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alt series technical reference note date: feb. 18, 2003 model : alt series s 1 / 25 alt isolated dc/dc converter module industry standard size: 36-75v input, 12v, 5v double output industry standard size: 2?x 1.6??package options choice of positive logic or negative logic for cnt function choice of short pins or long pins description the alt series is a new open frame dc-dc converter. it is one of the most cost effective options available in component power. the alt series uses an industry standard package size: 50.8mm x 40.6mm x 9.66mm (2?x1.6?x0.38?) and standard pin-out configuration, provides cnt and trim functions. alt series comes in 48v input versions, each of which uses a 2:1 input range of 36~75v. the series can provide 12v@1.25a and 5v@3a double outputs, outputs are isolated from input. and the converters are capable of providing up to 30 watts of output power. features ? 2 ? x 1.6 ?? package ? basic isolation ? high efficiency ? high power density ? 2:1 wide input of 36-75v ? cnt function ? trim function ? input under-voltage lockout ? output short circuit protection ? output over-voltage protection ? wide operating case temperature range
alt series technical reference note date: feb. 18, 2003 model : alt series s 2 / 25 contents o ptions ............................................................................................................................... ..................................1 d escription ............................................................................................................................... ...........................1 electrical specifications...................................................................................................... ..................4 i nput s pecifications ............................................................................................................................... .............4 a bsolute m aximum r at i n g s ..............................................................................................................................5 o utput s pecifications ............................................................................................................................... .........6 o utput s pecifications (c ont ) ............................................................................................................................7 f eature s pecifications ............................................................................................................................... ........8 characteristic curves.......................................................................................................... .....................9 p erformance c urves ? e fficiency and ocp ....................................................................................................9 p erformance c urves ? t ransient r esponse ..................................................................................................10 p erformance c urves ? s tartup c haracteristics .........................................................................................11 p erformance c urves ? s tartup from cnt c ontrol .....................................................................................11 feature description............................................................................................................ .......................12 cnt f unction ............................................................................................................................... .....................12 t rim ............................................................................................................................... .....................................13 m inimum l oad r equirements ..........................................................................................................................14 o utput o ver - current p rotection ..................................................................................................................14 o utput f ilters ............................................................................................................................... ...................14 d ecoupling ............................................................................................................................... .........................15 o utput o ver -v oltage p rotection ..................................................................................................................15 g round l oops ............................................................................................................................... .....................15 design consideration ........................................................................................................... .....................17 t ypical a pplication ............................................................................................................................... ...........17 f using ............................................................................................................................... ..................................18 i nput r everse v oltage p rotection ................................................................................................................18 emc............................................................................................................................ ........................................18 s afety c onsideration ............................................................................................................................... .......20 thermal consideration .......................................................................................................... .................21 mtbf ........................................................................................................................... ..........................................21 mechanical considerations...................................................................................................... ............22
alt series technical reference note date: feb. 18, 2003 model :alt series s 3 / 25 i nstallation ............................................................................................................................... .......................22 s oldering ............................................................................................................................... ...........................22 mechanical chart............................................................................................................... ........................23 ordering information ........................................................................................................... ...................24 model numbering................................................................................................................ .........................25
alt series technical reference note date: feb. 18, 2003 model :alt series s 4 / 25 electrical specifications unless otherwise indicated, specifications apply over all operating input voltage and temperature conditions. standard test condition on a single unit is as following: ta ( a m b i e n t ) : 2 5 c +vin: 48v +/ ? 2% ? vin: return pin for +vin cnt: open +vo: connect to load ? vo: connect to load com: connect to load trim(vadj): open input specifications notes: i(out1) is the load of +vo, i(out2) is the load of ?vo. parameter device symbol min typ max unit operating input voltage all v i 36 48 75 v dc maximum input current (v i = 0 to v i,max , i(out1) = i(out2)= io,max) 5v 12v i i,max i i,max - - - - 1.5 1.5 a a input reflected-ripple current ( 5hz to 20mhz: 12uh source impedance: t a = 25 oc.) all i i - - 40 map-p no load input power (v i = v i,nom ) all - - - 1 w caution: this power module is not internally fused. an input line fuse must always be used.
