AV 6 0 C H a l f - b r i c k S e r i e s Te c h n i c a l R e f e r e n c e N o t e s 48V Input, 15V Output 50-150W DC-DC Converter (Rev01) -1TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 Publishing Date: 20020625 AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output Introduction Design Feature The AV60C half-brick series of switching DC- ! High Efficiency DC converters is one of the most cost effective ! High power density ! Low output noise dard package size of 2.4"x2.28"x0.5" and ! Metal baseplate pinout configuration, provides standard control, ! CNT function ! Remote sense more selectivity to meet small size requirement. ! Trim function AV60C half-brick series comes in 48V input ver- ! Input under-voltage lockout ! Output short circuit protection ! Output current limiting tion. There are isolated single output 3.3V, 5V, ! Output over-voltage protection 12V, 15V, and the isolation voltage is 1500Vdc. ! Overtemperature protection ! High input-output isolation voltage options available in component power. The AV60C half-brick series uses an industry stan- trim, and sense functions, also features high power density up to 54.8W/in3 which gives sion with a 2:1 ( 36-75V ) input range. This series has input LVP, output OVP, OCP, short circuit protection and over temperature protec- 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 Options power converters. The unit employs an aluminum baseplate to carry all of the power components, and conduct the dissipated heat to the ! Heat sink available for extended operation. ! Choice of CNT control logic configuration. ambient. A conventional, multi-layer printed circuit board, over the top of the power substrate, contains all of the small signal control circuitry, all constructed with automated SMD technology. TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -2www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output Typical Application Fuse* +Vin +Sense +Vout CNT Vin Trim Case C1 C3 C4 C2 Load -Vout -Vin -Sense 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 -20C~ +100C: m 47F/100V electrolytic or ceramic type capacitor. -40C~ +100C: m 47F/100V ceramic type capacitor only. C2: Recommended output capacitor C2 -20C~ +100C: 1000F/25V (electrolytic capacitor) for 50W-75W 2200F/25V (electrolytic capacitor) for 100W-150W -40C~ +100C: For this temperature range, use two pieces of the recommended capacitor above. C3: Recommended 4700pF/2000V C4: Recommended 0.1F/25V TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -3www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output Block Diagram +Vin +Vout -Vin -Vout +Sense Trim -Sense CNT Ordering Information Model Number TEL: FAX: Input Voltage Output Voltage Output Current Ripple (mV rms) Noise (mV pp) Efficiency min typ AV60C-048L-150F03 36-75V 15V 3.33A 80 250 86% 88% AV60C-048L-150F03N 36-75V 15V 3.33A 80 250 86% 88% AV60C-048L-150F05 36-75V 15V 5A 80 250 86% 88% AV60C-048L-150F05N 36-75V 15V 5A 80 250 86% 88% AV60C-048L-150F06 36-75V 15V 6.7A 80 250 86% 88% AV60C-048L-150F06N 36-75V 15V 6.7A 80 250 86% 88% AV60C-048L-150F10 36-75V 15V 10A 80 250 86% 88% AV60C-048L-150F10N 36-75V 15V 10A 80 250 86% 88% USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -4www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output Absolute Maximum Rating Characteristic Min Typ Max Units Input Voltage(continuous) -0.3 80 Vdc Input Voltage(peak/surge) -0.3 100 Vdc Case temperature -40 100 C storage temperature -55 125 C Notes 100ms non-repetitive Input Characteristics Characteristic Input Voltage Range Min Typ Max Units 36 48 75 Vdc 30 50 mAp-p Input Reflected Current Notes Turn-off Input Voltage 30 33 35 V Turn-on Input Voltage 31 34 36 V 10 35 ms Typ Max Units 15 Vdc 1.2 Vdc 2 mA Max Units Notes k Hrs Bellcore TR332, Tc=40C Turn On Time Control Function Characteristic Logic High Min 3 Logic Low Control Current Notes General Specifications Characteristic MTBF Min Typ 2000 Isolation 1500 Vdc Pin solder temperature 260 C wave solder < 10 s 5 s iron temperature 425C Hand Soldering Time Weight TEL: FAX: USA 1-760-930-4600 1-760-930-0698 75 Europe 44-(0)1384-842-211 44-(0)1384-843-355 grams Asia 852-2437-9662 852-2402-4426 -5www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output AV60C-048L-150F03(N) Output Characteristics Characteristic Min Typ Power Max Units 50 Output Current 0.333 Output Setpoint Voltage 14.85 Notes W 3.33 A 15 15.15 Vdc Vin=48V, Io=3.33A Line Regulation 0.02 0.2 %Vo Vin=36~75V, Io=3.33A Load Regulation 0.1 0.5 %Vo Io=0~3.33A, Vin=48V 1 %Vo Ta=25C, DI/Dt=1A/10s 