48Vdc Input, 12Vdc@50A Output
Half-Brick Converter AVE600-48S12B
Document NO. 31020755 May 18, 2010 Rev 1.1
Description
The AVE600-48S12B is a single output DC-DC
converter with standard half-brick outline and
pin configuration. It delivers up to 50A output
current with 12V output voltage. The converter
can provide ultra-high efficiency of 95.6% and
excellent thermal performance, which makes it
an ideal choice for bus converter. For typical
applications, a heat sink and sufficient airflow is
required.
Operational Features
Up to 50A output current
Industry standard half-brick foot print
Basic isolation
Ultra-high efficiency: 95.6% at 12V half
load (V
in
= 48Vdc)
Improved thermal performance
High power density
Low output noise
No minimum load requirement
wide input voltage of 36V~75V
RoHS compliant
Control Features
Remote control function (negative or
positive logic optional)
Remote output sense
Trim function: 90% ~ 110%
Protection Features
Input under voltage lockout
Output over current protection
Output over voltage protection
Over temperature protection
Mechanical Features
Industry standard half-brick pin-out outline
Choice of short pins or long pins
Pin length option: 3.8mm, 4.8mm, 5.8mm
Safety & EMC
Meets safety standards UL 60950-1,
CSA-C22.2 NO. 60950-1, IEC/EN
60950-1 and GB4943
Approved by UL and TUV
Meets 2006/95/EEC and 93/68/EEC
directives which facilitates CE marking in
user’s end product
Meets conducted emission's requirements
of EN55022 Class B with external filter
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Electrical Characteristics
Full operating ambient temperature range is -40°C to +85°C.
Specifications are subject to change without notice.
Parameter Min.
Typ. Max.
Unit
Notes & conditions
Absolute max. ratings
Non-operating 100 V 100ms
Input voltage Operating 80 V Continuous
Operating temperature -40 85 °C Refer to Thermal Considerations
Storage temperature -55 125 °C
Voltage at remote ON/OFF pin -0.3 15 V
Input characteristics
Operating input voltage range 36 48 75 V
Turn-on voltage
threshold 35 36 V
Turn-off voltage
threshold 32 34 V
Input
under-voltage
lockout
Lockout voltage
hysteresis 1 3 V
Max. input current 24 A 36V
in
, full load
No-load input current 0.2 A 48V
in
, full load
Standby Input current 0.08 0.1 A Remote OFF
Input reflected ripple current 50 150 mA Through 12µH inductor; Figure 3
Recommended input fuse 30 A External fast blow fuse
recommended; Figure 11
Input filter component values (C\L)
17.6\0.56
µF\µH
Internal values
Recommended external input
capacitance 470 µF Low ESR capacitor
recommended; Figure 11
Output characteristics
Output voltage set point (standard
option) 11.80 12 12.20 V 48V
in
, full load
0.15 0.33 %
Output voltage line regulation 18 40 mV
0.1 0.2 %
Output voltage load regulation 12 24 mV
Output voltage temperature
regulation 0.02 %/°C
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Parameter Min.
Typ. Max.
Unit
Notes & conditions
Total output voltage range 11.70 12 12.30 V Over sample, line, load,
temperature & life
Output voltage ripple and noise 100 200 mVpp
Figure 2
20MHz bandwidth; Figure 17
Operating output current range 0 50 A
Output DC current-limit inception 52.5 65 A
Hiccup: auto-restart when
over-current condition is
removed
Output capacitance 680 2200 10000 µF High frequency and low ESR is
recommended
Dynamic characteristics
50% ~ 75% ~ 50%
I
o,max
, 0.1A/µs 250 mV
Figure 4
Test condition: 25°C, nominal
input voltage, see Figure 11
Setting time 110 µs Recovery to within 1% V
o,nom
50% ~ 75% ~ 50%
I
o,max
, 1A/µs 400 mV
Figure 5
Test condition: 25°C, nominal
input voltage, see Figure 11
Dynamic
response
Setting time 100 µs Recovery to within 1% V
o,nom
Rise time 40 100 ms Full load, Figure 6
Turn-on delay time 120 150 ms
Turn-on
transient Output voltage
overshoot 0 1 %V
o
Efficiency
100% load 94.8 % Figure 1
50% load 95.6 % Figure 1
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Electrical Characteristics (Continued)
Parameter Min. Typ.
