A AH H2 20 00 0W W4 48 8V V0 05 50 0V V4 40 0A AN N 48V 40A 5V High Efficiency, Isolated Half 48V 40A 5V High Efficiency, Isolated Half in out out in out out Brick DC-DC Converter Brick DC-DC Converter Features Features • Very high efficiency: 92%@20A, 91%@40A 48Vin, 25°C, 300LFM) • Wide input voltage range (36 to 75Vdc) • Total weight: 63g. (2.22oz.) Open-Frame Version; Max 85g. (2.99oz.) Metal-Plate Version • Low profile, industry standard footprint and pinout: 2.3" x 2.4" x 0.4" (58.4mm x 61.0mm x 10.2mm) • Adjustable output voltage (+10% / -20% ) • Input to Output Isolation at 2000Vdc, 10MΩ Ω Ω Ω • Fixed Frequency (300 KHz) • Undervoltage Lockout (UVLO) • Overcurrent protection • Overtemperature protection • Auto-restart after overcurrent shutdown • Remote sense Product Highlights Product Highlights • Remote ON/OFF • Operating temperature -40/+100°C • The AH DC-DC Converter family is Ault’s • ISO 9001 Certified manufacturing processes solution for next generation, cutting-edge • Fully Safety Certified board applications. • The synchronous rectification topology uses MOSFET instead of Schottky diodes providing extreme reduction in heat generation, boosting efficiency, eliminating the need for a heat sink and increasing reliability. • The low profile (0.4”), open frame construction allows smaller card pitch and improves ventilation. • The fixed switching frequency provides predictable EMI characteristics. AH200W48V050V40AN.doc– page 1 - AH200W 48V 5.0V High Efficiency DC-DC Converter M Me ec ch ha an niic ca all D Dr ra aw wiin ng gs s - All dimensions are in inches (mm) - Tolerances: x.xx in. +/-0.2 in. (0.5mm) - Pins 1-4, 6-8 are 0.040" (1.02mm) dia. with 0.080" (2.03mm) dia. standoff shoulders OPEN-FRAME VERSION METAL-PLATE VERSION PINOUT Description Pin Name Function 1 Vin (-) Return terminal for the -48V input bus 2 Not Present 3 ON/OFF Logic signal referenced to Vin (-), TTL compatible (internal pull up ) to turn converter on and off 4 Vin (+) Positive terminal for the +48V input bus 5 Vout (+) Positive terminal for output voltage 6 Sense (+) Positive remote sense 7 TRIM Output voltage TRIM 8 Sense (-) Negative remote sense 9 Vout (-) Return terminal for output voltage AH200W48V050V40AN.doc– page 2- AH200W 48V 5.0V High Efficiency DC-DC Converter S Sp pe ec ciif fiic ca at tiio on ns s (Typical values are at nominal input line, full load, airflow 300 LFM, 25°C ambient temperature unless otherwise specified) Input characteristics Notes & Conditions Min Typ Max Units Operating Input Voltage Range Note 1 36 48 75 V Input Surge Voltage T< 10μs 100 V Input Under-Voltage Lockout Turn-On Voltage Threshold 35.0 35.2 35.4 V Turn-Off Voltage Threshold 31.7 31.9 32.1 V Lockout Hysteresis Voltage 3.3 3.3 3.3 V V =36V; Full Load at IN Maximum Input Current (I ) nominal output 6.2 A INmax voltage No-load Input Current 70 100 mA Off Converter Input Current 8 10 mA 2 Inrush Current Transient Rating 0.03 A s Input Reflected-Ripple Current RMS; see figures 6,7 10 15 mA Output characteristics Notes & Conditions Min Typ Max Units Output Voltage Set Point 50 % Load 4.98 5.00 5.02 V Output Voltage Regulation Over Load ± 6 ± 10 mV Over Line ± 6 ± 10 mV Over Temperature ± 25 ± 40 mV Total Output Voltage Range 4.95 5.05 V Output Voltage Ripple and Noise 20 MHz bandwidth Peak to Peak 80 mV Full load, 2x10μF RMS ceramic; see fig. 6, 8 18 mV Operating Output Current Range 0 - 40 A Output Voltage Output DC Current Limit Inception 42 45 48 A 10% low Output DC Current Limit Shutdown See figure 5 2.3 V Voltage Admissible Output Capacitance Full load, resistive 0 40000 μF Dynamic Notes & Conditions Min