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 AIF25R48 Series Technical Reference Note
AIF25R48 Series Isolated DC/DC Converter Module
36-75V Input, 28V single Output
Features
* * * * * * * * * * * * * * * 4.6'' X 2.4'' X 0.5'' full brick package Basic insulation High efficiency High power density Current sharing function 2:1 wide input range of 36-75V CNT (input side and output side) function Trim function Sense function AUX/IOG/TMP signal output Over- temperature protection Input under-voltage protection Output short circuit protection Output over-voltage protection Wide operating case temperature range
Industry Standard Size: 4.6"X 2.4'' 0.5''package
Options
Choice of short pins or long pins
Choice of positive logic or negative logic for CNT function
Description
The AIF25R48 series is a new Aluminum baseplate full brick DC-DC converter. The AIF25R48 series uses an industry standard package size: 116.8mm X 61mm X 12.7mm (4.6"x2.4"x0.5"), provides CNT, current sharing, trim, sense, and IOG/TMP functions.
AIF25R48 series comes in 48V input versions, each of which uses a 2:1 input range of 36~75V. It can provide 28V@25A single output, which is isolated from input.
DATE: May 28, 2003
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AIF25R48 Series Technical Reference Note
Contents
Options ................................................................................................................................................................. 1 Description............................................................................................................................................................ 1 Electrical Specifications ............................................................................................................................................ 4 Input Specifications ............................................................................................................................................... 4 Absolute Maximum Ratings .................................................................................................................................. 5 Output Specifications ............................................................................................................................................ 6 Output Specifications (Cont).................................................................................................................................. 7 Feature Specifications............................................................................................................................................ 8 Characteristic Curves ................................................................................................................................................ 9 Performance Curves - Efficiency........................................................................................................................... 9 Performance Curves - Output Performance Curves................................................................................................ 9 Performance Curves - Transient Response........................................................................................................... 10 Performance Curves - Transient Response (Cont)................................................................................................ 10 Performance Curves - Startup Characteristics ...................................................................................................... 11 Performance Curves - Startup from CNT1 Control .............................................................................................. 11 Feature Description ................................................................................................................................................. 12 CNT Function ..................................................................................................................................................... 12 Trim .................................................................................................................................................................... 13 Minimum Load Requirement ............................................................................................................................... 14 Output Over-Current and Short Protection ........................................................................................................... 14 Output Over-Voltage Protection ........................................................................................................................... 14 Over Temperature Protection ............................................................................................................................... 14 Current Sharing ................................................................................................................................................... 15 Sense................................................................................................................................................................... 16 AUX/IOG/TMP................................................................................................................................................... 18 Output Filter........................................................................................................................................................ 18 Decoupling.......................................................................................................................................................... 19 Ground Loops ..................................................................................................................................................... 19 Design Consideration .............................................................................................................................................. 21 Typical Application ............................................................................................................................................. 21 Fusing ................................................................................................................................................................. 21 Input Reverse Voltage Protection ......................................................................................................................... 21
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AIF25R48 Series Technical Reference Note
EMC ................................................................................................................................................................... 22 Safety Consideration............................................................................................................................................ 23 Thermal Management.............................................................................................................................................. 24 Technologies ....................................................................................................................................................... 24 Basic Thermal Management ................................................................................................................................ 24 Module Derating with Heatsink ........................................................................................................................... 25 Module Derating without Heatsink ...................................................................................................................... 26 MTBF..................................................................................................................................................................... 26 Mechanical Considerations...................................................................................................................................... 27 Installation .......................................................................................................................................................... 27 Soldering............................................................................................................................................................. 27 Mechanical Chart (pin side view)......................................................................................................................... 28 Ordering Information .............................................................................................................................................. 29 Model Numbering ................................................................................................................................................... 29
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AIF25R48 Series Technical Reference Note
Electrical Specifications
Unless otherwise indicated, specifications apply over all operating input voltage and temperature conditions. Standard test condition on a single unit with a heatsink of 270mm 220mm 43mm is as following: Tc(case): +Vin: -Vin: CNT1: +Vout: -Vout: +Sense: -Sense: 25C 48V 2% Return pin for +Vin Connect to -Vin Connect to load Connect to load (return) Connect to +Vout Connect to -Vout Open Open Open Open Open
VB, Trim(Vadj): CNT2, CNT3: CB: IOG, TMP: AUX:
Input Specifications
Parameter Operating Input Voltage Maximum Input Current
(Vi = 0 to Vi,max, Io = Io,max)
Device All All
Symbol VI Ii,max
Min 36 -
Typ 48 -
Max 75 23
Unit VDC A
Input Reflected-ripple Current (Vi = Vi,nom ,
5Hz to 20MHz: 12uH source impedance: Tc = 25 C.)
