AMPSS Astec Modular Power Supply System AM80A Performance Series DC-DC Converter Module Technical Reference Manual Series Highlights * * * * * * High Efficiency - up to 88% 100C baseplate/ case operating temperature - no derating Fixed Switching Frequency Low output ripple and noise High Reliability - over 1 million hours MTBF Designed to meet all Telecom specifications TM AM80A Performance Series Contents Introduction ............................................................................................................ 4 Special Features ...................................................................................................... 4 Ordering Information............................................................................................... 5 Safety ..................................................................................................................... 5 Electrical Specifications ............................................................... 6 Absolute Maximum Ratings - all models ................................................................. 6 Pin Connections - all models ................................................................................... 7 Insulation - all models .............................................................................................. 8 Electrical Specifications for 48V Input Models (AM80A-048L-xxxFyy) .................... 9 Electrical Specifications for 150V Input Models (AM80A-150L-xxxFyy)..................11 Electrical Specifications for 300V Input Models (AM80A-300L-xxxFyy)................. 12 Electrical Specifications for 320V Input Models (AM80A-320L-xxxFyy)................. 14 Functional Description ............................................................... 15 Remote Sense (+SENSE, -SENSE) ....................................................................... 15 Enable Control (ENABLE) .................................................................................... 15 Output Voltage Adjustment (V ADJ) ...................................................................... 16 Current Limit Adjustment (C LIM ADJ) ................................................................. 16 Overvoltage Protection Adjustment (OVP ADJ) ..................................................... 16 Power Good/Identification (PG/ID) ....................................................................... 17 Clock Signals (CLK IN, CLK OUT)...................................................................... 17 Current Sharing (C SHARE).................................................................................. 18 Current Monitoring (C MON) ................................................................................ 18 Temperature Monitoring (TEMP MON) ................................................................. 18 Design Considerations ................................................................ 19 Input Bulk Capacitors ........................................................................................... 19 Remote Loads ...................................................................................................... 19 Thermal Data ........................................................................................................ 19 Overtemperature Protection ................................................................................... 19 Parallel Connection Considerations ........................................................................ 20 2 AMPSS(R) Reference Manual Rev. 06 Mar 03 Output Ripple and Noise....................................................................................... 20 Conducted EMI .................................................................................................... 20 Break Regulation................................................................................................... 20 Input Undervoltage Protection ............................................................................... 21 Application Examples................................................................. 22 AC Input Design ................................................................................................... 22 Parallel Connection Design .................................................................................... 22 Mechanical Information ............................................................. 23 Dimensions ........................................................................................................... 23 Recommended PCB Layout .................................................................................. 24 Heatsink Mounting Information.............................................................................. 