Max.
Unit Notes & conditions
Isolation characteristics
1500 V Basic insulation, pollution degree 2,
input to output
1500 V Basic insulation, pollution degree 2,
input to baseplate
Isolation voltage (conditions:
1mA for 60s, slew rate of
1500V/10s)
500 V Functional insulation, pollution degree
2, output to baseplate
EMC characteristics
ESD B IEC/EN61000-4-2 Level 3
EFT
[1]
B IEC/EN61000-4-4 Level 3
Surges
[1]
B
IEC/EN61000-4-5
Line to Ground (earth): 600V
Line to Line: 600V
Conducted disturbances
immunity A IEC/EN61000-4-6 Level 2
DC voltage dips, short
interruption, variation B EN61000-4-29
Conducted Emission EN55022, DC Input, Class B
Feature characteristics
Switching frequency 130 140 150 kHz
Off-state
voltage -0.7 1.2 V
Remote
ON/OFF
control
(positive logic)
On-state
voltage 3.5 12 V
Off-state
voltage 3.5 12 V
Remote
ON/OFF
control
(negative
logic)
On-state
voltage -0.7 1.2 V
See Figure 13
Output voltage trim range 10.8 13.2 V See Trim Characteristics of
Application Note
Output voltage remote sense
range 0.6 V
Output over-voltage
protection 14 17 V Hiccup: auto-restart when
over-voltage condition is removed
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Parameter Min. Typ.
Max.
Unit Notes & conditions
Over-temperature shutdown
120 °C
Auto recovery;
OTP test point on C86 see Figure 10;
Tested under thermal balance
condition.
Over-temperature hysteresis
10 °C
Reliability characteristics
Calculated MTBF (telcordia)
1.5 10
6
h Telcordia SR-332-2006; 80% load,
300LFM, 40°C T
a
Note 1:
Criterion A: Normal performance during and after test.
Criterion B: Normal performance after test, automatic restart is allowed after test.
For EFT and Surges, system reset is no allowed.
Criterion C: Normal performance after test, the module can be restarted manually after test.
Normal performance means that output noise (Vpp) meet the requirement of the specifications.
Qualification Testing
Parameter Unit (pcs)
Test condition
Halt test 4 ~ 5 T
a,min
-10°C to T
a,max
+10°C, 5°C step, V
in
=min to max, 0 ~ 105% load
Vibration 3
Frequency range: 5Hz ~ 20Hz, 20Hz ~ 200Hz, A.S.D: 1.0m
2
/s
3
, -3db/oct,
axes of vibration: X/Y/Z
Time: 30min/axis
Mechanical shock 3 30g, 6ms, 3axes, 6directions, 3time/direction
Thermal shock 3 -40°C to 100°C, unit temperature 20 cycles
Thermal cycling 3 -40°C to 55°C, temperature change rate: 1°C/min, cycle: 2 cycles
Humidity 3 40°C, 95%RH, 48h
Solder ability 15 IPC J-STD-002C-2007
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Characteristic Curves
60
65
70
75
80
85
90
95
100
5 10 15 20 25 30 35 40 45 50
Vin=36V
Vin=48V
Vin=75V
Figure 1 Efficiency and output current, T
a
=25°C, V
o
=12V
Figure 2 Output ripple & noise (2µs/div, 20mV/div),
see Figure 17 for test configuration
Figure 3 Input reflected ripple current (100ms/div,
50mA/div), see Figure 17 for test configuration
Figure 4 Dynamic response for 25% load step (50% ~
75% ~ 50%) and 0.1A/µs slew rate, (5ms/div), see
Figure 11 for test configuration; CH2-output voltage
(200mV/div); CH1-output current (20A/div)
Figure 5 Dynamic response for 25% load step (50% ~
75% ~ 50%) and 1A/µs slew rate, (5ms/div), see Figure
