A AQ Q0 03 38 8W W4 48 8V V0 01 15 5V V2 25 5A AN N AQ038W48V015V25AN 4 48 8V V 2 25 5A A 1 1..5 5V V H Hiig gh h E Ef ff fiic ciie en nc cy y,, iis so olla at te ed d in out out in out out Quarter Brick DC-DC Converter Quarter Brick DC-DC Converter Features Features Features · Very high efficiency: 88% · Wide input voltage range (36 to 75Vdc) · Total weight: 34g. (1.2oz.) · Low profile, industry standard footprint and pin out: 2.3" x 1.45" x 0.36" (58.4mm x 36.8mm x 9.15mm) · Adjustable output voltage (+/- 10%) · Input to Output Isolation at 2000Vdc,10M: · Fixed Frequency (Input-Output ripple 400 KHz) · Undervoltage Lockout (UVLO) · Overcurrent protection · Overtemperature protection · Auto-restart after overcurrent shutdown · Remote sense · Remote ON/OFF · Operating temperature -40/+100°C · ISO 9001 Certified manufacturing processes · CSA/US, CSA, Kema certified Product Highlights Product Highlights Product Highlights · The AQ DC-DC Converter family is Ault’s solution for next generation, cutting-edge 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 (0.36”), open frame construction allows smaller card pitch and improves ventilation. · The fixed switching frequency provides predictable EMI characteristics. 7105 Northland Terrace Minneapolis, MN 55428-1028 USA Tel:763.592.1900 FAX:763.592.1911 WEB:www.aultinc.com AQ038W- 48V-1.5V High Efficiency DC-DC Converter Mechanical Drawings Mechanical Drawings Mechanical Drawings - All dimensions are in inches (mm) - Tolerances: x.xx in. +/-0.2 in. (0.5mm) 2.3 (58.42) 0.14 2.01 (3.68) (51) Ø=0.06 (2 pcs) (Ø=1.5) (2 pcs) Ø=0.04 (6 pcs) (Ø=1) (6 pcs) Bottom View PINOUT Description Pin Nam e Function 1 Vin (-) Return terminal for the -48V input bus 2 ON/OFF Logic signal referenced to Vin (-), TTL com patible (internal pull up ) to turn converter on and off 3 Vin (+) Positive terminal for the +48V input bus 4 Vout (+) Positive terminal for output voltage 5 Sense (+) Positive rem ote sense 6 TRIM O utput voltage TRIM 7 Sense (-) Negative rem ote sense 8 Vout (-) Return terminal for output voltage 7105 Northland Terrace Minneapolis, MN 55428-1028 USA Tel:763.592.1900 FAX:763.592.1911 WEB:www.aultinc.com 1.45 (36.83) 0.36 0.15 (9.35) (4) 0.42 0.3 0.3 (10.8) (7.62) (7.62) 0.42 0.15x4 (10.8) (3.81x4). AQ038W- 48V-1.5V High Efficiency DC-DC Converter Specifications Specifications Specifications (Typical value standard 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 Under-Voltage Lockout Turn-On Voltage Threshold 34.3 34.8 35.4 V Turn-Off Voltage Threshold 33.8 34.3 34.8 V Lockout Hysteresis Voltage 0.4 0.5 0.6 V Maximum Input Current (I ) V =36V; Full Load 1.2 A INmax IN No-load Input Current 40 mA Off Converter Input Current 4.1 6 mA 2 Inrush Current Transient Rating 0.01 A s Input Reflected-Ripple Current RMS; see figures 1, 2 3 mA N NO OT TE E 1 1:: NOTE 1: Absolute max. input voltage 80V Output Characteristics Notes & Conditions Min Typ Max Units Output Voltage Set Point 50% Load 1.495 1.502 1.505 V Output Voltage Regulation Load V = 48V ± 5 ± 8 mV nom Line I = 15A ± 2 ± 5 mV Temperature ± 10 ± 20 mV Total Output Voltage Range 1.475 1.525 V Output Voltage Ripple and Noise 20 MHz bandwidth Peak to Peak Full load; 40 60 mV see figure 1, 4 RMS 20 mV Operating Output Current Range 0 - 25 A Output DC Current Limit Inception 26 27.5 29 A Output DC Current Limit Shutdown See figure 5 1.2 1.225 1.275 V Voltage Admissible Output Capacitance Full load, resistive 20 000 mF Dynamic Notes & Conditions Min Typ Max Units Characteristics 470mF load cap, Output Voltage Current Transient 1A/ms; see figure 9 Positive Step Change 50%I to 75% I 150 mV o o Negative Step Change 75% I to 50% I 150 mV o o ms Settling Time to 1% 200 Turn-On Transient See figures 6 and 7 Turn-On Time Full load 15 25 ms Start-Up Inhibit Period 120 ms Efficiency Notes & Conditions Min Typ Max Units @ 25A 88 % @ 20A 88.5 % @ 