25 Rev. 06 Mar 03 AMPSS(R) Reference Manual 3 AM80A Performance Series AM80A Performance Series DC-DC Converters Introduction Special Features The single output AM80A is an isolated, single output DC to DC converter module, providing up to 252W output with a maximum baseplate operating temperature of 100C with no derating. The AM80A features full safety isolated low voltage secondary side control and Astec Linear Programming (ALPTM) for convenient adjustment of the module's parameters. * High Efficiency - up to 88% * 1MHz fixed switching frequency * 100C baseplate/ case operating temperature - no The dual output AM80A provides two outputs, 3.3V and 5.0V. 4 AMPSS(R) Reference Manual derating * Low output ripple and noise * Excellent transient response * Safety isolated low voltage interface with ALP TM * * * * linear control High Reliability - over 1 million hours MTBF Wide input voltage range Parallelable with accurate current sharing Current and temperature monitoring outputs Rev. 06 Mar 03 Ordering Information Model Number Input Voltage Output Voltage Output Current Output Power AM80A-320L-280F09 AM80A-300L-022F60 AM80A-300L-033F50 AM80A-300L-050F40 AM80A-300L-120F18 AM80A-300L-150F16 AM80A-300L-065F33 AM80A-300L-240F10 AM80A-300L-280F09 320V 300V 300V 300V 300V 300V 300V 300V 300V 28V 2.2V 3.3V 5V 12V 15V 6.5V 24V 28V 9A 60A 50A 40A 18A 16A 33A 10A 9A 252W 132W 165W 200W 216W 240W 214.5W 240W 252W AM80A-150L-065F33 150V 6.5V 33A 214.5W AM80A-048L-012F60 AM80A-048L-022F60 AM80A-048L-033F50 AM80A-048L-050F40 AM80A-048L-120F18 AM80A-048L-150F16 AM80A-048L-240F10 48V 48V 48V 48V 48V 48V 48V 1.2V 2.2V 3.3V 5V 12V 15V 24V 60A 60A 50A 40A 18A 16A 10A 72W 132W 165W 200W 216W 240W 240W Please contact Astec for information on other output voltages, power ranges and configurations. Safety UL: CSA: VDE: CE: UL1950 CSA C22.2 No.950 VDE 0805 EN60950 CE Mark Please contact Astec for information on specific module approvals. Note: Ensure all modules are used according to the Installation Instructions provided with each module. All modules are designed to meet the following specifications: ETS300-132-2 ETS300-386-1(1) EN55022-A (1) EN55022-B(1) EN41003 IEC6100-44(1) IEC6100-45(1) IEC950 VDE0871-A (1) VDE0878-A (1) BTNR2511(5)(1) (1) Require additional circuitry for full compliance. Please refer to application section of this manual or contact technical support office for further information. Rev. 06 Mar 03 AMPSS(R) Reference Manual 5 AM80A Performance Series Electrical Specifications Absolute Maximum Ratings - all models Exceeding the specified absolute maximum ratings may severely damage the module. These ratings are intended as guidelines for absolute worst case operating conditions and are not to be interpreted as recommended operating condition General Continuous Input Voltage Input Surge Voltage (1 sec) Isolation, Input to Output* Isolation Input to Baseplate* Isolation, Output to Baseplate* Operating Temperature (Baseplate) /Case Storage Temperature Operating Relative Humidity (non-condensing) Storage Relative Humidity (non-condensing) Altitude (Operating) Altitude (Storage) Lead Temperature (soldering 5 Seconds) 320V Input 400V 425V 2700VDC 2121VDC 500VDC 300V Input 400V 425V 2700VDC 2121VDC 500VDC 150V Input 200V 225V 2700VDC 2121VDC 500VDC -20 to 100C * -40 to 105C 10% to 95% 95% Max < 3000m < 9000m 235C 48V Input 72V 75V (continuous) 2100VDC 2100VDC 500VDC Notes: * For 300/320V input : Secondary Control Pins +SENSE -SENSE TEMP MON C MON C SHARE CLK OUT CLK IN C LIM ADJ OVP ADJ V ADJ PG/ID ENABLE Vo - 0.5 to Vo + 0.5 VDC -0.5 to 0.5 VDC -0.5 to 7 VDC -0.5 to 7 VDC -0.5 to 7 VDC -50 to 50 VDC -50 to 50 VDC -0.5 to 7 VDC -0.5 to 7 VDC -0.5 to 7 VDC 0.5 to Vo + 0.5VDC -0.5 to 20 VDC All isolation barriers on 300V input modules have been designed and tested to meet 4242VDC as required by IEC950 for reinforced insulation. The complete module should NOT be subjected to a 3000VAC input-to-output test because this can result in inputbaseplate-output breakdown. AMPSS DC-DC modules are CLASS I equipment. Power supply systems using AMPSS modules MUST also be CLASS I equipment. Each AMPSS DC-DC module is fully tested in factory according to the standards. Therefore power supply systems need only be subjected to Hi-Pot test for BASIC insulation which is 1500Vac (AC) input to GROUND. Note : V o = module output voltage All voltage referenced to negative output Specifications Electrical characteristics are guaranteed over the full baseplate/ case temperature range (-20 to 100C) and for the full range of input voltage (VI) and for the full load range (0 to IO rated). Except where indicated , +SENSE and -SENSE are connected to the output terminals at the point of measurement, ENABLE is connected to -SENSE. All other pins are left floating. Definitions VI, VO and IO are actual operating conditions, VInom , VOnom and IOrated are nominal ratings. 