Data Sheet
May 1998
FC050S6R5 and FC150S6R5 Power Modules:
dc-dc Converters; 18 to 36 Vdc Input, 6.5 Vdc Output; 50 W to 150 W
The FC050S6R5 and FC150S6R5 Power Modules use
adv anced, surface-mount tec hnology and deliver high-quality,
compact, dc-dc conversion at an economical price.
Applications
■
Distributed and redundant power architectures
■
Telecommunications
Options
■
Output voltage set-point adjustment (trim)
Features
■
Wide input range
■
High efficiency: 84% typical
■
Parallel operation with load sharing
■
Low profile: 12.7 mm (0.5 in.)
■
Complete input and output filtering
■
Constant frequency
■
Case ground pin
■
Input-to-output isolation
■
Remote sense
■
Remote on/off
■
Short-circuit protection
■
Output overvoltage clamp
■
UL
* Recognized,
CSA
†
Certified,
TÜV
‡
Licensed
Description
The FC050S6R5 and FC150S6R5 Power Modules are dc-dc converters that operate over an input voltage
range of 18 Vdc to 36 Vdc and provide a precisely regulated dc output. The outputs are fully isolated from the
inputs, allowing versatile polarity configurations and grounding connections. The modules have maximum
power ratings from 50 W to 150 W at a typical full-load efficiency of 84%.
Built-in filtering, for both the input and output of each de vice, eliminates the need f or external filters. Two or more
modules may be paralleled with forced load sharing for redundant or enhanced power applications. The
package , which mounts on a printed-circuit board, accommodates a heat sink f or high-temperature applications.
*
UL
is a registered trademark of Underwriters Laboratories, Inc.
†
CSA
is a registered trademark of Canadian Standards Association.
‡
TÜV
is a registered trademark of Technischer Überwachungs-Verein.
2 Tyco Electronics Corp.
Data Sheet
May 1998
dc-dc Converters; 18 to 36 Vdc Input, 6.5 Vdc Output; 50 W to 150 W
FC050S6R5 and FC150S6R5 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, alwa ys use an input line fuse. The
safety agencies require a normal-blow, dc fuse with a maximum rating of 15 A (see Saf ety Consider ations 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) V
I
— 36 Vdc
I/O Isolation Voltage — — 500 V
Operating Case Temperature
(See Thermal Considerations section and
Figure 16.)
T
C
090°C
Storage Temperature T
stg
–55 125 °C
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):
FC050S6R5
FC150S6R5 I
I, max
I
I, max
—
——
—4
12 A
A
Inrush Transient i
2
t — — 2.0 A
2
s
Input Reflected-ripple Current, Peak-to-peak
(5 Hz to 20 MHz, 12 µH source impedance;
see Figure 7.)
— — 40 — mAp-p
Input Ripple Rejection (120 Hz) — — 60 — dB
Tyco Electronics Corp. 3
Data Sheet
May 1998 dc-dc Converters; 18 to 36 Vdc Input, 6.5 Vdc Output; 50 W to 150 W
FC050S6R5 and FC150S6R5 Power Modules:
Electrical Specifications
(continued)
Table 2. Output Specifications
Parameter Symbol Min Typ Max Unit
Output Voltage
(Over all operating input voltage, resistive load,
and temperature conditions until end of life; see
Figure 8 and Feature Descriptions.)
V
O
6.17 — 6.83 Vdc
Output Voltage Set Point
(V
I
= 28 V; I
O
= I
O, max
; T
C
= 25 °C):
Unit Operating in Parallel or PARALLEL Pin
Shorted to SENSE(–) (See Figure 8 and
Feature Descriptions.)
