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data sheet july 2001 qhw050g1, qhw075g1, and qhw100g1 power modules; dc-dc converters: 36 to 75 vdc input, 2.5 vdc output; 25 w to 50 w the qhw series power modules use advanced, surface- mount technology and deliver high-quality, efficient, and compact dc-dc conversion. applications distributed power architectures communications equipment computer equipment options heat sinks available for extended operation auto-restart after overtemperature, overvoltage, or overcurrent shutdown choice of short pin lengths case ground pin features small size: 36.8 mm x 57.9 mm x 12.7 mm (1.45 in. x 2.28 in. x 0.50 in.) high power density high efficiency: 86% typical low output noise constant frequency industry-standard pinout metal baseplate 2:1 input voltage range overtemperature, overvoltage and overcurrent pro- tection negative remote on/off remote sense adjustable output voltage iso * 9001 and iso 14001 certified manufacturing facilities ul ? 60950 recognized, csa ? c22.2 no. 60950-00 certified, and vde 0805 (iec60950) licensed ce mark meets 73/23/eec and 93/68/eec direc- tives** * iso is a registered trademark of the international organization for standardization. ? ul is a registered trademark of underwriters laboratories, inc. ? csa is a registered trademark of canadian standards associa- tion. vde is a trademark of verband deutscher elektrotechniker e.v. ** this product is intended for integration into end-use equipment. all the required procedures for ce marking of end-use equip- ment should be followed. (the ce mark is placed on selected products.) description the qhw050g1, qhw075g1, and qhw100g1 power modules are dc-dc converters that operate over an input voltage range of 36 vdc to 75 vdc and provide a precisely regulated dc output. the outputs are fully iso- lated from the inputs, allowing versatile polarity configurations and grounding connections. the modules have maximum power ratings from 25 w to 50 w at a typical full-load efficiency of 86%. the sealed modules offer a metal baseplate for excellent thermal performance. threaded-through holes are pro- vided to allow easy mounting or addition of a heat sink for high-temperature applications. the standard feature set includes remote sensing, output trim, and remote on/off for convenient flexibility in distributed power applications.
2 tyco electronics corp. data sheet july 2001 dc-dc converters: 36 to 75 vdc input, 2.5 vdc output; 25 w to 50 w qhw050g1, qhw075g1, and qhw100g1 power modules; 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 specifications unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. table 1. input specifications 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 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 20 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. parameter symbol min max unit input voltage: continuous transient (100 ms) v i v i, trans ? ? 80 100 vdc v operating case temperature (see thermal considerations section.) t c ? 40 100 c storage temperature t stg ? 55 125 c i/o isolation voltage (for 1 minute) ?? 1500 vdc parameter symbol min typ max unit operating input voltage v i 36 48 75 vdc maximum input current: v i = 0 v to 75 v; i o = i o, max ; see figures 1 ? 3: qhw050g1 qhw075g1 qhw100g1 v i = 36 v to 75 v; i o = i o, max : qhw050g1 qhw075g1 qhw100g1 i i, max i i, max i i, max i i, max i i, max i i, max ? ? ? ? ? ? ? ? ? ? ? ? 2.5 3.5 4.5 2.5 3.5 4.5 a a a a a a inrush transient i 2 t ?? 1.0 a 2 s input reflected-ripple current, peak-to-peak (5 hz to 20 mhz, 12 h source impedance; see figure 15.) i i ? 10 ? map-p input ripple rejection (100 ? 120 hz) ?? 60 ? db