6 AMPSS(R) Reference Manual Rev. 06 Mar 03 Pin Connections - all models INPUT PINS Pin No Pin Name Type Description 31 +INPUT Input Power input - positive 32 -INPUT Input Power input - negative (return) Recommended Connections A 220F electrolytic capacitor connected between the +INPUT and -INPUT pins is recommended See + INPUT for recommendations CONTROL PINS Pin No Pin Name Type 1 +SENSE Input 2 TEMP MON Output 3 C MON Output 4 C SHARE 5 CLK OUT Output 6 CLK IN Input Description Used for remote sense function to compensate for load bus resistance Provides a voltage signal proportional to the internal absolute temperature of the module Provides a current signal proportional to the current being supplied by the module Allows modules connected in Input/Output parallel to accurately share current 7 PG/ID Output 8 C LIM ADJ Input 9 OVP ADJ Input 10 V ADJ Input 11 ENABLE Input 12 -SENSE Input/ reference Provides a 1MHz clock output for synchronization with other modules Accepts a 1MHz clock input for synchronization with other modules Recommended Connections If remote sensing is not required connect to +OUTPUT pins 21-24 of the module Analog signal output. Leave unconnected if not used Analog signal output. Leave unconnected if not used Connect to C SHARE pins of other modules. Leave unconnected if not used Capacitor coupled output. Leave unconnected if not used Capacitor coupled input. Leave unconnected if not used H i g h l e v e l o u t p u t ( VP G / I D = V O ) indicates module converter is running. Can also be used to identify the nominal output voltage of the module by measuring resistance between PG/ID and +OUTPUT I D R e s i s t a n c e = [ V O ( n o m )] K W Leave unconnected if not use Used to adjust the current limit set point Used to adjust module output overvoltage threshold Used to adjust module output voltage Internal 1mA current source. Leave unconnected if not used Internal 1mA current source. Leave unconnected if not used Internal 1mA current source. Leave unconnected if not used Enables or disables the output of Must be connected to -SENSE pin or driven the module to <0.7V to enable the output of the module Used for remote sense function to compensate for load bus resistance If remote sensing is not required connect to -OUTPUT pins 26-29 of the module OUTPUT PINS Pin No Pin Name Type 21-24 +OUTPUT Output Power output - positive 26-29 -OUTPUT Output Power output - negative Rev. 06 Mar 03 Description Recommended Connections Ensure good electrical connection and sufficient copper on PCB layouts See +OUTPUT for recommendations AMPSS(R) Reference Manual 7 AM80A Performance Series All Models CONTROL SIGNALS Control Function TEMP MON - temperature monitor signal C MON - current monitor signal C SHARE - current share function CLK OUT - clock output Conditions IO = IOrated C SHARE pins of modules in parallel connected CLK IN open CLK IN - clock input PG/ID power good / Identification function C LIM ADJ - current limit adjustment 1 OVP ADJ - output overvoltage protection adjustment V ADJ - voltage adjust ENABLE - module enable Converter running : IO 5%IOrated for I Orated 20A IO > 1A for IOrated <20A Converter not running 320V, 300V & 150V Input Converter not running 48V Input 5V output 6.5V output 12V output 15V output 24V output 28V output VC LIM ADJ = 0.8V VC LIM ADJ = 4.0V VC LIM ADJ = 1V VO V P A D J = 0V VOVP ADJ >= 1V VOVP ADJ = 1V VVadj = 0V VVadj = 2V VVADJ = 1V Module enabled Module disabled VENABLE = 0.7V Parameter VT MON sensitivity Source impedence IC MON Measured Range C SHARE accuracy Max no. of units V CLK OUT Clock freq. Max fan out VC L K I N Clock freq VP G / I D Min 9.8 0.9 20 Typ 10 1 1 3% 3.3 0.98 3.3 0.9 1 1 100 Max 10.2 1.1 100 10 10 5.5 1.02 2 5.5 1.1 Units mV/C KW mA %IOrated %IO rated Vp-p MHz Vp-p MHz %VO VP G / I D 0.2 V VP G / I D 1.0 V 5.1 6.8 12 15 24 27 20 100 1 6.12 7.82 13.02 16.02 25.02 28.02 1 80 120 1 1.05 82 122 1.05 0.7 10 150 K K K K K K %I Omax %I Omax mA %VOnom %VOnom mA %VOnom %VOnom mA V V A Resistance; PG/ID to positive output terminal C LIM set point C LIM set point C LIM current source OVP set point OVP set point OVP ADJ current source VO VO V ADJ current source VENABLE VENABLE ENABLE current source 5.00 6.66 11.76 14.70 23.52 26.46 0.95 110 0.95 78 118 0.95 0 2 100 1.05 150 Notes : 1. OVP trip point must be adjusted to accomodate maximum remote sense compensation 8 AMPSS(R) Reference Manual Rev. 06 Mar 03 Electrical Specifications for 48V Input Models (AM80A-048L-xxxFyy) INPUT