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-1- a a v v 6 6 0 0 c c h h a a l l f f - - b b r r i i c c k k s s e e r r i i e e s s t t e e c c h h n n i i c c a a l l r r e e f f e e r r e e n n c c e e n n o o t t e e s s 48v input, 5v output 48v input, 5v output 50-150w dc-dc converter 50-150w dc-dc converter (rev01) usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 publishing date: 20020607
-2- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com introduction introduction the av60c half-brick series of switching dc- dc converters is one of the most cost effective options available in component power. the series uses an industry standard package size of 2.4?x2.28?x0.5 ? and pinout configuration, provides standard control, trim, and sense func- tions, also features high power density up to 54.8w/in 3 which gives more selectivity to meet small size requirement. av60c half-brick series comes in 48v input ver- sion with a 2:1 ( 36-75v ) input range. this series has input lvp, output ovp, ocp, short circuit protection and over temperature protec- tion. there are isolated single output 3.3v, 5v, 12v, 15v and the isolation voltage is 1500vdc. this series is designed to meet cispr22, fcc class a, ul and csa certifications. the design features of the av60c half-brick series set a new standard for high density power converters. the unit employs an alu- minum baseplate to carry all of the power com- ponents, and conduct the dissipated heat to the ambient. a conventional, multi-layer printed cir- cuit board, over the top of the power substrate, contains all of the small signal control circuitry, all constructed with automated smd technolo- gy. feature feature high efficiency high power density low output noise metal baseplate cnt function remote sense trim function input under-voltage lockout output short circuit protection output current limiting output over-voltage protection overtemperature protection high input-output isolation voltage options options heat sink available for extended operation. choice of cnt logic configuration.
-3- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com fuse* tr i m -vout -sense +vout +sense -vin cnt +vin load c4 c2 case vin c1 c3 fuse*: use external fuse ( fast blow type ) for each unit. 50w output : 5a fuse 75w output : 7.5a fuse 100w output : 10a fuse 150w output : 20a fuse c1*: recommended input capacitor c1 -20 c ~ +100 c: m 47 f/100v electrolytic or ceramic type capacitor. -40 c ~ +100 c: m 47 f/100v ceramic type capacitor only. c2*: recommended output capacitor c2 -20 c~ +100 c: 1000 f/10v (electrolytic capacitor) for 50w-75w 2200 f/10v (electrolytic capacitor) for 100w-150w -40 c~ +100 c: for this temperature range, use two pieces of the recommended capacitor above. c3: recommended 4700pf/2000v c4: recommended 0.1f/10v t t ypical application ypical application
a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com block diagram block diagram ordering information ordering information av60c-048l-050f10 36-75v 5v 10a 40 150 83% 84% av60c-048l-050f10n 36-75v 5v 10a 40 150 83% 84% av60c-048l-050f15 36-75v 5v 15a 40 150 83% 85% av60c-048l-050f15n 36-75v 5v 15a 40 150 83% 85% av60c-048l-050f20 36-75v 5v 20a 40 150 83% 85% AV60C-048L-050F20N 36-75v 5v 20a 40 150 83% 85% av60c-048l-050f30 36-75v 5v 30a 40 150 83% 85% av60c-048l-050f30n 36-75v 5v 30a 40 150 83% 85% -4- +vout -vout +sense -sense cnt +vin -vin trim model input output output ripple noise efficiency number voltage voltage current (mv rms) (mv pp) min. typ.
-5- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com absolute maximum rating input voltage(continuous) -0.3 80 vdc input voltage(peak/surge) -0.3 100 vdc 100ms non-repetitive case temperature -40 100 c storage temperature -55 125 c input characteristics input voltage range 36 48 75 vdc input reflected current 30 50 map-p turn-off input voltage 30 33 35 v turn-on input voltage 31 34 36 v turn on time 20 35 ms cnt function logic high 3 15 vdc logic low 1.2 vdc control current 2 ma general specifications mtbf 2000 k hrs bellcore tr332, t c=40c isolation 1500 vdc pin solder temperature 260 c wave solder < 10 s hand soldering time 5 s iron temperature 425c weight 75 grams characteristic min typ max units notes characteristic min typ max units notes characteristic min typ max units notes characteristic min typ max units notes
av60c-048l-050f10(n) output characteristics power 50 w output current 1 10 a output setpoint voltage 4.95 5 5.05 vdc vin=48v, io=10a line regulation 0.02 0.2 %vo vin=36~75v, io=10a load regulation 0.1 0.5 %vo io=0~10a, vin=48v dynamic response 50-75% load 2.5 5 %vo ta=25c, di/dt=1a/10s 100 250 s ta=25c, di/dt=1a/10s 50-25% load 2.5 5 %vo ta=25c, di/dt=1a/10s 100 250 s ta=25c, di/dt=1a/10s current limit threshold 11 13 14 a short circuit current 17 a efficiency 83 84 % vin=48v, io=10a trim range 90 110 %vo over voltage protection setpoint 5.75 7 v sense compensation 0.5 v 0.25v each leg temperature regulation 0.02 %v o/c ripple (rms) 20 40 mv ( 0 to 20mhz bandwidth ) noise (p-p) 100 150 mv ( 0 to 20mhz bandwidth ) over temperature protection 105 c switching frequency 300 khz maximum capacitor load 10000 f -6- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com characteristic min typ max units notes