200 s Ta=25C, DI/Dt=1A/10s 1 %Vo Ta=25C, DI/Dt=1A/10s 200 s Ta=25C, DI/Dt=1A/10s Dynamic Response 50-75% load 50-25% load Current Limit Threshold 3.66 Short Circuit Current Efficiency 4.33 A 5.66 A 88 % Vin=48V, Io=3.33A 1.7 A Vinmin=36V 86 Input Current Trim Range 90 110 %Vo Over Voltage Protection Setpoint 16.5 20 V Sense Compensation 0.5 V Temperature Regulation 0.02 %Vo/C Ripple (rms) 80 mV ( 0 to 20MHz Bandwidth ) Noise (p-p) 250 mV ( 0 to 20MHz Bandwidth ) Over Temperature Protection 105 C Switching Frequency 280 kHz Maximum Capacitor Load TEL: FAX: 4.66 USA 1-760-930-4600 1-760-930-0698 10000 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 0.25V each leg F -6www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output AV60C-048L-150F05(N) Output Characteristics Characteristic Min Typ Power Max Units 75 Output Current 0.5 Notes W 5 A 15 15.15 Vdc Vin=48V, Io=5A Line Regulation 0.02 0.2 %Vo Vin=36~75V, Io=5A Load Regulation 0.1 0.5 %Vo Io=0~5A, Vin=48V 1 %Vo Ta=25C, DI/Dt=1A/10s 200 s Ta=25C, DI/Dt=1A/10s 1 %Vo Ta=25C, DI/Dt=1A/10s 200 s Ta=25C, DI/Dt=1A/10s Output Setpoint Voltage 14.85 Dynamic Response 50-75% load 50-25% load Current Limit Threshold 5.5 Short Circuit Current Efficiency 6.5 A 8.5 A 88 % Vin=48V, Io=5A 2.5 A Vinmin=36V 86 Input Current Trim Range 90 110 %Vo Over Voltage Protection Setpoint 16.5 20 V 0.5 V 0.02 %Vo/C Ripple (rms) 80 mV ( 0 to 20MHz Bandwidth ) Noise (p-p) 250 mV ( 0 to 20MHz Bandwidth ) Sense Compensation Temperature Regulation Over Temperature Protection 105 C Switching Frequency 280 kHz Maximum Capacitor Load TEL: FAX: 7 USA 1-760-930-4600 1-760-930-0698 10000 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 0.25V each leg F -7www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output AV60C-048L-150F06(N) Output Characteristics Characteristic Min Power Typ Max Units 100 Output Current 0.67 Output Setpoint Voltage 14.85 Notes W 6.7 A 15 15.15 Vdc Vin=48V, Io=6.7A Line Regulation 0.02 0.2 %Vo Vin=36~75V, Io=6.7A Load Regulation 0.1 0.5 %Vo Io=0~6.7A, Vin=48V 1 %Vo Ta=25C, DI/Dt=1A/10s 150 s Ta=25C, DI/Dt=1A/10s 1 %Vo Ta=25C, DI/Dt=1A/10s 150 s Ta=25C, DI/Dt=1A/10s Dynamic Response 50-75% load 50-25% load Current Limit Threshold 7.4 Short Circuit Current 8.7 A 11.4 A 88 % Vin=48V, Io=6.7A 3.4 A Vinmin=36V 90 110 %Vo 16.5 20 V Sense Compensation 0.5 V Temperature Regulation 0.02 %Vo/C Ripple (rms) 80 mV ( 0 to 20MHz Bandwidth ) Noise (pp) 250 mV ( 0 to 20MHz Bandwidth ) Efficiency 86 Input Current Trim Range Over Voltage Protection Setpoint Over Temperature Protection 105 C Switching Frequency 280 kHz Maximum Capacitor Load TEL: FAX: 9.4 USA 1-760-930-4600 1-760-930-0698 10000 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 0.25V each leg F -8www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output AV60C-048L-150F10(N) Output Characteristics Characteristic Min Power Typ Max Units 150 Output Current 1 Notes W 10 A 15 15.15 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 Output Setpoint Voltage 14.85 Dynamic Response 50-75% load 1 %Vo Ta=25C, DI/Dt=1A/10s 200 s Ta=25C, DI/Dt=1A/10s 1 %Vo Ta=25C, DI/Dt=1A/10s 200 s Ta=25C, DI/Dt=1A/10s 50-25% load Current Limit Threshold 11 13 Short Circuit Current Efficiency 86 A 17 A 88 % Vin=48V, Io=10 A 5.1 A Vinmin=36V Input Current Trim Range 90 110 %Vo Over Voltage Protection Setpoint 16.5 20 V Sense Compensation 0.5 V Temperature Regulation 0.02 %Vo/C Ripple (rms) 80 mV ( 0 to 20MHz Bandwidth ) Noise (pp) 250 mV ( 0 to 20MHz Bandwidth ) Over Temperature Protection 105 C Switching Frequency 280 kHz Maximum Capacitor Load TEL: FAX: 14 USA 1-760-930-4600 1-760-930-0698 10000 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 0.25V each leg F -9www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output Ef ficiency Characteristic Curves Typical Efficiency AV60C-048L-150F05N 90 90 85 85 Efficiency (%) Efficiency (%) Typical Efficiency AV60C-048L-150F03N 80 75 70 Vin=36V 65 80 75 70 Vin=36V 65 Vin=48V Vin=48V Vin=75V 60 0 0.5 1 1.5 2 2.5 3 Vin=75V 60 0 3.5 1 90 85 85 80 75 70 Vin=36V Vin=48V Vin=75V 0 2 4 6 8 Efficiency (%) Efficiency (%) 90 60 4 5 80 75 70 Vin=36V 65 Vin=48V Vin=75V 60 0 Europe 44-(0)1384-842-211 44-(0)1384-843-355 2 4 6 8 10 Output Current (Amps) Output Current (Amps) USA 1-760-930-4600 1-760-930-0698 3 Typical Efficiency AV60C-048L-150F10N Typical Efficiency AV60C-048L-150F06N 65 2 Output Current (Amps) Output Current (Amps) TEL: FAX: (at 25 C ) Asia 852-2437-9662 852-2402-4426 -10www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output Overcurrent Protection (OCP) (at 25 C ) Typical Output Overcurrent Performance AV60C-048L-150F05N Typical Output Overcurrent Performance AV60C-048L-150F03N 16 Output Voltage (volts) Output Voltage (volts) 16 12 Vin=36V 8 Vin=48V Vin=75V 4 12 Vin=36V 8 Vin=48V Vin=75V 4 0 0 0 2 4 6 0 8 6 8 10 12 Typical Output Overcurrent Performance AV60C-048L-150F10N Typical Output Overcurrent Performance AV60C-048L-150F06N 16 16 Output Voltage (volts) Output Voltage (volts) 4 Output Curent (amps) Output Curent (amps) 12 Vin=36V 8 Vin=48V Vin=75V 4 12 Vin=36V 8 Vin=48V Vin=75V 4 0 0 0 3 6 9 12 15 0 Output Curent (amps) TEL: FAX: 2 USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 4 8 12 16 Output Curent (amps) Asia 852-2437-9662 852-2402-4426 -11www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output Characteristic Curves (at 25 C ) 2 Typical Input Current Characteristics AV60C-048L-150F05N Input Current (amps) Input Current (amps) Typical Input Current Characteristics AV60C-048L-150F03N 1.6 1.2 0.8 0.4 3 2.4 1.8 1.2 0.6 0 0 0 20 40 60 0 80 60 80 Typical Input Current Characteristics AV60C-048L-150F10N Typical Input Current Characteristics AV60C-048L-150F06N 6 4 Input Current (amps) Input Current (amps) 40 Input Voltage (volts) Input Voltage (volts) 3 2 1 0 5 4 3 2 1 0 0 20 40 60 80 0 Input Voltage (volts) TEL: FAX: 20 USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 20 40 60 80 Input Voltage (volts) Asia 852-2437-9662 852-2402-4426 -12www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output T ransient response TEL: FAX: (at 25 C ) Typical Transient Response to Step Load Change from 25%-50%-25% Iomax AV60C-048L-150F03N Typical Transient Response to Step Load Change from 25%-50%-25% Iomax AV60C-048L-150F05N Typical Transient Response to Step Load Change from 25%-50%-25% Iomax AV60C-048L-150F06N Typical Transient Response to Step Load Change from 25%-50%-25% Iomax AV60C-048L-150F10N USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -13www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output T ransient response TEL: FAX: (rated input voltage, step load, at 25 C) Typical Transient Response to Step Load Change from 50%-75%-50% Iomax AV60C-048L-150F03N Typical Transient Response to Step Load Change from 50%-75%-50% Iomax AV60C-048L-150F05N Typical Transient Response to Step Load Change from 50%-75%-50% Iomax AV60C-048L-150F06N Typical Transient Response to Step Load Change from 50%-75%-50% Iomax AV60C-048L-150F10N USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -14www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output Characteristic Curves TEL: FAX: (rated input voltage, full load, at 25 C) Typical Start-Up from Power On AV60C-048L-150F03N Typical Start-Up from Power On AV60C-048L-150F05N Typical Start-Up from Power On AV60C-048L-150F06N Typical Start-Up from Power On AV60C-048L-150F10N USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -15www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output Characteristic Curves TEL: FAX: (rated input voltage, full load, at 25 C) Typical Shut-down from Power Off AV60C-048L-150F03N Typical Shut-down from Power Off AV60C-048L-150F05N Typical Shut-down from Power Off AV60C-048L-150F06N Typical Shut-down from Power Off AV60C-048L-150F10N USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -16www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output Characteristic Curves TEL: FAX: (rated input voltage, full load, at 25 C) Typical Start-Up from CNT Control AV60C-048L-150F03N Typical Start-Up from CNT Control AV60C-048L-150F05N Typical Start-Up from CNT Control AV60C-048L-150F06N Typical Start-Up from Remote CNT Control AV60C-048L-150F10N USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -17www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output Characteristic Curves TEL: FAX: (rated input voltage, full load, at 25 C) Typical Shut-down from CNT Control AV60C-048L-150F03N Typical Shut-down from CNT Control AV60C-048L-150F05N Typical Shut-down from CNT Control AV60C-048L-150F06N Typical Shut-down from CNT Control AV60C-048L-150F10N USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -18www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output Characteristic Curves TEL: FAX: (rated input voltage, full load, at 25 C) Typical Output Ripple Voltage AV60C-048L-150F03N Typical Output Ripple Voltage AV60C-048L-150F05N Typical Output Ripple Voltage AV60C-048L-150F06N Typical Output Ripple Voltage AV60C-048L-150F10N USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -19www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output