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data sheet may 1999 FC250R power module: dc-dc converter; 18 vdc to 36 vdc input, 28 vdc output; 250 w the FC250R power module uses advanced, surface-mount technology and delivers high-quality, compact, dc-dc conversion at an economical price. applications n redundant and/or distributed power architectures n workstations n edp equipment n telecommunication options n heat sinks available for extended operation n choice of primary remote on/off logic con?ura- tions features n size: 61.0 mm x 116.8 mm x 13.5 mm (2.40 in. x 4.60 in. x 0.53 in.) n wide input voltage range n high ef?iency: 88% typical n parallel operation with load sharing n adjustable output voltage n thermal protection n synchronization n power good signal n current monitor n output overvoltage and overcurrent protection n constant frequency n case ground pin n input-to-output isolation n remote sense n remote on/off n short-circuit protection n output overvoltage clamp n iso9001 certi?d manufacturing facilities n ul* 1950 recognized, csa ? c22.2 no. 950-95 certi?d, and vde 0805 (en60950, iec950) licensed description the FC250R power module is a dc-dc converter that operates over an input voltage range of 18 vdc to 36 vdc and provides a precisely regulated dc output. the outputs are fully isolated from the inputs, allowing versatile polarity con?urations and grounding connections. the module has a maximum power rating of 250 w at a typ- ical full-load ef?iency of 88%. 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. * ul is a registered trademark of underwriters laboratories, inc. ? csa is a registered trademark of canadian standards association.
2 tyco electronics corp. data sheet may 1999 dc-dc converter; 18 vdc to 36 vdc input, 28 vdc output; 250 w FC250R power module: absolute maximum ratings stresses in excess of the absolute maximum ratings can cause permanent damage to the device. these are abso- lute 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. electrical speci?ations unless otherwise indicated, speci?ations apply over all operating input voltage, resistive load, and temperature conditions. table 1. input speci?ations 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 ?xibility, internal fus- ing is not included; however, to achieve maximum safety and system protection, always use an input line fuse. the safety agencies require a normal-blow fuse with a maximum rating of 25 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 manufacturers data for further information. parameter symbol min max unit input voltage continuous v i 50 vdc i/o isolation voltage 1500 v operating case temperature (see thermal considerations section and figure 18.) t c ?0 100 ? storage temperature t stg ?5 125 ? parameter symbol min typ max unit operating input voltage v i 18 28 36 vdc maximum input current (v i = 0 v to 36 v) i i, max 22 a inrush transient i 2 t 4.0 a 2 s input re?cted-ripple current, peak-to-peak (5 hz to 20 mhz, 12 ? source impedance; see figure 8.) 10 map-p input ripple rejection (120 hz) 60 db
tyco electronics corp. 3 data sheet may 1999 dc-dc converter; 18 vdc to 36 vdc input, 28 vdc output; 250 w FC250R power module: electrical speci?ations (continued) table 2. output speci?ations * these are manufacturing test limits. in some situations, results may differ. ? please consult your sales representative or the factory. table 3. isolation speci?ations parameter symbol min typ max unit output voltage set point (v i = 28 v; i o = i o, max ; t c = 25 ?) v o, set 27.45 28.0 28.55 vdc output voltage (over all operating input voltage, resistive load, and temperature conditions until end of life; see figure 9 and feature descriptions.) v o 27.16 28.84 vdc output regulation: line (v i = 18 v to 36 v) load (i o = i o, min to i o, max ) temperature (t c = ?0 ? to +100 ?) 