PARALLEL Pin Open
V
O, set
V
O, set
6.37
6.37
—
—
6.63
6.76
Vdc
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 °C to 90 °C)
—
—
—
—
—
—
0.05
0.2
10
0.2
0.4
50
%
%
mV
Output Ripple and Noise Voltage
(See Figure 4 and Figure 9.):
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 specifications.):
FC050S6R5
FC150S6R5 I
O
I
O
1
1—
—7.7
23.1 A
A
Output Current-limit Inception
(V
O
= 5.85 V ; see Figure 2 and F eature Descriptions.) — 103 — 130 % I
O, max
Output Short-circuit Current
(V
O
= 250 mV; see Figure 2.) — — 135 170 % I
O, max
External Load Capacitance
(electrolytic, total f or one unit or multiple par alleled
units):
FC050S6R5
FC150S6R5 —
—0
0—
—2200
5000 µF
µF
Efficiency
(V
I
= 28 V; I
O
= I
O, max
; T
C
= 25 °C;
see Figure 3 and Figure 8.)
η
82 84 — %
Dynamic Response
(
∆
I
O
/
∆
t = 1 A/10 µs, V
I
= 28 V, T
C
= 25 °C; see
Figure 5 and Figure 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)
—
—
—
—
—
—
—
—
150
300
150
300
—
—
—
—
mV
µs
mV
µs
4 Tyco Electronics Corp.
Data Sheet
May 1998
dc-dc Converters; 18 to 36 Vdc Input, 6.5 Vdc Output; 50 W to 150 W
FC050S6R5 and FC150S6R5 Power Modules:
Electrical Specifications
(continued)
Table 3. Isolation Specifications
General Specifications
Feature Specifications
Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature
conditions. See Feature Descriptions for further information.
Parameter Min Typ Max Unit
Isolation Capacitance — 1700 — pF
Isolation Resistance 10 — — M
Ω
Parameter Min Typ Max Unit
Calculated MTBF (I
O
= 80% of I
O, max
; T
C
= 40 °C) 2,000,000 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 10 and Feature Descriptions.):
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 µA
Leakage Current
Turn-on Time
(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
—
—
—
—
—
—
—
—
5
1.2
1.0
18
50
10
V
mA
V
µA
ms
Output Voltage Adjustment
(See Feature Descriptions.):
Output Voltage Remote-sense Range
Output Voltage Set-point Adjustment Range (trim) —
——
90 —
—0.6
110 V
%V
O, nom
Parallel Operation Load Sharing
(See Feature Descriptions.) ———20% I
O, max
Output Overvoltage Clamp V
O, clamp
7.5 8.1 9.1 V
Tyco Electronics Corp. 5
Data Sheet
May 1998 dc-dc Converters; 18 to 36 Vdc Input, 6.5 Vdc Output; 50 W to 150 W
FC050S6R5 and FC150S6R5 Power Modules:
Characteristic Curves
The f ollo wing figures pro vide typical char acteristics f or the FC150S6R5 Power Module. The FC050S6R5 char acter-
istics are similar to the FC150S6R5 characteristics provided here, scaled by power level where appropriate.
8-2097(C)
Figure 1. Typical FC150S6R5 Input Characteristics
at Room Temperature
8-1566(C)
Figure 2. Typical FC150S6R5 Output
Characteristics at Room T emperature and
28 V Input
8-1567(C)
Figure 3. Typical FC150S6R5 Efficiency vs. Output
Current at Room Temperature
4 8 12 16 20 24
0
8
INPUT VOLTAGE, V
I
(
V
)
4
2
6
INPUT CURRENT, I
I
(A)
12
28 36
0
10
32
I
O
= 15 A
I
O
= 30 A
9 12151821
0
4
OUTPUT CURRENT, I
O
(
A
)
2
1
3
OUTPUT VOLTAGE, V
O
(V)
7
243
6
27
630
5
91215
72
82
OUTPUT CURRENT, I
O
(
A
)
78
74
80
88
183
86
21 24
84
6
76
V
I
= 18 V
V
I
= 36 V
EFFICIENCY, (%)
V
I
= 28 V
66 Tyco Electronics Corp.
Data Sheet
May 1998
dc-dc Converters; 18 to 36 Vdc Input, 6.5 Vdc Output; 50 W to 150 W
FC050S6R5 and FC150S6R5 Power Modules:
Characteristic Curves
(continued)
8-1568(C)
Figure 4. Typical FC150S6R5 Output Ripple
Voltage at Room Temperature, 28 V Input,
and 23.1 A Output
8-1569(C)
Figure 5. Typical FC150S6R5 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.)