Characteristic Curves TEL: FAX: (rated input voltage, full load, at 25 C) Overvoltage Protection AV60C-048L-150F03N Overvoltage Protection AV60C-048L-150F05N Overvoltage Protection AV60C-048L-150F06N Overvoltage Protection AV60C-048L-150F10N USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -20www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output Characteristic Curves (rated input voltage, full load, Ci=100uF, at 25 C) TEL: FAX: Input Reflected Current AV60C-048L-150F03N Input Reflected Current AV60C-048L-150F05N Input Reflected Current AV60C-048L-150F06N Input Reflected Current AV60C-048L-150F10N USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -21www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output 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 48Vin converters can accept 36-75Vdc. Care should be taken to avoid applying reverse polarity to the input which can damage the converter. -Vin -Vout Case -Sense Trim CNT +Sense +Vin +Vout Component-side footprint Fig.1 Pin Location Input Characteristic Fusing The AV60C half-brick 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 AV60C half-brick series are shown in Table 1. Table 1 TEL: FAX: Series Fuse Rating(48Vin) 50W 75W 100W 150W 5A 7.5A 10A 20A USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Input Reverse Voltage 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 2. In both cases the diode rating is determined by the power of the converter. Diodes should be rated as shown in Table1. +Vin +Vin -Vin -Vin Fig.2 Reverse Polarity Protection Circuits 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. Input Undervoltage Protection The AV60C half-brick series is protected against undervoltage on the input. If the input voltage drops below the acceptable range, the converter will shut down. It will automatically restart when the undervoltage condition is removed. Input Filter Input filters are included in the converters to help achieve standard system emissions certifications. Some users however, may find that additional input filtering is necessary. The AV60C half-brick 15V output series has an internal switching frequency of 280 kHz so a high frequency capacitor mounted close to the input terminals produces the best results. To reduce reflected noise, a capacitor can be added across the input as shown in Figure 3, forming a filter. A 47F/100V electrolytic Asia 852-2437-9662 852-2402-4426 -22www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output capacitor is recommended for C1. +Vin C1 -Vin Fig.3 Ripple Rejection Input Filter For conditions where EMI is a concern, a different input filter can be used. Figure 4 shows an input filter designed to reduce EMI effects. C1 is a 47F/100V electrolytic capacitor, and C2 is a 1F/100V metal film or ceramic high frequency capacitor, Cy1 and Cy2 are each 1000pF/1500Vdc high frequency ceramic capacitors, and L1 is a 1mH common mode choke. 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 suffix `N' . Positive logic, device code suffix nothing is the factorypreferred. If the CNT pin is left open, the converter will default to " control off " operation in negative logic, but default to " control on " in positive logic. The maximum voltage that can be applied to the CNT pin is 15V. Figure 5 to Figure 8 are the four kinds of CNT circuit. CNT -Vin Fig.5 Simple Control CNT +Vin C2 Cy1 Cy2 C1 -Vin Fig.6 Transistor Control L1 -Vin CNT Fig.4 EMI Reduction Input Filter -Vin When a filter inductor is connected in series with the power converter input, an input capacitor C1 should be added. An input capacitor C1 should also be used when the input wiring is long, since the wiring can act as an inductor. Failure to use an input capacitor under these conditions can produce large input voltage spikes and an unstable output. CNT Function Two CNT control logic 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. TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Fig.7 Isolated Control CNT -Vin Fig.8 Relay Control Input-Output Characteristic 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, Asia 852-2437-9662 852-2402-4426 -23www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output CSA C22.2 No. 950-95, and EN60950. The input-to-output 1500VDC isolation is an operational 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 Vi pin and one Vo 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. 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. 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 emissions. 