CHARACTERISTICS Parameter Input voltage Input surge voltage Input low line power on voltage Input low line power off voltage No load input power Input capacitance Input current Conditions (continuous) Module power on Module shutdown VI = VInom Min 36 Typ 48 30 24 Low line, nom VO , max IO AM80A-048L-012F60 AM80A-048L-022F60 AM80A-048L-033F50 AM80A-048L-050F40 AM80A-048L-120F18 AM80A-048L-150F16 AM80A-048L-240F10 Max 72 75 35 31.5 5 5 Units V V V V W F 3.3 5.3 6.2 7.0 7.5 8.3 8.2 A A A A A A A TRANSIENT CHARACTERISTICS Parameter Turn-on time Transient response (25% to 75% load change @ 0.1A/S, recovery to 1% V O ) Rev. 06 Mar 03 Conditions V I = 0 t o VI n o m Step-load excursion AM80A-048L-012F60 AM80A-048L-022F60 AM80A-048L-033F50 AM80A-048L-050F40 AM80A-048L-120F18 AM80A-048L-150F16 AM80A-048L-240F10 Step-load response AM80A-048L-012F60 AM80A-048L-022F60 AM80A-048L-033F50 AM80A-048L-050F40 AM80A-048L-120F18 AM80A-048L-150F16 AM80A-048L-240F10 Min Typ 1 Max 10 Units msec 36 66 100 150 360 450 720 60 110 165 250 600 750 1200 mV mV mV mV mV mV mV 400 400 400 400 300 250 300 S S S S S S S AMPSS(R) Reference Manual 9 AM80A Performance Series Electrical Specifications for 48V Input Models (Cont'd) OUTPUT CHARACTERISTICS Parameter Nominal (factory set) output voltage Output voltage set point accuracy Remote sense compensation Output voltage adjust Nominal (factory set) output overvoltage protection trip point Overvoltage protection trim range Line regulation Load regulation Noise and ripple Output current Output current limit Short circuit current Temperature coefficient Overtemperature shutdown Efficiency 10 Conditions AM80A-048L-012F60 AM80A-048L-022F60 AM80A-048L-033F50 AM80A-048L-050F40 AM80A-048L-120F18 AM80A-048L-150F16 AM80A-048L-240F10 T C = +25C, VI = VInom , IO = IOrated VI = VImin Min Typ 1.2 2.2 3.3 5.0 12.0 15.0 24.0 -1 80 110 115 110 VImin to VImax ; All models except : AM80A-048L-012F60 AM80A-048L-022F60 AM80A-048L-033F50 IOmin to I Omax ; All models except : AM80A-048L-012F60 AM80A-048L-022F60 AM80A-048L-033F50 20Mhz bandwidth AM80A-048L-012F60 AM80A-048L-022F60 AM80A-048L-033F50 AM80A-048L-050F40 AM80A-048L-120F18 AM80A-048L-150F16 AM80A-048L-240F10 AM80A-048L-012F60 AM80A-048L-022F60 AM80A-048L-033F50 AM80A-048L-050F40 AM80A-048L-120F18 AM80A-048L-150F16 AM80A-048L-240F10 VO dropped to 90% of VO n o m AM80A-048L-012F60 AM80A-048L-022F60 AM80A-048L-033F50 AM80A-048L-050F40 AM80A-048L-120F18 AM80A-048L-150F16 AM80A-048L-240F10 Per C Baseplate temperature All models VO = VO n o m, VI = VInom, IO = IOrated AM80A-048L-012F60 AM80A-048L-022F60 AM80A-048L-033F50 AM80A-048L-050F40 AM80A-048L-120F18 AM80A-048L-150F16 AM80A-048L-240F10 AMPSS(R) Reference Manual 50 50 50 50 120 240 240 0 0 0 0 0 0 0 105 110 105 110 60 70 75 83 85 84 85 64 72 80 84 87 87 88 Max 1 0.5 120 120 Units V V V V V V V %VO n o m V %VO n o m %VO 150 0.2 %VO %VO n o m 10 10 10 0.2 mV mV mV %VO n o m 10 10 10 mV mV mV 100 100 100 100 240 300 480 60 60 50 40 18 16 10 115 160 160 160 160 200 200 200 0.02 120 mV mV mV mV mV mV mV A A A A A A A %IOmax %IOmax %IOmax %IOmax %IOmax %IOmax %IOmax %IOmax %VO /C C % % % % % % % Rev. 06 Mar 03 Electrical Specifications for 150V Input Models (AM80A-150L-xxxFyy) INPUT CHARACTERISTICS Parameter Input voltage Input surge voltage Input low line power on voltage Input low line power off voltage No load input power Input capacitance Input current Input current Conditions Min 90 (1 second) Module power on Module shutdown VI = V I n o m Output voltage set point accuracy 1 Remote sense compensation Output voltage adjust Nominal (factory set) output overvoltage protection trip point Overvoltage protection trim range Line regulation Load regulation Noise and ripple Max 200 220 88 79 5 1.2 Units V V V V W F 3 A 2.1 A Typ 1 Max 10 Units msec 195 325 250 mV S Max Units 1 0.5 120 V %VOnom V %VOnom 115 120 150 0.2 0.2 %VO %VOnom %VOnom %VOnom 65 130 mV 110 33 115 A %IOmax 105 110 160 0.02 120 %IOmax %VO /C C 80 83 75 60 Low line, nom V O , max I O AM80A-150L-065F33 Nom line, max V O , max I O AM80A-150L-065F33 TRANSIENT CHARACTERISTICS Parameter Conditions Turn-on time VI = 0 to VI n o m Transient response Step-load excursion (25% to 75% load change @ AM80A-150L-065F33 0.1A/S, recovery to 1% VO) Step-load response OUTPUT CHARACTERISTICS Parameter Nominal (factory set) output voltage Typ 150 Min Conditions Min AM80A-150L-065F33 T C = +25C, VI = VInom, IO = IOrated VI = VImin Typ 6.5 -1 80 110 110 VImin to VImax 0 to I Omax 20MHz bandwidth AM80A-150L-065F33 Output current Output current limit Short circuit current Temperature coefficient Overtemperature shutdown Efficiency Rev. 06 Mar 03 AM80A-150L-065F33 VO dropped to 90% of VOnom 0 105 AM80A-150L-065F33 