-7- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com av60c-048l-050f15(n) output characteristics power 75 w output current 1.5 15 a output setpoint voltage 4.95 5 5.05 vdc vin=48v, io=15a line regulation 0.02 0.2 %vo vin=36~75v, io=15a load regulation 0.1 0.5 %vo io=0~15a, vin=48v dynamic response 50-75% load 2.5 5 %vo ta=25c, di/dt=1a/10s 100 250 s ta=25c, di/dt=1a/10s 50-25% load 2.5 5 %vo ta=25c, di/dt=1a/10s 100 250 s ta=25c, di/dt=1a/10s current limit threshold 16.5 19 21 a short circuit current 25 a efficiency 83 85 % vin=48v, io=15a trim range 90 110 % vo over voltage protection setpoint 5.75 7 v sense compensation 0.5 v 0.25v each leg temperature regulation 0.02 %v o/c ripple (rms) 20 40 mv ( 0 to 20mhz bandwidth ) noise (p-p) 100 150 mv ( 0 to 20mhz bandwidth ) over temperature protection 105 c switching frequency 300 khz maximum capacitor load 10000 f characteristic min typ max units notes
av60c-048l-050f20(n) output characteristics power 100 w output current 2 20 a output setpoint voltage 4.95 5 5.05 vdc vin=48v, io=20a line regulation 0.02 0.2 %vo vin=36~75v, io=20a load regulation 0.1 0.5 %vo io=0~20a, vin=48v dynamic response 50-75% load 2.5 5 %vo ta=25c, di/dt=1a/10s 100 250 s ta=25c, di/dt=1a/10s 50-25% load 2.5 5 %vo ta=25c, di/dt=1a/10s 100 250 s ta=25c, di/dt=1a/10s current limit threshold 22 25 28 a short circuit current 34 a efficiency 83 85 % vin=48v, io=20a trim range 90 110 %vo over voltage protection setpoint 5.75 7 v sense compensation 0.5 v 0.25v each leg temperature regulation 0.02 %v o/c ripple (rms) 20 40 mv ( 0 to 20mhz bandwidth ) noise (pp) 100 150 mv ( 0 to 20mhz bandwidth ) over temperature protection 105 c switching frequency 300 khz maximum capacitor load 10000 f -8- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com characteristic min typ max units notes
-9- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com av60c-048l-050f30(n) output characteristics power 150 w output current 3 30 a output setpoint voltage 4.95 5 5.05 vdc vin=48v, io=30a line regulation 0.02 0.2 %vo vin=36~75v, io=30a load regulation 0.1 0.5 %vo io=0~30a, vin=48v dynamic response 50-75% load 2.5 5 %vo ta=25c, di/dt=1a/10s 100 250 s ta=25c, di/dt=1a/10s 50-25% load 2.5 5 %vo ta=25c, di/dt=1a/10s 100 250 s ta=25c, di/dt=1a/10s current limit threshold 32 36 40 a short circuit current 50 a efficiency 83 85 % vin=48v, io=30a trim range 90 110 % vo over voltage protection setpoint 5.75 7 v sense compensation 0.5 v 0.25v each leg temperature regulation 0.02 %v o/c ripple (rms) 20 40 mv ( 0 to 20mhz bandwidth ) noise (pp) 100 150 mv ( 0 to 20mhz bandwidth ) over temperature protection 105 c switching frequency 300 khz maximum capacitor load 10000 f characteristic min typ max units notes
-10- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com ef ef ficiency characteristic curves ficiency characteristic curves (at 25 (at 25 c) c) 60 65 70 75 80 85 0 2040 6080100 vin=36v vin=48v vin=75v output current (%io) efficiency (%) 60 65 70 75 80 85 90 0 102030405060708090100 vin=36v vin=48v vin=75v output current (%io) efficiency (%) 60 65 70 75 80 85 90 0 102030405060708090100 vin=36v vin=48v vin=75v output current (%io) efficiency (%) 60 65 70 75 80 85 90 0 102030405060708090100 vin=36v vin=48v vin=75v output current (%io) efficiency (%) typical efficiency av60c-048l-050f10n typical efficiency AV60C-048L-050F20N typical efficiency av60c-048l-050f15n typical efficiency av60c-048l-050f30n
-11- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com overcurrent protection (ocp) overcurrent protection (ocp) (at 25 (at 25 c) c) 0 1 2 3 4 5 6 0 5 10 15 20 vin=36v vin=48v vin=75v output voltage (volts) output current (amps) 0 1 2 3 4 5 6 0102030 vin=36v vin=48v vin=75v output voltage (volts) output current (amps) 0 1 2 3 4 5 6 0 5 10 15 20 25 30 35 vin=36v vin=48v vin=75v output voltage (volts) output current (amps) 0 1 2 3 4 5 6 0 9 18 27 36 45 vin=36v vin=48v vin=75v output voltage (volts) output current (amps) typical output overcurrent performance av60c-048l-050f10n typical output overcurrent performance AV60C-048L-050F20N typical output overcurrent performance av60c-048l-050f15n typical output overcurrent performance av60c-048l-050f30n
-12- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com t t ransient response ransient response (at 25 (at 25 c) c) typical transient response load increased from 50%iomax to 75%iomax av60c-048l-050f30n typical transient response load decreased from 50%iomax to 25%iomax av60c-048l-050f30n typical start-up from cnt control av60c-048l-050f30n typical shut-down from cnt control av60c-048l-050f30n vin falling vin rising 0 1 2 3 4 5 6 20 40 60 80 input voltage (volts) input current (amps) typical output voltage start-up from power on typical input current av60c-048l-050f30n
-13- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com pins pins the +vin and -vin input connection pins are located as shown in figure 1. av60c half-brick converters have a 2:1 input voltage range and 48 vin converters can accept 36-75vdc. care should be taken to avoid applying reverse polarity to the input which can damage the con- verter. input characteristic input characteristic fusing fusing the av60c half-brick power module has 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 av60c half-brick series are shown in table 1. input reverse v input reverse v oltage protection oltage 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 2. in both cases the diode rating is deter- mined by the power of the converter. diodes should be rated as shown in table1. placing the diode across the inputs rather than in-line with