All
Ii
-
-
160
mAp-p
No Load Input Power (Vi = Vi,nom )
All
-
-
-
7
W
CAUTION: This power module is not internally fused. An input line fuse must always be used.
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AIF25R48 Series Technical Reference Note
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 Input Voltage: Continuous: Transient (100ms) Highest voltage to CNT1 Operating Ambient Temperature Operating Case Temperature (with a heatsink) Storage Temperature Operating Humidity I/O Isolation (Conditions : 50A for 5 sec, slew rate of 1500V/10sec) Input-Output Input-Case Output-Case Output Power Device Symbol Min Typ Max Unit
All All All All All All All
Vi VI, trans Ta Tc TSTG -
0 0 -20 -55 -
-
80 100 15 55
Vdc Vdc Vdc C C C %
-
100 125 85
All
Po,max
-
-
1500 1500 500 700
Vdc Vdc Vdc W
All
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AIF25R48 Series Technical Reference Note
Output Specifications
Parameter Output Ripple and Noise
(Across 1F @50V, X7R ceramic
Device All
Symbol -
Min -
Typ 100
Max 200
Unit mVp-p
capacitor & 1000F @50V LOW ESR Aluminum capacitor)
Peak-to-Peak (5 Hz to 20 MHz) External Load Capacitance Output Voltage Setpoint (Vi = Vinom: Io =18A; Tc = 25 C ) Output Regulation:
Line (Vi,min to Vi,max) Load(Io = Io,min to Io,max) Temperature
All All
Vo,set
470 27.5
1000 28
6800 28.5
F Vdc
All
All All
-
2.5 26.25 86
0.01 0.1 89
0.2 0.5 0.02 25 35 -
% % %Vo/C
A
Rated Output Current Output Current-limit Inception
(when unit is shut down)
All All All
Io Io
A (RMS) %
Efficiency
(Vi = Vi,nom ; Io,nom ; Tc= 25C)
Switching Frequency
All
-
340
KHz
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AIF25R48 Series Technical Reference Note
Output Specifications (Cont)
Parameter
Device
Symbol
Min
Typ
Max
Unit
Dynamic Response :
(Io/t = 1A/10s ) Load Change from Io = 50% to 75% of Io,nom : Peak Deviation Settling Time (to Vo,nom) Load Change from Io = 50% to 25% of Io,nom : Peak Deviation Settling Time (to Vo,nom)
All
-
-
-
3 500
%Vo,nom sec
All
-
-
-
3 500 200 5
%Vo,nom sec msec %Vo,nom
Turn-On Time
(Io = Io,nom ; Vo within 1%)
All All
Output Voltage Overshoot
(Io = Io,nom ; TA = 25C)
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AIF25R48 Series Technical Reference Note
Feature Specifications
Parameter
Device All All
Symbol
Min -0.7 3.5
Typ -
Max 1 7
Unit V V
CNT1 pin voltage : Logic Low Logic High Enable pin current : Logic Low Output Voltage Adjustment Range Output Over-voltage Over Temperature protect Under-Voltage Lockout
Turn-on Point Turn-off Point
All All ALL All All All All All All All All All All All All All T -
80 32.2 101 31 30
-
1 110 39.2 120
mA
%Vo,nom
V
34 33 3
36 35 10 1 1
V V
Current Sharing Accuracy +SENSE -SENSE AUX IOG TMP Isolation Capacitance Isolation Resistance Calculated MTBF
(Io = Io,nom ; TA = 25C)
%Vo,nom %Vo,nom V V V
13 5 5 10 1600 1,500, 000 150
16
-
PF M Hours g
Weight
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AIF25R48 Series Technical Reference Note
Characteristic Curves
Performance Curve - Efficiency
95
Efficiency(%)
85 Vin=36V 75 65 55 0 5 10 15 20 25 Vin=48V Vin=75V
Output Current(A)
Typical Efficiency Curve
Performance Curves - Output Performance Curve
30 Output Voltage(V) 25 20 15 10 5 0 0 10 20 Output Current(A) 30 40 Vin=36V Vin=48V Vin=75V
Output Performance Curve
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AIF25R48 Series Technical Reference Note
Performance Curves - Transient Response
50%-25%Ioman load change