tyco electronics corp. 3 data sheet july 2001 dc-dc converters: 36 to 75 vdc input, 2.5 vdc output; 25 w to 50 w qhw050g1, qhw075g1, and qhw100g1 power modules; electrical specifications (continued) table 2. output specifications * consult your sales representative or the factory. ? these are manufacturing test limits. in some situations, results may differ. table 3. isolation specifications parameter device symbol min typ max unit output voltage set point (v i = 48 v; i o = i o, max ; t c = 25 c) all v o, set 2.46 2.5 2.54 vdc output voltage (over all operating input voltage, resistive load, and temperature conditions until end of life. see figure 17.) all v o 2.42 ? 2.58 vdc output regulation: line (v i = 36 v to 75 v) load (i o = i o, min to i o, max ) temperature (t c = ? 40 c to +100 c) all all all ? ? ? ? ? ? 0.01 0.1 8 0.1 0.4 25 %v o %v o mv output ripple and noise voltage (see figure 16.): rms peak-to-peak (5 hz to 20 mhz) all all ? ? ? ? ? ? 40 200 mvrms mvp-p external load capacitance all ? 0 ? * f output current qhw050g1 qhw075g1 qhw100g1 i o i o i o 0 0 0 ? ? ? 10 15 20 a a a output current-limit inception (v o = 90% of v o, nom ) qhw050g1 qhw075g1 qhw100g1 i o, cli i o, cli i o, cli ? ? ? 12 18 24 20 ? 25 ? 30 ? a a a efficiency (v i = 48 v; i o = i o, max ; t c = 70 c; see figure 17.) qhw050g1 qhw075g1 qhw100g1 ? ? ? 84 86 85 ? ? ? % % % switching frequency all ?? 380 ? khz dynamic response ( ? i o / ? t = 1 a/10 s, v i = 48 v, t c = 25 c; tested with a 220 f aluminum and a 1.0 f ceramic capacitor across the load): 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) all all all all ? ? ? ? ? ? ? ? 300 300 300 300 ? ? ? ? mv s mv s parameter min typ max unit isolation capacitance ? 2500 ? pf isolation resistance 10 ?? m ?
4 tyco electronics corp. data sheet july 2001 dc-dc converters: 36 to 75 vdc input, 2.5 vdc output; 25 w to 50 w qhw050g1, qhw075g1, and qhw100g1 power modules; general specifications feature specifications unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. see the feature descriptions section for additional information. * these are manufacturing test limits. in some situations, results may differ. solder, cleaning, and drying considerations post solder cleaning is usually the final circuit-board assembly process prior to electrical testing. the result of inad- equate circuit-board cleaning and drying can affect both the reliability of a power module and the testability of the finished circuit-board assembly. for guidance on appropriate soldering, cleaning, and drying procedures, refer to the board-mounted power modules soldering and cleaning application note (ap97-021eps). parameter min typ max unit calculated mtbf (i o = 80% of i o, max ; t c = 40 c) 2,341,000 hours weight ?? 75 (2.7) g (oz.) parameter symbol min typ max unit remote on/off signal interface (v i = 0 v to 75 v; open collector or equivalent compatible; signal referenced to v i ( ? ) terminal): logic low ? module on logic high ? module 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 a leakage current turn-on time (see figure 14.) (i o = 80% of i o, max ; v o within 1% of steady state) v on/off i on/off v on/off i on/off ? 0 ? ? ? ? ? ? ? ? 20 1.2 1.0 15 50 35 v ma v a ms output voltage adjustment: output voltage remote-sense range output voltage set-point adjustment range (trim) ? ? ? 90 ? ? 0.5 110 v %v o, nom output overvoltage protection v o, sd 3.0* ? 3.4* v overtemperature protection t c ? 105 ? c
data sheet july 2001 tyco electronics corp. 5 dc-dc converters: 36 to 75 vdc input, 2.5 vdc output; 25 w to 50 w qhw050g1, qhw075g1, and qhw100g1 power modules; characteristic curves the following figures provide typical characteristics for the power modules. 1-0001 figure 1. typical qhw050g1 input characteristics at 25 c 1-0002 figure 2. typical qhw075g1 input characteristics at 25 c 8-3370 (f) figure 3. typical qhw100g1 input characteristics at 25 c 1-0003 figure 4. typical qhw050g1 converter efficiency vs. output current at 25 c characteristic curves (continued) 1.2 1.0 0.8 0.6 0.4 0.2 0 input current, i i (a) input voltage, v i (v) i o = 10 a i o = 6 a i o = 1 a 20 25 30 35 40 45 50 55 60 65 70 75 1.8 1.6 1.4 1.2 1.0 0.8 0.6 0.4 0.2 0 20 25 30 35 40 45 50 55 60 65 70 75 input current, i i (a) input voltage, v i (v) i o = 15 a i o = 8 a i o = 1.5 a 20 input voltage, v i (v) input current, i i (a) 2 0 25 30 35 40 45 1.5 1 0.5 2.5 50 55 60 65 70 75 i o = 20 a i o = 11 a i o = 2 a 87 84 81 78 75 72 69 66 63 12345678910 efficiency, (%) output current, i o (a) v i = 36 v v i = 48 v v i = 75 v
