for Figure 10.
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MR2502, MR2504, MR2510
ASSEMBLY AND SOLDERING INFORMATION
There are two basic areas of consideration for successful implementation of button rectifiers: 1. Mounting and Handling 2. Soldering each should be carefully examined before attempting a finished assembly or mounting operation.
MOUNTING AND HANDLING
Exceeding these recommended maximums can result in electrical degradation of the device.
SOLDERING
The button rectifier lends itself to a multitude of assembly arrangements but one key consideration must always be included:
One Side of the Connections to the Button Must Be Flexible!
Strain Relief Terminal for Button Rectifier Copper Terminal Button Base (Heat Sink Material)
This stress relief to the button should also be chosen for maximum contact area to afford the best heat transfer -- but not at the expense of flexibility. For an annealed copper terminal a thickness of 0.015 is suggested.
The base heat sink may be of various materials whose shape and size are a function of the individual application and the heat transfer requirements.
Common Materials Advantages and Disadvantages
Steel Copper Aluminum
Low Cost; relatively low heat conductivity High Cost; high heat conductivity Medium Cost; medium heat conductivity Relatively expensive to plate and not all platers can process aluminum. Handling of the button during assembly must be relatively gentle to minimize sharp impact shocks and avoid nicking of the plastic. Improperly designed automatic handling equipment is the worst source of unnecessary shocks. Techniques for vacuum handling and spring loading should be investigated. The mechanical stress limits for the button diode are as follows: Compression 32 lbs. 142.3 Newton Tension 32 lbs. 142.3 Newton Torsion 6-inch lbs. 0.68 Newton-meters Shear 55 lbs. 244.7 Newton MECHANICAL STRESS
COMPRESSION
The button rectifier is basically a semiconductor chip bonded between two nickel-plated copper heat sinks with an encapsulating material of thermal-setting silicone. The exposed metal areas are also tin plated to enhance solderability. In the soldering process it is important that the temperature not exceed 250C if device damage is to be avoided. Various solder alloys can be used for this operation but two types are recommended for best results: 1. 95% Sn, 5% Sb; melting point 237C 2. 96.5% tin, 3.5% silver; melting point 221C 3. 63% tin, 37% lead; melting point 183C Solder is available as preforms or paste. The paste contains both the metal and flux and can be dispensed rapidly. The solder preform requires the application of a flux to assure good wetting of the solder. The type of flux used depends upon the degree of cleaning to be accomplished and is a function of the metals involved. These fluxes range from a mild rosin to a strong acid; e.g., Nickel plating oxides are best removed by an acid base flux while an activated rosin flux may be sufficient for tin plated parts. Since the button is relatively light-weight, there is a tendency for it to float when the solder becomes liquid. To prevent bad joints and misalignment it is suggested that a weighting or spring loaded fixture be employed. It is also important that severe thermal shock (either heating or cooling) be avoided as it may lead to damage of the die or encapsulant of the part. Button holding fixtures for use during soldering may be of various materials. Stainless steel has a longer use life while black anodized aluminum is less expensive and will limit heat reflection and enhance absorption. The assembly volume will influence the choice of materials. Fixture dimension tolerances for locating the button must allow for expansion during soldering as well as allowing for button clearance.
HEATING TECHNIQUES
TORSION
TENSION
SHEAR
The following four heating methods have their advantages and disadvantages depending on volume of buttons to be soldered. 1. Belt Furnaces readily handle large or small volumes and are adaptable to establishment of "on-line'' assembly since a variable belt speed sets the run rate. Individual furnace zone controls make excellent temperature control possible. 2. Flame Soldering involves the directing of natural gas flame jets at the base of a heatsink as the heatsink is indexed to various loading-heating-cooling-unloading positions. This is the most economical labor method of soldering large volumes. Flame soldering offers good temperature control but requires sophisticated temperature monitoring systems such as infrared.