the input offers an advan- tage in that the diode only conducts in a reverse polarity condition, which increases circuit efficiency and thermal performance. input undervoltage protection input undervoltage protection the av60c half-brick is protected against undervoltage on the input. if the input voltage drops below the acceptable range, the convert- er will shut down. it will automatically restart when the undervoltage condition is removed. input filter input filter input filters are included in the converters to help achieve standard system emissions certifi- cations. some users however, may find that additional input filtering is necessary. the series has an internal switching frequency of 300 khz so a high frequency capacitor mount- ed close to the input terminals produces the -vin case cnt -vout -sense trim +sense +vout +vin component-side footprint fig.1 pin location table 1 series fuse rating(48vin) 50w 5a 75w 7.5a 100w 10a 150w 20a +vin -vin +vin -vin fig.2 reverse polarity protection circuits
-14- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com best results. to reduce reflected noise, a capacitor can be added across the input as shown in figure 3, forming a filter. a 47 f/100v electrolytic capacitor is recom- mended for c1. for conditions where emi is a concern, a differ- ent input filter can be used. figure 4 shows an input filter designed to reduce emi effects. c 1 is a 47 f/100v electrolytic capacitor, and c 2 is a 1 f/100v metal film or ceramic high frequency capacitor, c y1 and c y2 are each 1000pf/1500vdc high frequency ceramic capacitors, and l1 is a 1mh common mode choke. when a filter inductor is connected in series with the power converter input, an input capac- itor c 1 should be added. an input capacitor c 1 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. cnt function cnt function two cnt logic options are available. negative logic applying a voltage less than 1.2v to the cnt pin will enable the output, and applying a voltage greater than 3v will disable it. positive logic applying a voltage larger than 3v to the cnt pin will enable the output, and applying a voltage less than 1.2v will disable it. negative logic, device code suf fix ? n ? . positive logic, device code suffix nothing is the factory-preferred. if the cnt pin is left open, the converter will default to ? control off ? operation in nega- tive logic, but default to ? control on ? in positive logic. the maximum voltage that can be applied to the control pin is 15v. +vin -vin c1 fig.3 ripple rejection input filter +v in -v in c 1 c 2 c y1 c y2 l 1 fig.4 emi reduction input filter -v in cnt -v in cnt -v in cnt -v in cnt fig.8 relay control fig.5 simple control fig.6 transistor control fig.7 isolated control
-15- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com input-output characteristic input-output characteristic safety consideration 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 input-to-output 1500vdc isolation is an operational insulation. the dc/dc power mod- ule should be installed in end-use equipment, in compliance with the requirements of the ulti- mate 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(<60vdc), the output is considered to remain within selv limits (level 3). if connected to a 60vdc 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 vin pin and one vout 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 com- bination with the dc/dc power module to demonstrate that the output meets the require- ment 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. case grounding case grounding for proper operation of the module, the case or baseplate of the av60c half-brick module does not require a connection to a chassis ground. whether to ground the case must be decided by safety considerations, and entirely deter- mined by the final application. if the av60c half-brick module is not in a metallic enclosure in a system, it may be advisable to directly ground the case to reduce electric field emis- sions. leaving the case floating can help to reduce magnetic field radiation from common mode noise currents. if the case has to be grounded for safety or other reasons, an induc- tor can be connected to chassis at dc and ac line frequencies, but be left floating at switching frequencies. under this condition, the safety requirements are met and the emissions are minimized. in general, the inductor maintains a dc resistance from the case to chassis ground of no more than 0.1 s during the safely con- ducting of all the available input current. all the available input current refer to the value of the input fuse to the module. iec 950 requires test- ing the dc resistance at 1.5 times that value. specific safety requirements may dictate some- thing different. output characteristics output characteristics minimum load requirements minimum load requirements there is a 10% (of full load) minimum load required in the main output. the series modules will maintain regulation and operate properly with a no load condition. however, the transient response is altered below a minimum output load condition. when the module is operating below the minimum load, the transient amplitude and recovery time are both increased when the load is stepped higher, the output ripple continues to meet the peak to peak requirements. for the av60c half- brick modules, the 10% minimum load require- ment is strictly in order to meet all performance specifications.