6 tyco electronics corp. data sheet july 2001 dc-dc converters: 36 to 75 vdc input, 2.5 vdc output; 25 w to 50 w qhw050g1, qhw075g1, and qhw100g1 power modules; 1-0004 figure 5. typical qhw075g1 converter efficiency vs. output current at 25 c 8-3371 figure 6. typical qhw100g1 converter efficiency vs. output current at 25 c 1-0020 note: see figure 16 for test conditions. figure 7. typical qhw050g1, qhw075g1, qhw100g1 output ripple voltage at room temperature; i o = 15 a 1-0006 note: tested with a 220 f aluminum and a 1.0 f ceramic capacitor across the load. figure 8. typical qhw050g1 transient response to step increase in load from 50% to 75% of full load at room temperature and 48 vdc input (waveform averaged to eliminate ripple component.) 88 87 86 85 84 83 82 81 80 79 78 77 3456789101112131415 v i = 36 v v i = 48 v v i = 75 v efficiency, (%) output current, i o (a) 412 14 16 18 output current, i o (a) 810 35 9 11 13 15 17 19 20 87 86 85 84 83 82 81 80 79 78 77 67 efficiency, (%) v i = 48 v v i = 75 v v i = 36 v time, t (1 s/div) output voltage, v o (v) (100 mv/div) v i = 75 v v i = 48 v v i = 36 v output voltage, v o (v) (200 mv/div) output current, i o (a) (2 a/div) time, t (100 s/div) 7.5 a 5.0 a
tyco electronics corp. 7 data sheet july 2001 dc-dc converters: 36 to 75 vdc input, 2.5 vdc output; 25 w to 50 w qhw050g1, qhw075g1, and qhw100g1 power modules; characteristic curves (continued) 1-0007 note: tested with a 220 f aluminum and a 1.0 f ceramic capacitor across the load. figure 9. typical qhw075g1 transient response to step increase in load from 50% to 75% of full load at room temperature and 48 vdc input (waveform averaged to eliminate ripple component.) 1-0009 note: tested with a 220 f aluminum and a 1.0 f ceramic capacitor across the load. figure 10. typical qhw100g1 transient response to step increase in load from 50% to 75% of full load at room temperature and 48 vdc input (waveform averaged to eliminate ripple component.) 1-0018 note: tested with a 220 f aluminum and a 1.0 f ceramic capacitor across the load. figure 11. typical qhw050g1 transient response to step decrease in load from 50% to 25% of full load at room temperature and 48 vdc input (waveform averaged to eliminate ripple component.) 1-0019 note: tested with a 220 f aluminum and a 1.0 f ceramic capacitor across the load. figure 12. typical qhw075g1 transient response to step decrease in load from 50% to 25% of full load at room temperature and 48 vdc input (waveform averaged to eliminate ripple component.) output voltage, v o (v) (200 mv/div) output current, i o (a) (2 a/div) time, t (100 s/div) 11.25 a 7.50 a output voltage, v o (v) (200 mv/div) output current, i o (a) (5 a/div) time, t (100 s/div) 15 a 10 a output voltage, v o (v) (200 mv/div) output current, i o (a) (1 a/div) time, t (100 s/div) 5.0 a 2.5 a output voltage, v o (v) (200 mv/div) output current, i o (a) (2 a/div) time, t (100 s/div) 7.50 a 3.75 a
8 8 tyco electronics corp. data sheet july 2001 dc-dc converters: 36 to 75 vdc input, 2.5 vdc output; 25 w to 50 w qhw050g1, qhw075g1, and qhw100g1 power modules; characteristic curves (continued) 8-2685(c).a note: tested with a 220 f aluminum and a 1.0 f ceramic capacitor across the load. figure 13. typical qhw100g1 transient response to step decrease in load from 50% to 25% of full load at room temperature and 48 vdc input (waveform averaged to eliminate ripple component.) 