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MR2502, MR2504, MR2510
ASSEMBLY AND SOLDERING INFORMATION (continued)
3. Ovens are good for batch soldering and are production limited. There are handling problems because of slow cooling. Response time is load dependent, being a function of the watt rating of the oven and the mass of parts. Large ovens may not give an acceptable temperature gradient. Capital cost is low compared to belt furnaces and flame soldering. 4. Hot Plates are good for soldering small quantities of prototype devices. Temperature control is fair with overshoot common because of the exposed heating surface. Solder flow and positioning can be corrected during soldering since the assembly is exposed. Investment cost is very low. Regardless of the heating method used, a soldering profile giving the time-temperature relationship of the particular method must be determined to assure proper soldering. Profiling must be performed on a scheduled basis to minimize poor soldering. The time-temperature relationship will change depending on the heating method used.
SOLDER PROCESS EVALUATION
1. Peeling or plating separation is generally seen when a button is broken away for solder inspection. If heatsink or terminal base metal is present the plating is poor and must be corrected. 2. Thin plating allows the solder to penetrate through to the base metal and can give a poor connection. A suggested minimum plating thickness is 300 microinches. 3. Contaminated soldering surfaces may out-gas and cause non-wetting resulting in voids in the solder connection. The exact cause is not always readily apparent and can be because of: (a) improper plating (b) mishandling of parts (c) improper and/or excessive storage time
SOLDER PROCESS MONITORING
Characteristics to look for when setting up the soldering process: I Overtemperature is indicated by any one or all three of the following observations. 1. Remelting of the solder inside the button rectifier shows the temperature has exceeded 285C and is noted by "islands'' of shiny solder and solder dewetting when a unit is broken apart. 2. Cracked die inside the button may be observed by a moving reverse oscilloscope trace when pressure is applied to the unit. 3. Cracked plastic may be caused by thermal shock as well as overtemperature so cooling rate should also be checked. II Cold soldering gives a grainy appearance and solder build-up without a smooth continuous solder fillet. The temperature must be adjusted until the proper solder fillet is obtained within the maximum temperature limits. III Incomplete solder fillets result from insufficient solder or parts not making proper contact. IVTilted buttons can cause a void in the solder between the heatsink and button rectifier which will result in poor heat transfer during operation. An eight degree tilt is a suggested maximum value. V Plating problems require a knowledge of plating operations for complete understanding of observed deficiencies.
Continuous monitoring of the soldering process must be established to minimize potential problems. All parts used in the soldering operation should be sampled on a lot by lot basis by assembly of a controlled sample. Evaluate the control sample by break-apart tests to view the solder connections, by physical strength tests and by dimensional characteristics for part mating. A shear test is a suggested way of testing the solder bond strength.
POST SOLDERING OPERATION CONSIDERATIONS
After soldering, the completed assembly must be unloaded, washed and inspected. Unloading must be done carefully to avoid unnecessary stress. Assembly fixtures should be cooled to room temperature so solder profiles are not affected. Washing is mandatory if an acid flux is used because of its ionic and corrosive nature. Wash the assemblies in agitated hot water and detergent for three to five minutes. After washing; rinse, blow off excessive water and bake 30 minutes at 150C to remove trapped moisture. Inspection should be both electrical and physical. Any rejects can be reworked as required.
SUMMARY
The Button Rectifier is an excellent building block for specialized applications. The prime example of its use is the output bridge of the automative alternator where millions are used each year. Although the material presented here is not all inclusive, primary considerations for use are presented. For further information, contact the nearest ON Semiconductor Sales Office or franchised distributor.
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MR2502, MR2504, MR2510
PACKAGE DIMENSIONS
MICRODE BUTTON CASE 193-04 ISSUE J
A
DIM A B D F M
MILLIMETERS MIN MAX 8.43 8.69 4.19 4.45 5.54 5.64 5.94 6.25 5 _NOM
INCHES MIN MAX 0.332 0.342 0.165 0.175 0.218 0.222 0.234 0.246 5 _NOM
M D B F
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PUBLICATION ORDERING INFORMATION
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