-16- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com remote sensing remote sensing the av60c half-brick converter can remotely sense both lines of its output which moves the effective output voltage regulation point from the output of the unit to the point of connection of the remote sense pins. this feature automat- ically adjusts the real output voltage of the series in order to compensate for voltage drops in distribution and maintain a regulated voltage at the point of load. when the converter is supporting loads far away, or is used with undersized cabling, sig- nificant voltage drop can occur at the load. the best defense against such drops is to locate the load close to the converter and to ensure ade- quately sized cabling is used. when this is not possible, the converter can compensate for a drop of up to 0.25v per lead, or a total of 0.5v, through use of the sense leads. when used, the + and - sense leads should be connected from the converter to the point of load as shown in figure 9 using twisted pair wire. the converter will then regulate its output voltage at the point where the leads are con- nected. care should be taken not to reverse the sense leads. if reversed, the converter will trig- ger ovp protection and turn off. when not used, the +sense lead must be connected with +vo, and -sense with -vo. also note that the output voltage and the remote sense voltage offset must be less than the minimum overvolt- age trip point. note that at elevated output voltages the maximum power rating of the module remains the same, and the output current capability will decrease correspondingly. output t output t rimming rimming users can increase or decrease the output volt- age set point of a module by connecting an external resistor between the trim pin and either the sense (+ ) or sense ( - ) pins. the trim resistor should be positioned close to the module. if not using the trim feature, leave the trim pin open. trimming up by more than 10% of the nominal output may damage the converter. trimming down more than 10% can cause the converter to regulate improperly. trim down and trim up circuits and the corresponding configuration are shown in figure 10 and figure 11. note that at elevated output voltages the maximum power rating of the module remains the same, and the output current capability will decrease correspondingly. the circuits and test results for the trim up and trim down configurations are displayed as fol- lowing: output over-current protection output over-current protection av60c half-brick series dc/dc converters fea- ture foldback current limiting as part of their overcurrent protection (ocp) circuits. when output current exceeds 110 to 140% of rated current, such as during a short circuit condition, the output will shutdown immediately, and can tolerate short circuit conditions indefinitely. when the overcurrent condition is removed, the converter will automatically restart. +v out -v out load +sense -sense twisted pair +s -s fig.9 sense connections
a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com output over-v output over-v oltage protection oltage protection the over-voltage protection has a separate feedback loop which activates when the output voltage is between 5.75v-7v. when an over- voltage condition occurs, a ? turn off ? signal was sent to the input of the module, and shut off the output. the module will restart after power on again. -17- adjusting percentage of output voltage ( % ) trim up resistor value (ohm) 0 2 4 6 8 10 100 m 10 m 1 m 100 k 10 k r adj-down = where y is the adjusting percentage of the voltage. 0 < y < 10 radj-down is in k ? . r adj-down r load 100 y - 2 +vin -vin cnt case +vout -vout sense(+) trim sense(?) 100 1k 100k 1m adjusting percentage of output voltage ( % ) 10k 0 10 20 30 40 trim down resistor value (ohm) fig.11. trimming down circuit and curves vo(100+y) r adj-up = (100+2y) 1.26y y - +vin -vin cnt case +vout -vout sense(+) trim sense( ? ) r adj-up r load where y is the adjusting percentage of the voltage. 0 < y < 10 radj-up is in k ? . fig.10. trim up circuit and curves
-18- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com output filters 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 across the output as shown in figure 12. the recommended value for the output capacitor is 2200 f/10v. extra care should be taken when long leads or traces are used to provide power to the load. long lead lengths increase the chance for noise to appear on the lines. under these con- ditions c2 can be added across the load as shown in figure 13. the recommended compo- nent for c2 is 2200 f/10v capacitor and con- necting a 0.1 f ceramic capacitor in parallel generally. decoupling 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 capacitor in paral- lel 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. ground loops ground loops ground loops occur when different circuits are given multiple paths to common or earth ground, as shown in figure 14. 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 con- nection as shown in figure 15. parallel power distribution parallel power distribution figure 16 shows a typical parallel power distrib- ution design. such designs, sometimes called daisy chains, can be used for very low output currents, but are not normally recommended. the voltage across loads far from the source can vary greatly depending on the ir drops along the leads and changes in the loads clos- er to the source. dynamic load conditions increase the potential problems. +v out -v out load c 1 c 2 fig.13 output ripple filter for a distant load +v out -v out load c 1 fig.12 output ripple filter +vout -vout load load r line r line r line r line r line r line ground loop fig.14 ground loops fig.15 single point ground +vout -vout load load r line r line r line r line r line load 1 load 2 load 3 +vout -vout r l1 r l2 r l3 r g1 r g2 r g3 i 1 + i 2 + i 3 i 2 + i 3 i 3 r l = lead resistance r g = ground lead resistance fig.16 parallel power distribution
