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technical reference notes hercules (aeh/alh60) open frame or hs adapted model: aeh/ALH60F48 sheet 1 of 21 september 26, 2002 - revision 02 aeh60f48 /ALH60F48 isolated dc/dc converter module industry standard ? brick ? 36-75v input, 3.3v / 60a output the aeh60f48 / ALH60F48 is part of astec?s new ultra high density ? brick family capable of running 60amps at 3.3v output. with efficiencies up to 92% typical at 3.3v - 60amps, this product provides a 1% to 2% performance increase in efficiency over the leading 60amp competitors and up to 10% higher output current. the operating temperature range (- 40c to 85c for the alh; -40c to 100c baseplate for aeh) assures maximum application flexibility. new single- output models feature superior transient response with excellent stability in high capacitance/low esr load applications. this family has an effective thermal adapter plate which allows for heat sinking under particularly harsh conditions. without the adapter plate (alh60) provides a very effective low profile which performs extremely well in convection cooled applications. environmental specifications ? operating temperature: -40c to +85c for open frame (alh60) -40c to +100c (baseplate) for (aeh60) ? storage temperature: -40c to +125c ? mtbf: >1 million hours electrical parameters input input range 36-75 vdc input surge 100v / 100ms efficiency 91%@3.3v (typical @ 60 amps) control enable ttl compatible (positive & negative enable options) output regulation (line, load, temp) <2% ripple and noise 2% typical (100mv p-p max) remote sense up to 10%vout output voltage adjust range 10% of nominal output transient response 150mv max deviation with 50% to 75% full load 300 s (max) recovery over voltage protection 130% nom inal special features ? high efficien cy, 92% (30-70%load)) ? -40c to 100c baseplate operating temp ? open frame version also available (alh60) ? positive and negative enable function ? low output ripple and noise ? high capacitive load limit ? remote sense compensation ? regulation to zer o load ? fixed frequency switching (190 khz) safety ul, cul 60950 recognized en 60950 through tuv-ps industry standard ? brick package
technical reference notes (aeh60/ALH60F48) model: aeh/ALH60F48 sheet 2 of 21 september 26, 2002 - revision 02 aeh60 / alh60 series this specification covers the requirements for an industry standard half brick (max 198 w @ 3.3v ) single output ultra high efficiency isolated dcdc converter model name / sis code construction vout, iout aeh60f48 hs adapter 3.3v/60a aeh60g48 hs adapter 2.5v/60a aeh60y48 hs adapter 1.8v/60a aeh60k48 hs adapter 1.2v/60a ALH60F48 open frame 0.4? 3.3v/60a alh60g48 open frame 0.4? 2.5v/60a alh60y48 open frame 0.4? 1.8v/60a alh60k48 open frame 0.4? 1.2v/60a options : suffix negative enable: "n" positive enable: no suffix
technical reference notes (aeh60/ALH60F48) model: aeh/ALH60F48 sheet 3 of 21 september 26, 2002 - revision 02 electrical specifications standard test condition on a single unit, unless otherwise specified. t a : 25c (ambient air) +v in : 48v 2% -v in : return pin for +v in enable: open (positive enable) +v out : connect to load -v out : connect to load (return) trim (v adj ): open +sense: connect to +v out -sense: connect to -v out absolute maximum ratings stresses in excess of the absolute maximum ratings can cause permanent damage to the device. functional operation of the device is not implied at these or any other conditions in excess of those given in the operational sections of the specs. exposure to absolute maximum ratings for extended periods can adversely affect device reliability. parameter device symbol min typ max unit input voltage: continuous: transient (100ms) all all v i v i, trans 0 0 - - 75 100 vdc vdc operating temperature aeh alh t c t a -40 -40 - - 100 85 oc c storage temperature all t stg -55 - 125 oc operating humidity all - - - 85 % i/o isolation (conditions : 50 m a for 5 sec, slew rate of 1500v/10sec) input-output input-case output-case all aeh aeh - - - - - - - - - 1500 1500 1500 vdc vdc vdc output power 3.3v p o,max - - 198 w