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 inductor can be connected to chassis at DC and AC line frequencies, but be left floating at switching frequencies. Under this condition, the safety TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 requirements are met and the emissions are minimized. Output Characteristics Minimum Load Requirement The AV60C half-brick series 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 requirement is strictly in order to meet all performance specifications. Remote Sensing The AV60C half-brick converters 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 automatically adjusts the real output voltage of the AV60C half-brick 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, significant 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 adequately 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 Asia 852-2437-9662 852-2402-4426 -24www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output 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 connected. Care should be taken not to reverse the sense leads. If reversed, the converter will trigger 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 overvoltage trip point. +Sense +S Twisted Pair Load -Sense -S -Vout +Vout CNT Sense(+) Case Trim Radj-up RLOAD Sense(-) -Vin -Vout Radj-up = Vo(100+y) 1.26y (100+2y) y - Where y is the adjusting percentage of the voltage. 0 < y < 10 Radj-up is in k. Adjustment Resistor Value (k) +Vout +Vin 1200 1000 800 600 400 200 0 0 1 2 3 4 5 6 7 8 9 10 % Change In Output Voltage (y) Fig.9 Sense Connections Fig.10 Trim Up Circuit and Curves Note that at elevated output voltages the maximum power rating of the module remains the same, and the output current capability will decrease correspondingly. +Vin +Vout CNT Sense(+) Case Trim RLOAD Radj-down Sense(-) -Vin -Vout TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Radj-down = 100 y -2 where y is the adjusting percentage of the voltage. 0 < y < 10 Radj-down is in k. Adjustment Resistor Value (k) Output Trimming Trimming Users can increase or decrease the output voltage 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. 100 90 80 70 60 50 40 30 20 10 0 0 1 2 3 4 5 6 7 8 9 10 % Change In Output Voltage (y) Fig.11 Trimming Down Circuit and Curves Asia 852-2437-9662 852-2402-4426 -25www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output Output Over-Voltage Over-Voltage Protection The over-voltage protection has a separate feedback loop which activates when the output voltage is between 16.5V-20V. When an overvoltage 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. Output Over-Current Protection AV60C half-brick series DC/DC converters feature 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. 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 C1 is 1,000F/25V. +Vout C1 C2 Load -Vout Fig.13 Output Ripple Filter For a Distant Load Decoupling Noise on the power distribution system is not always created by the converter. High speed analog or digital loads with dynamic power demands can cause noise to cross the power inductor back onto the input lines. Noise can be reduced by decoupling the load. In most cases, connecting a 10 F tantalum 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 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 connection as shown in Figure 15. RLine +Vout RLine +Vout C1 Load Load -Vout Load RLine -Vout RLine RLine Fig.12 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 as shown in Figure 13. The recommended component for C2 is 1000F/25V capacitor and connecting a 0.1F ceramic capacitor C1 in parallel. TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Ground Loop RLine Fig.14 Ground Loops RLine RLine +Vout Load Load RLine -Vout RLine RLine Fig.15 Single Point Ground Asia 852-2437-9662 852-2402-4426 -26www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output Parallel Power Distribution Figure 16 shows a typical parallel power distribution 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 closer to the source. Dynamic load conditions increase the potential problems. can be connected in parallel. This combined approach minimizes the drawbacks of a parallel design when a purely radial design is not feasible. +Vout RL3 RL1 RG1 RL4 RL2 Load 1 Load 2 Load 3 Load 4 RG2 RG3 -Vout RG4 RL = Lead Resistance RG = Ground Lead Resistance Fig.18 Mixed Power Distribution I1 + I2 + I3 I2 + I3 I3 RL2 RL1 RL3 +Vout Load 1 Load 2 Load 3 -Vout RG2 RG1 RG3 RL = Lead Resistance RG = Ground Lead Resistance Fig.16 Parallel 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. +Vout RL3 RL1 RL2 