0.01 0.05 100 0.1 0.2 300 % % mv output ripple and noise voltage (see figures 4 and 10.): rms peak-to-peak (5 hz to 20 mhz) 50 100 mvrms mvp-p output current (at i o < i o, min , the modules may exceed output ripple speci?ations.) i o 0.3 9.0 a output current-limit inception (v o = 90% of v o, set ; see feature descriptions.) i o, cli 103* 130* % i o, max output short-circuit current (v o = 1.0 v; inde?ite duration, no hiccup mode; see figure 2.) 150 % i o, max external load capacitance (total for one unit or multiple paralleled units) 330 ? ? ef?iency (v i = 28 v; i o = i o, max ; t c = 25 ?; see figures 3 and 9.) h ?8 % switching frequency 500 khz dynamic response ( d i o / d t = 1 a/10 ?, v i = 28 v, t c = 25 ? (tested with a 330 ? aluminum and a 1.0 ? ceramic capacitor across the load); see figures 5 and 6.): load change from i o = 50% to 75% of i o, max : peak deviation settling time (v o < 10% of peak deviation) load change from i o = 50% to 25% of i o, max : peak deviation settling time (v o < 10% of peak deviation) 300 250 400 250 mv ? mv ? parameter min typ max unit isolation capacitance 1700 pf isolation resistance 10 m w
4 tyco electronics corp. data sheet may 1999 dc-dc converter; 18 vdc to 36 vdc input, 28 vdc output; 250 w FC250R power module: general speci?ations feature speci?ations unless otherwise indicated, speci?ations apply over all operating input voltage, resistive load, and temperature conditions. see feature descriptions for further information. * these are manufacturing test limits. in some situations, results may differ. parameter min typ max unit calculated mtbf (i o = 80% of i o, max ; t c = 40 ?) 1,800,000 hours weight 200 (7) g (oz.) parameter symbol min typ max unit remote on/off signal interface (v i = 0 v to 36 v; open collector or equivalent compatible; signal referenced to v i (? terminal; see figure 11 and feature descriptions.): logic low?odule on logic high?odule off logic low: at i on/off = 1.0 ma at v on/off = 0.0 v logic high: at i on/off = 0.0 ? leakage current turn-on time (i o = 80% of i o, max ; v o within ?% of steady state) output voltage overshoot v on/off i on/off v on/off i on/off 0 50 0 1.2 1.0 15 50 100 5 v ma v ? ms %v o, set output voltage adjustment (see feature descriptions.): note: do not allow the combination of remote-sense and trim to exceed 28.5 v on the output. output voltage remote-sense range output voltage set-point adjustment range (trim) 60 0.5 102 v %v o, nom output overvoltage protection (shutdown) 30.9 37.0 v output current monitor (i o = i o , max , t c = 70 ?) i o, mon 0.34* 0.40 0.45* v/a synchronization: clock amplitude clock pulse width fan-out capture frequency range 4.00 0.4 450 5.00 1 550 v ? khz overtemperature shutdown (see figure 18.) t c 105 c current share accuracy 10 %i o, rated power good signal interface (see feature descriptions.): low impedance?odule operating high impedance?odule off r pwr/good i pwr/good r pwr/good v pwr/good 1 100 1 40 w ma m w v
tyco electronics corp. 5 data sheet may 1999 dc-dc converter; 18 vdc to 36 vdc input, 28 vdc output; 250 w FC250R power module: characteristic curves the following ?ures provide typical characteristics for the power module. 8-2175 (c) figure 1. typical FC250R input characteristics at room temperature, i o = full load 8-2176 (c) figure 2. typical FC250R output characteristics at room temperature 8-1667 (c) figure 3. typical FC250R ef?iency vs. output current at room temperature 8-1668 (c) figure 4. typical FC250R output ripple voltage at room temperature and 9 a output 5 10 15 25 20 30 0 12 input voltage, v i ( v ) 8 6 10 35 16 4 0 0 14 4 2 input current, i i (a) i o = 0.89 a i o = 8.93 a 18 i o = 4.47 a ouput voltage, v o (v) 24 6810 0 15 output current, i o ( a ) 10 20 1 4 0 5 12 25 30 v i = 18 v v i = 28 v v i = 36 v 87 83 1 2 3 5 4 6 80 86 output current, i o (a) 84 85 82 81 78 0 88 efficiency, (%) v i = 36 v v i = 24 v v i = 18 v time, t ( 500 ns/div ) output voltage, v o (v) (50 mv/div) v i = 24 v v i = 18 v v i = 36 v