technical reference notes (aeh60/ALH60F48) model: aeh/ALH60F48 sheet 4 of 21 september 26, 2002 - revision 02 electrical specifications (continued) input specifications parameter device symbol min typ max unit operating input voltage all v in 36 48 75 v dc maximum input current 1 (v in = 0 to v in,max : i o = i o,max ) f (3.3v) i in,max - - 7.2 a input reflected-ripple current 2 (5hz to 20mhz: 12uh source impedance: t a = 25 oc.) all i i - - 15 ma pk-pk no load input power (v in = v in,nom ) all - - - 5 w note: 1. t he power module is not internally fused. an input line fuse must always be used. 2. see figure 1 for the input reflected-ripple current test setup. output specifications parameter device symbol min typ max unit output voltage setpoint (v in = v in,min to v in,max at i o = i o,max ; t a = 25 oc ) 3.3v v o,set 3.24 3.3 3.34 vdc output regulation: line load (i o = i o,min to i o,max ) temp (aeh: -40 oc to 100oc) (alh: -40c to 85c) all all all - - - - - - 0.1 0.1 - 0.4 0.4 1.0 % % %vo output ripple and noise 3 peak-to-peak (5 hz to 20 mhz) v in = 36v, 48v v in = 75v 3.3v - - - - 66 - 100 150 mv pk-pk mv pk-pk external load capacitance (see stability curves for detail) all - - - 50,000 m f rated output current all io 0 - 60 a output current-limit inception (when unit is shut down) all io 63 - 77 a efficiency 4 (v i = v in,nom ; i o,max ; t a = 25 c) 3.3v - 90 91 - % switching frequency all - 180 195 210 khz note: 3. see figure 2 for the output ripple test setup 4. refer to figures 5 and 6 for the efficiency curves
technical reference notes (aeh60/ALH60F48) model: aeh/ALH60F48 sheet 5 of 21 september 26, 2002 - revision 02 electrical specifications (continued) output specifications parameter device symbol min typ max unit dynamic response 5 : ( d i o / d t = 1a/10 m s ; v i = v in,nom ; t a = 25 c) load change from i o = 50% to 75% of i o,max : peak deviation settling time (to v o,nom ) all - - - - - - 150 300 mv m sec load change from i o = 50% to 25% of i o,max : peak deviation settling time (to v o,nom ) all - - - - - - 150 300 mv m sec turn-on time (i o = i o,max ; vo within 1%) all - - 4 10 msec output voltage overshoot (i o = i o,max ; t a = 25 c) all - - 0 4 %vo note: 5. refer to the transient charac teristics on figures 7 and 8. feature specifications parameter device symbol min typ max unit enable pin voltage : logic low logic high all all -0.7 2.95 - - 1.2 10 v v enable pin current : logic low logic high (i leakage at 10v) all all - - - - 1.0 50 ma m a module output voltage @ logic hi aeh/alh60x48n - - 0.2 v module output voltage @ logic low aeh/alh60x48 - - 0.2 v output voltage adjustment range 6 all - 90 - 110 %vo output overvoltage clamp 3.3v v o,clamp 3.90 4.10 5.00 v undervoltage lockout turn-on point turn-off point all all - - 34.0 33.0 34.8 33.5 35.5 34.5 v v isolation capacitance all - - 2700 - pf isolation resistance all - 10 - - m w calculated mtbf (i o = i o,max ; t a = 25 c) all - - tbd - hours note: 6. for output voltage adjustment setup, refer to figures 3 and 4.
technical reference notes (aeh60/ALH60F48) model: aeh/ALH60F48 sheet 6 of 21 september 26, 2002 - revision 02 safety approval the series have been certified through: ul, cul 60950 (recognized) en 60950 through tuv- ps figure 1. input reflected -ripple test setup figure 2. peak to peak output noise and ripple test measurement setup battery cs 220 uf esr < 0.1 ohm @ 20 oc, 100 khz ltest 12 uh 33 uf esr < 0.7 ohm @ 20 oc, 100 khz vi(+) vi(-) to oscilloscope note: measure the input reflected-ripple current with a simulated source inductance (l test ) of 12uh. capacitor c s offsets possible battery impedance. measure current as shown above. vo(+) vo(-) resistive load 10 uf 0.1 uf scope copper strip note: use a 0.1 m f @50v x7r ceramic capacitor and a 10 m f @ 25v tantalum 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 module.