11 for test configuration; CH2-output voltage
(200mV/div); CH1-output current (20A/div)
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Figure 6 Output voltage startup by power on,
(100ms/div), see Figure 11 for test configuration;
CH2-output voltage (5V/div); CH1-intput voltage
(20V/div)
Figure 7 Output voltage shut down by power off,
(5ms/div), see Figure 11 for test configuration;
CH2-output voltage (5V/div); CH1-input voltage
(20V/div)
Figure 8 Output voltage startup by remote ON,
(100ms/div), see Figure 11 for test configuration;
CH2-output voltage (5V/div); CH1-remote ON voltage
(2V/div)
Figure 9 Output voltage shutdown by remote OFF,
(5ms/div), see Figure 11 for test configuration;
CH2-output voltage (5V/div); CH1-remote OFF voltage
(2V/div)
OTP test point
Figure 10 OTP test point
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Application Note
Typical Application
EMI filter
Fuse
Vdc
In+
In-
Out+
Out-
C1 C2
Vin+
Vin-
AVE600
C3 C4 Load
Vo+
S+
Trim
S-
Vo-
CNT
DC/DC
Figure 11 Typical application
C1: 470µF/100V electrolytic capacitor, P/N: UPM2A101MHD (Nichicon) or equivalent caps
C2, C3: 1µF/100V X7R ceramic capacitor, P/N: C3225X7R2A105KT0L0U (TDK) or equivalent caps
C4: 2200µF electrolytic capacitor, P/N: UPM1E102MHP (Nichicon) or equivalent caps
Note: The converter cannot be used in parallel mode directly!
Fuse: External fast blow fuse with a rating of 30A. The recommended fuse model is 314030P from
LITTLEFUSE.
Remote ON/OFF
The converter is equipped with a primary ON/OFF (CNT) pin used to remotely turn the converter
on or off via a system signal. Two CNT logic options are available. For the positive logic model a
system logic low signal will turn the converter off. For the negative logic model a system logic high
signal will turn the converter off. For negative logic models where no control signal will be used the
ON/OFF pin should be connected directly to -V
in
to ensure proper operation. For positive logic
models where no control signal will be used the ON/OFF pin should be left unconnected.
Below is the detailed internal circuit and reference in AVE600-48S12B.
CNT
5V
20K
30.1K
14K
MCU
Figure 12 Remote ON/OFF internal diagram
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The voltage between pin remote ON/OFF and pin Vin- must not exceed the range listed in table
“Feature characteristics” to ensure proper operation. The external remote ON/OFF circuit is highly
recommended as shown in Figure 13.
Vin+
Vin-
Vo+
S+
Trim
S-
Vo-
Remote
ON/OFF
Vin+
Vin-
Vo+
S+
Trim
S-
Vo-
Remote
ON/OFF
Isolated remote ON/OFF circuit Non-isolated remote ON/OFF circuit
Figure 13 External remote ON/OFF circuit
Trim Characteristics
Connecting an external resistor between Trim pin and V
o
- pin will decrease the output voltage.
While connecting it between Trim and V
o
+ will increase the output voltage. The following equations
determine the external resistance to obtain the trimmed output voltage.
Ω−
∆
=
−
k)2
%
100%
(R
downtrim
Ω−
∆
−
∆
∆+
=
−
k)2
%
100%
%
225
.
1
%)100%(V
(R
nominal
uptrim
100
V
VV
%
nominal
desirednominal
×
−
=∆
%
norm
V
: Nominal output voltage.