6 6 tyco electronics corp. data sheet may 1999 dc-dc converter; 18 vdc to 36 vdc input, 28 vdc output; 250 w FC250R power module: characteristic curves (continued) 8-1669 (c) note: tested with a 330 ? aluminum and a 1.0 ? ceramic capacitor across the load. figure 5. typical FC250R 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.) 8-1670 (c) note: tested with a 330 ? aluminum and a 1.0 ? ceramic capacitor across the load. figure 6. typical FC250R 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.) 8-2177 (c) note: tested with a 330 ? aluminum and a 1.0 ? ceramic capacitor across the load. figure 7. typical FC250R start-up transient at room temperature, 28 v input, and full load time, t (50 ?/div) output voltage, v o (v) (200 mv/div) output current, i o (a) (1 a/div) 2.25 28.0 4.50 time, t (50 ?/div) output voltage, v o (v) (200 mv/div) output current, i o (a) (1 a/div) 6.75 28.0 4.50 time, t (20 ms/div) remote on/off voltage, v on/off (v) output voltage, v o (v) (10 v/div) 0 v 28 v
tyco electronics corp. 7 data sheet may 1999 dc-dc converter; 18 vdc to 36 vdc input, 28 vdc output; 250 w FC250R power module: test con?urations 8-203 (c).o note: measure input re?cted-ripple current with a simulated source inductance (l test ) of 12 ?. capacitor c s offsets possible bat- tery impedance. measure current as shown above. figure 8. input re?cted-ripple test setup 8-683 (c).f note: all measurements are taken at the module terminals. when socketing, place kelvin connections at module terminals to avoid measurement errors due to socket contact resistance. figure 9. output voltage and ef?iency measurement test setup 8-513 (c).n note: use a 0.1 ? ceramic capacitor and a 330 ? aluminum or tantalum capacitor. the 330 ? capacitor is needed for stability. scope measurement should be made using a bnc socket. position the load between 50 mm and 76 mm (2 in. and 3 in.) from the module. figure 10. peak-to-peak output noise measurement test setup design considerations input source impedance the power module should be connected to a low ac-impedance input source. highly inductive source impedances can affect the stability of the power mod- ule. for the test con?uration in figure 8, a 100 ? electrolytic capacitor (esr < 0.3 w at 100 khz) mounted close to the power module helps ensure sta- bility of the unit. for other highly inductive source impedances, consult the factory for further application guidelines. 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, csa c22.2 no. 950-95, and vde 0805 (en60950, iec950). for the converter output to be considered meeting the requirements of safety extra-low voltage (selv), the input must meet selv requirements. the power module has extra-low voltage (elv) outputs when all inputs are elv. the input to these units is to be provided with a maxi- mum 25 a normal-blow fuse in the ungrounded lead. feature descriptions overcurrent protection to provide protection in a fault (output overload) condi- tion, the unit is equipped with internal current-limiting circuitry and can endure current limiting for an unlim- ited 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 speci?d range. to oscilloscope 12 ? v i (+) v i (? battery l test cs 220 ? esr < 0.1 w @ 20 c, 100 khz 100 ? esr < 0.3 w @ 100 khz v i (? v o (+) sense(+) sense(? v o (? v i (+) i o load contact and distribution losses supply i i contact resistance h v o + () v o () [] i o v i + () v i () [] i i ------------------------------------------------- - ? ?? x 100 % = v o (+) v o (? 1.0 ? resistive load scope copper strip 330 ?