Per C Baseplate temperature Baseplate temperature VO = VOnom , VI = VInom, IO = IOrated AM80A-150L-065F33 % AMPSS(R) Reference Manual 11 AM80A Performance Series Electrical Specifications for 300V Input Models (AM80A-300L-xxxFyy) INPUT CHARACTERISTICS Parameter Input voltage Input surge voltage Input low line power on voltage Input low line power off voltage No load input power Input capacitance Input current Conditions All models except : AM80A-300L-065F33 AM80A-300L-280F09 (1 second) Module power on Module shutdown VI = V I n o m Typ 300 Max 400 Units V 240 200 300 300 400 400 425 175 157.5 5 0.5 V V V V V W F 1.1 1.3 1.4 1.5 1.5 1.6 1.6 1.6 A A A A A A A A Typ 1 Max 10 Units msec 66 100 150 195 360 450 720 700 110 165 250 325 600 750 1200 1400 250 mV mV mV mV mV mV mV mV sec 150 120 Low line, nom VO , max IO AM80A-300L-022F60 AM80A-300L-033F50 AM80A-300L-050F40 AM80A-300L-065F33 AM80A-300L-120F18 AM80A-300L-150F16 AM80A-300L-240F10 AM80A-300L-280F09 TRANSIENT CHARACTERISTICS Parameter Conditions Turn-on time VI = 0 to V I n o m Transient response Step-load excursion (25% to 75% load change @ AM80A-300L-022F60 0.1A/S, recovery to 1% VO) AM80A-300L-033F50 AM80A-300L-050F40 AM80A-300L-065F33 AM80A-300L-120F18 AM80A-300L-150F16 AM80A-300L-240F10 AM80A-300L-280F09 Step load response 12 Min 180 AMPSS(R) Reference Manual Min Rev. 06 Mar 03 Electrical Specifications for 300V Input Models (Cont'd) OUTPUT CHARACTERISTICS Parameter Nominal (factory set) output voltage Output voltage set point accuracy Remote sense compensation Output voltage adjust Nominal (factory set) output overvoltage protection trip point Overvoltage protection trim range Line regulation Load regulation Noise and ripple Output current Output current limit Short circuit current Temperature coefficient Overtemperature shutdown Efficiency Rev. 06 Mar 03 Conditions AM80A-300L-022F60 AM80A-300L-033F50 AM80A-300L-050F40 AM80A-300L-065F33 AM80A-300L-120F18 AM80A-300L-150F16 AM80A-300L-240F10 AM80A-300L-280F09 T C = +25C, VI = VInom , IO = IOrated VI = VImin Min Typ 2.2 3.3 5.0 6.5 12.0 15.0 24.0 28.0 -1 80 110 115 110 VImin to VImax ; All models except : AM80A-300L-022F60 AM80A-300L-033F50 IOmin to I Omax ; All models except : AM80A-300L-022F60 AM80A-300L-033F50 20MHz bandwidth AM80A-300L-022F60 AM80A-300L-033F50 AM80A-300L-050F40 AM80A-300L-065F33 AM80A-300L-120F18 AM80A-300L-150F16 AM80A-300L-240F10 AM80A-300L-280F09 AM80A-300L-022F60 AM80A-300L-033F50 AM80A-300L-050F40 AM80A-300L-065F33 AM80A-300L-120F18 AM80A-300L-150F16 AM80A-300L-240F10 AM80A-300L-280F09 VO dropped to 90% of VO n o m AM80A-300L-022F60 AM80A-300L-033F50 AM80A-300L-050F40 AM80A-300L-065F33 AM80A-300L-120F18 AM80A-300L-150F16 AM80A-300L-240F10 AM80A-300L-280F09 Per C Baseplate temperature Baseplate temperature VO = VO n o m , VI = VInom , IO = IOrated AM80A-300L-022F60 AM80A-300L-033F50 AM80A-300L-050F40 AM80A-300L-065F33 AM80A-300L-120F18 AM80A-300L-150F16 AM80A-300L-240F10 AM80A-300L-280F09 50 50 50 65 120 240 240 280 0 0 0 0 0 0 0 0 105 110 105 110 70 75 82 83 84 82 84 85 74 78 83 85 86 86 87 87 Max 1 0.5 120 120 Units V V V V V V V V %VO n o m V %VO n o m %VO 150 0.2 %VO %VO n o m 10 10 0.2 mV mV %VO n o m 10 10 mV mV 100 100 100 130 240 300 480 560 60 50 40 33 18 16 10 9 115 160 160 160 165 200 200 200 200 0.02 120 mV mV mV mV mV mV mV mV A A A A A A A A %IOmax %IOmax %IOmax %IOmax %IOmax %IOmax %IOmax %IOmax %IOmax %VO /C C AMPSS(R) Reference Manual % % % % % % % % 13 AM80A Performance Series Electrical Specifications for 320V Input Models (AM80A-320L-xxxFyy) INPUT CHARACTERISTICS Parameter Input voltage Input surge voltage Input low line power on voltage Input low line power off voltage No load input power Input capacitance Input current Conditions (1 second) Module power on Module shutdown VI = VInom Output voltage set point accuracy Remote sense compensation Output voltage adjust Nominal (factory set) output overvoltage protection trip point Overvoltage protection trim range Line regulation Load regulation Noise and ripple Typ 320 Max 400 425 230 205 5 0.5 Units V V V V W F 1.2 A Typ 1 Max 10 Units msec 700 1400 800 mV S 200 160 Low line, nom VO , max I O AM80A-320L-280F09 TRANSIENT CHARACTERISTICS Parameter Conditions Turn-on time VI = 0 to VI n o m Transient response Step-load excursion (25% to 75% load change @ AM80A-320L-280F09 0.1A/S, recovery to 1% VO) Step-load response OUTPUT CHARACTERISTICS Parameter Nominal (factory set) output voltage Min 256 Conditions AM80A-320L-280F09 T C = +25C, VI = VInom , IO = IOrated VI = VImin Min Min Typ Max Units 1 0.5 120 V %VO n o m V %VO n o m 120 150 56 56 %VO %VO n o m mV mV 375 mV 110 9 115 A %IOmax 102 105 200 0.02 108 %IOmax %VO /C C 86 88 28 -1 80 110 110 115 