Performance Curves - Transient Response (Cont)
25%-50%Ioman load change
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AIF25R48 Series Technical Reference Note
Performance Curves - Startup Characteristics
Start-up from Power On
Performance Curves - Startup from CNT1 Control
Start-up from CNT1 On
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AIF25R48 Series Technical Reference Note
Feature Description
CNT Function
CNT function is available on both side of input (CNT1) and output (CNT2/CNT3). Input side CNT(CNT1) Function Two CNT1 logic options are available. The CNT1 logic, CNT1 voltage and the module working state are as the following Table 1.The ground pin of CNT1 is "-Vin" pin. And CNT2/CNT3 must be open when CNT1 is used. L N P ON OFF H OFF ON
Table 1
OPEN OFF ON
N--- means "Negative Logic", P--- means "Positive Logic" L--- means "Low Logic Voltage", -0.7V L 1V H--- means "High Logic Voltage", 3.5V H 7V ON--- means "Module is on", OFF--- means "Module is off" Open--- means "CNT1 pin is left open " Note: Normally, VCNT1 8V, but when CNT1 is left open, VCNT may reach to 15V.
The following Figure shows a few simple CNT1 circuits.
Fig.1 A few simple CNT1 Circuits
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AIF25R48 Series Technical Reference Note
Output Side CNT (CNT2/CNT3) Function Two CNT2/CNT3 logic options are available. CNT2/CNT3 can be used as shown in Fig2 with a "Negative Logic" module. The switch is opposite with a "Positive Logic" module. CNT1 must be connected to -Vin when CNT2/CNT3 is used. And make sure that sink current of output side CNT circuit should be less than 12mA.
Fig.2 Output Side CNT (CNT2/CNT3) Function for "Negative Logic" Module
Trim
The output voltage of the AIF25R48 series can be trimmed using the trim pin provided. Applying a resistor to the trim pin through a voltage divider from the VB will cause the output to increase 10% or decrease 20%. Trimming up by more than 10% of the nominal output may activate the OVP circuit or damage the converter. Trimming down more than 20% can cause the converter to regulate improperly. If the trim pin is not needed, it should be left open.
Fig.3 Trim Up Circuit and Formula
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AIF25R48 Series Technical Reference Note
Fig.4 Trim Down Circuit and Formula
Minimum Load Requirement
The minimum load of AIF25R48 series is 2.5A.
Output Over-Current and Short Protection
AIF25R48 series DC/DC converters feature foldback 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 indefinitely. When the over-current condition is removed, the converter will automatically restart. A sound may occur from module when the output is shorted.
Output Over-Voltage Protection
The over-voltage protection has a separate feedback loop, which activates when the output voltage exceeds 120% to 140% of the nominal output voltage. The module can restart by turning on the power or turning on the CNT (CNT1 or CNT2/CNT3) signal again.
Over Temperature Protection
AIF25R48 series DC/DC converters will shut down when the temperature of the baseplate reaches 101 to 120 , and the module will automatically restart if the temperature of the
baseplate is under 100 . The measurement point is indicated in below Fig 5. The module must be mounted on a heatsink of 270mm 220mm 43mm when measuring OTP point.
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AIF25R48 Series Technical Reference Note
The OTP point is about 85 without a heatsink.