technical reference notes (aeh60/ALH60F48) model: aeh/ALH60F48 sheet 7 of 21 september 26, 2002 - revision 02 basic operation and features aeh60 / alh60 converters were designed specifically to address applications where ultra high power density is required. these modules provide basic insulation and 1500v isolation with very high output current capability in an industry standard half size module. operating from 36 to 75v input, they have standard features such as remote sense, trim, ovp, ocp and otp. aeh60 series devices will accept industry standard heat sinks to enhance thermal performance in applications with conductive cooling. remote sense (+sense, -sense) connect the + sense and ? sense pins close to the load to allow the module to compensate for the voltage drop across conductors carrying high load current. if remote sense is not required (for example if the load is close to the module) the sense pins should be connected to the corresponding output pins. maximum voltage drop compensation is 10% vout. it is important to avoid introducing lumped inductance or capacitance into the remote path. do not connect remote sense lines ?beyond? any external output filter stages used with the module. trim function output voltage adjustment is accomplished by connecting an external resistor between the trim pin and either the +sense or ?sense pins. to adjust vo to a higher value , please refer to figure 3. an external resistor, radj_up should be connected between the trim pin and the +sense pin. from equation (1), radj_up resistor can be determined for the required output voltage increment. equation (1) where: radj_up - in k w %vo, adj - percent change in output voltage to adjust vo to a lower value , please refer to figure 4. an external resistor, radj_down should be connected between the trim pin and the -sense pin. from equation (2), radj_down resistor can be determined for the required output voltage change. equation (2) where: radj_down - in k w %vo, adj - percent change in output voltage figure 3. radj_up setup to increase output voltage figure 4. radj_down setup to decrease output voltage radj_up = vo*(100 + %vo,adj) 1.225*%vo,adj 100+ 2%vo,adj %vo,adj kohm radj_down . 100 , %vo adj 2 kohm
technical reference notes hercules (aeh/alh60) open frame or hs adapted model: aeh/ALH60F48 sheet 8 of 21 september 26, 2002 - revision 02 basic operation and features (continued) output over voltage protection the output over voltage system consists of a separate control loop, independent of the primary feedback path. this control loop has a higher voltage set point than the main circuit. in a fault condition, the converter latches which ensures that the output voltage does not exceed v o,clamp,max . the converter will operate back normally once the fault is removed and the input voltage is cycled or the enable pin is toggled. output over current protection to provide protection in an output overload or short circuit condition, the converter is equipped with current limiting circuitry and can endure fault conditions for an unlimited duration. at the point of current-limit inception, the converter latches, causing the output current to be limited both in peak and duration. the converter will operate back normally once the overload/ fault is removed and the input voltage is cycled or the enable pin is toggled. enable function two enable options are available. positive logic enable (no suffix required in part number) and negative logic enable (suffix ?n?). positive logic enable turns the converter on during a logic-high voltage on the enable pin, and off during a logic-low. negative logic enable turns the converter off during a logic-high and on during a logic-low.
technical reference notes (aeh60/ALH60F48) model: aeh/ALH60F48 sheet 9 of 21 september 26, 2002 - revision 02 performance curves efficiency figure 5. aeh/alh60 3v3 efficiency curve at t c = 25 c figure 6. aeh/alh60 3v3 efficiency curve at t c = 70 c transient response 3v3 efficiency vs load current @ tc = 25 deg c 55% 60% 65% 70% 75% 80% 85% 90% 95% 0 10 20 30 40 50 60 load current [amp] efficiency [%] vin = 36vdc vin = 48vdc vin = 75vdc 3v3 efficiency vs load current @ tc = 70 deg c 55% 60% 65% 70% 75% 80% 85% 90% 95% 0 10 20 30 40 50 60 load current [amp] efficiency [%] vin = 36vdc vin = 48vdc vin = 75vdc figure 7. 3v3 output: 50% to 75% load change with no external capacitor at 0.1a/us slew rate (ch1 at 1a/10mv). figure 8: 3v3 output: 50% to 75% load change with 10,000uf e xternal capacitor at 0.1a/us slew rate (ch1 at 1a/10mv).