8 8 tyco electronics corp. data sheet may 1999 dc-dc converter; 18 vdc to 36 vdc input, 28 vdc output; 250 w FC250R power module: feature descriptions (continued) 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 v i (? terminal (v on/off ). the switch can be an open collector or equivalent (see figure 11). a logic low is v on/off = 0 v to 1.2 v, during which the module is on. the maximum i on/off during a logic low is 1 ma. the switch should maintain a logic-low voltage while sinking 1 ma. during a logic high, the maximum v on/off generated by the power module is 15 v. the maximum allowable leakage current of the switch at v on/off = 15 v is 50 ?. if not using the remote on/off feature, short the on/off pin to v i (?. 8-580 (c).d figure 11. remote on/off implementation remote sense remote sense minimizes the effects of distribution losses by regulating the voltage at the remote-sense connections. the voltage between the remote-sense pins and the output terminals must not exceed the out- put voltage sense range given in the feature speci?a- tions table, i.e.: [v o (+) ?v o (?] ?[sense(+) ?sense(?] 0.5 v the voltage between the v o (+) and v o (? terminals must not exceed the minimum value indicated in the output overvoltage shutdown section of the feature speci?ations table. this limit includes any increase in voltage due to remote-sense compensation and output voltage set-point adjustment (trim), see figure 12. if not using the remote-sense feature to regulate the out- put at the point of load, connect sense(+) to v o (+) and sense(? to v o (? at the module. 8-651 (c).e figure 12. effective circuit con?uration for single-module remote-sense operation output voltage set-point adjustment (trim) output voltage trim allows the user to increase or decrease the output voltage set point of a module. this is accomplished by connecting an external resistor between the trim pin and either the sense(+) or sense(? pins. the trim resistor should be posi- tioned close to the module. if not using the trim feature, leave the trim pin open. with an external resistor between the trim and sense(? pins (r adj-down ), the output voltage set point (v o , adj ) decreases (see figure 13). the following equa- tion determines the required external-resistor value to obtain a percentage output voltage change of d %. the test results for this con?uration are displayed in figure 14. this ?ure applies to all output voltages. with an external resistor connected between the trim and sense(+) pins (r adj-up ), the output voltage set point (v o , adj ) increases (see figure 15). note: the output voltage of this module may be increased to a maximum of 0.5 v. the 0.5 v is the combination of both the remote sense and the output voltage set-point adjustment (trim). do not exceed 28.5 v between the v o (+) and v o (? terminals. the following equation determines the required exter- nal-resistor value to obtain a percentage output voltage change of d %. only trim up to 0.5 v maximum; see note above. + i on/off v on/off case on/off v i (+) v i (? sense(+) sense(? v o (+) v o (? v o (+) sense(+) sense(? v o (? v i (+) v i (? i o load contact and distribution losses supply i i contact resistance r adj-down 205 d % --------- - 2.255 ? ?? k w = radj-up v o 100 d % + () 1.225 d % -------------------------------------- - 100 2 d % + () d % --------------------------------- - ? ?? = k w
tyco electronics corp. 9 data sheet may 1999 dc-dc converter; 18 vdc to 36 vdc input, 28 vdc output; 250 w FC250R power module: feature descriptions (continued) output voltage set-point adjustment (trim) (continued) the test results for this con?uration are displayed in figure 15. 8-748 (c).b figure 13. circuit con?uration to decrease output voltage 8-1933 (c) figure 14. resistor selection for decreased output voltage 8-715 (c).b figure 15. circuit con?uration to increase output voltage 8-2178 (c) figure 16. resistor selection for increased output voltage output overvoltage protection the output voltage is monitored at the v o (+) and v o (? pins of the module. if the voltage at these pins exceeds the value indicated in the feature speci?ations table, the module will shut down and latch off. recovery from latched shutdown is accomplished by cycling the dc input power off for at least 1.0 s or toggling the primary referenced on/off signal for at least 1.0 s. v i (+) v i (? on/off case v o (+) v o (? sense(+) trim sense(? r adj-down r load 10 20 30 1 10 percent change in output voltage ( d % ) adjustment resistor value ( w ) 10k 4 0 0 100 1k v i (+) v i (? on/off case v o (+) v o (? sense(+) trim sense(? r adj-up r load 0.4 0.8 1.2 1.6 2.0 1m 10m 0.0 100m adjustment resistor value ( w ) % change in output voltage ( d %)