Fig.5 Measuring OTP Point of AIF25R48 series
Current Sharing
Parallel operation is available by connecting the modules as shown in Fig 6. As variance of output current drew from each power supply is 10% maximum, the total output current must not exceed the value determined by the following equation. (Output current in parallel operation)=(the rated current per module)*(number of module)*0.9 In parallel operation, the maximum operative number of modules is 7. When output voltage adjustment is not used. TRM, VB open, R1, R2, VR1, Rva, Rvb, Rta, Rtb... are not needed. Thick wire should be used for wiring between the power supply and load, and line drop should be less than 0.3V. Connect the sensing line and the power line by one point after connecting each power supply's sense pins (+Sense, -Sense).
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AIF25R48 Series Technical Reference Note
+VOUT +SENSE VB TRM CB -SENSE -VOUT
Rva Rta Csa
Co1a
Co2a
LOAD
VR1
+VOUT +SENSE VB TRM CB -SENSE -VOUT
Rvb Rtb Csb
Co1b Co2b
+VOUT +SENSE VB TRM CB -SENSE -VOUT
Rvc Rtc Csc
Co1c Co2c
. . .
Fig.6 Parallel operation
Rva, Rvb,.....: 470 Rta, Rtb,...: 22K Vr1 10K
Csa,Csb,...: 0.1 F
Sense
Sense terminal is provided to compensate for voltage drop across the load wire. When sense function is not used, short +sense terminal to +Vout terminal and, -sense terminal to -Vout terminal.
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AIF25R48 Series Technical Reference Note
When sense function is used, it should pay attention to that voltage compensation range for line drop must be less than 1%Vo. Using shield wire, twist pair, or parallel pattern to reduce noise effect.
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AIF25R48 Series Technical Reference Note
AUX/IOG/TMP
AUX AUX is built in to operate the output side CNT(CNT2/CNT3). If AUX is not used for CNT2/CNT3, AUX can be used for IOG or TMP signal output by opto coupler. Short protection resistance(2.7k ) is built in.
AUX voltage at open circuit is 13Vtpy, 16Vmax. IOG IOG signal turns "H" from "L" within 1 second when the output of the module is shut down. The specification of IOG is shown in table 2. TMP TMP signal turns "L" from "H" within 1 second when over temperature is detected. The specification of TMP is shown in Table 2. item Function Base pin Level voltage "L" Level voltage "H" Maximum sink current Maximum applicable voltage TMP IOG Normal operation "H" Normal operation "L" Over temperature "L" Malfunction "H" -Sense 0.5Vmax at 5mA 5V typ 10mA max 35V max
Table 2 The specification of IOG and TMP
Output Filter
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 C1 across the output as shown in Figure `Output Ripple Filter'. The recommended value for the output capacitor C1 is 1000F.
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AIF25R48 Series Technical Reference Note
Fig.7 Output Ripple Filter
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 conditions C2 can be added across the load, with a 0.47F ceramic capacitor C2 in parallel generally as shown in Figure `Output Ripple Filter for a Distant Load'.
Fig.8 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 10F tantalum or ceramic capacitor in parallel with a 0.1F ceramic capacitor across the load will decouple it. The capacitors should be connected as close to the load as possible.
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'.
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AIF25R48 Series Technical Reference Note
Fig.9 Ground Loops
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AIF25R48 Series Technical Reference Note
Design Consideration
Typical Application
F1
+VIN
Vin Cin
+VOUT +SENSE
CNT1
S1
TRM -SENSE -VIN -VOUT
Co1
Co2
LOAD
Fig.10 typical application
F1: 30A Cin: Recommended 470 F/100V low ESR Aluminum capacitor. Co1: Recommended 1 F/50V film capacitor. Co2: Recommended 1000 F/50V low ESR Aluminum capacitor.
Fusing
The AIF25R48 series 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 AIF25R48 series are 30A.
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 40A/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.
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AIF25R48 Series Technical Reference Note
Fig 11 Reverse Polarity Protection Circuit
EMC
For conditions where EMI is a concern, a different input filter can be used. Fig 12 `EMI Reduction Filter` shows a filter designed to reduce EMI effects. AIF25R48 SERIES can meet EN55022 CLASS A with Fig 12.