VImin to VImax 0 to I Omax 20MHz bandwidth AM80A-320L-280F09 Output current Output current limit Short circuit current Temperature coefficient Overtemperature shutdown Efficiency 14 AM80A-320L-280F09 VO dropped to 90% of VO n o m AM80A-320L-280F09 Per C Baseplate temperature Baseplate temperature VO = VO n o m, VI = VInom , IO = IOrated AM80A-320L-280F09 AMPSS(R) Reference Manual 0 105 % Rev. 06 Mar 03 Functional Description This section explains how to implement the functions found on the AM80A Performance Series. Remote Sense (+SENSE, -SENSE) Connect the +SENSE and -SENSE pins of the AM80A directly to the load to allow the module to compensate for the voltage drop across the conductors carrying the load current. If remote sensing is not required (for example if the load is close to the module) the sense pins should be connected directly to the module's output pins to ensure accurate regulation. Enable Control (ENABLE) The enable pin is a TTL compatible input used to turn the output of the module on or off. The module output is enabled when the ENABLE pin is connected to SENSE or driven to a logic low of <0.7V (but not negative). The output is disabled when the enable pin is open or driven to a logic high >2V. All monitoring and housekeeping functions (including clock signals) continue to operate normally. Note: If the sense leads fail open circuit, the module will revert to local sense at the output pins. Incorrect connection of sense leads may damage the module Rev. 06 Mar 03 AMPSS(R) Reference Manual 15 AM80A Performance Series Output Voltage Adjustment (V ADJ) The output voltage of the module may be accurately adjusted by up to 20% of the nominal factory set output. Adjustment is carried out using either an external voltage source (0 to 2V, capable of sinking 1mA) or a resistor (0 to 2K) connected between V ADJ and -SENSE. Overvoltage Protection Adjustment (OVP ADJ) An independent overvoltage circuit monitors the module's output pins and will shut the module down in the event of an internal or external fault which causes the output voltage to rise above the preset limit. The module is reset by removing and re-applying the input power or toggle the ENABLE OFF/ON. Current Limit Adjustment (C LIM ADJ) A constant current limiting circuit protects the module under overload or short circuit conditions. With the C LIM ADJ pin left unconnected the current limit is factory set to 115% of the module's rated output, but may be adjusted across the range from 20% to 100% using an external voltage source (0.8 to 4V, capable of sinking 1mA) or a resistor (800R to 4K) connected between C LIM ADJ and -SENSE. 16 AMPSS(R) Reference Manual Rev. 06 Mar 03 The overvoltage set point may be adjusted between 10% and 50% above the output voltage (VO), and automatically tracks adjustments made to the output voltage using V ADJ. OVP ADJ should be used to increase the OVP margin if the voltage drop between power output pins and remote sense is more than 0.2V The resistance between the PG/ID pin and the +ve output of the module can be used to determine the output voltage of the module with no power applied according to the table: Power Good/Identification (PG/ID) Clock Signals (CLK IN, CLK OUT) This pin provides an indication that the module's converters are working, and can also be used to identify the factory set output voltage of the module. The PG/ID pin goes high to the level of the output voltage (VO) to indicate that the module is operating and delivering power. The output goes low if the converters stop operating due to a fault such as an overtemperature or overvoltage condition. The PG/ID pin will also go low if the module is disabled via the ENABLE pin or under light load condition (seespecification). Output Voltage (V) 1.2 2.2 6.5 3.3 5 12 15 24 28 Resistance (K ) 1.2 2.2 6.8 3.3 5.1 12 15 24 27 The module's internal clock is accurate and stable over its full operating range and synchronization is not normally required, but it can reduce noise in paralleled systems. Clock signals can be wired in series (the CLK OUT pin of one module to the CLK IN pin of the next etc) in which case all the modules will be synchronized with the first module in the chain. Alternatively, an external clock signal of 5Vpk-pk at 1MHz10% can be connected to the CLK IN pins of all the modules. If the clock input to any module fails, the module will automatically switch back to its internal clock and will continue to operate normally. The CLK IN and CLK OUT signals are AC coupled, so any module can clock another module regardless of polarity. Rev. 06 Mar 03 AMPSS(R) Reference Manual 17 AM80A Performance Series Current Sharing (C SHARE) To ensure that all modules in a parallel system