10 10 tyco electronics corp. data sheet may 1999 dc-dc converter; 18 vdc to 36 vdc input, 28 vdc output; 250 w FC250R power module: feature descriptions (continued) output current monitor the current mon pin provides a dc voltage propor- tional to the dc output current of the module given in the feature speci?ations table. for example, on the FC250R, the v/a ratio is set at 370 mv/a 10% @ 70 c case. at a full load current of 9.0 a, the voltage on the current mon pin is 3.33 v. the current mon- itor signal is referenced to the sense(? pin on the secondary and is supplied from a source impedance of approximately 2 k w . it is recommended that the cur- rent mon pin be left open when not in use, although no damage will result if the current mon pin is shorted to secondary ground. directly driving the cur- rent mon pin with an external source will detrimen- tally affect operation of the module and should be avoided. synchronization any module can be synchronized to any other module or to an external clock using the sync in or sync out pins. the modules are not designed to operate in a master/slave con?uration; that is, if one module fails, the other modules will continue to operate. sync in pin this pin can be connected either to an external clock or directly to the sync out pin of another fc250x mod- ule. if an external clock signal is applied to the sync in pin, the signal must be a 500 khz (?0 khz) square wave with a 4 vp-p amplitude. operation outside this frequency band will detrimentally affect the perfor- mance of the module and must be avoided. if the sync in pin is connected to the sync out pin of another module, the connection should be as direct as possible, and the v i (? pins of the modules must be shorted together. unused sync in pins should be tied to v i (?. if the sync in pin is unused, the module will operate from its own internal clock. sync out pin this pin contains a clock signal referenced to the v i (? pin. the frequency of this signal will equal either the mod- ules internal clock frequency or the frequency estab- lished by an external clock applied to the sync in pin. when synchronizing several modules together, the modules can be connected in a daisy-chain fashion where the sync out pin of one module is connected to the sync in pin of another module. each module in the chain will synchronize to the frequency of the ?st module in the chain. to avoid loading effects, ensure that the sync out pin of any one module is connected to the sync in pin of only one module. any number of modules can be synchronized in this daisy-chain fashion. overtemperature protection to provide protection in a fault condition, the unit is equipped with an overtemperature shutdown circuit. the shut down circuit will not engage unless the unit is operated above the maximum case temperature. recovery from overtemperature shutdown is accomplished by cycling the dc input power off for at least 1.0 s or toggling the primary referenced on/off signal for at least 1.0 s. forced load sharing (parallel operation) for either redundant operation or additional power requirements, the power modules can be con?ured for parallel operation with forced load sharing (see figure 17). for a typical redundant con?uration, 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.