Typ Max Units characteristics 470μF load cap. Output Voltage Current Transient 1A/μs; see figure 3 50% to 75% load 150 mV Positive Step Change in IOUT Negative Step Change in I 75% to 50% load 150 mV OUT Settling Time to 1% 100 μs Turn On Transient See figures 1, 2 Turn On Time Full load 4 ms 10mF load Output Voltage Overshoot 0 % capacitance, Iout= 0A Efficiency Notes & Conditions Min Typ Max Units Load 100% Vin=50V 90.5 91 % Load 75% Vin=50V 91.5 92 % Load 50% Vin=50V 91.5 92 % NOTE 1 : Absolute max. input voltage 80V AH200W48V050V40AN.doc– page 3- AH200W 48V 5.0V High Efficiency DC-DC Converter Isolation Notes & Conditions Min Typ Max Units characteristics Isolation Voltage input to output Basic isolation 2000 V DC Isolation Voltage Input to plate Basic isolation 2000 V DC Isolation Capacitance 3300 pF Isolation Resistance 10 MΩ General Max Notes & Conditions Min Typ Units characteristics Operating Range Temperature Maximum Rating -40 +100 °C Storage Temperature Maximum Rating -50 +120 °C Relative Humidity Non condensing 5 95 % Bellcore Issue 4 Calculated MTBF 1,965,099 hours RDF93 HRD Issue 5 EN60950; UL & CSA 60950 & IEC 60950. Approvals CE to LVD Feature characteristics Min. Typ. Max Units Switching frequency 300 kHz ON/OFF Control Off-State Voltage 2.7 15 V On-State Voltage 0 0.8 V Output Voltage Trim Range -20 +10 % Output Over-Voltage Protection 130 % Over-Temperature shutdown PCB Hot spot 125 °C AH200W48V050V40AN.doc– page 4- AH200W 48V 5.0V High Efficiency DC-DC Converter P Pe er rf fo or rm ma an nc ce e C Cu ur rv ve es s Figure 1. Turn-on transient at full rated current (resistive load) Figure 2. Turn-on transient at zero load. Top Trace: Vout; 2V/div (Vin=50V) Top Trace: Vout; 2V/div (Vin=50V) Bottom Trace: ON/OFF; 5V/div Bottom Trace: ON/OFF; 5V/div Figure 3. Output Voltage response (200mV/div ) to a step- Figure 4. Output Voltage response (50mV/div ) to a step- change in load current (50% - 75% - 50% of change in load current (50% - 75% - 50% of Imax:dI/dt=1A/μs. Imax:dI/dt=0.1A/μs). Load capacitance: 470μF, 30mOhm ESR tantalum Load capacitance: 470μF, 100mOhm ESR tantalum capacitor . capacitor . AH200W48V050V40AN.doc– page 5- AH200W 48V 5.0V High Efficiency DC-DC Converter Figure 7 Figure 8 Source impedance DC/DC Vout Is Converter - Ic - Cerami c Cerami c cap ESR cap Figure 5. Load current (0.5A/div) vs time when converter Figure 6. Test set-up diagram showing measurement point for attempts to turn on into 10mOhm short circuit. Input Reflected Ripple Current and Output Voltage Ril Figure 7. Input reflected ripple current at nominal input voltage Figure 8. Output voltage ripple at nominal input voltage and and rated load current (see Fig.6) rated load current. Load cap: 20μF ceramic capacitor ** see note below (see Fig.6) ** Output ripple measure: care must be taken to insert the output capacitors in the output current paths. The measurements is taken with the following output capacitors: -2x AVX PN CM316X5R106K006AT -2x Murata PN GRM31CR60J106KC01L -2x Taiyo Yuden PN JMK316B106KL AH200W48V050V40AN.doc– page 6- AH200W 48V 5.0V High Efficiency DC-DC Converter 97 94 91 88 85 36 48 75 82 79 Figure 9. Efficiency vs. load current for 76 minimum, nominal and maximum input voltage. 73 70 0 8 16 24 32 40 output current [A] 20 18 16 14 12 36 10 48 75 8 Figure 10. Power dissipation vs. load current for 6 minimum, nominal and maximum input voltage. 