For example, to get 13.2V output, the trimming resistor is
Ω=−
−
−
−×
=
−
k75.95)2
12/)122.13(
%100
12/)122.31(225.1
2.31
(R
uptrim
The output voltage can also be trimmed by potential applied at the Trim pin.
898.4)225.1( ×+=
trimO
VV
Where
trim
V
is the potential applied at the Trim pin, and
o
V
is the desired output voltage.
Load
C
out
Vo+
S+
Trim
S-
Vo-
R
trim _up
Load
C
out
Vo+
S+
Trim
S-
Vo-
R
trim _down
Figure 14 Trim up Figure 15 Trim down
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When trimming up, the output current should be decreased accordingly so as not to exceed the
maximum output power and the minimum input voltage should be increased as shown in Figure16.
12.0
36
13.2
39 75
Input voltage(V)
Maximum trim-up voltage(V)
Figure 16 Maximum trim-up voltage and input voltage
Sense Characteristics
If the load is far from the unit, connect S+ and S- to the terminal of the load respectively to
compensate the voltage drop on the transmission line. See Figure 11.
If the sense compensate function is not necessary, connect S+ to V
o
+ and S- to V
o
- directly.
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Input Ripple & Inrush Current And Output Ripple & Noise Test
Configuration
S+
AVE600
DC/DC
Vin+ Vo+
CNT
Vin- Vo-
S-
Cin C1 C2 C3 C4 Load
Probe
50mm
Current probe
L1
Trim
Figure 17 Input ripple & inrush current, output ripple & noise test configuration
Vdc: DC power supply
L1: 12µH
Cin: 220µF/100V typical
C1 ~ C4: See Figure 11
Note: It is recommended to use a coaxial cable with series 50Ω resistor and 0.68µF ceramic
capacitor or a ground ring of probe to test output ripple & noise.
EMC Filter Configuration
Vin-
Vin+ Vo+
Vo-
U2
DC/DC
Resislive load
C12
C6 C7
L2
L1 C4 C5
C1 C2 C3
C8 C9 C10 C11 GND
GND
In+
In-
Figure 18 EMC test configuration
C1~C5: SMD ceramic capacitor -100V-1000nF-X7R-1210
C6: SMD ceramic capacitor -100V-100nF-±10%-X7R-1206
L1, L2: Common mode inductor - single phase -473µH-±25%-14A magnetic ring 1*25.4*12.7mm -
working temperature range includes module temperature rise. Temperature rise at rated current:
55°C max
C8 ~ C11: High-voltage CHIP ceramic capacitor. Capacitance: 0.1U/630V/X7R. Size: 2220.
Capable of withstanding 1kV voltage
C7: Input electrolytic capacitor, according to the same type as C1 in Figure 11
C12: Output electrolytic capacitor, according to the same type as C4 in Figure 11
U2: Module to test, AVE600-48S12B
PE: Connected to output
Baseplate: Be not connected
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Thermal Considerations
The converter is designed to operate in different thermal environments and sufficient cooling must
be provided. Proper cooling of the DC-DC converter can be verified by measuring the temperature
at the test points as shown in the Figure 19. The temperature at these points should not exceed the
max values in the Table 1.
Test point
on C86
Test point
on C18A
Test point
on U11
Figure 19 Temperature test points
Table 1 Temperature limit of the test points
Test point Temperature limit
Test point on C86 116°C
Test point on U11 113°C
Test point on C18A 118°C
The converter can operate with a smaller heatsink and sufficient airflow. Figure 21 shows the
derating output current vs. ambient air temperature at different air velocity with a specified heat
sink.
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The typical test condition is shown in Figure 20.