technical reference notes (aeh60/ALH60F48) model: aeh/ALH60F48 sheet 10 of 21 september 26, 2002 - revision 02 performance curves (continued) current vs temperature curves figure 9. load current vs. temperature (open frame) figure 10. load current vs. temperature (baseplate) 3v3 alh (open frame) load current vs. temperature 0 10 20 30 40 50 60 25 30 35 40 45 50 55 60 65 70 75 80 85 ambient temperature (oc) load current[amp] nat. conv. 0.5 m/s (100 ft/min) 1.0 m/s (200 ft/min) 2.0 m/s (400 ft/min) 3v3 aeh (baseplate) load current vs. temperature 0 10 20 30 40 50 60 25 30 35 40 45 50 55 60 65 70 75 80 85 ambient temperature (oc) load current [amp] nat. conv. 0.5 m/s (100 ft/min) 1.0 m/s (200 ft/min) 2.0 m/s (400 ft/min)
technical reference notes (aeh60/ALH60F48) model: aeh/ALH60F48 sheet 11 of 21 september 26, 2002 - revision 02 performance curves (continued) startup characteristics figure 11. aeh60f48 (3.3v): o/p startup characteristic with no external capacitor at vin = 48v / 20a resistive load figure 12. aeh60f48 (3.3v): o/p startup characteristic with 9400 uf external capacitor at vin = 48v / 20a resistive load.
technical reference notes (aeh60/ALH60F48) model: aeh/ALH60F48 sheet 12 of 21 september 26, 2002 - revision 02 input filter for fcc class b conducted noise a reference design for an input filter that can provide fcc class b conducted noise levels is shown below (see figure 13). two common mode connected inductors are used in the circuit along with balanced bypass capacitors to shunt common mode currents into the ground plane. shunting noise current back to the converter reduces the amount of energy reaching the input lisn for measurement. the application circuit shown has an earth ground (frame ground) connected to the converter output (-) terminal. such a configuration is common practice to accommodate safety agency requirements. grounding an output terminal results in much higher conducted emissions as measured at the input lisn because a hard path for common mode current back to the lisn is created by the frame ground. ?floating? loads generally result in much lower measured emissions. the electrical equivalent of a floating load, for emi measurement purposes, can be created by grounding the converter output (load) through a suitably sized inductor(s) while maintaining the necessary safety bonding. also shown is a sketch of a pcb layout used to achieve class b conducted noise levels (see figure 14). it is important to avoid extending the ground plane or any other conductors under the inductors (particularly l2) because capacitive coupling to that track or plane can effectively bypass the inductor and degrade high frequency performance of the filter. parts list circuit code description l1, l2 pulse engineering p0353 / 590uh c1, c3, c4, c5, c6, c11, c12 0.01uf / 2000v c2, c7, c9 100uf / 100v aluminum c13, c14 470pf / 100v ceramic c8, c10 2.2uf / 100v film figure 13: class b filter circuit c1 c2 c5 c6 c7 c8 c14 c13 c9 l1a l1b l2a l2b c10 c12 + + + vin - vin converter + 48 vdc input - + c11 + vout - vout c4 c3
technical reference notes (aeh60/ALH60F48) model: aeh/ALH60F48 sheet 13 of 21 september 26, 2002 - revision 02 input filter for fcc class b conducted noise (continued) figure 14: recommended pcb layout for class b filter figure 15: aeh60f48 and ALH60F48 noise spectrum input noise spectrum 0 10 20 30 40 50 60 70 80 90 2.e+04 5.e+04 1.e+05 3.e+05 7.e+05 2.e+06 4.e+06 9.e+06 2.e+07 frequency (hz) lisn voltage db/uv fcc part 15 & cispr 22 a & b limits - conducted noise average limits - vin + vin c2 c1 c7 c5 c6 c12 c9 c10 c8 gnd plane gnd plane c o n v e r t e r 1 1 2 2 3 4 3 4 top view +48 vdc 48 v return l1 a / b l2 a / b c3 c4 c11 c13 c14