TIME, t
(
500 ns/div
)
OUTPUT VOLTAGE, V
O
(V)
(50 mV/div)
TIME, t
(
50
µ
s/div
)
OUTPUT VOLTAGE, VO (V)
(100 mV/div)
OUTPUT CURRENT, IO (V)
(3 A/div)
11.5
5.8
8-1570(C)
Figure 6. Typical FC150S6R5 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.)
TIME, t
(
50
µ
s/div
)
OUTPUT VOLTAGE, V
O
(V)
(100 mV/div)
OUTPUT CURRENT, I
O
(V)
(3 A/div)
17.3
11.5
Tyco Electronics Corp. 7
Data Sheet
May 1998 dc-dc Converters; 18 to 36 Vdc Input, 6.5 Vdc Output; 50 W to 150 W
FC050S6R5 and FC150S6R5 Power Modules:
Test Configurations
8-203(C).l
Note: Measure input reflected-ripple current with a simulated source
inductance (L
TEST
) of 12 µH. Capacitor C
S
offsets possible bat-
tery impedance. Measure current as shown above.
Figure 7. Input Reflected-Ripple Test Setup
8-683(C).c
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 8. Output Voltage and Efficiency
Measurement Test Setup
8-513(C)
Note: Use a 0.1 µF ceramic capacitor. Scope measurement should
be made using a BNC socket. Position the load between
50 mm and 80 mm (2 in. and 3 in.) from the module.
Figure 9. 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 configuration in Figure 7, a 33 µF
electrolytic capacitor (ESR < 0.7
Ω
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
22.2-950, and EN60950.
For the converter output to be considered meeting the
requirements of safety extra-low voltage (SELV), the
input must meet SELV requirements.
If the input meets extra-low voltage (ELV) require-
ments, then the converter’s output is considered ELV.
The input to these units is to be provided with a maxi-
mum 15 A normal-blow fuse in the ungrounded lead.
Electrical Descriptions
Current Limit
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 specified range.
TO OSCILLOSCOPE
12 µH V
I
(+)
V
I
(–)
CURRENT
PROBE
L
TEST
BATTERY C
S
220 µF
ESR < 0.1 Ω
@ 20 °C, 100 kHz 33 µF
ESR < 0.7 Ω
@ 100 kHz
V
I
(–)
V
O
(+)
PARALLEL
SENSE(+)
SENSE(–)
V
O
(–)
V
I
(+) I
O
LOAD
CONTACT AND
DISTRIBUTION LOSSES
SUPPLY I
I
CONTACT
RESISTANCE
ηVO+()
–
V
O
–
()[]
I
O
V
I
+
()
–
V
I
–
()[]
I
I
--------------------------------------------------
x
100=
V
O
(+)
V
O
(–)
RESISTIVE
LOAD
SCOPE
0.1 µF
COPPER STRIP
88 Tyco Electronics Corp.
Data Sheet
May 1998dc-dc Converters; 18 to 36 Vdc Input, 6.5 Vdc Output; 50 W to 150 W
FC050S6R5 and FC150S6R5 Power Modules:
Feature Descriptions
Remote On/Off
To turn the power module on and off , the user must
supply a s witch to control the v oltage between the on/off
terminal and the V
I
(–) terminal (V
on/off
). The switch can be
an open collector or equivalent (see Figure 10). 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 s witch
should maintain a logic-low v oltage while sinking 1 mA.
During a logic high, the maximum V
on/off
generated by
the power module is 18 V. The maximum allowable
leakage current of the switch at V
on/off
= 18 V is 50 µA.
If not using the remote on/off feature, short the
ON/OFF pin to V
I
(–).
8-580(C).b
Figure 10. Remote On/Off Implementation
Remote Sense
Remote sense minimizes the effects of distribution
losses by regulating the voltage at the remote-sense
connections. For single-unit operation, the PARALLEL
pin should be connected to SENSE(–). The voltage
between the remote-sense pins and the output termi-
nals must not exceed the output voltage sense range
given in the Feature Specifications table, i.e.:
[V
O
(+) – V
O
(–)] – [SENSE(+) – SENSE(–)]
≤
2.4 V
The voltage between the V
O
(+) and V
O
(–) terminals
must not exceed the minimum output overvoltage
clamp 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 11.