15A 88.5 % Isolation Characterisitcs Notes & Conditions Min Typ Max Units Isolation Voltage input - output Basic Isolation 2000 V DC Isolation Capacitance Basic Isolation 2200 pF MW Isolation Resistance 10 7105 Northland Terrace Minneapolis, MN 55428-1028 USA Tel:763.592.1900 FAX:763.592.1911 WEB:www.aultinc.com AQ038W- 48V-1.5V High Efficiency DC-DC Converter Feature Characteristics Notes & Conditions Min. Typ. Max Units Double Frequency for Switching frequency 190 200 210 kHz Input-Output Ripple ON/OFF Control Off-State Voltage 2.7 15 V On-State Voltage 0.8 V Output Voltage Trim Range -10 +10 % Output Voltage Remote Sense +10 % Range Output Over-Voltage Protection 115 118.6 123 % Overcurrent Protection Threshold 26 - 35 A Over-Temperature shutdown 125 °C General Characteristics Notes & Conditions Min Typ Max Units Operating Range Temperature Maximum Rating -40 +100 °C Storage Temperature Maximum Rating -50 +120 °C Relative Humidity Non condensing 95 % Bellcore Issue 4 Calculated MTBF Min. 1,500,000 hours RDF93 HRD Issue 5 Approvals EN60955; UL1950; CSA22.2; CE Characteristic Curves Characteristic Curves Characteristic Curves Figure 3 Figure 2 Figure 4 DC/DC Vout Is Converter - Ic - Cerami c cap ESR FIGURE 1: Set-up diagram showing measurement Points for Input Terminal Ripple Current, Input Reflected Ripple Current and Output Voltage Ripple 7105 Northland Terrace Minneapolis, MN 55428-1028 USA Tel:763.592.1900 FAX:763.592.1911 WEB:www.aultinc.com AQ038W- 48V-1.5V High Efficiency DC-DC Converter FIGURE 2: Input Reflected Ripple Current, through a FIGURE 3: Input Terminal Ripple Current. 10mH source inductor at nominal input voltage Full rated output current and nominal input voltage with 10mH source impedance and and rated load current. (Ref. figure 1) 47mF electrolytic capacitor. (Ref. figure 1) FIGURE 4: Output voltage ripple at nominal input FIGURE 5: Load current as a function of time when the voltage and rated load current. converter attempts to turn into a 10mW Load capacitance: 1mF ceramic capacitor short circuit and 10mF tantalum capacitor. 7105 Northland Terrace Minneapolis, MN 55428-1028 USA Tel:763.592.1900 FAX:763.592.1911 WEB:www.aultinc.com AQ038W- 48V-1.5V High Efficiency DC-DC Converter FIGURE 6 : Turn-on transient at full load. FIGURE 7 : Turn-on transient at zero load. FIGURE 8: Output voltage response to step-change in FIGURE 9: Output voltage response to step-change in load current (50%-75%-50% of I : load current (50%-75%-50% of I : outmax outmax dI/dt = 0.1A/ms). Load cap: 10mF tantalum dI/dt = 1A/ms). Load cap: 10mF tantalum capacitor and 1mF ceramic capacitor. capacitor and 1mF ceramic capacitor. 7105 Northland Terrace Minneapolis, MN 55428-1028 USA Tel:763.592.1900 FAX:763.592.1911 WEB:www.aultinc.com AQ038W- 48V-1.5V High Efficiency DC-DC Converter 0,95 0,9 0,85 0,8 0,75 Vin=48V Vin=36V 0,7 Vin=75V 0,65 0,6 0,55 0,5 0 5 10 15 20 25 30 output current [A] FIGURE 10: Efficiency vs. load current for different input voltages at 25°C 7 6 5 4 Vin=36V Vin=48V Vin=75V 3 2 1 0 0 5 10 15 20 25 30 output current [A] FIGURE 11: Power dissipation vs. load current for different input voltages at 25°C 7105 Northland Terrace Minneapolis, MN 55428-1028 USA Tel:763.592.1900 FAX:763.592.1911 WEB:www.aultinc.com power dissipation [W] efficiency [%] AQ038W- 48V-1.5V High Efficiency DC-DC Converter To be provided in the next issue To be provided in the next issue FIGURE 13: Thermal plot of converter at 23 amp load FIGURE 12: Maximum output power derating curves vs. current with 25°C air flowing at the rate of 200 LFM. ambient air temperature for airflow rates of 0 LFM through Air is flowing across the converter sideways from pin 1 to 400 LFM with air flowing across the converter from pin 1 to pin 3 at nominal input voltage. pin 3 at nominal input voltage. To be provided in the next issue To be provided in the next issue FIGURE 14: Maximum output power derating curves vs. FIGURE 15: Thermal plot of converter at 25 amp load ambient air temperature for airflow rates of 100 LFM current with 25°C air flowing at the rate of 200 LFM. through 400 LFM with air flowing lengthwise from output to Air is flowing across the converter in the long direction input at nominal input voltage. from output to input at nominal input voltage. 