Load 1 RG1 Load 2 Load 3 RG2 RG3 -Vout RL = Lead Resistance RG = Ground Lead Resistance Redundant Operation A common requirement in high reliability systems is to provide redundant power supplies. The easiest way to do this is to place two converters 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 determining load voltage requirements. Fig.17 Radial Power Distribution +Vout -Vout Load 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 TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 +Vout -Vout Fig.19 Redundant Operation Asia 852-2437-9662 852-2402-4426 -27www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output Thermal Management Technologies AV60C half-brick series 50W to 150W modules feature high efficiency and the 15 V output units have typical efficiency of 88% at full load. With less heat dissipation and temperature-resistant components such as ceramic capacitors, these modules exhibit good behavior during prolonged 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 20 can verify the proper cooling. Figure 20 shows the metal surface of the module and the pin locations. The module should work under 90C for the reliability of operation and TC must not exceed 100 C 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. The following text and graphs show guidelines to predict the thermal performance of the module 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 TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 29.0 (1.14) 30.5 (1.2) VI (+) MEASURE CASE TEMPERATURE HERE VO (+) ON/OFF + SEN CASE - SEN VI (-) VO (-) TRIM Top View Dimensions: millimeters (inches) Fig.20 Case Temperature Measurement 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- )/ 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 AV60C half-brick series 15V output are shown as Fig.21 to Fig.24. Asia 852-2437-9662 852-2402-4426 -28www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output Module Derating Power Dissipation (W) 10 8 6 4 Vin=36V 2 Vin=48V 0 0 0.5 1 1.5 2 2.5 3 Vin=75V 3.5 Output Current (amps) Fig.21 AV60C-048L-150F03N Power Dissipation Power Dissipation (W) 14 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 vertically. The passage has a rectangular crosssection. The clearance between the facing PWB and the top of the module is kept 13 mm (0.5 in.) constantly. 12 10 8 6 4 Vin=36V 2 Vin=48V Vin=75V 0 0 1 2 3 4 Convection Without Without 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. 5 13(0.5) Output Current (amps) Fig.22 AV60C-048L-150F05N Power Dissipation Power Dissipation (W) 16 PWB facing PWB 14 12 10 Air velocity and Ambient Temperature Testing Point Module 8 6 4 Vin=36V 2 50.8(2.0) Vin=48V Vin=75V 0 0 1 2 3 4 5 6 7 Air flow Output Current (amps) Fig.23 AV60C-048L-150F06N Power Dissipation Dimensions: millimeters (inches). Power Dissipation (W) 24 Fig.25 Experiment Set Up 21 18 15 12 9 6 Vin=36V 3 Vin=48V Vin=75V 0 0 2 4 6 8 10 12 Output Current (amps) Fig.24 AV60C-048L-150F10N Power Dissipation TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 In the test, natural convection airflow was measured 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. Asia 852-2437-9662 852-2402-4426 -29www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output 35 4.0 m/s (800 ft./min.) 3.0 m/s (600 ft./min.) 2.0 m/s (400 ft./min.) 1.0 m/s (200 ft./min.) 0.5 m/s (100 ft./min.) Power Dissipation PD (W) 30 25 20 15 Natural Convection (10-20 ft./min.) 10 5 0 0 10 20 30 40 50 60 70 80 90 100 PD = 16 W Determine IO (Fig.24): IO = 9 A Calculate PO: PO = (VO) x (IO) = 15 x 9 = 135 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 32. Ambient Temperature, TA (C) Fig.26 Forced Convection Power Derating without Heat Sink Example 1. How to calculate the minimum airflow required to maintain a desired Tc? If a AV60C-048L-150F10N module operates with a 48V line voltage, a 10 A output current, and a 40 C maximum ambient temperature, What is the minimum airflow necessary for the operating? Determine PD ( referenced Fig.24 ) with condition: Vin = 48 V lO = 10 A Get: PD = 19 W And with TA = 40 C Determine airflow ( Fig.26 ): v = 2 m/s (400 ft./min.) Heat Sink Configuration Several standard heat sinks are available for the AV60C half-brick 50W to 150W modules as shown in Figure 27 to Figure 29. 57.0 (2.24) 4.9(0.193) 11.8 (0.465) Dimensions: millimeters (inches). 