accurately share current, the C SHARE pins on each module should be connected together. output current of the module, where 0.2 to 1mA = 20 to 100% IO rated. The C MON output can be paralleled with C MON outputs from other modules to indicate the total current supplied in a paralleled system. Temperature Monitoring (TEMP MON) The TEMP MON pin provides an indication of the module's internal temperature.The voltage at the TEMP MON pin is proportional to the temperature of the module baseplate at 10mV per C, where: Module temperature (C) = (VTEMP MON x 100) - 273 The voltage on the C SHARE pins represents the average load current per module. Each module compares this average with its own current and adjusts its output voltage to correct the error. In this way the module maintains accurate current sharing. Note: The -SENSE and +SENSE pins of each module must also be connected together to ensure accurate current sharing. The temperature monitor signal can be used by thermal management systems (e.g. to control a variable speed fan). It can also be used for overtemperature warning circuits and for thermal design verification of prototype power supplies and heatsinks. Current Monitoring (C MON) The C MON pin provides an indication of the amount of current supplied by the module. The output of the C MON pin is a current source proportional to the 18 AMPSS(R) Reference Manual Rev. 06 Mar 03 Design Considerations Input Bulk Capacitors Electrolytic bulk reservoir capacitors placed close to the module input pins are recommended to ensure the module is fed with a low source impedance. For the AM80A Performance Series module typical values are 220F/100V for 48V modules and 220F/450V for 300/320V modules. Thermal Data Input Fusing AMPSS modules do not have an in-line fuse fitted internally. In order to comply with CSA, VDE and UL safety regulations it is recommended that a fuse of the following rating be fitted at the module's input. Natural convection thermal impedance of the AM80A package without a heatsink is approximately 4C/W. The below characteristic is for a standard horizontal fin heatsink available from Astec (part number APA501-80002) with 11mm fins and 8mm pitch. The heatsink will reduce module thermal impedance to 1C /W with a forced air flow of 250 LFM when mounted with a thermal pad (ASTEC P/N APA502-80-001) between heatsink and module. Forced Convection for APA501-80-002 at 200W Output Fuse Rating 10A / 250V 10A / 250V 10A / 250V 1 Ambient (C/W) Input 300V/320V 150V 48V Thermal Resistance Baseplate to 1.2 0.8 0.6 0.4 0.2 0 0 200 400 600 800 1000 Vair (LFM) Remote Loads If the sensed load is some distance from the module, the module's output voltage may rise sufficiently to trigger the OVP protection circuit during a step load change due to bus inductance. For this reason the OVP margin should be increased in extreme cases. Fitting a decoupling capacitor at the load can reduce this effect. It should be noted that a distributed power solution, using AMPSSTM modules placed close to their loads, will optimize transient response. Rev. 06 Mar 03 Overtemperature Protection If the module's baseplate temperature exceeds 110C, the module will latch OFF. To reset the module the input supply or the enable pin of the module must be cycled off and then on again, allowing a period of time for the module to cool down. Overtemperature shutdown can also be programmed to occur at lower temperatures by using the TEMP MON output to control the ENABLE pin. AMPSS(R) Reference Manual 19 AM80A Performance Series Parallel Connection Considerations Conducted EMI A master-slave configuration is not required for AMPSSTM modules. AM80A modules may be connected in parallel using a simple, single wire connection. Although AMPSS modules contain both common mode and differential mode input EMI filtering, power supply systems using these modules will require additional EMI filtering to enable the system to meet relevant EMI standards. AM80A modules have an effective input to ground (baseplate) capacitance of 700pF for 300V input models and 580pF for 48V input models. This should be accounted for when calculating the maximum EMI `Y' capacitance to meet ground leakage current specifications. Break Regulation Current Sharing In multi-module paralleled systems, all modules will share current to within 3% (typical) of the rated load current per module when the C SHARE pins of each module are connected together. The +SENSE and -SENSE pins of each module should be connected to common points as close as possible to the load. AM80A Performance Series modules are designed to deliver full rated output current at up to 0.5V above VO nom at the minimum specified input voltage. Synchronization Modules are synchronized by connecting the CLK OUT pin of one module to the CLK IN pin of the next. Consecutively connected modules operate out of phase with each other, resulting in ripple cancellation at the inputs and outputs of paralleled modules. If the clock input to a module fails, it will automatically revert to its internal clock and continue to operate normally. Output Ripple and Noise AM80A Performance Series modules are designed to generate very low ripple and noise. When mounted on logic boards, for example, sufficient decoupling is normally provided by the components used to decouple the logic ICs, and no additional decoupling is required. 