1-0010 note: tested with a 220 f aluminum and a 1.0 f ceramic capacitor across the load. figure 14. qhw050g1, qhw075g1, and qhw100g1 typical start-up from remote on/off; i o = i o , max test configurations 8-203 (f).l note: measure input reflected-ripple current with a simulated source inductance (l test ) of 12 h. capacitor c s offsets possible bat- tery impedance. measure current as shown above. figure 15. input reflected-ripple test setup 8-513 (f).d note: use a 1.0 f ceramic capacitor and a 10 f aluminum or tan- talum capacitor. scope measurement should be made using a bnc socket. position the load between 51 mm and 76 mm (2 in. and 3 in.) from the module. figure 16. peak-to-peak output noise measurement test setup 8-749 (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 17. output voltage and efficiency measurement test setup time, t (100 s/div) output voltage, v o (v) (200 mv/div) output current, i o (a) (2 a/div) 5 a 10 a remote on/off, v on/off (v) output voltage, v o (v) (1 v/div) time, t (2 ms/div) to oscilloscope current probe battery l test 12 h c s 220 f esr < 0.1 ? @ 20 c, 100 khz 33 f esr < 0.7 ? @ 100 khz v i (+) v i ( ? ) 1.0 f resistive scope copper strip 10 f load v o (+) v o ( ? ) v i (+) i i i o supply contact contact and load sense(+) v i ( ? ) v o (+) v o ( ? ) sense( ? ) resistance distribution losses v o (+) ? v o ( ? ) [] i o v i (+) ? v i ( ? ) [] i i ------------------------------------------------ ?? ?? x100 =%
tyco electronics corp. 9 data sheet july 2001 dc-dc converters: 36 to 75 vdc input, 2.5 vdc output; 25 w to 50 w qhw050g1, qhw075g1, and qhw100g1 power modules; 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 configuration in figure 15, a 33 f electrolytic capacitor (esr < 0.7 ? 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 60950, csa c22.2 no. 60950-00, and vde 0805 (iec60950). if the input source is non-selv (elv or a hazardous voltage greater than 60 vdc and less than or equal to 75 vdc), for the module ? s output to be considered meeting the requirements of safety extra-low voltage (selv), all of the following must be true: the input source is to be provided with reinforced insulation from any hazardous voltages, including the ac mains. one v i pin and one v o pin are to be grounded, or both the input and output pins are to be kept floating. the input pins of the module are not operator acces- sible. another selv reliability test is conducted on the whole system, as required by the safety agencies, on the combination of supply source and the subject module to verify that under a single fault, hazardous voltages do not appear at the module ? s output. note: do not ground either of the input pins of the module without grounding one of the output pins. this may allow a non-selv voltage to appear between the output pin and ground. 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 20 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 up to one second. if overcurrent exists for more than one second, the unit will shut down. at the point of current-limit inception, the unit shifts from voltage control to current control. if the output volt- age is pulled very low during a severe fault, the current- limit circuit can exhibit either foldback or tailout charac- teristics (output current decrease or increase). the module is available in two overcurrent configura- tions. in one configuration, when the unit shuts down it will latch off. the overcurrent latch is reset by either cycling the input power or by toggling the on/off pin for one second. in the other configuration, the unit will try to restart after shutdown. if the output overload con- dition still exists when the unit restarts, it will shut down again. this operation will continue indefinitely until the overcurrent condition is corrected. remote on/off negative logic remote on/off turns the module off dur- ing a logic high and on during a logic low. to turn the power module on and off, the user must supply a switch to control the voltage between the on/off terminal and the v i ( ? ) terminal (v on/off ). the switch can be an open collector or equivalent (see figure 18). a logic low is v on/off = 0 v to 1.2 v. 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 a. if not using the remote on/off feature, short the on/off pin to v i ( ? ).