If not using the remote-sense f eature 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 11. Effective Circuit Configuration for
Single-Module Remote-Sense Operation
Output Voltage Set-P oint Adjustment (Trim)
When not using the trim feature , leav e the TRIM pin open.
Adjustment with TRIM Pin
Output voltage adjustment allows the output voltage
set point to be increased or decreased by adjusting an
external resistor connected between the TRIM pin and
either the SENSE(+) or SENSE(–) pins (see Figure 12
and Figure 13).
Connecting the external resistor (R
trim-up
) between the
TRIM and SENSE(–) pins (V
O , adj
) increases the output
voltage set point as defined in the following equation:
Connecting the external resistor (R
trim-down
) between
the TRIM and SENSE(+) pins (V
O
,
adj
) decreases the
output voltage set point as defined in the following
equation:
The voltage between the V
O
(+) and V
O
(–) terminals
must not exceed the minimum output overvoltage
clamp 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 11.
+
I
on/off
–
V
on/off
CASE
ON/OFF
V
I
(+)
V
I
(–)
PARALLEL
SENSE(+)
SENSE(–)
V
O
(+)
V
O
(–)
VO(+)
PARALLEL
SENSE(+)
SENSE(–)
VO(–)
VI(+)
VI(–)
IOLOAD
CONTACT AND
DISTRIBUTION LOSSES
SUPPLY II
CONTACT
RESISTANCE
Rtrim-up 1.25 5.620×
VO adj,5–
---------------------------------
k
Ω
=
Rtrim-down VO,
adj
1.25
–
()
5.620
×
5V
O,
adj
–
----------------------------------------------------------- k
Ω
=
Tyco Electronics Corp. 9
Data Sheet
May 1998 dc-dc Converters; 18 to 36 Vdc Input, 6.5 Vdc Output; 50 W to 150 W
FC050S6R5 and FC150S6R5 Power Modules:
Feature Descriptions
(continued)
Output Voltage Set-Point Adjustment
(Trim)
(continued)
8-717(C).c
Figure 12. Circuit Configuration to Trim Up Output
Voltage
8-718(C).c
Figure 13. Circuit Configuration to Trim Down
Output V oltage
Adjustment Without TRIM Pin
The output voltage can be adjusted by placing an
external resistor (R
adj
) between the SENSE(+) and
V
O
(+) terminals (see Figure 14). By adjusting R
adj
, the
output voltage can be increased b y 10% of the nominal
output voltage. The equation below shows the
resistance required to obtain the desired output
voltage.
R
adj
= (V
O, adj
– V
O, nom
) 944.3
Ω
8-710(C).c
Figure 14. Circuit Configuration to Adjust Output
Voltage
Forced Load Sharing (Parallel Operation)
For either redundant operation or additional power
requirements, the po wer modules can be configured for
parallel operation with forced load sharing (see
Figure 15). For a typical redundant configuration,
Schottky diodes or an equivalent should be used to
protect against short-circuit conditions. Because of the
remote sense, the forward-voltage drops across the
Schottky diodes do not affect the set point of the
voltage applied to the load. For additional power
requirements, where multiple units are used to develop
combined power in excess of the rated maximum, the
Schottky diodes are not needed.
Good layout techniques should be observed for noise
immunity. To implement forced load sharing, the follow-
ing connections must be made:
■
The parallel pins of all units must be connected
together. The paths of these connections should be
as direct as possible.
■
All remote-sense pins should be connected to the
power bus at the same point, i.e., connect all
SENSE(+) pins to the (+) side of the power b us at the
same point and all SENSE(–) pins to the (–) side of
the power b us at the same point. Close proximity and
directness are necessary for good noise immunity.
When not using the parallel feature, short the
PARALLEL pin to SENSE(–).