technical reference notes (aeh60/ALH60F48) model: aeh/ALH60F48 sheet 14 of 21 september 26, 2002 - revision 02 thermal considerations while the alh60 (open frame converter) is designed to provide the maximum performance at the lowest profile, the aeh60 (power converter with hs adapter) operates in a variety of thermal environments. sufficient cooling should be provided to help ensure reliable operation of either device. heat generating components are thermally coupled to the adapter where heat energy is removed by conduction, convection, and radiation to the surrounding environment. heat sinks can provide enhanced output performance as shown below. proper cooling can be verified by measuring the case temperature (center of adapter plate/baseplate). heat transfer characteristics increasing airflow over the converter enhances heat transfer via convection. figure 16 shows worse case maximum power that can be dissipated by the converter, without exceeding the maximum adapter plate temperature, versus local ambient temperature (t a ) for natural convection through 2.0 m/s (400 ft/min). figure 17 shows actual maximum power that can be dissipated through both the adapter plate and through the output pins (unit soldered into a 4? square copper plane (2 oz.) or equivalent). figure 16. forced convection power dissipation note: this is worse case dissipation - additional heat transfer through o/p pins will increase allowable dissipation considerably. see figure 17. aeh60 series power dissipation vs temp forced convection without hs 0 5 10 15 20 25 30 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 ambient temperature (oc) power dissipation (watts) nat. conv. 1.0 m/s (200 ft/min) 1.5 m/s (300 ft/min) 2.0 m/s (400 ft/min)
technical reference notes (aeh60/ALH60F48) model: aeh/ALH60F48 sheet 15 of 21 september 26, 2002 - revision 02 thermal considerations (continued) figure 17. actual measured forced convection power dissipation note: this is an actual measured maximum dissipation with heat transfer through output pins included. figure 18. alh/aeh60f48 power dissipation vs. load current. aeh60 series actual power dissipation vs temp forced convection without hs 0 5 10 15 20 25 30 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 ambient temperature (oc) power dissipation [w] nat. conv. 1.0 m/s (200 ft/min) 1.5 m/s (300 ft/min) 2.0 m/s (400 ft/min) power dissipation vs output current tc = 25 deg celsius 0.0 5.0 10.0 15.0 20.0 25.0 0 10 20 30 40 50 60 output current [amps] power dissipation [w] vin = 36 vdc vin = 48 vdc vin = 75 vdc
technical reference notes (aeh60/ALH60F48) model: aeh/ALH60F48 sheet 16 of 21 september 26, 2002 - revision 02 thermal considerations (continued) heatsink selection illustrated figure 19 shows case-to-ambient thermal resistance, q (c/w), for aeh / alh60 modules. these curves can be used to predict which heat sink will be needed for a particular environment. as an illustration, let's refer to below application requirement: an application requires 45 amps of 3.3v in a 55 c environment with airflow of 1.0 m/s (200 ft/min); the minimum heat sink required can be determined through equation (3). equation (3) q (t c, max ? t a ) / p d where: q = module?s total thermal resistance t c, max = case temperature (100 c) t a = ambient te mperature (55 c) p d = power dissipation (15w) from figure 18, the power dissipation for a 45a-load requirement can be determined ( p d = 15w ). through equation (3), the thermal resistance can be calculated to be at q q 3.0 c/w . based on figure 19, the ?" hs (heatsink) , or greater, will be able to handle the required 45a-load at 55 c environment and with 1.0 m/s (200 ft/min) airflow. figure 19. case-to-ambient thermal resistance vs. air velocity aeh60 series case to ambient thermal resistance curves 0 1 2 3 4 5 6 7 0 100 200 300 400 500 600 airflow [ ft / min] thermal resistance r ca ( o c/w) no hs 1/4" hs 1/2" hs 1" hs