10 10 tyco electronics corp. data sheet july 2001 dc-dc converters: 36 to 75 vdc input, 2.5 vdc output; 25 w to 50 w qhw050g1, qhw075g1, and qhw100g1 power modules; feature descriptions (continued) remote on/off (continued) 8-720 (f).c figure 18. 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 specifica- 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 output overvoltage pro- tection value shown 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 19. if not using the remote-sense feature to regulate the output at the point of load, then connect sense(+) to v o (+) and sense( ? ) to v o ( ? ) at the module. although the output voltage can be increased by both the remote sense and by the trim, the maximum increase for the output voltage is not the sum of both. the maximum increase is the larger of either the remote sense or the trim. consult the factory if you need to increase the output voltage more than the above limitation. the amount of power delivered by the module is defined as the voltage at the output terminals multiplied by the output current. when using remote sense and trim, the output voltage of the module can be increased, which at the same output current would increase the power output of the module. care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power. 8-651 (f).m figure 19. effective circuit configuration 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 positioned 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 20). the following equa- tion determines the required external-resistor value to obtain a percentage output voltage change of ? %. 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 21). the following equation determines the required exter- nal-resistor value to obtain a percentage output voltage change of ? %. sense(+) v o (+) sense( ? ) v o ( ? ) v i ( ? ) + ? i on/off on/off v i (+) load v on/off sense(+) sense( ? ) v i (+) v i ( ? ) i o load contact and supply i i contact v o (+) v o ( ? ) distribution losses resistance r adj-down 511 ? % --------- - 10.22 ? ?? ?? k ? = r adj-up 5.11 v o 100 ? % + () 1.225 ? % -------------------------------------------------- 511 ? % --------- - ? 10.22 ? ?? ?? k ? =
tyco electronics corp. 11 data sheet july 2001 dc-dc converters: 36 to 75 vdc input, 2.5 vdc output; 25 w to 50 w qhw050g1, qhw075g1, and qhw100g1 power modules; feature descriptions (continued) output voltage set-point adjustment (trim) (continued) the voltage between the v o (+) and v o ( ? ) terminals must not exceed the minimum output overvoltage pro- tection value shown 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 19. although the output voltage can be increased by both the remote sense and by the trim, the maximum increase for the output voltage is not the sum of both. the maximum increase is the larger of either the remote sense or the trim. consult the factory if you need to increase the output voltage more than the above limitation. the amount of power delivered by the module is defined as the voltage at the output terminals multiplied by the output current. when using remote sense and trim, the output voltage of the module can be increased, which at the same output current would increase the power output of the module. care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power. 8-748 (f).b figure 20. circuit configuration to decrease output voltage 8-715 (f).b figure 21. circuit configuration to increase output voltage note: the output voltage of this module may be increased by 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 3.0 v between the v o (+) and v o ( ? ) terminals. output overvoltage protection the output overvoltage protection consists of circuitry that monitors the voltage on the output terminals. if the voltage on the output terminals exceeds the overvolt- age protection threshold, then the module will shut down and latch off. the overvoltage latch is reset by either cycling the input power for one second or by tog- gling the on/off signal for one second. if the auto-restart option is chosen, the unit will ? hiccup ? until the tempera- ture is within specification. overtemperature protection these modules feature an overtemperature protection circuit to safeguard against thermal damage. the cir- cuit shuts down and latches off the module when the maximum case temperature is exceeded. the module can be restarted by cycling the dc input power for at least one second or by toggling the remote on/off signal for at least one second. if the auto-restart option is cho- sen, the unit will ? hiccup ? until the temperature is within specification. v i (+) v i ( ? ) on/off case v o (+) v o ( ? ) sense(+) trim sense( ? ) r adj-down r load v i (+) v i ( ? ) on/off case v o (+) v o ( ? ) sense(+) trim sense( ? ) r adj-up r load