8-581(C)
Figure 15. Wiring Configuration for Redundant
Parallel Operation
V
O
(+)
PARALLEL
SENSE(+)
SENSE(–)
V
O
(–)
V
I
(+)
V
I
(–)
I
O
LOAD
CONTACT AND
DISTRIBUTION LOSSES
SUPPLY I
I
CONTACT
RESISTANCE
TRIM R
trim-up
V
O
(+)
PARALLEL
SENSE(+)
SENSE(–)
V
O
(–)
V
I
(+)
V
I
(–)
I
O
LOAD
CONTACT AND
DISTRIBUTION LOSSES
SUPPLY I
I
CONTACT
RESISTANCE
TRIM R
trim-down
V
O
(+)
PARALLEL
SENSE(+)
SENSE(–)
V
O
(–)
V
I
(+)
V
I
(–) I
O
LOAD
CONTACT AND
DISTRIBUTION LOSSES
SUPPLY I
I
CONTACT
RESISTANCE
R
adj
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
(–)
1010 Tyco Electronics Corp.
Data Sheet
May 1998dc-dc Converters; 18 to 36 Vdc Input, 6.5 Vdc Output; 50 W to 150 W
FC050S6R5 and FC150S6R5 Power Modules:
Feature Descriptions
(continued)
Output Overvoltage Clamp
The output overvoltage clamp consists of control cir-
cuitry, independent of the primary regulation loop, that
monitors the voltage on the output terminals. The con-
trol loop of the clamp has a higher voltage set point
than the primary loop (see Feature Specifications
table). This provides a redundant voltage-control that
reduces the risk of output overvoltage.
Thermal Considerations
Introduction
The power modules operate in a variety of thermal
environments; however, sufficient cooling should be
provided to help ensure reliable operation of the unit.
Heat-dissipating components inside the unit are 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 occurs
at the position indicated in Figure 16.
8-582(C).v
Note: Top view, measurements shown in millimeters and (inches).
Pin locations are for reference only.
Figure 16. Case Temperature Measurement
Location
The temperature at this location should not exceed
95 °C . The maximum case temperature can be limited to
a lower value for extremely high reliability. The output
pow er of the module should not exceed the rated power
f or the module as listed in the Ordering Information table.
For additional information about these modules, refer to
the
Thermal Management for High-Power Board-
Mounted Power Modules
Technical Note (TN97-009EPS).
Heat Transfer Without Heat Sinks
Derating curves for forced-air cooling without a heat
sink are shown in Figure 17. These curves can be used
to determine the appropriate airflow for a given set of
operating conditions. F or e xample , if the unit dissipates
20 W of heat, the correct airflow in a 40 °C en vironment
is 1.0 m/s (200 ft./min.).
8-587(C)
Figure 17. Power Derating vs. Local Ambient
Temperature and Air Velocity
Heat Transfer with Heat Sinks
The power modules have threaded #4-40 fasteners,
which enable heat sinks or cold plates to be attached to
the module. The mounting torque must not exceed
0.56 N-m (5 in.-lb.).
Thermal derating with heat sinks is expressed b y using
the ov er all thermal resistance of the module. Total mod-
ule thermal resistance (
θ
ca) is defined as the maximum
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 16. Case-to-ambient thermal resis-
tance vs. airflow for various heat sink configurations is
shown in Figure 18 and Figure 19. These curves were
obtained by experimental testing of heat sinks, which
are offered in the product catalog.
IN:DC 28V, 6.5A OUT:DC 6.5V, 23.1A
150W
PARALLEL
+
SENSE
–
+
OUT
–
CASE
ON/OFF
+
–IN
FC150S6R59
DC-DC Power Module
MADE IN USA
Protected by U.S. Paterts: 5,036,452 5,179,365
MEASURE CASE
TEMPERATURE HERE
76 (3.0)
18 (0.7)
Lucent
TRIM
TUV Rheinland¨
30
POWER DISSIPATION, P
D
(W)
LOCAL AMBIENT TEMPERATURE, T
A
(°C)
20
10
020406080
40
100
0
0.1 m/s (20 ft./min.)
NATURAL CONVECTION
0.5 m/s (100 ft./min.)