-19- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com radial power distribution radial power distribution radial power distribution is the preferred method of providing power to the load. figure 17 shows how individual loads are connected directly to the power source. this arrangement requires additional power leads, but it avoids the voltage variation problems associated with the parallel power distribution technique. mixed distribution mixed distribution in the real world a combination of parallel and radial power distribution is often used. dynamic and high current loads are connected using a radial design, while static and low current loads can be connected in parallel. this combined approach minimizes the drawbacks of a parallel design when a purely radial design is not feasi- ble. redundant operation redundant operation a common requirement in high reliability sys- tems is to provide redundant power supplies. the easiest way to do this is to place two con- verters in parallel, providing fault tolerance but not load sharing. oring diodes should be used to ensure that failure of one converter will not cause failure of the second. figure 19 shows such an arrangement. upon application of power, one of the converters will provide a slightly higher output voltage and will support the full load demand. the second converter will see a zero load condition and will ?idle?. if the first converter should fail, the second converter will support the full load. when designing redundant converter circuits, shottky diodes should be used to minimize the forward voltage drop. the voltage drop across the shottky diodes must also be considered when deter- mining load voltage requirements. load 1 load 2 load 3 +vout -vout r l1 r l2 r l3 r g1 r g2 r g3 r l = lead resistance r g = ground lead resistance fig.17 radial power distribution load 1 load 2 load 3 +vout -vout r l1 r l2 r l3 r g1 r g2 r g3 r l = lead resistance r g = ground lead resistance load 4 r l4 r g4 fig.18 mixed power distribution +v out -v out +v out -v out load fig.19 redundant operation
-20- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com thermal management thermal management t t echnologies echnologies av60c half-brick series 50 w to 150 w mod- ules feature high efficiency and the 5v output units have typical efficiency of 85% at full load. with less heat dissipation and temperature- resistant components such as ceramic capaci- tors, these modules exhibit good behavior dur- ing prolonged exposure to high temperatures. maintaining the operating case temperature (tc) within the specified range help keep inter- nal-component temperatures within their speci- fications which in turn help keep mtbf from falling below the specified rating. proper cool- ing of the power modules is also necessary for reliable and consistent operation. basic thermal management basic thermal management measuring the case temperature of the module (tc) as the method shown in figure 20 can ver- ify the proper cooling. figure 20 shows the metal surface of the module and the pin loca- tions. the module should work under 90c for the reliability of operation and t c must not exceed 100 c while operating in the final sys- tem configuration. the measurement can be made with a surface probe after the module has reached thermal equilibrium. if a heat sink is mounted to the case, make the measurement as close as possible to the indicated position. it makes the assumption that the final system configuration exists and can be used for a test environment. the following text and graphs show guidelines to predict the thermal performance of the mod- ule for typical configurations that include heat sinks in natural or forced airflow environments. note that tc of module must always be checked in the final system configuration to verify proper operational due to the variation in test condi- tions. thermal management acts to transfer the heat dissipated by the module to the surrounding environment. the amount of power dissipated by the module as heat (p d ) is got by the equa- tion below: p d = p i ? p o where : p i is input power; p o is output power; p d is dissipated power. also, module efficiency ( ) is defined as the fol- lowing equation: = p o / p i if eliminating the input power term, from two above equations can yield the equation below: p d = p o (1- ) / the module power dissipation then can be cal- culated through the equation. because each power module output voltage has a different power dissipation curve, a plot of power dissipation versus output current over three different line voltages is given in each module-specific data sheet. the typical power dissipation curve of av60c half-brick series 5v output are shown as figure 21 to figure 24. 29.0 (1.14) 30.5 (1.2) cnt case +sense trim ? sense +vin measure case temperature here base-plate side view dimensions: millimeters (inches) -vin +vout -vout fig.20 case temperature measurement