Pin 1
Pin 4
Pin 5
Pin 9
Air flow
Figure 20 Typical test condition, heat sink size (L×W×H): 61mm×58mm×25.4mm
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0
5
10
15
20
25
30
35
40
45
50
25 40 55 70 85
Tem perature: Ta (℃
℃℃
℃)
Output current Io (A)
400LFM(2m/s) 300LFM(1.5m/s)
200LFM(1m/s) 100LFM(0.5m/s)
Figure 21 Output power derating, 48V
in
, air flowing across the converter from pin 4 to pin 1
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Mechanical Diagram
4-M3
15.24 [0.600]
35.56 [1.400]
50.8 [2.000]
61.0[2.402]
15.24 [0.600]
35.56 [1.400]
50.8 [2.000]
4
3
2
1
5
6
7
8
9
48.26 [1.900]
57.9 [2.280]
L
12.7 [0.500]
Base plate
Bottom view
4-Ф4±0.1
Side view
2-Ф2.0±0.17-Ф1.0±0.1
Load board
Unit: mm[inch] Bottom view: pin on upside
Tolerance: X.Xmm±0.5mm[X.X in.±0.02in.]
X.XXmm±0.25mm[X.XX in.±0.01in.]
Figure 22 Mechanical diagram
Pin length option
Device code suffix L
-4 4.8mm ± 0.5mm
-6 3.8mm ± 0.5mm
-8 2.8mm ± 0.5mm
None 5.8mm ± 0.5mm
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Pin Designations
Pin No. Name Function
1 V
in
+ Positive input terminal
2 Remote ON/OFF ON/OFF control terminal
3 Case Pin connected to baseplate
4 V
in
- Negative input terminal
5 V
o
- Negative output terminal
6 Sense- Negative remote sense
7 Trim Output voltage trim
8 Sense+ Positive remote sense
9 Vo+ Positive output terminal
Soldering
The product is intended for standard manual, wave soldering.
When wave soldering is used, the temperature on pins is specified to maximum 260°C for
maximum 7s.
When soldering by hand, the iron temperature should be maintained at 300°C ~ 380°C and applied
to the converter pins for less than 10s. Longer exposure can cause internal damage to the
converter.
Cleaning of solder joint can be performed with cleaning solvent IPA or similative.
Ordering Information
AVE600 - 48 S 12 P B - 4 L
① ② ③ ④ ⑤ ⑥ ⑦ ⑧
① Model series AVE: high efficiency half brick series, 600: output power 600W
② Input voltage 48: 36V ~ 75V input range, rated input voltage 48V
③ Output number S: single output
④ Rated output voltage 12: 12V output
⑤ Remote ON/OFF logic Default: negative; P: positive logic
⑥ Baseplate With baseplate
⑦ Pin length -4: 4.8mm±0.5mm
⑧ RoHS status L: RoHS, R6; Y: RoHS, R5
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Model number Description
AVE600-48S12B-4L 4.8mm pin length; negative on/off logic; without thread inside mounting hole; R6
compliant
AVE600-48S12PB-4L 4.8mm pin length; positive on/off logic; without thread inside mounting hole; R6
compliant
AVE600-48S12B-4Y 4.8mm pin length; negative on/off logic; without thread inside mounting hole; R5
compliant
AVE600-48S12PB-4Y 4.8mm pin length; positive on/off logic; without thread inside mounting hole; R5
compliant
Hazardous Substances Announcement (RoHS Of China)
Hazardous substances
Parts Pb Hg Cd Cr
6
＋
＋＋
＋
PBB PBDE
AVE600-48S12B
х х х х х х
х: Means the content of the hazardous substances in all the average quality materials of the part is within the limits
specified in SJ/T-11363-2006
√: Means the content of the hazardous substances in at least one of the average quality materials of the part is
outside the limits specified in SJ/T11363-2006
Emerson Network Power Co., Ltd. has been committed to the design and manufacturing of environment-friendly
products. It will reduce and eventually eliminate the hazardous substances in the products through unremitting
efforts in research. However, limited by the current technical level, the following parts still contain hazardous
substances due to the lack of reliable substitute or mature solution:
1. Solders (including high-temperature solder in parts) contain plumbum.
2. Glass of electric parts contains plumbum.
3. Copper alloy of pins contains plumbum