alt series technical reference note date: feb. 18, 2003 model : alt series s 5 / 25 absolute maximum ratings stresses in excess of the absolute maximum ratings can cause permanent damage to the device. these are absolute stress ratings only. functional operation of the device in not implied at these or any other conditions in excess of those given in the operational sections of the ips. 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 - - 80 100 v dc v dc operating ambient temperature all tc/ta -40 - 55 oc storage temperature all t stg -55 - 125 oc operating humidity all - - - 85 % i/o isolation (conditions: 50 a for 5 sec, slew rate of 1500v/10sec) input-output all - - - 1500 v dc output power 5v 12v po,max po,max - - - - 30 30 w w
alt series technical reference note date: feb. 18, 2003 model :alt series s 6 / 25 output specifications parameter device symbol min typ max unit output ripple and noise (across 1 f @50v, x7r ceramic capacitor & 10 f @25v tantalum capacitor) peak-to-peak (5 hz to 20 mhz) 5v 12v - - - - - - ripple 85 70 noise 150 150 mvp-p mvp-p external load capacitance of every load all - 100 - 2200 f cross regulation (-vo) i(out1)= io,min i(out2)= io,min -100% io,max or i(out1)=100% io,max , i(out2)= io,min -100% io,max all - 7% 10% %-vonom output voltage setpoint (v i = v i,min to v i,max : io = io,max; t a = 25 oc ) 5v 12v v o,set v o,set 4.93 4.80 11.80 11.70 5.07 5.20 12.20 12.30 v dc v dc v dc v dc output regulation: line load(test only for +vo) (i(out2) = io,max i(out1) = io,min to io,max) +vo -vo all - - - - - - 0.1 0.1 0.2 0.2 0.5 0.5 % % %vo rated output current (for every load) 5v 12v io io 0.3 0.125 - - 3 1.25 a a output current-limit inception (test is between +vo and ?vo) 5v 12v io io 3.1 1.35 - - 5 2.9 a a efficiency (v i = v i,nom ; i o,max ; t a = 25 c) 5v 12v - - 82 85 84 87 - - % % switching frequency all - 330 khz
alt series technical reference note date: feb. 18, 2003 model :alt series s 7 / 25 output specifications (cont) parameter device symbol min typ max unit dynamic response : ( test only for +vo , ? io/ ? t = 1a/10 s ; v i = v i,nom ; ta = 25 c) load change from i(out1) = 50% to 75% of io,max :i(out2)= io,max peak deviation settling time (to v o,nom ) load change from i(out1) = 25% to 50% of io,max :i(out2)= io,max peak deviation settling time (to v o,nom ) all all - - - - - - - - - - - - 3 200 3 200 %+vo sec %+vo sec turn-on time (io = io,max ; vo within 1%) all - - - 20 msec output voltage overshoot (io = io,max ; t a = 25 c) all - - - 5 %vo
alt series technical reference note date: feb. 18, 2003 model :alt series s 8 / 25 feature specifications parameter device symbol min typ max unit enable pin voltage : logic low logic high enable pin current : logic low logic high(leakage current, @10v) all all all all -0.7 3.5 - - - - - - 0.8 12 2.0 v v ma a output voltage adjustment range all - 90 - 110 %vo output over-voltage clamp 5v 12v vo clamp vo clamp 5.9 13.9 - 7.00 16.00 v v under-voltage lockout turn-on point turn-off point all all - - 31 30 34 33 36 35 v v isolation capacitance all - - 2200 - pf isolation resistance all - 100 - - m ? calculated mtbf (io = io,max ; t a = 25 c) all - - 2,000, 000 - hours weight all - - - 25 g(oz.)
alt series technical reference note date: feb. 18, 2003 model :alt series s 9 / 25 characteristic curves performance curves ? efficiency and ocp typical efficiency of alt03aa48 typical efficiency of alt01bb48 typical ocp of alt03aa48 typical ocp of alt01bb48
alt series technical reference note date: feb. 18, 2003 model :alt series s 10 / 25 performance curves ? transient response alt01bb48 alt01bb48 i(out1) = 50% to 25% of io,max load change i(out1) =50% to75% of io,max load change i(out2)=1.25a i(out2) =1.25a alt03aa48 alt03aa48 i(out1) =50% to 25% of io,max load change i(out1) =50% to75% of io,max load change i(out2)=3a i(out2) =3a
alt series technical reference note date: feb. 18, 2003 model :alt series s 11 / 25 performance curves ? startup characteristics alt01bb48 start-up from power on alt03aa48 start-up from power on performance curves ? startup from cnt control alt03aa48 start-up from cnt on alt01bb48 start-up from cnt on
alt series technical reference note date: feb. 18, 2003 model :alt series s 12 / 25 feature description cnt function two cnt logic options are available. the cnt logic, cnt voltage and the module working state are as the following table 1. l h open n on off off p off on on table 1 n--- means ?negative logic?, p--- means ?positive logic? l--- means ?low voltage?, -0.7v l 0.8v h--- means ?high voltage?, 3.5v h 12v on--- means ?module is on?, off--- means ?module is off? open--- means ?cnt pin is left open ? note: normally, v cnt 12v but when cnt is left open,v cnt may reach to 18v. the following figure shows a few simple cnt circuits.