12 12 tyco electronics corp. data sheet july 2001 dc-dc converters: 36 to 75 vdc input, 2.5 vdc output; 25 w to 50 w qhw050g1, qhw075g1, and qhw100g1 power modules; 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 ther- mally coupled to the case. heat is removed by conduc- tion, convection, and radiation to the surrounding environment. proper cooling can be verified by mea- suring the case temperature. peak temperature (t c ) occurs at the position indicated in figure 22. 8-2104 (f).a note: top view, pin locations are for reference only. measurements shown in millimeters and (inches). figure 22. case temperature measurement location the temperature at this location should not exceed 100 c. the output power of the module should not exceed the rated power for the module as listed in the ordering information table. although the maximum case temperature of the power modules is 100 c, you can limit this temperature to a lower value for extremely high reliability. heat transfer without heat sinks increasing airflow over the module enhances the heat transfer via convection. figures 23 and 24 show the maximum power that can be dissipated by the module without exceeding the maximum case temperature ver- sus local ambient temperature (t a ) for natural convec- tion through 3 m/s (600 ft./min.). note that the natural convection condition was mea- sured at 0.05 m/s to 0.1 m/s (10 ft./min. to 20 ft./min.); however, systems in which these power modules may be used typically generate natural convection airflow rates of 0.3 m/s (60 ft./min.) due to other heat dissipat- ing components in the system. the use of figure 23 is shown in the following example. example what is the minimum airflow necessary for a qhw100g1 operating at v i = 48 v, an output current of 20 a, transverse orientation, and a maximum ambient temperature of 55 c? solution given: v i = 48 v i o = 20 a t a = 40 c determine p d (use figure 27): p d = 8.7 w determine airflow (v) (use figure 23): v = 1.5 m/s (300 ft./min.) 8-2321 (f) figure 23. forced convection power derating with no heat sink; transverse orientation on/off trim (+)sense ( ? )sense 33 (1.30) 14 (0.55) v i (+) v i ( ? )v o ( ? ) v o (+) 0 local ambient temperature, t a ( c) power dissipation, p d (w) 20 15 10 5 0 10 20 30 40 50 60 70 80 3.0 m/s (600 ft./min.) 2.0 m/s (400 ft./min.) 1.0 m/s (200 ft./min.) 0.1 m/s (20 ft./min.) 90 100 natural convection
tyco electronics corp. 13 data sheet july 2001 dc-dc converters: 36 to 75 vdc input, 2.5 vdc output; 25 w to 50 w qhw050g1, qhw075g1, and qhw100g1 power modules; thermal considerations (continued) heat transfer without heat sinks (continued) 8-2318 (f).a figure 24. forced convection power derating with no heat sink; longitudinal orientation 1-0063 figure 25. qhw050g1 power dissipation vs. output current at 25 c 1-0064 figure 26. qhw075g1 power dissipation vs. output current at 25 c 8-3374 (f) figure 27. qhw100g1 power dissipation vs. output current at 25 c 0 local ambiemt temperature, t a ( c) power dissipation, p d (w) 20 15 10 5 0 10 20 30 40 50 60 70 80 3.0 m/s (600 ft./min.) 2.0 m/s (400 ft./min.) 1.0 m/s (200 ft./min.) 0.1 m/s (20 ft./min.) 90 100 natural convection 7.0 6.5 6.0 5.5 5.0 4.5 4.0 3.5 3.0 2.5 power dissipation, p d (w) output current, i o (a) 1 2345678910 v i = 75 v v i = 48 v v i = 36 v 8 7 6 5 4 3 2 power dissipation, p d (w) output current, i o (a) 1 2345 11 12 13 14 15 678910 v i = 75 v v i = 48 v v i = 36 v 3 output current, i o (a) power dissipation, p d (w) 45678 11 9 1011121314 15 16 17 18 19 20 10 9 8 7 6 5 4 3 2 v i = 75 v v i = 48 v v i = 36 v