89.1(3.51) Fig.27 Non Standard Heatsink WDL02540 1/4 IN. WDL05040 1/2 IN. 61 (2.4) WDL10040 1 IN. 57.9 (2.28) Dimensions: millimeters (inches). Example 2. How to calculate the maximum output power of a module in a certain convection and a max. TA? What is the maximum power output for a AV60C-048L-150F10N operating at following conditions: Vin = 48 V v = 2.0 m/s (600 ft./min.) TA = 40 C Determine PD ( Fig.26 ) Fig.28 Longitudinal Fins Heat Sink WDT02540 1/4 IN. WDT05040 1/2 IN. 57.9 (2.28) WDT10040 1 IN. 61 (2.4) Dimensions: millimeters (inches). Fig.29 Transverse Fins Heat Sink TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -30www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output 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 measures 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 impedance 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 The power derating for a module with the heat sinks ( shown as figure 27 to figure 29) in natural 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. 30 Power dissipation PD (W) 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 (typically 0.1 C/W to 0.3 C/W) and temperature differential. 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. 1 in. heat sink 25 1/2 in. heat sink 20 1/4 in. heat sink 15 NO heat sink 10 5 0 0 10 20 30 40 50 60 70 80 90 100 Ambient Temperature, TA (C) Fig.31 Heat Sink Power Derating Curves, Natural Convection Example 3. How to select a heat sink? What heat sink would be appropriate for a AV60C-048L-150F10N in a natural convection environment at nominal line, 3/4 load, and maximum ambient temperature of 40C? Determine PD ( referenced Fig.24 ) with con- Fig.30 Heat Sink Mounting TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 dition: Vin = 48 V IO = 3/4 (10) = 7.5 A TA = 40 C Get: PD = 13 W Determine Heat Sink (Fig.31): 1 in. allows up to TA = 65C Asia 852-2437-9662 852-2402-4426 -31www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output rise, PD is the module power dissipation. In this model, PD, TC, max, and RCA are equals to current flow, voltage drop, and electrical resistance, respectively, in Ohm's law, as shown in Figure 32. Also, TC, max is defined as the difference between the module case temperature (TC) and the inlet ambient temperature (TA). TC, max = TC TA Where TC is the module case temperature, TA is the inlet ambient temperature. RCA: Thermal Resistance PD Fig.32 Basic Thermal Resistance Model For AV60C half-brick series 50W to 150W 15V output converters, the module's thermal resistance values versus air velocity have been determined experimentally and shown in Figure 33. The highest values on each curve represents the point of natural convection. Figure 33 is used for determining thermal performance under various conditions of airflow and heat sink configurations. TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 8 Case-Ambient Thermal Resistance R CA (C/W) Basic Thermal Model There is another approach to analyze module thermal performance, to model the overall thermal 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 . RCA = TC, max / PD Where RCA is the module thermal resistance, TC, max is the maximum case temperature 7 1 in. heat sink 6 1/2 in. heat sink 1/4 in. heat sink 5 NO heat sink 4 3 2 1 0 0 0.5(100) 1.0(200) 1.5(300) 2.0(400) 2.5(500) 3.0(600) Air Velocity m/s (ft./min.) Fig.33 Case-to-Ambient Thermal Resistance Curves; Either Orientation 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-150F10 heat sink combinations at desired Tc of 80 C? The working condition is as following: Vin = 48 V, IO = 10 A, TA = 40 C Determine PD ( Fig.24 ) PD = 19 W Then solve RCA: RCA = TC, max / PD RCA = (TC - TA) / PD RCA = (80 - 40) / 19 = 2C/W determine air velocity from figure 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.) Asia 852-2437-9662 852-2402-4426 -32www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output Example 5. How to determine case temperature ( Tc ) for the various heat sink configurations at certain air velocity? What is the allowable Tc for AV60C-048L150F10N 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 PD ( Fig.24 ) with condition: VI = 48 V IO = 10 A TA = 40 C v = 2.0 m/s (400 ft./min.) Get: PD = 19 W Determine TC: TC = (RCA x PD) + TA Determine the corresponding thermal resistances ( RCA ) from figure 33: No heat sink: RCA = 3.8 C/W TC = (3.8 x 19) + 40 = 112 C 1/4 in. heat sink: RCA = 2.8 C/W TC = (2.8 x 19) + 40 = 93 C 1/2 in. heat sink: RCA = 2.0 C/W TC = (2.0 x 19) + 40 = 78 C 1 in. heat sink: RCA = 1.2 C/W TC = (1.2 x 19) + 40 = 63 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. AV60C Half-brick Series other system equipment cooler and increase component life spans. Soldering AV60C half-brick converters are