tyco electronics corp. 11 data sheet may 1999 dc-dc converter; 18 vdc to 36 vdc input, 28 vdc output; 250 w FC250R power module: feature descriptions (continued) forced load sharing (parallel operation) (continued) good layout techniques should be observed for noise immunity. to implement forced load sharing, the follow- ing connections must be made: n the parallel pins of all units must be connected together. the paths of these connections should be as direct as possible. n 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. when not using the parallel feature, leave the parallel pin open. 8-581 (c) figure 17. wiring con?uration for redundant parallel operation power good signal the pwr good pin provides an open-drain signal (referenced to the sense(? pin) that indicates the operating state of the module. a low impedance (<100 w ) between pwr good and sense(? indi- cates that the module is operating. a high impedance (>1 m w ) between pwr good and sense(? indi- cates that the module is off or has failed. the pwr good pin can be pulled up through a resistor to an external voltage to facilitate sensing. this external volt- age level must not exceed 40 v, and the current into the pwr good pin during the low-impedance state should be limited to 1 ma maximum. thermal considerations introduction the power modules operate in a variety of thermal environments; however, suf?ient cooling should be provided to help ensure reliable operation of the unit. heat-dissipating components inside the unit are ther- mally coupled to the case. heat is removed by conduc- tion, convection, and radiation to the surrounding environment. proper cooling can be veri?d by mea- suring the case temperature. peak temperature occurs at the position indicated in figure 18. 8-1303 (c).a note: top view, measurements shown in millimeters and (inches). pin locations are for reference only. figure 18. case temperature measurement location the temperature at this location should not exceed 100 ?. 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. for additional information about these modules, refer to the thermal management for fc- and fw-series 250 w?00 w board-mounted power modules technical note (tn96-009eps). v o (+) parallel sense(+) sense(? v o (? case v i (+) on/off v i (? v o (+) parallel sense(+) sense(? v o (? case v i (+) on/off v i (? 30.5 (1.20) 82.6 (3.25) case sync in v i (? v i (+) v o (+) v o (? sync out measure case temperature here on/off
12 12 tyco electronics corp. data sheet may 1999 dc-dc converter; 18 vdc to 36 vdc input, 28 vdc output; 250 w FC250R power module: thermal considerations (continued) heat transfer without heat sinks derating curves for forced-air cooling without a heat sink are shown in figures 19 and 20. these curves can be used to determine the appropriate air?w for a given set of operating conditions. for example, if the unit with air?w along its length dissipates 20 w of heat, the correct air?w in a 40 ? environment is 1.0 m/s (200 ft./min.). 8-1315 (c) figure 19. convection power derating with no heat sink; air?w along width (transverse) 8-1314 (c) figure 20. convection power derating with no heat sink; air?w along length (longitudinal) heat transfer with heat sinks the power modules have through-threaded, m3 x 0.5 mounting holes, 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.). for a screw attachment from the pin side, the recommended hole size on the customers pwb around the mounting holes is 0.130 ?0.005 inches. if a larger hole is used, the mounting torque from the pin side must not exceed 0.25 n-m (2.2 in.-lbs.). thermal derating with heat sinks is expressed by using the overall thermal resistance of the module. total mod- ule thermal resistance ( q ca) is de?ed as the maximum case temperature rise ( d t c, max ) divided by the module power dissipation (p d ): the location to measure case temperature (t c ) is shown in figure 18. case-to-ambient thermal resis- tance vs. air?w for various heat sink con?urations is shown in figure 21 and figure 22. these curves were obtained by experimental testing of heat sinks, which are offered in the product catalog. 