-21- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com module derating module derating experiment setup experiment setup from the experimental set up shown in figure 25, the derating curves as figure 26 can be drawn. note that the pwb ( printed-wiring board ) and the module must be mounted verti- cally. the passage has a rectangular cross- section. the clearance between the facing pwb and the top of the module is kept 13 mm (0.5 in.) constantly. convection w convection w ithout heat sinks ithout heat sinks heat transfer can be enhanced by increasing the airflow over the module. figure 26 shows the maximum power that can be dissipated by the module. in the test, natural convection airflow was mea- sured at 0.05 m/s to 0.1 m/s (10 ft./min. to 20 ft./min.). the 0.5 m/s to 4.0 m/s (100 ft./min. to 800 ft./min.) curves are tested with externally adjustable fans. the appropriate airflow for a given operating condition can be determined through figure 26. 0 2 4 6 8 10 12 14 16 18 20 02468101214161820 vin=36v vin=48v vin=75v power dissipation ( w ) output current ( a ) 0 2 4 6 8 10 12 14 16 18 01 23 456 78 9101112131415 vin=36v vin=48v vin=75v power dissipation ( w ) output current ( a ) 0 3 6 9 12 15 18 21 24 27 30 0 3 6 9 12 15 18 21 24 27 30 vin=36v vin=48v vin=75v power dissipation ( w ) output current ( a ) fig.22 av60c-048l-050f15n power dissipation fig.23 AV60C-048L-050F20N power dissipation fig.24 av60c-048l-050f30n power dissipation dimensions: millimeters (inches). facing pwb pwb module 50.8(2.0) air velocity and ambient temperature testing point air flow 13(0.5) fig.25 experiment set up 2.4 3 3.6 4.2 4.8 5.4 6 6.6 7.2 7.8 8.4 9 012345678910 vin=36v vin=48v vin=75v power dissipation ( w ) output current ( a ) fig.21 av60c-048l-050f10n power dissipation
-22- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com example 1. how to calculate the minimum airflow required to maintain a desired tc? if a av60c-048l-050f30n module operates with a 48v line voltage, a 25 a output current, and a 40 c maximum ambient temperature, what is the minimum airflow necessary for the operating? determine p d ( referenced fig.24 ) with con- dition: v in = 48 v l o = 25 a get: p d = 20 w and with t a = 40 c determine airflow ( fig.26 ): v = 3 m/s (600 ft./min.) example 2. how to calculate the maximum output power of a module in a certain con- vection and a max. t a ? what is the maximum power output for a av60c-048l-050f30n operating at following conditions: v in = 48 v v = 3.0 m/s (600 ft./min.) t a = 40 c determine p d ( fig.26 ) p d = 21 w determine i o (fig.24): i o = 26 a calculate p o : p o = (v o ) x (i o ) = 5 x 26 = 130 w although the two examples above use 100 c as the maximum case temperature, for extremely high reliability applications, one may design to a lower case temperature as shown in example 4 on page 24. heat sink configuration heat sink configuration several standard heat sinks are available for the av60c half-brick 50 w to 150 w modules as shown in figure 27 to figure 29. dimensions: millimeters (inches). 57.9 (2.28) 61 (2.4) wdl10040 wdl02540 wdl05040 1/4 in. 1/2 in. 1 in. fig.28 longitudinal fins heat sink dimensions: millimeters (inches). wdt10040 61 (2.4) wdt02540 wdt05040 57.9 (2.28) 1/4 in. 1/2 in. 1 in. fig.29 transverse fins heat sink 89.1(3.51) 57.0 (2.24) 11.8 (0.465) 4.9(0.193) dimensions: millimeters (inches). fig.27 non standard heatsink 0 10203040 100 0 35 ambient temperature, t a (c) power dissipation p d (w) 25 20 10 90 80 70 60 50 4.0 m/s (800 ft./min.) 1.0 m/s (200 ft./min.) 2.0 m/s (400 ft./min.) 3.0 m/s (600 ft./min.) 5 15 30 0.5 m/s (100 ft./min.) natural convection (10-20 ft./min.) fig.26 forced convection power derating without heat sink
-23- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com the heat sinks mount to the top surface of the module with screws torqued to 0.56 n-m (5 in.- lb). a thermally conductive dry pad or thermal grease is placed between the case and the heat sink to minimize contact resistance (typi- cally 0.1 c/w to 0.3 c/w) and temperature dif- ferential. nomenclature for heat sink configurations is as follows: wdxyyy40 where: x = fin orientation: longitudinal (l) or trans verse (t) yyy = heat sink height (in 100ths of inch) for example, wdt5040 is a heat sink that is transverse mounted (see figure 29) for a 61 mm x 57.9 mm (2.4 in.x 2.28 in.) module with a heat sink height of 0.5 in. heatsink mounting advice heatsink mounting advice a crucial part of the thermal design strategy is the thermal interface between the baseplate of the module and the heatsink. inadequate mea- sures taken here will quickly negate any other attempts to control the baseplate temperature. for example, using a conventional dry insulator can result in a case-heatsink thermal imped- ance of >0.5 c/w, while use one of the rec- ommended interface methods (silicon grease or thermal pads available from astec) can result in a case-heatsink thermal impedance around 0.1c/w. natural convection with heat sink natural convection with heat sink the power derating for a module with the heat sinks ( shown as figure 27 to figure 29) in nat- ural convection is shown in figure 31. in this test, natural convection generates airflow about 0.05 m/s to 0.1 m/s ( 10ft./min to 20ft./min ). figure 31 can be used for heat-sink selection in natural convection environment. example 3. how to select a heat sink ? what heat sink would be appropriate for a av60c-048l-050f30n in a natural convection environment at nominal line, 3/4 load, and max- imum ambient temperature of 40c? determine p d ( referenced fig.24 ) with con- dition: v in = 48 v i o = 3/4 (30) = 23 a t a = 40 c get: p d = 19 w determine heat sink ( fig.31 ): 1 in. allows up to t a = 45 c fig.30 heat sink mounting 0 10203040 90100 0 20 25 30 ambient temperature, t a (c) power dissipation p d (w) 15 10 5 50 60 70 80 1 in. heat sink 1/2 in. heat sink 1/4 in. heat sink no heat sink fig.31 heat sink power derating curves, natural convection