7105 Northland Terrace Minneapolis, MN 55428-1028 USA Tel:763.592.1900 FAX:763.592.1911 WEB:www.aultinc.com AQ038W- 48V-1.5V High Efficiency DC-DC Converter Features and Pins description Features and Pins description Features and Pins description SAFETY The converter is certified according to EN60950 (Kema), UL 1950 and CSA 22.2. 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 1.65V to shut the module off. Consult the factory for availability of positive logic modules. ON /OFF ON /OFF ON /OFF Vin (-) Vin (-) V Viin n ( (- -) ) Vin (-) Negative logic (permanently Enabled) Open Collector Enable Circuit Direct Logic Drive Remote Enable Circuit OUTPUT VOLTAGE TRIM The output voltage can be trimmed by means of an external resistor connected between Trim and either of the Remote sense pins, +S or -S pins. The selection of the resistor follows the industry standard trim equations. A resistor connected between Trim and –S pins will decrease the output voltage. For a decrease in the nominal output voltage, D%, the value of the resistor can be calculated using the following equation: æ - ö 511 1.5 V æ ö target ç ÷ R = -10.22kW where D = ´100% trim-down ç ÷ ç ÷ D% è ø 1.5 è ø TRIM DOWN 10000 1000 100 10 0 2 4 6 8 10 % Decrease in Output Voltage 7105 Northland Terrace Minneapolis, MN 55428-1028 USA Tel:763.592.1900 FAX:763.592.1911 WEB:www.aultinc.com Trim Resistance (kOhms) AQ038W- 48V-1.5V High Efficiency DC-DC Converter A resistor connected between Trim and + S pins will increase the output voltage. For a desired increase, D%, of the nominal output voltage, the value of the resistor can be calculated using the following equation: 5.11*1.5 (100 + D%) æ ö 511 ç ÷ R = - -10.22 KW trim-up ç ÷ 1.225D% D% è ø TRIM UP 10000 1000 trim up 100 10 0 1 2 3 4 5 6 7 8 9 10 % Increase in Output Voltage REMOTE SENSE (+S or -S) The remote sense inputs, +S or –S pins, must be connected to the load and/or output pins of the converter. To ensure tight regulation at the system critical load, then the remote sense pins should be connected to the system critical load. Reference applicable section of data sheet for maximum voltage compensation. Ensure sufficient margin to the over voltage threshold, reference applicable sections of the data sheet and system loading: output over-voltage protection –vs- system transient load condition(s). THERMAL PROTECTION The converter has internal thermal protection preventing hot spots on PCB from exceeding 120°C (248 °F). Depending on the air flow rate and the ambient temperature, the over temperature protection limit is reached according to Figures 12, 13, 14 and 15. When the over temperature protection is active the converter will enter into hiccup mode. The converter will auto-recover when the fault condition is corrected. OVERCURRENT PROTECTION The overcurrent limit inception is typically 110% of the rated output current. When the overcurrent limit inception is exceeded the output voltage will decrease, or constant current mode. Further increase in the current will induce the voltage to decrease where the converter will eventually enter fault protection, or hiccup mode, reference Figure 5. The converter will enter fault protection typically at 125% of rated output current. When the fault is removed the converter will auto recover. Ordering code Ordering code Ordering code AQ038W48V015V25AN 7105 Northland Terrace Minneapolis, MN 55428-1028 USA Tel:763.592.1900 FAX:763.592.1911 WEB:www.aultinc.com Trim Resistance (kOhms)