8-1321 (c) figure 21. case-to-ambient thermal resistance curves; transverse orientation 0 10203040 100 0 40 60 70 local ambient temperature, t a ( c) power dissipation, p d (w) 30 20 10 90 80 70 60 50 50 4.0 m/s (800 ft./min.) 3.5 m/s (700 ft./min.) 3.0 m/s (600 ft./min.) 2.5 m/s (500 ft./min.) 2.0 m/s (400 ft./min.) 1.5 m/s (300 ft./min.) 1.0 m/s (200 ft./min.) 0.5 m/s (100 ft./min.) 0.1 m/s (20 ft./min.) nat. conv. 0 10203040 100 0 40 60 70 local ambient temperature, t a ( c) power dissipation, p d (w) 30 20 10 90 80 70 60 50 4.0 m/s (800 ft./min.) 3.5 m/s (700 ft./min.) 3.0 m/s (600 ft./min.) 2.5 m/s (500 ft./min.) 2.0 m/s (400 ft./min.) 1.5 m/s (300 ft./min.) 1.0 m/s (200 ft./min.) 0.5 m/s (100 ft./min.) 50 0.1 m/s (20 ft./min.) nat. conv. q ca d t c max , p d -------------------- - t c t a () p d ------------------------ == 0.5 (100) 1.0 (200) 1.5 (300) 2.0 (400) 2.5 (500) 3.0 (600) air velocity, m/s ( ft./min. ) 0 0.0 0.5 3.0 3.5 4.0 4.5 2.5 2.0 1.0 1 1/2 in. heat sink 1 in. heat sink 1/2 in. heat sink 1/4 in. heat sink no heat sink 1.5 case-to-ambient thermal resistance, r ca ( c/w)
tyco electronics corp. 13 data sheet may 1999 dc-dc converter; 18 vdc to 36 vdc input, 28 vdc output; 250 w FC250R power module: thermal considerations (continued) heat transfer with heat sinks (continued) 8-1320 (c) figure 22. case-to-ambient thermal resistance curves; longitudinal orientation these measured resistances are from heat transfer from the sides and bottom of the module as well as the top side with the attached heat sink; therefore, the case-to-ambient thermal resistances shown are gener- ally lower than the resistance of the heat sink by itself. the module used to collect the data in figures 21 and 22 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 23 shows typical heat dissipation for a range of output currents and three voltages for the FC250R. 8-2471 (c) figure 23. FC250R power dissipation vs. output current example if an 85 ? case temperature is desired, what is the minimum air?w necessary? assume the FC250R module is operating at nominal line and an output cur- rent of 9.0 a, maximum ambient air temperature of 40 ?, and the heat sink is 0.5 inch. solution given: v i = 28 v i o = 9.0 a t a = 40 ? t c = 85 ? heat sink = 0.5 inch. determine p d by using figure 23: p d = 34 w then solve the following equation: use figures 21 and 22 to determine air velocity for the 0.5 inch heat sink. the minimum air?w necessary for this module depends on heat sink ? orientation and is shown below: n 1.6 m/s (320 ft./min.) (oriented along width) n 2.0 m/s (400 ft./min.) (oriented along length) 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 ( q cs) and sink-to-ambient ( q sa) as shown in figure 24. 8-1304 (c) figure 24. resistance from case-to-sink and sink- to-ambient 0 0.5 (100) 1.0 (200) 1.5 (300) 2.0 (400) 2.5 (500) 3.0 (600) air velocity, m/s ( ft./min. ) 0.0 0.5 3.0 3.5 4.0 4.5 2.5 2.0 1.0 case-to-ambient thermal resistance, r ca ( c/w) 1 1/2 in. heat sink 1 in. heat sink 1/2 in. heat sink 1/4 in. heat sink no heat sink 1.5 234567 0 35 output current, i o (a) 25 20 30 40 1 5 v i = 36 v v i = 28 v v i = 18 v 10 15 power dissipation, p d (w) 9 8 q ca t c t a () p d ------------------------ = q ca 85 40 () 34 ----------------------- - = q ca 1.32 ?/w = p d t c t s t a cs sa
14 14 tyco electronics corp. data sheet may 1999 dc-dc converter; 18 vdc to 36 vdc input, 28 vdc output; 250 w FC250R power module: thermal considerations (continued) custom heat sinks (continued) for a managed interface using thermal grease or foils, a value of q cs = 0.1 ?/w to 0.3 ?/w is typical. the solution for heat sink resistance is: this equation assumes that all dissipated power must be shed by the heat sink. depending on the user- de?ed application environment, a more accurate model, including heat transfer from the sides and bot- tom of the module, can be used. this equation provides a conservative estimate for such instances. solder, cleaning, and drying considerations post solder cleaning is usually the ?al circuit-board assembly process prior to electrical testing. the result of inadequate circuit-board cleaning and drying can affect both the reliability of a power module and the testability of the ?ished circuit-board assembly. for guidance on appropriate soldering, cleaning, and dry- ing procedures, refer to the board-mounted power modules soldering and cleaning application note (ap97-021eps). emc considerations for assistance with designing for emc compliance, please refer to the fltr100v10 data sheet (ds98-152eps). layout considerations copper paths must not be routed beneath the power module mounting inserts. for additional layout guide- lines, refer to the fltr100v10 data sheet (ds98-152eps). q sa t c t a () p d ------------------------ - q cs =