-24- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com basic thermal model basic thermal model there is another approach to analyze module thermal performance, to model the overall ther- mal resistance of the module. this presentation method is especially useful when considering heat sinks. the following equation can be used to calculate the total thermal resistance . r ca = ? t c , max / p d where r ca is the module thermal resistance. ? t c , max is the maximum case temperature rise. p d is the module power dissipation. in this model, p d , ? t c, max , and r ca are equals to current flow, voltage drop, and electrical resistance, respectively, in ohm's law, as shown in figure 32. also, ? t c, max is defined as the difference between the module case tem- perature (t c ) and the inlet ambient temperature (t a ). ? t c , max = t c ? t a where t c is the module case temperature; t a is the inlet ambient temperature. for av60c half-brick series 50w to 150w 5v output converters, the module's thermal resis- tance values versus air velocity have been determined experimentally and shown in figure 33. the highest values on each curve repre- sents the point of natural convection. figure 33 is used for determining thermal per- formance under various conditions of airflow and heat sink configurations. example 4. how to determine the allowable minimum airflow to heat sink combinations necessary for a module under a desired tc and a certain condition? although the maximum case temperature for the av60c half-brick series converters is 100 c, you can improve module reliability by limiting tc,max to a lower value. how to decide? for example, what is the allowable minimum airflow for av60c-048l-050f30n heat sink combinations at desired tc of 80 c? the working condition is as following: v in = 48 v, i o = 25a, t a = 40 c determine p d ( fig.24 ) p d = 20 w then solve r ca : : r ca = ? t c , max / p d r ca = ( t c ? t a ) / p d r ca = ( 80 ? 40 ) / 20 = 2c/w determine air velocity from fig.33: if no heat sink: v > 3.0 m/s (600 ft./min.) if 1/4 in. heat sink: v = 3.0 m/s (600 ft./min.) if 1/2 in. heat sink: v = 2.0 m/s (400 ft./min.) if 1 in. heat sink: v = 1.2 m/s (240 ft./min.) p d thermal r ca: resistance fig.32 basic thermal resistance model 0 0.5(100) 1.0(200) 1.5(300) 2.0(400) 2.5(500) 3.0(600) 0 1 5 6 7 8 air velocity m/s (ft./min.) 4 3 2 case-ambient thermal resistance r ca (c/w) 1 in. heat sink 1/2 in. heat sink 1/4 in. heat sink no heat sink fig.33 case-to-ambient thermal resistance curves; either orientation
-25- a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com example 5. how to determine case tempera- ture ( tc ) for the various heat sink configu- rations at certain air velocity? what is the allowable tc for av60c-048l- 050f30n heat sink configurations at desired air velocity of 2.0 m/s, and it is operating at a 48 v line voltage, a 25 a output current, a 40 c maximum ambient temperature? determine p d ( fig.24 ) with condition: v in = 48 v i o = 25 a t a = 40 c v = 2.0 m/s (400 ft./min.) get: p d = 20 w determine t c : t c = (r ca x p d ) + t a determine the corresponding thermal resis- tances ( r ca ) from fig.33: no heat sink: r ca = 3.8 c/w t c = (3.8 x 20) + 40 = 116 c 1/4 in. heat sink: r ca = 2.8 c/w t c = (2.8 x 20) + 40 = 96 c 1/2 in. heat sink: r ca = 2.0 c/w t c = (2.0 x 20) + 40 = 80 c 1 in. heat sink: r ca = 1.2 c/w t c = (1.2 x 20) + 40 = 64 c in this configuration, the heat sink would have to be at least 1/4 in. high so that the power module does not exceed the maximum case temperature of 100 c. a a v60c half-brick series v60c half-brick series mechanical considerations mechanical considerations installation installation although av60c half-brick series converters can be mounted in any orientation, free air-flow- ing 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 soldering av60c half-brick series converters are compat- ible with standard wave soldering techniques. when wave soldering, the converter pins should be preheated for 20-30 seconds at 110c, and wave soldered at 260c for less than 10 seconds. when hand soldering, the iron temperature should be maintained at 4 25c 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. mtbf mtbf the mtbf, calculated in accordance with bellcore tr-nwt-000332 is 2,000,000 hours. obtaining this mtbf in practice is entirely pos- sible. if the ambient air temperature is expected to exceed +25c, then we also advise a heatsink on the av60c half-brick series, orient- ed for the best possible cooling in the air stream. astec can supply replacements for converters from other manufacturers, or offer custom solu- tions. please contact the factory for details.