compatible with standard wave soldering techniques. When wave soldering, the converter pins should be preheated for 20-30 seconds at 110 C, and wave soldered at 260C for less than 10 seconds. When hand soldering, the iron temperature should be maintained at 425C 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 The MTBF, calculated in accordance with Bellcore TR-NWT-000332 is 2,000,000 hours. Obtaining this MTBF in practice is entirely possible. If the ambient air temperature is expected to exceed +25C, then we also advise a heatsink on the AV60C half-brick series, 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 company for details. Mechanical Considerations Installation Although AV60C half-brick 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 TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -33www.astec.com AV 6 0 C S e r i e s 1 5 V O u t p u t H a l f - B r i c k P o w e r C o n v e r t e r s 36 VDC to 75 VDC Input, 50-150W Output Recommend Hole Pattern Base-plate side view Dimensions are in millimeters and (inches). 57.9 (2.28) Max 4.8 (0.19) 48.3 (1.90) 48.26 (1.900) +Vin 35.56 (1.400) 50.8 (2.00) +Vout 35.56 (1.400) +Sense CNT 25.40 (1.000) Trim 25.40 (1.000) 17.78 10.16 (0.700) (0.400) -Sense Case 10.16 (0.400) 61.0 (2.40) Max -Vout -Vin 5.1 (0.20) 12.7 (0.50) Mounting Inserts Module Outline Mechanical Chart 5.1 (0.2) 61.0 (2.4) 7.62 (0.3) +Vin +Vout CNT +Sense 10.16 (0.4) 10.16 (0.4) 7.62 (0.3) 15.24 (0.6) Trim 7.62 (0.3) Case -Sense -Vin -Vout 10.16 (0.4) 10.16 (0.4) Mounting Inserts M3 thru hole x4 4.8 (0.19) 48.26 (1.9) mm (inches) 57.9 (2.28) Length optional 4.8 (0.189) default 12.7 (0.5) 7- 1.0 (0.04) all pins except +Vo and -Vo 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. TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Device Code Suffix none (default) -6 -7 -8 2- 2.0 (0.08) only +Vo and -Vo Tolerances: Inches .xx !0.020 .xxx !0.010 Pins >4mm <4mm Millimeters .x !0.5 .xx !0.25 !0.02inch ( !0.5mm) !0.01inch ( !0.25mm) Base-plate side view Asia 852-2437-9662 852-2402-4426 -34www.astec.com PART NUMBER DESCRIPTION ss pp c - 0 iv L - iv = Input Voltage 05 = Range centered on 5V 12 = Range centered on 12V 24 = 18 to 36(2:1), 9 to 36V(4:1) 36 = 20 to 60V 46 = 18V to 75V (4:1) 48 = Typ 36 to 75V xxx f yy h n - p - mx-Options p = Pin Length Omit this digit for Standard 5mm 6 = 3.8mm, 7= 5.8mm 8 = 2.8mm Enable Logic Polarity Omit for Positive Enable Logic N = Negative Enable Except: AK60C-20H, BK60C-30H Omit for Negative Logice P = Positive Logic c = Pinout compatability A= Astec Footprint or "non Lucent" footprint C= Ind Std, Exact Lucent drop in pp = Package Type 40 = 1" x 2" SMD 42 = 1.5" x 2" SMD 45 = 1.45" X 2.3" (1/4 Brk) 60 = 2.4" X 2.3" (1/2 Brk) 80 = Full size 4.6" x 2.4" 72= 2.35" X 3.3 (3/4 Brk) H = High Efficiency (Synch rect.) Omit H if Conventional Diode (low Eff) yy = Output Current ie. 08 = 8 Amps f = # of Outputs F = Single Output D = Dual Output xxx = Output Voltage Format is XX.X (ie 1.8V = 018) ss = Series AA = 1/2brick Dual (Old designator) mx = Options M1,M2 = .25" Height Heatsink M3,M4 = .5" height Heatsink M5.M6 = 1.0" Height Heatsink AK = Ind Std sizes (1/4, 1/2, full) <150W AM/BM = Full size, astec pin out AL = Half size, astec pin-out BK = Ind Std size =>150W or feature rich 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 A c s ii V1 V2 V3 Output Voltage A = 5.0V F = 3.3V G = 2.5V D = 2.0V / 2.1V Y = 1.8V M = 1.5V K = 1.2V J = 0.9V Vin - e t p Mx E = 7.5V B = 12V, C = 15V L = 8V, H = 24V, R = 28V Omit V2 and V3 if Single Output Omit V3 if Dual Output ie for Dual Output 5 and 3.3V V1 =A, V2 = F, V3 =Omit V1 =A, V2 = F, V3 =Omit ii = Output Current Max ie 60 = 60 Amps Vin = Input Voltage range 300 = 250V to 450V 48 = 36V to 75V 24 = 18V to 36V 03 = 1.8V to 5.0V 08 = 5.0V to 13.0V PFC: Power Factor Corrected S = Size F = Full Brick H = Half Brick Q = Quarter Brick S = 1 X 2 18 Pin SMT E = 1 X 2 Thru Hole C = (.53X1.3X.33) SMT (Austin Lite drop in) V = Conventional Package (2X2.56") or ( A = SIP W = Convent pkg (Wide 2.5X3) R = 1 X 1 Thru Hole A = SIP T = 1.6 X 2 E = Enable Logic for > 15W Omit this digit for Positive enable N = Negative Logic E = Enable Logic for < 15W Omit this digit for no enable option 1 = Negative Logic 4 = Positive Logic c = Construction E = Enhanced Thermals (Baseplate or adapter plate) I = Integrated (Full Featured) Hong Kong models L = Low Profile (Open Frame, No case - Isolated) P = Open Frame (SIP or SMT) non-isolated Trim for 1W to 15W 9 = Trim Added 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