1.0 m/s (200 ft./min.)
1.5 m/s (300 ft./min.)
2.0 m/s (400 ft./min.)
2.5 m/s (500 ft./min.)
3.0 m/s (600 ft./min.)
3.5 m/s (700 ft./min.)
4.0 m/s (800 ft./min.)
θca ∆TC max,
PD
--------------------- TCTA–()
PD
------------------------
==
Tyco Electronics Corp. 11
Data Sheet
May 1998 dc-dc Converters; 18 to 36 Vdc Input, 6.5 Vdc Output; 50 W to 150 W
FC050S6R5 and FC150S6R5 Power Modules:
Thermal Considerations (continued)
Heat Transfer with Heat Sinks (continued)
8-696(C)
Figure 18. Heat Sink Resistance Curves; Fins
Oriented Along Width
8-697(C)
Figure 19. Heat Sink Resistance Curves; Fins
Oriented Along Length
These measured resistances are from heat transfer
from the sides and bottom of the module as well as the
top side with the attached heat sink; therefore, the
case-to-ambient thermal resistances shown are gener-
ally lower than the resistance of the heat sink by itself.
The module used to collect the data in Figure 18 and
Figure 19 had a thermal-conductive dry pad between
the case and the heat sink to minimize contact resis-
tance.
To choose a heat sink, determine the power dissipated
as heat by the unit for the particular application.
Figure 20 shows typical heat dissipation for a range of
output currents and three voltages for the FC050S6R5
and FC150S6R5.
8-1571(C)
Figure 20. Power Dissipation as Heat vs. Output
Current
Example
If an 85 °C case temperature is desired, what is the
minimum airflow necessary? Assume the FC150S6R5
module is operating at nominal line and an output cur-
rent of 21 A, maximum ambient air temperature of
40 °C, and the heat sink is 0.5 inch.
Solution
Given: VI = 28 V
IO = 21 A
TA = 40 °C
TC = 85 °C
Heat sink = 0.5 inch.
Determine PD by using Figure 20:
PD = 24 W
Then solve the following equation:
Use Figure 18 and Figure 19 to determine air velocity
for the 0.5 inch heat sink. The minimum airflow neces-
sary for the FC150S6R5 module depends on heat sink
fin orientation and is shown below:
■0.4 m/s (80 ft./min.) (oriented along width)
■0.45 m/s (90 ft./min.) (oriented along length)
5.0
4.0
3.0
2.0
1.0
0.0
NAT
CONV 0.5
(100) 1.0
(200) 1.5
(300) 2.0
(400) 2.5
(500)
THERMAL RESISTANCE, (°C/W)
AIR VELOCITY, m/s (ft./min.)
NO HEAT SINK
0.5 in. HEAT SINK
1 in. HEAT SINK
0.25 in. HEAT SINK
5.0
4.0
3.0
2.0
1.0
0.0
NAT
CONV 0.5
(100) 1.0
(200) 1.5
(300) 2.0
(400) 2.5
(500)
THERMAL RESISTANCE, (°C/W)
AIR VELOCITY, m/s (ft./min.)
NO HEAT SINK
0.5 in. HEAT SINK
1 in. HEAT SINK
0.25 in. HEAT SINK
6 9 12 15 18 21
0
25
OUTPUT CURRENT, I
O
(
A
)
15
10
20
POWER DISSIPATION, P
D
(W)
35
2
4
3
30
5
V
I
= 36 V
V
I
= 18 V
V
I
= 28 V
θca TCTA–()
PD
------------------------
=
θca 85 40–()
24
------------------------
=
θca 1.88 °C/W=
1212 Tyco Electronics Corp.
Data Sheet
May 1998dc-dc Converters; 18 to 36 Vdc Input, 6.5 Vdc Output; 50 W to 150 W
FC050S6R5 and FC150S6R5 Power Modules:
Thermal Considerations (continued)
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 (θcs) and
sink-to-ambient (θsa) as shown in Figure 21.
8-1304(C)
Figure 21. Resistance from Case-to-Sink and Sink-
to-Ambient
For a managed interface using thermal grease or foils,
a value of θcs = 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 provides
a conservative estimate for such instances.