a a a a v v v v 6 6 6 6 0 0 0 0 c c c c s s s s e e e e r r r r i i i i e e e e s s s s 5 5 5 5 v v v v o o o o u u u u t t t t p p p p u u u u t t t t h h h h a a a a l l l l f f f f - - b b b b r r r r i i i i c c c c k k k k p p p p o o o o w w w w e e e e r r r r c c c c o o o o n n n n v v v v e e e e r r r r t t t t e e e e r r r r s s s s 3 3 3 3 6 6 6 6 v v v v d d d d c c c c t t t t o o o o 7 7 7 7 5 5 5 5 v v v v d d d d c c c c i i i i n n n n p p p p u u u u t t t t , , , , 5 5 5 5 0 0 0 0 - - 1 1 1 1 5 5 5 5 0 0 0 0 w w w w o o o o u u u u t t t t p p p p u u u u t t t t usa europe asia tel: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662 fax: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com recommend hole pattern recommend hole pattern mechanical chart mechanical chart -26- base-plate side view dimensions are in millimeters and (inches). 10.16 (0.400) 10.16 (0.400) 12.7 (0.50) 48.3 (1.90) 48.26 (1.900) 4.8 (0.19) mounting inserts module outline 5.1 (0.20) 57 . 9 (2 . 28) max 17.78 (0.700) 25.40 (1.000) 35.56 (1.400) 25.40 (1.000) 50.8 (2.00) 35.56 (1.400) 61.0 (2.40) -vout -vin ?sense trim +sense case cnt +vin +vout max -vin case cnt +vin +vout +sense trim -sense -vout 5.1 (0.2) 10.16 (0.4) 15.24 (0.6) 4.8 (0.19) 48.26 (1.9) 10.16 (0.4) 10.16 (0.4) 10.16 (0.4) 7.62 (0.3) 7.62 (0.3) 7.62 (0.3) 57.9 (2.28) 61.0 (2.4) mm (inches) 7- 12.7 (0.5) mounting inserts m3 thru hole x4 2- 2.0 (0.08) only +vo and -vo 1.0 (0.04) all pins except +vo and -vo length optional 4.8 (0.189) default base-plate side view tolerances: inches millimeters .xx ! 0.020 .x ! 0.5 .xxx ! 0.010 .xx ! 0.25 pins >4mm ! 0.02inch ( ! 0.5mm) <4mm ! 0.01inch ( ! 0.25mm) pin length option 4.80mm ! 0.5mm 0.189in. ! 0.020in. 3.80mm ! 0.25mm 0.150in. ! 0.010in. 5.80mm ! 0.5mm 0.228in. ! 0.02in. 2.80mm ! 0.25mm 0.110in. ! 0.010in. device code suffix none (default) -6 -7 -8
part number description ss pp c -0 iv l- xxx f yy h n - p - mx -options p = pin length omit this digit for standard 5mm 6 = 3.8mm, 7= 5.8mm iv = input voltage 8 = 2.8mm 05 = range centered on 5v 12 = range centered on 12v enable logic polarity 24 = 18 to 36(2:1), 9 to 36v(4:1) omit for positive enable logic 36 = 20 to 60v n = negative enable 46 = 18v to 75v (4:1) except: ak60c-20h, bk60c-30h 48 = typ 36 to 75v omit for negative logice p = positive logic c = pinout compatability a= astec footprint or "non lucent" footprint h = high efficiency (synch rect.) c= ind std, exact lucent drop in omit h if conventional diode (low eff) yy = output current pp = package type ie. 08 = 8 amps 40 = 1" x 2" smd 42 = 1.5" x 2" smd f = # of outputs 45 = 1.45" x 2.3" (1/4 brk) f = single output 60 = 2.4" x 2.3" (1/2 brk) d = dual output 80 = full size 4.6" x 2.4" 72= 2.35" x 3.3 (3/4 brk) xxx = output voltage format is xx.x (ie 1.8v = 018) ss = series aa = 1/2brick dual (old designator) ak = ind std sizes (1/4, 1/2, full) <150w mx = options am/bm = full size, astec pin out m1,m2 = .25" height heatsink al = half size, astec pin-out m3,m4 = .5" height heatsink bk = ind std size =>150w or feature rich m5.m6 = 1.0" height heatsink av = avansys product note: for some products, they may not conform with the part number description above absolutely. revision q attachment i page 1 of 2
new part number description acs ii v 1 v 2 v 3 v in - e t p mx output voltage a = 5.0v e = 7.5v f = 3.3v b = 12v, c = 15v g = 2.5v l = 8v , h = 24v, r = 28v d = 2.0v / 2.1v omit v2 and v3 if single output y = 1.8v omit v3 if dual output m = 1.5v ie for dual output 5 and 3.3v k = 1.2v v1 =a, v2 = f, v3 =omit j = 0.9v v1 =a, v2 = f, v3 =omit ii = output current max ie 60 = 60 amps vin = input voltage range 300 = 250v to 450v s = size 48 = 36v to 75v f = full brick 24 = 18v to 36v h = half brick 03 = 1.8v to 5.0v q = quarter brick 08 = 5.0v to 13.0v s = 1 x 2 18 pin smt pfc: power factor corrected e = 1 x 2 thru hole c = (.53x1.3x.33) smt (austin lite drop in) e = enable logic for > 15w v = conventional package (2x2.56") or ( omit this digit for positive enable a = sip n = negative logic w = convent pkg (wide 2.5x3) e = enable logic for < 15w r = 1 x 1 thru hole omit this digit for no enable option a = sip 1 = negative logic t = 1.6 x 2 4 = positive logic c = construction trim for 1w to 15w e = enhanced thermals (baseplate or adapter plate) 9 = trim added i = integrated (full featured) hong kong models l = low profile (open frame, no case - isolated) p = open frame (sip or smt) non-isolated p = pin length omit this digit for standard 5mm 6 = 3.8mm 8 = 2.8mm 7 = 5.8 mm mx - factory options customer specific note: for some products, they may not conform with the new part number description above absolutely. revision q attachment i page 2 of 2

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