alt series technical reference note date: feb. 18, 2003 model :alt series s 13 / 25 trim the +vo output voltage of the alt series can be trimmed using the trim pin provided. applying a resistor to the trim pin through a voltage divider from the output will cause the +vo output to increase or decrease by up to 10%. trimming up by more than 10% of the nominal output may activate the ovp circuit or damage the converter. trimming down more than 10% can cause the converter to regulate improperly. if the trim pin is not needed, it should be left open. trim up trim down
alt series technical reference note date: feb. 18, 2003 model :alt series s 14 / 25 minimum load requirements parameter device symbol typ unit minimum load (for every load) 5v 12v i min i min 0.3 0.125 a a output over-current protection alt series dc/dc converters feature fold-back current limiting as part of their over-current protection (ocp) circuits. when output current exceeds 110 to 140% of rated current, such as during a short circuit condition, the module will work on intermittent mode, also can tolerate short circuit conditions infinitely. when the over-current condition is removed, the converter will automatically restart. output filters when the load is sensitive to ripple and noise, an output filter can be added to minimize the effects. a simple output filter to reduce output ripple and noise can be made by connecting a capacitor c2 and c3 across the output as shown in figure ?output ripple filter?. the recommended value for the output capacitor c2&c3 is 220 f. load load + + c3 c2 vo+ vo- trim com output ripple filter extra care should be taken when long leads or traces are used to provide power to the load. long lead length increases the chance for noise to appear on the lines. under these
alt series technical reference note date: feb. 18, 2003 model :alt series s 15 / 25 conditions capacitor can be added across the load, with a 0.47 f ceramic capacitor c4 and c5 in parallel generally as shown in figure ?output ripple filter for a distant load?. load load + + c3 c2 vo+ vo- trim com c4 c4 c5 c5 output ripple filter for a distant load decoupling noise on the power distribution system is not always created by the converter. high speed analog or digital loads with dynamic power demands can cause noise to cross the power inductor back onto the input lines. noise can be reduced by decoupling the load. in most cases, connecting a 10 f tantalum or ceramic capacitor in parallel with a 0.1 f ceramic capacitor across the load will decouple it. the capacitors should be connected as close to the load as possible. output over-voltage protection the over-voltage protection has a separate feedback loop, which activates when the output voltage is between 120% and 140% of the nominal output voltage. ground loops ground loops occur when different circuits are given multiple paths to common or earth ground, as shown in figure ?ground loops?. multiple ground points can slightly different potential and cause current flow through the circuit from one point to another. this can result in additional noise in all the circuits. to eliminate the problem, circuits should be designed with a single ground connection as shown in figure ?single point ground?.
alt series technical reference note date: feb. 18, 2003 model :alt series s 16 / 25 + load load + load + load + load + load load ++ load + rline rline rline rline r rline vo+ vo- trim com rline rline rline vo+ vo- trim com rline rline rline rline rline rline rline r ground loops single point
alt series technical reference note date: feb. 18, 2003 model :alt series s 17 / 25 design consideration typical application
alt series technical reference note date: feb. 18, 2003 model :alt series s 18 / 25 fusing the alt power modules have no internal fuse. an external fuse must always be employed! to meet international safety requirements, a 250 volt rated fuse should be used. if one of the input lines is connected to chassis ground, then the fuse must be placed in the other input line. standard safety agency regulations require input fusing. recommended fuse ratings for the alt series are 2a. input reverse voltage protection under installation and cabling conditions where reverse polarity across the input may occur, reverse polarity protection is recommended. protection can easily be provided as shown in figure ?reverse polarity protection circuit?. in both cases the diode used is rated for 3a/100v. placing the diode across the inputs rather than in-line with the input offers an advantage in that the diode only conducts in a reverse polarity condition, which increases circuit efficiency and thermal performance. reverse polarity protection circuit emc input filters are included in the converters to help achieve standard system emissions certifications. some users however, may find that additional input filtering is necessary. the alt series has an internal switching frequency of 330 khz so a high frequency capacitor mounted close to the input terminals produces the best results. to reduce reflected noise, a capacitor can be added across the input as shown in figure ?ripple rejection input filter?, forming a filter. a 0.47 f/100v electrolytic capacitor is recommended for c1.