Layout Considerations
Copper paths must not be routed beneath the power
module standoffs.
PDTCTSTA
cs sa
θsa TCTA–()
PD
------------------------ θcs–=
Tyco Electronics Corp. 13
Data Sheet
May 1998 dc-dc Converters; 18 to 36 Vdc Input, 6.5 Vdc Output; 50 W to 150 W
FC050S6R5 and FC150S6R5 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.)
T op View
Side View
Bottom View
8-719(C).v
FC150S6R59
DC-DC Power Module
MADE IN USA
Lucent
IN:DC 28V, 6.5A OUT:DC 6.5V, 23.1A
150W
Protected by U.S. Patents: 5,036,452 5,179,365
121.9 (4.80)
52.83
(2.080)
55.63 (2.190)
5.3
(0.21)
FOR OPTIONAL HEAT SINK MOUNTING
#4-40 THD 4.6 (0.18) DEEP
6 PLCS
PARALLEL
+
SENSE
–
+
OUT
–
CASE
ON/OFF
+
–IN
TRIM
5.3
(0.21)
63.5
(2.50)
TRIM OPTION ONLY
55.63 (2.190)
TUV Rheinland¨
3.8 (0.15)
TYP 8 PLCS
12.7
(0.50)
4.1
(0.16 )
1.0 (0.04)
1.57 (0.062) ± 0.05 (0.002) DIA
TIN-PLATED BRASS
TYP 12 PLCS
113.54
(
4.470
)
12.2
(0.48)
25.40
(1.000) 30.48
(1.200)
4.3
(
0.17
)
10.16
(0.400)
15.24
(0.600)
35.56
(1.400)
20.32
(0.800)
5.08
(0.200)
TRIM OPTION ONLY
14 Tyco Electronics Corp.
Data Sheet
May 1998
dc-dc Converters; 18 to 36 Vdc Input, 6.5 Vdc Output; 50 W to 150 W
FC050S6R5 and FC150S6R5 Power Modules:
Recommended Hole Pattern
Component-side footprint.
Dimensions are in millimeters and (inches).
8-719(C).v
Ordering Information
This family of modules is not recommended f or ne w designs. For new designs, we recommend the JFC family
of power modules. Please refer to the
Power Systems Selection Guide
or to individual data sheets. Please contact
your Tyco Electronics’ Account Manager or Field Application Engineer for pricing and availability.
Optional TRIM pin is designated by the ending 9 in device code name.
Input
Voltage Output
Voltage Output
Power Trim Device
Code Comcode
28 V 6.5 V 50 W Yes FC050S6R59 Not Available
28 V 6.5 V 150 W Yes FC150S6R59 Not Available
28 V 6.5 V 50 W No FC050S6R5 106949837
28 V 6.5 V 150 W No FC150S6R5 106793987
113.54 (4.470)
4.3 (0.17)
12.2
(0.48)
20.32
(0.800) 25.40
(1.000) 30.48
(1.200)
5.08
(0.200)
10.16
(0.400)
15.24
(0.600) 35.56
(1.400)
TRIM OPTION ONLY
PARALLEL
+
SENSE
–
+
OUT
–
ON/OFF
+IN
TRIM
CASE
–
Tyco Electronics Corp. 15
Data Sheet
May 1998 dc-dc Converters; 18 to 36 Vdc Input, 6.5 Vdc Output; 50 W to 150 W
FC050S6R5 and FC150S6R5 Power Modules:
Notes
Data Sheet
May 1998dc-dc Converters; 18 to 36 Vdc Input, 6.5 Vdc Output; 50 W to 150 W
FC050S6R5 and FC150S6R5 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.tycoeleectronics.com
Tyco Electronics Corportation reserv es the right to mak e changes to the product(s) or information contained herein without notice. No liability is assumed as a result of their use or application.
No rights under any patent accompany the sale of any such product(s) or information.
© 2001 Tyco Electronics Corporation, Harrisburg, PA. All International Rights Reserved.
Printed in U.S.A.
May 1998
DS97-523EPS