14 14 tyco electronics corp. data sheet july 2001 dc-dc converters: 36 to 75 vdc input, 2.5 vdc output; 25 w to 50 w qhw050g1, qhw075g1, and qhw100g1 power modules; thermal considerations (continued) 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 attach 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 customer ? s 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 module thermal resistance ( ca) is defined as the max- imum case temperature rise ( ? t c, max ) divided by the module power dissipation (p d ): the location to measure case temperature (t c ) is shown in figure 22. case-to-ambient thermal resis- tance vs. airflow is shown, for various heat sink config- urations, heights, and orientations, as shown in figures 28 and 29. longitudinal orientation is defined as when the long axis of the module is parallel to the airflow direction, whereas in the transverse orientation, the long axis is perpendicular to the airflow. these curves were obtained by experimental testing of heat sinks, which are offered in the product catalog. 8-2323 (f) figure 28. case-to-ambient thermal resistance curves; transverse orientation 8-2324 (f) figure 29. case-to-ambient thermal resistance curves; longitudinal orientation 8-2889 (f) figure 30. heat sink power derating curves; natural convection; transverse orientation ca ? t cmax , p d -------------------- - t c t a ? () p d ------------------------ == 0 velocity, m/s (ft./min.) case-to-anbient thermal 10 0 0.5 1.0 1.5 2.0 2.5 3.0 resistance, ca ( c/w) 9 8 7 6 5 4 3 2 1 (100) (200) (300) (400) (500) (600) no heat sink 1/4 in. heat sink 1/2 in. heat sink 1 in. heat sink 0 velocity, m/s (ft./min.) case-to-anbient thermal 10 0 0.5 1.0 1.5 2.0 2.5 3.0 resistance, ca ( c/w) 9 8 7 6 5 4 3 2 1 (100) (200) (300) (400) (500) (600) 11 no heat sink 1/4 in. heat sink 1/2 in. heat sink 1 in. heat sink 0 local ambient temperature, t a ( c) power dissipation, p d (w) 20 15 10 5 0 10 20 30 40 50 60 70 80 1 in. heat sink 1/2 in. heat sink 1/4 in. heat sink no heat sink 90 100
tyco electronics corp. 15 data sheet july 2001 dc-dc converters: 36 to 75 vdc input, 2.5 vdc output; 25 w to 50 w qhw050g1, qhw075g1, and qhw100g1 power modules; thermal considerations (continued) heat transfer with heat sinks (continued) 8-2890 (f) figure 31. heat sink power derating curves; natural convection; longitudinal orientation 8-2891 (f) figure 32. heat sink power derating curves; 1.0 m/s (200 lfm); transverse orientation 8-2892 (f) figure 33. heat sink power derating curves; 1.0 m/s (200 lfm); 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 figure 28 had a thermal-conductive dry pad between the case and the heat sink to minimize contact resistance. the use of figure 28 is shown in the following example. example if an 85 c case temperature is desired, what is the minimum airflow necessary? assume the qhw100g1 module is operating at v i = 48 v and an output current of 20 a, maximum ambient air temperature of 40 c, and the heat sink is 1/4 inch. the module is oriented in the transverse direction. solution given: v i = 48 v i o = 20 a t a = 40 c t c = 85 c heat sink = 1/4 inch determine p d by using figure 27: p d = 9.5 w 0 local ambiemt temperature, t a ( c) power dissipation, p d (w) 20 15 10 5 0 10 20 30 40 50 60 70 80 90 100 1 in. heat sink 1/2 in. heat sink 1/4 in. heat sink no heat sink 0 local ambient temperature, t a ( c) power dissipation, p d (w) 20 15 10 5 0 10 20 30 40 50 60 70 80 90 100 1 in. heat sink 1/2 in. heat sink 1/4 in. heat sink no heat sink 0 local ambient temperature, t a ( c) power dissipation, p d (w) 20 15 10 5 0 10 20 30 40 50 60 70 80 90 100 1 in. heat sink 1/2 in. heat sink 1/4 in. heat sink no heat sink
16 16 tyco electronics corp. data sheet july 2001 dc-dc converters: 36 to 75 vdc input, 2.5 vdc output; 25 w to 50 w qhw050g1, qhw075g1, and qhw100g1 power modules; thermal considerations (continued) heat transfer with heat sinks (continued) then solve the following equation: use figure 28 to determine air velocity for the 1/4 inch heat sink. the minimum airflow necessary for this module is 0.8 m/s (180 ft./min.). 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) as shown in figure 34. 8-1304 (f).e figure 34. resistance from case-to-sink and sink-to-ambient 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: this equation assumes that all dissipated power must be shed by the heat sink. depending on the user- defined application environment, a more accurate model, including heat transfer from the sides and bot- tom of the module, can be used. this equation pro- vides a conservative estimate for such instances. emc considerations for assistance with designing for emc compliance, please refer to the fltr100v10 filter module data sheet (ds99-294eps). layout considerations copper paths must not be routed beneath the power module mounting inserts. for additional layout guide- lines, refer to the fltr100v10 filter module data sheet (ds99-294eps). ca t c t a ? () p d ------------------------ = ca 85 40 ? () 9.5 ----------------------- - = ca 4.74 c/w = p d t c t s t a cs sa sa t c t a ? () p d ------------------------ - cs ? =