alt series technical reference note date: feb. 18, 2003 model :alt series s 19 / 25 ripple rejection input filter for conditions where emi is a concern, a different input filter can be used. figure ?emi reduction input filter? shows an input filter designed to reduce emi effects. l1 is an 8mh common mode inductor, c1 is a 47 f/100v electrolytic capacitor, and c2 is a 0.47 f/100v metal film or ceramic high frequency capacitor, and cy1 and cy2 are each 4700pf high frequency ceramic capacitors. emi reduction input filter when a filter inductor is connected in series with the power converter input, an input capacitor c1 should be added. an input capacitor c1 should also be used when the input wiring is long, since the wiring can act as an inductor. failure to use an input capacitor under these conditions can produce large input voltage spikes and an unstable output.
alt series technical reference note date: feb. 18, 2003 model :alt series s 20 / 25 safety consideration 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., ul1950, csa c22.2 no. 950-95, and en60950. the alt series input-to-output isolation is a basic insulation. the module should be installed in end-use equipment, in compliance with the requirements of the ultimate application, and is intended to be supplied by an isolated secondary circuit. when the supply to the dc/dc power module meets all the requirements for selv(<60v dc ), the output is considered to remain within selv limits (level 3). if connected to a 60v dc power system, double or reinforced insulation must be provided in the power supply that isolates the input from any hazardous voltages, including the ac mains. one vinput pin and one voutput pin are to be grounded or both the input and output pins are to be kept floating. single fault testing in the power supply must be performed in combination with the dc/dc power module to demonstrate that the output meets the requirement for selv. the input pins of the module are not operator accessible. 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.
alt series technical reference note date: feb. 18, 2003 model :alt series s 21 / 25 thermal consideration when 48v input, 55 ambient temperature, and 200lfm airflow, alt series are rated for full power, and in this condition the case temperature can reach 100 . for operation above ambient temperature of 55 , output power must be derated as shown in figure ?temperature derating?, meantime, airflow at least 200lfm over the converter must be provided to make the module working properly. the case temperature should be used to determine maximum temperature limits. the minimum operating temperature for the alt is -40 . temperature derating curves mtbf the mtbf, calculated in accordance with bellcore tr-nwt-000332 is 2,000,000 hours. obtaining this mtbf in practice is entirely possible. if the ambient air temperature is expected to exceed +25 , then we also advise an oriented for the best possible cooling in the air stream. emerson network power can supply replacements for converters from other manufacturers, or offer custom solutions. please contact the factory for details.
alt series technical reference note date: feb. 18, 2003 model :alt series s 22 / 25 mechanical considerations installation although alt series converters can be mounted in any orientation, free air-flowing must be taken. normally power components are always put at the end of the airflow path or have the separate airflow paths. this can keep other system equipment cooler and increase component life spans. soldering alt series converters are compatible with standard wave soldering techniques. when wave soldering, the converter pins should be preheated for 20-30 seconds at 110 , and wave soldered at 260 for less than 10 seconds. when hand soldering, the iron temperature should be maintained at 425 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.
alt series technical reference note date: feb. 18, 2003 model :alt series s 23 / 25 mechanical chart (pin side view) no supporting point *: pin length default: 5mm 0.5mm ( 0.228in. 0.02in.) product name with suffix ?-7?: 5.8mm 0.5mm ( 0.189in. 0.02in.) product name with suffix ?-6?: 3.8mm 0.25mm ( 0.15in. 0.01in.) product name with suffix ?8?: 2.8mm 0.25mm ( 0.11in. 0.01in.)
alt series technical reference note date: feb. 18, 2003 model :alt series s 24 / 25 ordering information model number input voltage (v dc ) output voltage (v dc ) output current (a) ripple (mv rms) typ. noise (mv pp) typ. efficiency % typ. alt03aa48 36-75 5 3 30 150 84 alt01bb48 36-75 12 1.25 25 150 87
alt series technical reference note date: feb. 18, 2003 model :alt series s 25 / 25 model numbering

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