technical reference notes (aeh60/ALH60F48) model: aeh/ALH60F48 sheet 17 of 21 september 26, 2002 - revision 02 stability: figures 20 and 21 are plots of internal module loop gain and phase shift vs frequency. curves for typical resistive and reactive loads are shown. system stability (phase and gain margins) when the module is connected to other loads can be determined from the young's stability curves on figures 23 and 24. figure 22 shows an operating zone in which phase margin can be determined for virtually any load resistance and shunt capacitance. see ref. 1 for application of curves. figure 20. loop gain vs. frequency at 0.171 w load with no output capacitance, figure 21. phase shift vs. frequency at 0.171 w load with 9400uf cap load (3.9m w esr) figure 22: phase margin vs load resistance 100 1 . 10 3 1 . 10 4 1 . 10 5 40 30 20 10 0 10 20 30 40 50 60 loop gain vs frequency frequency hz gain db 100 1 . 10 3 1 . 10 4 1 . 10 5 50 0 50 100 150 200 loop phase shift vs frequency frequency hz phase shift deg 0.01 0.1 1 50 60 70 80 90 100 phase margin vs load res load resistance ohms phase margin deg 9.4k uf, 3.9 mohms no output capacitance
technical reference notes (aeh60/ALH60F48) model: aeh/ALH60F48 sheet 18 of 21 september 26, 2002 - revision 02 young?s stability curves phase margin figure 23. young?s stability curve ? phase margin 100 1 . 10 3 1 . 10 4 1 . 10 5 1 . 10 3 0.01 0.1 1 ysc impedance magnitude in ohms impedance magnitude ( ohms ) 100 1 . 10 3 1 . 10 4 1 . 10 5 150 100 50 0 50 frequency impedance phase angle ( degrees ) _______ 15 _______ 30 _______ 45 _______ 60 _______ 75 _______90
technical reference notes (aeh60/ALH60F48) model: aeh/ALH60F48 sheet 19 of 21 september 26, 2002 - revision 02 young?s stability curves gain margin figure 24. young?s stability curve ? gain margin 100 1 . 10 3 1 . 10 4 1 . 10 5 1 . 10 6 1 . 10 5 1 . 10 4 1 . 10 3 0.01 0.1 1 ysc gain margin gain 100 1 . 10 3 1 . 10 4 1 . 10 5 200 150 100 50 0 50 frequency phase ______ 10db ______ 20db ______ 30db ______ 40db ______ 50db
technical reference notes (aeh60/ALH60F48) model: aeh/ALH60F48 sheet 20 of 21 september 26, 2002 - revision 02 mechanical specifications parameter device symbol min typ max unit dimension aeh/alh l - 2.40 [60.96] - in [mm] aeh/alh w - 2.30 [58.42] - in [mm] aeh h - 0.50 [12.70] - in [mm] alh h - 0.40 [10.16] - in [mm] weight aeh - 130 [4.60] - g [oz] alh - 110 [3.90] - g [oz] pin assignment 1 + v in 6 - sense 2 enable on/off 7 trim 3 case (aeh version) 8 + sense 4 - v in 9 + output 5 - output note: nominal diameter for pins 5 & 9 = 0.08", remaining pins at 0.04" outline drawing figure 25. aeh60 - baseplate outline drawing (bottom view)
technical reference notes (aeh60/ALH60F48) model: aeh/ALH60F48 sheet 21 of 21 september 26, 2002 - revision 02 please call 1-888-41-astec for further inquiries or visit us at www.astecpower.com mechanical specifications (continued) outline drawing figure 26. alh60 - open-frame outline drawing (bottom view) soldering considerations the aeh/alh series converters are compatible with standard wave soldering techniques. when wave soldering, the converter pins should be preheated for 20?30 seconds at 110 c and wave soldered at 260 c for less than 10 seconds. when hand soldering, the iron temperature should be maintained at 425 c and applied to the converter pins for less than 5 seconds. longer exposure can cause internal damage to the converter. cleaning can be performed with cleaning solvent ipa or with water. part number coding scheme for ordering a x h60 y 48 z x construction e : enhanced thermals; heatsink adapted l : low profile; open frame y output voltage f = 3.3v y = 1.8v g = 2.5v k = 1.2v z option n : negative enable no suffix : positive enable

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