tyco electronics corp. 17 data sheet july 2001 dc-dc converters: 36 to 75 vdc input, 2.5 vdc output; 25 w to 50 w qhw050g1, qhw075g1, and qhw100g1 power modules; 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 side view bottom view 8-1769 (f).b * side label includes tyco name, product designation, safety agency markings, input/output voltage and current ratings, and bar code. 57.9 (2.28) 36.8 (1.45) 1.02 (0.040) dia solder-plated brass, 6 places 1.57 (0.062) dia solder-plated brass, 2 places 12.7 (0.50) 4.1 (0.16) min, 2 places 0.51 (0.020) 4.1 (0.16) min, 6 places 3.5 (0.14) min side label* 3.6 (0.14) 10.9 (0.43) 5.3 (0.21) 26.16 (1.030) 15.24 (0.600) 5.3 (0.21) mounting inserts m3 x 0.5 through, 4 places ? sense trim + sense on/off 3.81 (0.150) 7.62 (0.300) 11.43 (0.450) 15.24 (0.600) 50.80 (2.000) 7.62 (0.300) 47.2 (1.86) v o (+) v o ( ? ) v i ( ? ) v i (+) 11.2 (0.44) 12.7 (0.50) riveted case pin (optional) 1.09 x 0.76 (0.043 x 0.030)
18 tyco electronics corp. data sheet july 2001 dc-dc converters: 36 to 75 vdc input, 2.5 vdc output; 25 w to 50 w qhw050g1, qhw075g1, and qhw100g1 power modules; recommended hole pattern component-side footprint. dimensions are in millimeters and (inches). 8-1769 (f).b ordering information please contact your tyco electronics ? account manager or field application engineer for pricing and availability. table 4. device codes optional features can be ordered using the suffixes shown in table 5. to order more than one option, list device codes suffixes in numerically descending order. for example, the device code for a qhw100g1 module with the following option is shown below: table 5. device options input voltage output voltag e output power output current remote on/off logic device code comcode 48 vdc 2.5 vdc 25 w 10 a negative qhw050g1 108728494 48 vdc 2.5 vdc 37.5 w 15 a negative qhw075g1 108446972 48 vdc 2.5 vdc 50 w 20 a negative qhw100g1 108447038 negative logic and auto-restart after overtemperature, overvoltage, or overcurrent shutdown qhw100g41 option device code suffix short pins: 2.79 mm 0.25 mm (0.110 in. +0.020 in./ ? 0.010 in.) 8 case ground pin 7 short pins: 3.68 mm 0.25 mm (0.145 in. 0.010 in.) 6 auto-restart after overtemperature, over- voltage, or overcurrent shutdown 4 3.6 (0.14) 10.9 (0.43) 26.16 (1.030) 15.24 (0.600) 7.62 (0.300) 5.3 (0.21) mounting inserts m3 x 0.5 through, 4 places ? sense trim + sense on/off 5.3 (0.21) 47.2 (1.86) 15.24 (0.600) 7.62 (0.300) 11.43 (0.450) 3.81 (0.150) v o (+) v o ( ? ) v i ( ? ) v i (+) case pin (optional) 11.2 (0.44) 12.7 (0.50) 50.80 (2.000)
data sheet july 2001 tyco electronics corp. 19 dc-dc converters: 36 to 75 vdc input, 2.5 vdc output; 25 w to 50 w qhw050g1, qhw075g1, and qhw100g1 power modules; ordering information (continued) table 6. device accessories dimensions are in millimeters and (inches). accessory comcode 1/4 in. transverse kit (heat sink, thermal pad, and screws) 848060992 1/4 in. longitudinal kit (heat sink, thermal pad, and screws) 848061008 1/2 in. transverse kit (heat sink, thermal pad, and screws) 848061016 1/2 in. longitudinal kit (heat sink, thermal pad, and screws) 848061024 1 in. transverse kit (heat sink, thermal pad, and screws) 848061032 1 in. longitudinal kit (heat sink, thermal pad, and screws) 848061040 8-2473 (f) figure 35. longitudinal heat sink 8-2472 (f) figure 36. transverse heat sink 26.16 0.13 (1.030 0.005) 57.91 0.38 (2.280 0.015) 1/4 in. 1/2 in. 1 in. 36.83 0.38 (1.450 0.015) 47.24 0.13 (1.850 0.005) 1/4 in. 1/2 in. 1 in.
data sheet july 2001 dc-dc converters: 36 to 75 vdc input, 2.5 vdc output; 25 w to 50 w qhw050g1, qhw075g1, and qhw100g1 power modules; 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.tycoelectronics.com tyco electronics corporation reserves the right to make changes to the product(s) or information contained herein without notic e. 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 power systems, inc., (mesquite, texas) all international rights reserved. printed in u.s.a. july 2001 fds01-068eps (replaces ds99-084eps)

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