20 AMPSS(R) Reference Manual Rev. 06 Mar 03 Input Undervoltage Protection An input undervoltage protection circuit protects the module under low input voltage conditions. Hysteresis is built into the AM80A Performance Series module to allow for high levels of ripple on the input supply voltage without causing the module to cycle on and off. Typically 320V modules will turn on when the input exceeds 220V and turn off below 180V. 300V modules will turn on when the input exceeds 160V and turn off below 140V. 48V modules will turn on above 33V and turn off below 28V (see Electrical Specifications for exact figures). Rev. 06 Mar 03 AMPSS(R) Reference Manual 21 AM80A Performance Series Application Examples AC Input Design Parallel Connection Design 22 AMPSS(R) Reference Manual Rev. 06 Mar 03 Mechanical Information Dimensions The dimensions are given in mm (inches). Note that the baseplate must be connected to protective earth before power is supplied to the module. Rev. 06 Mar 03 AMPSS(R) Reference Manual 23 Recommended PCB Layout The AM80A Performance Series module may be mounted to a board either by soldering or by using spring sockets. Materials : Control pins are tin plated phospher-bronze. Input and output pins are tin plated copper. Heatsink Mounting Information Heatsinks for AMPSSTM modules are available in a variety of sizes and fin orientation. Mounting kits and thermal pads are also available. The table below shows the options available for AM80A Performance Series. A heatsink mounting kit provides the most convenient way to mount the heatsink to the module and then mount the assembly onto a circuit board AMPSSTM modules may be retained by their in put and output pins only, or may be fixed to the board th cases the studs provide clearance between the module and the circuit board to facilitate PCB cleaning operations. Note: 1) Baseplate and heatsink must be connected to protective earth. 2) Mechanical support must not induce twist in the module baseplate and must incorporate strain relief, e.g. spring washers. 1 2 Description Model Number Heatsink, "80" size, vertical fin. Heatsink, "80" size, horizontal fin Heatsink, "80" size, vertical fin. Heatsink, "80" size, horizontal fin Heatsink, "80" size, vertical fin. Heatsink, "80" size, horizontal fin Heatsink, "80" size, low profile Thermal Pad, "80" size Mounting Kit, Tapped Studs Mounting Kit, Solder Studs Mounting Kit, Tapped Studs for low profile heatsink Mounting Kit, Solder Studs for low profile heatsink Spring Sockets (20 cont. 15pwr) APA501-80-001 APA501-80-002 APA501-80-003 APA501-80-004 APA501-80-005 APA501-80-006 APA501-80-007 APA502-80-001 APA503-00-001 APA503-00-002 APA503-00-007 Dimensions inches mm 4.53x2.32x0.6 115x59x15 4.53x2.32x0.6 115x59x15 4.53x2.32x0.9 115x59x22.5 4.53x2.32x0.9 115x59x22.5 4.53x2.32x1.5 115x59x37 4.53x2.32x1.5 115x59x37 4.55x3.50x0.5 115.6x89x12 Free air thermal resistance 2.7C/W 2.4C/W 2.2C/W 2.0C/W 2.0C/W 1.7C/W 2.2C/W APA503-00-008 APA504-00-001 To provide optimal thermal contact between heatsink and module, it is recommended that the mating surface of the heatsink should have a surface flatness of no greater than 0.1mm. The use of a thermal pad or thermal grease is also recommended. The recommended torque of using AMPSS mounting kit for module/heatsink is: Screw size M3 M3.5 Torque 4-6kg-cm (3.5-5.2 lb-in) 6-8kg-cm (5.2-6.9 lb-in) Torque sequence: It is assumed that all four mounting screws are being torqued to a common surface. Other thermal management schemes are at customer discretion as long as the maximum thermal rating of the specific module is not exceeded. For further information contact : NORTH AMERICA ASTEC AMERICA, INC,. 5810 Van Allen Way, Carlsbad CA 92008, USA. Tel : 760-930-4600 Fax : 760-930-0698 EUROPE ASTEC EUROPE LTD. Astec House, Unit 9, Waterfront Business Park, Merry Hill, Dudley DY5 1LX U.K. Tel : 01384-842211 Fax : 01384-843355 ASIA ASTEC AGENCIES LIMITED Unit 2111-2116, Level 21 223, Hing Fong Raod Kwai Fong N.T. Hong Kong Tel : 852 2437-9662 Fax : 852 2402-4426 APA701-AM80 Rev. 06 Mar03