4 2 0 0 8 16 24 32 40 o u t p u t c u rre n t [A ] AH200W48V050V40AN.doc– page 7- efficiency % Power Dissipation [W] AH200W 48V 5.0V High Efficiency DC-DC Converter To be provided in the next issue To be provided in the next issue Figure 11: Maximum output power derating curves vs. ambient Figure 12: Thermal plot of converter at 30 amp load current with air temperature for airflow rates of 0 LFM through 400 40°C air flowing at the rate of 300 LFM. LFM with air flowing from input to output and Converter in vertical position with air flowing from nominal input voltage. input to output. To be provided in the next issue To be provided in the next issue Figure 13: Maximum output power derating curves vs. ambient Figure 14: Thermal plot of converter at 30 amp load current with air temperature for airflow rates of 0 LFM through 400 40°C air flowing at the rate of 300 LFM. LFM with air flowing from output to input and Converter in vertical position with air flowing from nominal input voltage. output to input. AH200W48V050V40AN.doc– page 8- AH200W 48V 5.0V High Efficiency DC-DC Converter F Fe ea at tu ur re es s a an nd d P Piin ns s d de es sc cr riip pt tiio on n SAFETY rd The converter is certified according to EN60950, UL and CSA 60950, 3 ed., and IEC 60950. The converter has basic insulation rating. The converter meets NEBS compatibility. An external input fuse must always be used. ON-OFF CONTROL The default logic is negative: the on/off (pin #2) voltage is referenced to the -Vin (pin #4) and must be lower than 0.8V to turn the module on, and higher than 2.7V to shut the module off. Consult the factory for availability of positive logic modules. TRIMMING The output voltage can be trimmed by means of an external resistor connected between the Trim and the +S or -S pins. The selection of the resistor follows the industry standard. A resistor connected between Trim 8and - S pins will decrease the output voltage. For a decrease of Δ% of the nominal output voltage, the value of the resistor should be: � − � 100% V V � � nominal target � � R = − 2kΩ , where Δ = ×100% trim-down � � � � Δ � � V nominal � � TRIM DOWN 1000 100 10 1 0 2 4 6 8 10 12 14 16 18 20 % Decrease in Output Voltage Figure A A resistor connected between Trim and + S pins will increase the output voltage. For a desired increase of Δ% of the nominal output voltage, the value of the resistor should be: � � V nom � � −2 • + V V tar nom � � V ref � � R = kΩ , where V = Nominal Voltage, V = Target Voltage, V =1.225 V trim-up nom tar ref − V V tar nom AH200W48V050V40AN.doc– page 9- Trim Resistance (kOhms) AH200W 48V 5.0V High Efficiency DC-DC Converter TRIM UP 1000 100 10 0 1234 56789 10 Figure B % Increase in Output Voltage SENSE (+ or -) The + or – S pins should be connected to the load to have a tight regulation. The maximum voltage drop that can be compensated for is 10% of Vout. Note that the overvoltage protection senses the output voltage directly at + Vout and – Vout pins. Care must be taken to avoid that the voltage at the output terminals + Vout and –Vout pins exceeds 5.5. THERMAL CONSIDERATIONS The module is provided with thermal protection that prevents the hot spot on the PCB from exceeding 125°C. Depending on the air flow rate and the ambient temperature the maximum current reachable when the thermal protection kicks in is shown in Figure 11-12-13-14. OVERCURRENT PROTECTION The overcurrent limit inception is typically at 110% of the rated output current. When this limit is exceeded the output voltage decreases. A further current increase will trigger the hiccup protection. The behavior of the converter when the output is short circuited is shown in Figure 5. Ault Incorporated 7105 Northland Terrace Phone: 1-800-635-3311 763-592-1900 Fax: 7630592-1911 Website: http: // www.aultinc.com AH200W48V050V40AN.doc– page 10- Trim Resistance (kOhms)