Vin+ +Vin C1 L1 C5 C3 + C2 L2 C7 + +Sense +Vout C8 L3 Vout+
AIF25R48 AVF700 SERIES
C9
+ C10 C11
C12
C6
-Vin Vin-
-Vout Vout-Sense
CASE
Fig.12 EMI Reduction Filter
L1, L2: 3.25mH L3: 110 H C3, C7: 470 F/100V low ESR Aluminum capacitor. C10: 1000 F/50V low ESR Aluminum capacitor. C1, C2: 2.2 F/250V C5, C6: 0.15 F/250V C8, C9: 4.7Nf/1000V C11, C12: 1 F/50V
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AIF25R48 Series Technical Reference Note
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 AIF25R48 SERIES input-to-output isolation is an basic insulation. The DC/DC power 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 (<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 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.
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AIF25R48 Series Technical Reference Note
Thermal Management
Technologies
AIF25R48 series module has typical efficiency of 89% at full load. With less heat dissipation and temperature-resistant components such as ceramic capacitors, the module exhibit good behavior during pro-longed exposure to high temperatures. Maintaining the operating case temperature (Tc) within the specified range help keep internal component temperatures within their specifications, which in turn help keep MTBF from falling below the specified rating. Proper cooling of the power modules is also necessary for reliable and consistent operation.
Basic Thermal Management
Measuring the case temperature of the module (Tc) as the method shown in Figure 5 can verify the proper cooling. The module should work under 55C ambient for the reliability of operation and Tc must not exceed 100C while operating in the final system 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. Note that Tc of module must always be checked in the final system configuration to verify proper operational due to the variation in test conditions. 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 (Pd) is got by the equation below: Pd = Pi Po
where : Pi is input power; Po is output power; Pd is dissipated power. Also, module efficiency ( ) is defined as the following equation: = Po / Pi If eliminating the input power term, from two above equations can yield the equation below: Pd = Po (1- ) /
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AIF25R48 Series Technical Reference Note
The module power dissipation then can be calculated 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 AIF25R48 SERIES is shown as Fig.13.
120 Power Dissipation 100 80 60 40 20 0 0 5 10 15 20 25 Output Current(A) Fig.13 Typical Power Dissipation Curve of AIF25R48 series Vin=36V Vin=48V Vin=75V
Module Derating with Heatsink
Usually a customized heatsink is used for AIF25R48 SERIES because the power dissipation of AIF25R48 series is too large. A heatsink of full brick size can not consume so much heat. A derating curve is shown in Fig14 with a heatsink of 270mm 220mm 43mm size. The
module will have different derating curves with different heatsink designed by customer.
Fig.14 Temperature Derating Curve with Heatsink DATE: May 28, 2003 MODEL : AIF25R48 SERIES S 25 / 29
AIF25R48 Series Technical Reference Note
Module Derating without Heatsink
The derating curves of AIF25R48 series without heatsink are shown in the following Fig15. We recommend that the customer use the AIF25R48 SERIES with proper heatsink for the better operation.
Fig.15 Temperature Derating Curve without Heatsink
MTBF
The MTBF, calculated in accordance with Bellcore TR-NWT-000332 is 1,500,000 hours. Obtaining this MTBF in practice is entirely possible. If the case temperature is expected to exceed +25 , then we also advise an oriented for the best possible cooling in the air stream. ASTEC can supply replacements for converters from other manufacturers, or offer custom solutions. Please contact the factory for details.
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AIF25R48 Series Technical Reference Note
Mechanical Considerations
Installation
Although AIF25R48 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
AIF25R48 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. and applied to
When hand soldering, the iron temperature should be maintained at 425
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.
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AIF25R48 Series Technical Reference Note
Mechanical Chart (pin side view)
*: Pin length Default: 4.8mm 0.5mm ( 0.189in. 0.02in.)
Product name with suffix "-6": 3.8mm 0.25mm ( 0.15in. 0.01in.) Product name with suffix "-7": 5.8mm 0.5mm ( 0.228in. 0.02in.) Product name with suffix "-8": 2.8mm 0.25mm ( 0.11in. 0.01in.)
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AIF25R48 Series Technical Reference Note
Ordering Information
Model Number Input Voltage (V) Output Voltage (V) Output Current (A) Ripple (mV PP) typ. Noise (mV pp) typ. Efficiency % typ.
AIF25R48 SERIES
36-75
28
25
160
200
89
Model Numbering
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