tyco electronics corp. 15 data sheet may 1999 dc-dc converter; 18 vdc to 36 vdc input, 28 vdc output; 250 w FC250R power module: 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.) 8-1650 (c).a * side label includes tyco name, product designation, safety agency markings, input/output voltage and current ratings, and bar code. top view side view bottom view 5.1 (0.20) min 13.5 (0.53) 1.57 0.05 (0.062 0.002) dia solder-plated brass, 11 plcs (vout? vout+, vin? vin+) 1.02 0.05 (0.040 0.002) dia solder-plated brass 9 plcs side label* case sync in on/off v i v i + 2.54 (0.100) typ v o v o + sync out sense sense+ trim parallel current mon pwr good 5.1 (0.20) 50.8 (2.00) 30.48 (1.200) 22.86 (0.900) 12.7 (0.50) 5.08 (0.200) 10.16 (0.400) 15.24 (0.600) 20.32 (0.800) 25.40 (1.000) 30.48 (1.200) 35.56 (1.400) 66.04 (2.600) mounting inserts m3 x 0.5 through 4 plcs 5.1 (0.20) 2.54 (0.100) typ 106.68 (4.200) 7.62 (0.300) 17.78 (0.700) 12.70 (0.500) 116.8 (4.60) 61.0 (2.40)
16 tyco electronics corp. data sheet may 1999 dc-dc converter; 18 vdc to 36 vdc input, 28 vdc output; 250 w FC250R power module: recommended hole pattern component-side footprint. dimensions are in millimeters and (inches). 8-1650 (c).a ordering information input voltage output voltage output power device code comcode 28 v 28 v 250 w FC250R1 107430316 5.1 (0.20) 10.16 (0.400) m o untin g in s ert s 5.1 (0.20) 2.54 (0.100) typ 2.54 (0.100) typ 5.08 (0.200) 15.24 (0.600) 20.32 (0.800) 25.40 (1.000) 30.48 (1.200) 35.56 (1.400) 106.68 (4.200) 66.04 (2.600) 50.8 (2.00) 30.48 (1.200) 22.86 (0.900) 17.78 (0.700) 12.70 (0.500) 12.7 (0.50) 7.62 (0.300) case sync in on/off v i v i + v o v o + sense sense+ trim parallel current mon pwr good sync out 7.62 (0.300) 7.62 (0.300)
tyco electronics corp. 17 data sheet may 1999 dc-dc converter; 18 vdc to 36 vdc input, 28 vdc output; 250 w FC250R power module: ordering information (continued) table 4. device accessories d000-a.cvs figure 25. longitudinal heat sink d000-b.cvs figure 26. transverse heat sink accessory comcode 1/4 in. transverse kit (heat sink, thermal pad, and screws) 847308335 1/4 in. longitudinal kit (heat sink, thermal pad, and screws) 847308327 1/2 in. transverse kit (heat sink, thermal pad, and screws) 847308350 1/2 in. longitudinal kit (heat sink, thermal pad, and screws) 847308343 1 in. transverse kit (heat sink, thermal pad, and screws) 847308376 1 in. longitudinal kit (heat sink, thermal pad, and screws) 847308368 1 1/2 in. transverse kit (heat sink, thermal pad, and screws) 847308392 1 1/2 in. longitudinal kit (heat sink, thermal pad, and screws) 847308384 1/4 in. 1/2 in. 1 in. 1 1/2 in. 4.56 in. 2.38 in. 1/4 in. 1/2 in. 1 in. 1 1/2 in. 2.36 in. 4.56 in.
18 18 tyco electronics corp. data sheet may 1999 dc-dc converter; 18 vdc to 36 vdc input, 28 vdc output; 250 w FC250R power module: notes
tyco electronics corp. 19 data sheet may 1999 dc-dc converter; 18 vdc to 36 vdc input, 28 vdc output; 250 w FC250R power module: notes
data sheet march 26, 2001 dc-dc converter; 18 vdc to 36 vdc input, 28 vdc output; 250 w FC250R power module: printed on recycled paper tyco electronics power systems, inc. 3000 skyline drive, mesquite, tx 75149, usa +1-800-526-7819 fax: +1-888-315-5182 (outside u.s.a.: +1-972-284-2626 , fax: +1-972-284-2900 http://power.tycoeleectronics.com tyco electronics corportation reserves the right to make changes to the product(s) or information contained herein without noti ce. 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. ?2001 tyco electronics corporation, harrisburg, pa. all international rights reserved. printed in u.s.a. may 1999 ds97-544eps (replaces ds95-158eps)

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